AATC SPEC 114012

AATC_SPEC_114012.docx APPROVED 18 November 2008 of 39

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ACSA SPECIFICATION 114012

DESIGN, FABRICATION, INSTALLATION AND MAINTENANCE OF OPEN GRID GRATING FOR

FLOORS, STAIRWAYS AND HANDRAILING

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CONTENTS PAGE

1 SCOPE 2

2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 2

3 DEFINITIONS 2

4 REQUIREMENTS 3

4.1 WELDING CONSUMABLES 3 4.2 CERTIFICATION 3 4.3 MATERIALS 3 4.4 MATERIALS SUBSTITUTION 3 4.5 CORROSION PROTECTION 4 4.6 DRAWINGS 4 4.7 CONSTRUCTION 4 4.8 WELDING 5 4.9 SPAN OF GRATING 5 4.10 TOLERANCES 6 4.11 PANEL SIZE 6 4.12 FLOORING PATTERN 8 4.13 FIXING OF FLOOR GRATING PANELS 9 4.14 LANDING OF FLOORING 12 4.15 BANDING 13 4.16 KICK PLATES 15 4.17 STAIR TREAD 16 4.18 FLOORING PANELS 17 4.19 CLOSING OF EXISTING REDOUNDED EQUIPMENT OPENINGS 24 4.20 HANDRAILING 25

5 QUALITY ASSURANCE PROVISIONS 37

5.1 QUALITY MANAGEMENT 37 5.2 QUALITY PLAN 37 5.3 TEST FACILITIES 37 5.4 INSPECTION 37

6 TEST AND INSPECTION METHODS 37

7 MARKING AND IDENTIFICATION 37

7.1 GENERAL 37 7.2 STAMP IDENTIFICATION 37 7.3 MARKING 38

APPENDIX A: RELATED DOCUMENTS 39

APPENDIX B: RECORD OF AMENDMENTS 39






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1 SCOPE

This specification details the Anglo Coal South Africa requirements for the design, fabrication, installation and maintenance of open grid grating for floors, stairways and handrailing. It is not intended for mobile machinery.

2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

The following requirements shall be specified on all invitations to tender, contracts or orders:

Number, title, date and issue of this specification Number, title and issue of the relevant AAC drawings Type of material to be used in the manufacturing of flooring (Commercial quality,

grade 350W, 3CR12 or stainless steels - see clause 4.1 Size of flooring (pitch of bars, height and widths of bearer bars and dimensions) Corrosion protection requirements Panel fastening methods (fixing clamps, bolts or clips) Banding required (see Clause 4.6.6)

3 DEFINITIONS

For the purpose of this specification the following definitions shall apply:

APPROVED : Approved by the Engineer in writing

BS : British Standard

SANS : South African National Standards

QUALITY ASSURANCE REPRESENTATIVE (QAR)

: An independent inspection agency appointed by the Engineer.

LOAD-BEARING BAR : (Or bearing bar, carrier bar, span bar). The load carrying member running between supports.

TRANSVERSE BAR : Member at right angles to the load-bearing bars to provide lateral restraint.

PITCH : The distance centre to centre of load-bearing bars or centre to centre of transverse bars.

BANDING : A bar of equal depth and thickness to the load-bearing bars which is welded to the grating.






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WIDTH : Overall dimension of a grating panel measured at right angles to the load-bearing bars.

LENGTH : Overall dimension of a grating panel measured parallel to the load bearing bars.

NOSING : (Or sighting edge). A special non-slip edging welded to the front edge of a stair tread or landing edge.

KICK PLATE : A flat bar welded to the end or side of a floor panel, projecting 100 mm minimum above the grating.

SIDE PLATE : A flat plate welded to the ends of a stair tread and drilled for bolting to the stringer.

STAIR TREAD : A rectangular pattern bar grating with an abrasive nosing.

The following terms are defined in the General Conditions of Contract:

AAC, Company, Contractor, Engineer

4 REQUIREMENTS 4.1 WELDING CONSUMABLES

Shall comply with the requirements of SANS 1200H.

4.2 CERTIFICATION

Chemical composition and mechanical properties certification of materials shall be submitted to the Engineer on request.

