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AA SPEC 114005 Stairs, Platforms and Handrails

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97 views61 pages

AA SPEC 114005 Stairs, Platforms and Handrails

Uploaded by

Stewan Botes

We take content rights seriously. If you suspect this is your content, claim it here.

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AA SPECIFICATION 114005

ISSUE 00
STEEL AND FRP FLOORING, STAIRS,
LADDERS AND GUARDRAILS COPYRIGHT

CONTENTS PAGE

1 SCOPE 4

2 SAFETY AND RISK 4

2.1 ANGLO FATAL RISK STANDARDS 4

2.2 RISK ASSESSMENT 4

3 TECHNICAL REQUIREMENTS 6

3.1 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 6

3.2 REFERENCE STANDARDS AND SPECIFICATIONS 6

4 DEFINITIONS 8

5 GENERAL REQUIREMENTS 10

5.1 COMPLIANCE WITH LEGISLATION AND AA PLC REQUIREMENTS 10

5.2 DEVIATION FROM THIS SPECIFICATION 10

5.3 MEANING AND PRECEDENCE OF INFORMATION 10

6 REQUIREMENTS FOR DESIGN 11

6.1 GENERAL 11

6.2 ALTERNATIVE DESIGNS 11

6.3 M ATERIALS 11

6.4 LOADS 15

6.5 DESIGN DRAWINGS 16

6.6 LAYOUT OF FLOOR GRATING 16

6.7 LAYOUT OF FLOOR PLATING 19

6.8 OPENINGS IN FLOORING 21

6.9 LAYOUT OF GUARDRAILS 22

6.10 LAYOUT OF STAIRS AND LADDERS 24

6.11 USE OF STAIRS OR LADDERS 26

6.12 ROOF ACCESS AND EDGE PROTECTION 27

AA_SPEC_114005 2014-06-11 June 2014 Page 1 of 61

Anglo American Group Engineering accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AA SPECIFICATION 114005
ISSUE 00
STEEL AND FRP FLOORING, STAIRS,
LADDERS AND GUARDRAILS COPYRIGHT

7 REQUIREMENTS FOR FABRICATION AND SUPPLY 27

7.1 M ATERIALS 27

7.2 COMPLIANCE WITH DESIGN DRAWINGS 27

7.3 MODULAR DESIGN 28

7.4 CONSTRUCTION DETAILS 28

7.5 WELDING 30

7.6 PAINTING AND PROTECTIVE COATING 30

7.7 CERTIFICATION 31

7.8 TOLERANCES 31

7.9 TEST AND INSPECTION METHODS 33

7.10 PACKING AND M ARKING 33

7.11 PERFORMANCE AND GUARANTEE 34

8 REQUIREMENTS FOR INSTALLATION 34

8.1 SAFETY 34

8.2 INSTALLATION PROCEDURE 35

8.3 FASTENING OF FLOORING, STAIRS AND GUARDRAILS 36

8.4 INSTALLATION TOLERANCES 39

8.5 INSPECTION AND ACCEPTANCE 39

9 REQUIREMENTS FOR USE 40

9.1 SUPPORT OF EQUIPMENT 40

9.2 STORAGE 41

9.3 LIFTING 41

9.4 OPENINGS 41

9.5 COVERING OF FLOOR 43

9.6 REINSTATEMENT FOLLOWING REMOVAL FOR M AINTENANCE 44

9.7 REGULAR INSPECTIONS 44

9.8 RETROFIT REQUIREMENTS FOR NON-COMPLIANT ITEMS 46

10 REQUIREMENTS FOR MAINTENANCE AND REPAIR 49

AA_SPEC_114005 2014-06-11 June 2014 Page 2 of 61

10.1 FABRICATION AND SUPPLY 49

10.2 INSTALLATION 49

10.3 GRATING 50

10.4 FASTENERS 51

10.5 STAIRS 52

10.6 LADDERS 52

10.7 GUARDRAILS 54

11 QUALITY ASSURANCE PROVISIONS 55

11.1 QUALITY M ANAGEMENT 55

11.2 QUALITY PLAN 55

11.3 TEST FACILITIES 55

11.4 INSPECTION 56

APPENDIX A: RECORD OF AMENDMENTS 57

APPENDIX B : RELATED DOCUMENTS 58

APPROPRIATE NATIONAL STANDARDS 58

AA_SPEC_114005 2014-06-11 June 2014 Page 3 of 61

1 SCOPE

This specification details the Anglo American plc minimum requirements for the design, supply, fabrication,
installation, use and maintenance of steel and FRP flooring and walkways, stairs and guardrails. Steel
flooring includes open grid flooring, expanded metal flooring and patterned plate flooring.