4.3 MATERIALS

All materials shall comply with the following specifications, whichever is applicable:

Steelwork - SANS 1431 – Grade 350 WA BS 1449 and shall have a minimum yield stress of 220MPa before manufacture

(commercial flooring quality and Stainless Steel) AAC Specification No 114002 – Appendix B (3CR12)

4.4 MATERIALS SUBSTITUTION

Materials shall be as specified on the relevant approved drawings. Substitution of materials shall not be permitted without approval. Additional costs of approved substitutions shall be borne by the Contractor.






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4.5 CORROSION PROTECTION

Corrosion protection shall be by hot dip galvanising to SANS 121/ISO 1461. For particularly corrosive environments it is recommended that the flooring panels be hot dip galvanised to SANS 121/ISO 1461 followed by dipping in black bitumen in accordance with the requirements of SANS 1137.

Should any shaping of the panel be carried out after the application of the corrosion protection, the appropriate area shall be made good by wire brushing and hand painting two coats of Zinc Chromate Type 1, complying with SANS 679. If the panel also had a coat of bitumen before shaping, the two coats of Zinc Chromate Type 1 shall be followed by one coat of bitumen.

4.6 DRAWINGS

Drawings shall comply with the requirements of AA Specification 114001.

4.7 CONSTRUCTION

Grating shall be of the open grid type with non-skid characteristics.

4.7.1 Load–bearing bar or bearer bar is the load carrying member running between supports. 4.7.2 Transverse bar is the member at right angles to load bearing bars to provide lateral

restraint. 4.7.3 Maximum pitch of bars (unless otherwise specified on the approved drawings), shall

be:

Load-bearing bars - 50 mm

Transverse bars - 50 mm

4.7.4 The minimum thickness: of a load bearing bar shall be 4,5mm. 4.7.5 The overall height: of a bearer bar shall be one of the following as specified by the

Company:

30 and 40mm

Grating shall not be repaired. Damaged panels must be replaced.

Grating shall not support any form of equipment (e.g. pipe bracket, lifting slings etc.)






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4.7.6 Grating Replacement

Where the surrounding panels have deeper bearer – bars the new panel shall have the same depth.

Where the surrounding panels have bearer – bars with a depth of less than 30mm sufficient panels shall be replaced to blend smoothly into 30 mm deep bearer – bars.

By this it is intended that all panels up to a natural break in the floor, where a change in panel depth will not be noticed, must be replaced.

4.7.7 Dimensions: of panels shall be as specified on the approved drawings or by the Company.

4.8 WELDING

Welding design shall comply with the requirements of SANS 0162 and welding practice shall comply with the requirements of BS 5135.

Every third bearer bar shall be welded on one side only to the banding, kick plate or side plate using a 3mm continuous fillet weld equal in length to the depth of the bar.

Every third transverse bar shall be welded all round to the banding or kick plate using a 3mm continuous fillet weld. All other intermediate transverse bars shall be tack welded to the top of banding/kick plates.

4.9 SPAN OF GRATING

The span shall be based on the manufacturer of the grating’s recommendations, usually contained in a table in their catalogues. The minimum imposed floor loads listed below shall be used to decide which table to use (refer to Anglo American Specification 114001 Design Criteria for Steel Structures 4.6.2)

Floors and platforms : 5,0kN/m2

Stairs, landings and walkways : 3,0kN/m2

Conveyor gantry walkways : 2,5kN/m2

Where machinery or parts there of maybe placed during maintenance or change outs the flooring shall be designed to resist a minimum concentrated load of 10kN.

Note: if these spans are not listed in the catalogue the suppliers must be consulted.

Grating shall not exceed the manufacture recommended maximum safe span for bearer bars.






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4.10 TOLERANCES 4.10.1 Maximum camber: (positive or negative) of any panel shall not exceed 10mm or 1/200 of

the span, whichever is the lesser. 4.10.2 Maximum clearance: between adjacent grating panels after erection shall not exceed

10,0mm. 4.10.3 The length and width of any panel: shall be within the tolerance of +0,0mm

and -5,0mm. 4.10.4 The out of squareness: measured diagonally across the corners of any panel shall not

exceed 5,0mm. 4.10.5 Longitudinal bow: parallel to the bearer bars of any panel shall not exceed 1/200 of the

span or 5mm whichever is the lesser before fastening panel to supporting steelwork. 4.10.6 Transverse bow: perpendicular to the bearer bars shall not exceed 5 mm before fastening

to supporting steelwork. 4.10.7 Bearer bars: shall have a thickness tolerance of +0,4mm to -0,1mm and a height tolerance

of +1,2mm to -0,0mm. 4.10.8 Width of stairtreads: shall be within the tolerance of ±5,0mm. 4.10.9 Lengths of stairtreads: shall be within the tolerance of +0,0mm, -3,0mm. 4.10.10 Landing of flooring: on supporting steelwork shall be not less than 50mm. In the case of

panels landing on channels, a seating/ledge angle may be necessary. 4.11 PANEL SIZE