This specification is intended for use with flooring, stairs, ladders and guardrails on steel framed structures
on surface and underground, in processing plants, materials handling systems, heavy mobile machinery, and
mine shaft structures. All areas under the management of AA plc, or any of its operating divisions are
included.

This specification should be read in conjunction with AA BPG S006 “Guidelines for Layout and Inspection of
Steel and FRP Floors, Stairs and Guardrails”.

This specification shall also be read in conjunction with any applicable requirements of local legislation and
standards. The more stringent of this specification and local requirements shall apply. In particular, in
Australia the draft standard DR01136 “Fixed Platforms, Walkways, Stairways and Ladders – Design,
Construction and Installation” shall be read in conjunction with this specification.

It must be noted that the use of cat ladders, FRP products and expanded metal flooring is prohibited on all
Anglo American Thermal Coal operations.

2 SAFETY AND RISK

2.1 ANGLO FATAL RISK STANDARDS

All work on new installations, maintenance or repair of steel and FRP floors and walkways, stairs, ladders
and guardrails shall take cognisance of the Anglo Fatal Risk Standards, in particular the standard AA GTS
007 “AFRS Working at Heights”.

2.2 RISK ASSESSMENT

2.2.1 New Installations

The Project Engineer shall ensure that the Mine Engineer, the Project Engineer and the Design Engineer
conduct a risk assessment and generally work in compliance with AA STD 99 “Risk Management on
Projects” for all new installations prior to any work being carried out.

AA_SPEC_114005 2014-06-11 June 2014 Page 4 of 61

2.2.2 Existing Installations

The Mine Engineer shall conduct a risk assessment and generally work in compliance with AA STD 99 “Risk
Management on Projects” for all existing plant installations prior to any maintenance or operations activity
that affects the steel and FRP floors and walkways, stairs, ladders or guardrails.

2.2.3 Minimum Requirements

The risk assessment shall consider at least the following:

(a) Installation

The installation of all flooring and stairs shall be considered under the risks associated with working at
heights, because there is no working surface in place. The installation of guardrails shall also be considered
under the risks associated with working at heights, because the work takes place at unprotected edges.
Specific risks associated with at least the following shall be considered:

• Working at heights
• Lifting and temporary support of components prior to fixing in place
• Unauthorised access of persons, and falls from unfixed components
• Inappropriate alteration of incorrectly manufactured components

(b) Fire

Many of the FRP products are “fire retardant”. This means that they will not burn if removed from a fire
source. However, if subjected to a significant fire for any length of time the resins deteriorate completely, so
that they become unsafe to use as flooring. When considering the use of FRP products the speed of
emergency evacuation and access for fire-fighting personnel should be carefully considered.

(c) Access and Escape

Walkways and stairs are often an integral part of emergency escape routes. All walkways and stairs
designated as escape routes shall be sufficiently wide, and be kept clear of obstructions, so as to allow free
movement of people. Dedicated green coloured plates in steel or fire retardant FRP may be used to
demarcate these escape routes.

Where ladders are installed, it is particularly important that this is taken into account, as they provide only
limited and slow movement of people.

Open grid floors allow escaping gases or flames from a fire below to pass through the openings. Solid plates
below emergency escape routes can deflect flames or gases and provide safer egress for people in the
event of an emergency.
AA_SPEC_114005 2014-06-11 June 2014 Page 5 of 61

(d) Falling objects

Where open grid steel of FRP grating is used, it is possible for small objects to fall through the grating.
Objects may also fall through whatever cutouts are formed in the flooring. Spillage may also pass through
open grid flooring and accumulate below. The risk assessment should include consideration of any risks to
workers or equipment below the floor due to falling objects, or accumulation of spillage.

(e) Ventilation

Open grid flooring allows free movement of dust, air and gases. This allows escape of noxious and
explosive gases which may be present in certain areas of plants. This may be desirable or undesirable
under different conditions, so it should be considered within the risk assessment.

3 TECHNICAL REQUIREMENTS

3.1 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

For all new work the Project Engineer, and for all repair or replacement work the Mine Engineer, shall specify
the following requirements on all invitations to tender, contracts or orders:

• Number, title, date and issue of this specification

• Number, title and issue of the relevant drawings

• Type of material to be used in the manufacturing of flooring, stairways and handrails

• Corrosion protection requirements

• Fire rating and fire protection requirements

• Panel fastening methods

3.2 REFERENCE STANDARDS AND SPECIFICATIONS

The latest versions of the following specifications, standards and regulations, form part of this specification.

AA_SPEC_114005 2014-06-11 June 2014 Page 6 of 61

3.2.1 International Standards

The latest versions of the following international standards form part of this specification. Where these
international standards are not applicable, and it is desired to use an equivalent local standard, approval
shall be obtained from Group Engineering (M&T) prior to proceeding.

• ISO 834 “Fire resistance tests. Elements of building construction”

• ISO 1461 “Hot dip galvanised coatings on fabricated iron and steel articles”.

• ISO 8501 “Preparation of steel substrates before application of paints and related products. Visual
assessment of surface cleanliness”.

• ISO 9001 “Quality management systems”.

3.2.2 National Standards

The latest versions of appropriate national standards form part of this specification. In order to be applicable
globally, this standard does not reference specific national standards, but utilises International Standards
Organisation (ISO) standards and national standards referenced by the code letters defined below. A list of
some appropriate national standards is given for information only in Appendix B.

• DLS – The appropriate national standard for limit states structural design of mine shafts.

• GWS – The appropriate national standard defining the chemical and mechanical properties of
weldable structural steels.

• LSD – The appropriate national standard for limit states design of structural steel.

• SLO – The appropriate national standard for structural loading.

• SSC – The appropriate national standard for structural steel construction.

• STS – The appropriate national standard for stainless steel sections.

3.2.3 AA plc Specifications

The latest versions of the following AA plc standards form part of this specification.

• AA GTS 007 “AFRS Working at Heights”.

• AA GTS 008 “AFRS Lifting Operations”.

• AA GTS 019 “Structural Integrity Standard”.

• AA SPEC 114001 “Design of Structural Steelwork”.

• AA SPEC 114002 “Construction of Structural Steelwork”.

AA_SPEC_114005 2014-06-11 June 2014 Page 7 of 61

• AA SPEC 164000 “Users Guide for Corrosion Protection: System Selection”.

• AA CPS 000124 “New Work, Non-Immersion Two Coat Epoxy Coal Tar”.

• AA CPS 41A “Galvanised Iron and Steel Repair Procedure (Single Pack Zinc Rich)”.

• AA STD 99 “Risk Management on Projects”.

• AA STD 100 “Quality Requirements for Critical and Major Products and Services”.

• AA BPG S003 “SIMM Guidelines for Plant Structures”

• AA BPG S006 “Guidelines for Layout and Inspection of Steel and FRP Floors, Stairs and
Guardrails”

4 DEFINITIONS

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

APPROVED : Approved by the Design Engineer in writing

ATD : Anglo Technical Division

A bar of equal depth and thickness to the bearer bars which is welded
BANDING :
to the grating around the outer ends and edges of the panel.

The load carrying component of walkway grating running between

structural supports.
BEARER BAR :
Note: This may also be referred to as a load-bearing bar, a carrier
bar, or a span bar.

BS : British Standard

The company appointed to install steel or FRP flooring, stairs and

CONTRACTOR :
guardrails.

DESIGN DRAWINGS : As defined by AA SPEC 114001

DESIGN ENGINEER : As defined by AA SPEC 114001

A Foreman who is appointed in writing by the Mine Engineer as

having responsibility for steel and FRP flooring, stairs and
DESIGNATED FOREMAN : guardrails. The Designated Foreman should have specific training
and experience in the use and inspection of steel and FRP flooring,
stairs, ladders and guardrails

AA_SPEC_114005 2014-06-11 June 2014 Page 8 of 61

Fibre Reinforced Polymer. The fibre used is usually glass, but may
FRP : also be carbon or other materials. A variety of polymers is used,
depending on the requirements of the specific application

A fixed safety handrail system, or barrier, around working areas or

GUARDRAIL : floor areas. It consists of a hand rail, a middle rail, and a toeboard
at the floor level.

Materials supplied to a guaranteed strength, and having a fully

GRADED :
traceable origin

Overall dimension of a grating panel measured parallel to the bearer

LENGTH OF PANEL :
bars.

A toeboard designed to carry loads from flooring which is not directly

LOAD BEARING TOEBOARD :
supported on beams.

The Engineering Manager of the Purchaser, or a person appointed in

MINE ENGINEER : writing by the Engineering Manager to take responsibility for the
particular area of the mine.

A special non-slip edging attached to, or formed along, the front edge
NOSING : of a stair tread or landing edge.
Note: This may also be referred to as the sighting edge.