Panels shall be made to the size of the opening that they are to fit in with the following tolerances:

To facilitate erection, clearances shall be allowed as follows: a maximum of 3mm between floor panel sections and a maximum of 10mm between the edge of the flooring panel and any adjacent structure.

The length and width of each panel measured over the load-beading bars and banding bars shall be within the limits of +0mm and -5mm of the specified dimensions of the panel.

The squareness of the panel shall be checked by measuring the diagonals of the panel, which shall not differ, by more than 5mm.






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4.12 FLOORING PATTERN

The Flooring Pattern shall remain uninterrupted at joints.






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Main and transverse bars of adjacent panels shall be in line with each other.

4.13 FIXING OF FLOOR GRATING PANELS

Field welding shall not be performed unless approved by the engineer.

Panels shall be securely fastened to the supporting steelwork at each corner or as close as possible to each corner by the system described below.

The HILTI threaded stud, in conjunction with the saddle clamp, washer and nylock nuts must be utilised. Special care must be taken not to over tighten the nuts. Should excessive torque be applied, the stud will be pulled out of the support steel.






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The length of a panel is defined as the spanning length of the bearer bars. Panels will be securely fastened along the width of the panel and thus along the landing steelwork where the bearer bars rest upon at intervals not greater than 1000mm.

Typical Double Span Panel

Typical Single Span Panel






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Hilti stud and saddle

HILTI EM8 Threaded Stud Hilty Power Tool

Securing Saddle Typical Fixing Arrangement






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4.14 LANDING OF FLOORING

Landing of flooring on supporting steelwork shall be not less than 50mm. In the case of panels landing on channels, a seating/ledge angle may be necessary.






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4.15 BANDING

All grating panels shall be provided with banding bars around the perimeter of the panel except when

the load bearing bar forms the banding bar; the kick plate forms the banding bar; specified otherwise by the engineer.

Every fourth bearer bar shall be welded on one side only to the banding, kick plate or side plate using a 3mm continuous fillet weld equal in length to the depth of the bar.

Every fourth transverse bar shall be welded all round to the banding or kick plate using a 3mm continuous fillet weld. All other intermediate transverse bars shall be tack welded to the top of banding/kick plates.

Care should be taken during detailing so that panel sizes are multiples of the grating aperture dimensions. This is to ensure that the aperture at the panel perimeter, where fixture must be done, is adequate for the securing system.






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Banding for Drainage






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4.16 KICK PLATES

A flat bar 130mm x 8mm should be welded to the end or side of a floor panel as appropriate. Note that 6mm thick kick plates are also acceptable but cutting will be required given that it is a non standard flat section.

Kick plates shall be provided at all open edges of flooring including stair landing and equipment openings. Kick plates are essential to prevent tools or other items from dropping off platforms or walkways and causing injury.

Kick plate shall have a minimum height of 100mm above the flooring.






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Note: Above detail shows K/FLT not less than 100mm above floor level.

4.17 STAIR TREAD

A rectangular pattern bar grating with an abrasive nosing and side plates shall be provided.

All stair treads shall be bolted to stair stringers using a minimum of 4 - M12 bolts with self-locking nuts.

Nosing shall be a special non – slip edging, welded to the front edge of the stair tread.

a + 100mm = K/FLAT HEIGHT






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Side plates shall have a minimum thickness of 4.5mm and shall be welded to the ends, the stair tread and drilled for bolting to stringer.

4.18 FLOORING PANELS

Flooring panels shall be formed from approved open grid grating by cutting stock sheets to the correct size and providing cut-outs, banding and kick plates as required. Before forming, the panel’s accurate dimensions of the required size, cut–outs and supporting steelwork must be determined and a drawing of the panel. These drawings must be filed for future reference.