The distance centre to centre of bearer bars or centre to centre of

PITCH :
transverse bars.

The company appointed by the Purchaser to be responsible for the

PROJECT ENGINEER :
management of the project.

PURCHASER : The mine company that places the order and receives the goods.

Quality Assurance Representative. An independent inspection

QAR :
agency appointed by the Purchaser.

SANS : South African National Standards

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

SS : Stainless steel

STAIR TREAD : A rectangular pattern bar grating with a non-slip nosing.

A stair stringer or ladder stringer is the structural side member of the

STRINGER :
stair or ladder.

AA_SPEC_114005 2014-06-11 June 2014 Page 9 of 61

A company that manufactures and supplies walkway grating,

SUPPLIER :
guardrail and/or stair components.

A flat bar welded to the end or side of a floor panel, projecting at

TOEBOARD : least 100 mm minimum above the grating.
Note: This may also be referred to as a kick plate.

TRANSVERSE BAR : Member at right angles to the bearer bars to provide lateral restraint.

Overall dimension of a grating panel measured at right angles to the

WIDTH OF PANELS :
bearer bars.

5 GENERAL REQUIREMENTS

5.1 COMPLIANCE WITH LEGISLATION AND AA PLC REQUIREMENTS

All material and services shall comply with the mandatory requirements of applicable legislation, relevant to
the country and jurisdiction in which the mine site is located. The Contractor shall confirm this compliance in
writing to the Purchaser.

All work done on installation, maintenance and repair of steel and FRP flooring and walkways, stairs and
guardrails shall be done in compliance with the Anglo Fatal Risk Standard “Working at Heights”.

5.2 DEVIATION FROM THIS SPECIFICATION

Any proposed deviation from this Specification and its requirements, or modifications for application to
specific items proposed by the Supplier, shall be submitted to the Principal Structural and Civil Engineer of
Anglo American (M&T) for written approval.

5.3 MEANING AND PRECEDENCE OF INFORMATION

If any doubt arises as to the meaning or effect of any part of this Specification or if conflict occurs between
this Specification and other information it shall be referred to the Principal Structural and Civil Engineer of
Anglo American (M&T) for a ruling.

The decision of the Principal Structural and Civil Engineer shall be final.

AA_SPEC_114005 2014-06-11 June 2014 Page 10 of 61

In the event of any conflict between the technical requirements of relevant documents, the order of
precedence shall be:

• This specification.

• The data sheets and/or drawings.

• Other relevant documents.

6 REQUIREMENTS FOR DESIGN

6.1 GENERAL

The design shall comply with the requirements of AA SPEC 114001, as amended by this specification.

6.2 ALTERNATIVE DESIGNS

This specification defines the minimum prescribed standards. Alternative designs that represent an
improved or equivalent standard may be proposed and presented to the Principal Civil & Structural Engineer,
Group Engineering for approval. Alternative designs may only be used after they have been approved in
writing.

6.3 M ATERIALS

All materials used shall comply with the requirements below. All materials shall be clearly specified on the
Design Drawings.

6.3.1 Condition of Material

All material shall be new.

Pitting or rusting of steel surfaces shall not be more severe than grade C of ISO 8501 unless otherwise
agreed by the Design Engineer.

AA_SPEC_114005 2014-06-11 June 2014 Page 11 of 61

6.3.2 Structural Carbon Steel

(a) Steel sections

All materials shall be graded hot formed steel, complying with the relevant GWS, with guaranteed yield
strength not less than 350 MPa. No commercial quality or ungraded steel shall be used. Surface defects
shall not exceed the extent allowed by the relevant GWS.

(b) Bolts

Steel bolts for use in structural bolt connections shall comply with the requirements of AA SPEC 114001.

Bolts for attachment of stair treads and guardrail standards shall have a diameter of not less than 16 mm and
shall be graded as a minimum class 4.8 structural bolts.

Bolts for clips and attachment of flooring and toeboards shall have a diameter of not less than 8 mm and
shall be graded standard strength structural bolts.

6.3.3 Stainless Steel

(a) Material

General stainless steel materials used for flooring, stairs, ladders and guardrails shall:

• Be either Grade 304 or Grade 316

• Have a guaranteed minimum yield stress in the annealed condition of not less than 200 MPa

• Have a guaranteed minimum yield stress, achieved by cold working before manufacture, of not less
than 220 MPa and not more than half the minimum tensile strength

(b) General sections, tubes and plate

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

• Stainless steel tubing, plate and strip shall conform to the requirements of the relevant STS.

The dimensions of stainless steel fasteners shall comply with an approved national or international standard.