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Flooring Cut-Out Details






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4.19 CLOSING OF EXISTING REDOUNDED EQUIPMENT OPENINGS

Where openings have been left in concrete floors due to equipment having been removed and not replaced the following shall apply:

Handrail the area. This is the preferred method as it eliminates steps in flooring and tripping hazards. This method shall be used wherever possible.

If removable covers are required use method as shown below.

This method shall only be used on openings smaller than 1500mm square.






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4.20 HANDRAILING

Handrailing should preferably, and always in the case of stairs, be continuous, and should have no obstruction on, above or near to it that might obstruct a hand moving along it. The recommended clearance between a handrail and any wall or other obstruction behind or below it is 65mm.

Handrailing to platforms, walkways, landings and unguarded edges of raised floors shall not be less than 1100mm high above finished floor level. Handrailing to stairs shall have a height of not less than 1100mm measured vertically from the top of the stanchion base plate to the upper surface of the handrail. Refer to figure Typical Angular Handrailing (Sheet 10 of 10).

Stanchions shall be : 60 x 60 x 6 angle

All stanchions shall be bolted to steelwork or concrete kerbs using M16 bolts

All stanchions shall be painted : Black if steel is not galvanized

Top rail shall be welded to every stanchion on one side only using a 3mm continuous fillet weld.

Top rail shall be : 50 x 50 x 6 angle

Kneerail shall be : 50 x 5 flat bar

Solid 25mm bars may be used on conveyor gantries if approved in writing by the engineer.

Kneerail shall be welded to every stanchion on top only using a 3mm continuous fillet weld

Top rail and Kneerail shall be painted : Yellow if steel is not galvanised






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5 QUALITY ASSURANCE PROVISIONS 5.1 QUALITY MANAGEMENT

The requirements of SANS ISO9001 shall apply. All optional requirements in SABS ISO9001 shall be compulsory requirements for material supplied against this specification.

5.2 QUALITY PLAN

Contractors shall compile and submit a quality plan which shall be approved prior to commencement of manufacture. The quality plan shall list all major works, specifications, tests, methods of test, equipment to be used and acceptance/rejection criteria.

5.3 TEST FACILITIES

The Contractor shall provide test samples, qualified labour and approved testing equipment for tests. If facilities are not available at Contractor's premises the Contractor shall arrange for tests to be conducted by approved test authorities. The costs of all tests shall be borne by the Contractor.

5.4 INSPECTION

The QAR shall have access at all reasonable times to those parts of the manufacturing facilities engaged in the manufacture of articles to this specification. The QAR is authorised to witness any stage of manufacture, tests and to inspect documentation. The QAR is authorised to reject any items not complying with the requirements of this specification. In the event of a dispute arising regarding the interpretation of test results the decision of the Engineer shall be final.

6 TEST AND INSPECTION METHODS

Testing and inspection shall be in accordance with the requirements of BS 4592.

7 MARKING AND IDENTIFICATION 7.1 GENERAL

The Contractor shall prepare marking drawings and supply one sepia print to the Engineer for approval.

7.2 STAMP IDENTIFICATION

Each element shall be hard stamped in accordance with the requirements of the drawing.






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7.3 MARKING

Each element shall be hard stamped with the following information

a) Manufacturer's name or logo b) Batch number or date of manufacture






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APPENDIX A: RELATED DOCUMENTS

Unless otherwise specified the latest issue of the following documents shall be deemed to form part of this specification:

AA 114002 : Fabrication and erection of structural steelwork

AA 114001 : Design of Steel Structures

AA 164005 : Corrosion protection by thin films, eggcrate floor panels and cable racks

BS 1449 : Steel plate and strip

BS 4592 : Specification for industrial open type metal flooring and stair treads

BS 5135 : Metal arc welding of carbon and carbon-manganese steels

SANS ISO 1461 : Hot dip galvanised coatings on fabricated iron and steel articles

SANS 0162 : The use of structural steel

SANS 1137 : Hot applied bitumen for steel pipeline protection

SANS 1200H : Civil engineering construction, Part H, structural steelwork

SANS 1431 : Weldable structural steels

SANS ISO 9001 : Quality management systems

APPENDIX B: RECORD OF AMENDMENTS

Issue 0 : New document

Issue 1 : Amended clauses 4.13, 4.15, 4.16 and 4.20, amended drawings (page 11) - T Schmidt (November 2008)

Issue 2 : Amended clause 4.20 - M du Plessis (April 2010)

AATC SPEC 114012

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