AA_SPEC_114005 2014-06-11 June 2014 Page 12 of 61

(d) Surface finish

Stainless steel surface finishes shall not be less than a 2D finish.

6.3.4 3CR12

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

• AA SPEC 114002 – Appendix B (3CR12)

6.3.5 Welding Consumables

Welding consumables shall produce weld metal, which when tested in accordance with the applicable
method given in AWS D1.1, has a minimum yield stress and minimum tensile strength at least equal to that
of the parent metal.

6.3.6 FRP

(a) Construction

Grating should be of a moulded construction with the roving of the bearing bars and transverse bars
interwoven to ensure maximum strength of construction. The resin rich outer surface of the grating shall be a
minimum of 0,25 mm thick. Any drilled hole or cutting area shall be resin sealed to a minimum thickness of
0,25 mm.

(b) Resin Content and Ultraviolet Absorber

FRP grating shall be constructed by thoroughly wetting out fibreglass roving with a suitable synthetic resin,
and shall have a resin content of between 60 - 70%. All grating shall be manufactured with an ultraviolet
absorber.

(c) Fire Resistance

All grating shall be fire retardant, and shall be non-combustible at a temperature of not less than 750 °C. All
grating shall maintain its full strength for a period of not less than 2 hours in a fire with a temperature
following the standard time temperature curve as defined in ISO 834.

AA_SPEC_114005 2014-06-11 June 2014 Page 13 of 61

(d) Approval

The Mine Engineer shall approve the proposed resin system before use.

(e) Use and application

The use of all FRP products is prohibited on all Anglo American Thermal Coal operations.

6.3.7 Specific Material and Corrosion Protection Applications

The specific materials and corrosion protection systems listed in Table 6.1 shall be used in different areas of
plants and mines.

Table 6.1: Specific Materials

Description Hand rails Floor grating

Knee rails Stair treads
Stanchions

General dry areas. Structural carbon steel. Structural carbon steel hot dip
galvanised, or painted in
Crushing and screening. Hollow sections to be hot dip accordance with AA CPS
galvanised. 000124.
Conveyor gantries.
Headgears.
Well ventilated, dry underground
areas.

Wet plant area with no acid Structural carbon steel hot dip Structural carbon steel hot dip
present. galvanised. galvanised.

Poorly ventilated, or wet Structural carbon steel hot dip Structural carbon steel hot dip
underground areas galvanised. galvanised or 3CR12.

High temperature furnace area. Structural carbon steel. Structural carbon steel hot dip
galvanised.

Converter area. Structural carbon steel. Structural carbon steel glass

flake/epoxy (dipped).

Flash drier area. 304 SS 304 SS or 3CR12

Wet or dry areas where sulphurous 304 SS or 316 SS 304 SS or 316 SS

(SO3/SO2) fumes or dust is present.

Areas where sulphuric acid (H2SO4) 304 or 316 SS FRP

is present.

AA_SPEC_114005 2014-06-11 June 2014 Page 14 of 61

Description Hand rails Floor grating

Knee rails Stair treads
Stanchions

Wet or dry plant areas where FRP sections or 3CR12 FRP or structural carbon steel
chloride liquid, fumes or dust is glass flake/epoxy (dipped).
present.

Special requirements for all Anglo Use hot dip galvanised angular
American Thermal Coal operations sections, with the exception of
poorly ventilated, or wet
underground areas, where the
hot dip galvanising is replaced
with an appropriate corrosion
protection system.

Note: Where no paint or other corrosion protection system is specified for structural carbon steel, the same
paint system as used for the surrounding structural steelwork shall be used.

Painting and protective coating shall be in accordance with AA CPS 000124.

Hot dip galvanising shall be in accordance with ISO 1461. For particularly corrosive environments it is
recommended that the flooring panels be hot dip galvanised to ISO 1461 followed by hot dipping in black
bitumen in accordance with an agreed procedure.

Nuts, bolts, washers and screw threads shall be protected with a suitable corrosion inhibitor.

Where a glass flake/epoxy coating is required, this shall be a coating approved for use in a chloride
environment (for example “Vitaglass/VPB747-ST”). The grating and stair treads shall be coated by dipping
to a thickness of 150 to 300 microns. Hand rails and guardrail standards can be hand painted or spray
painted to a thickness of 150 to 300 microns. Group Engineering (M&T) shall approve the coating system
before use.

6.4 LOADS

6.4.1 General

The minimum imposed floor and stair loads defined by SLO, as modified and supplemented by the Anglo
American Specification AA SPEC 114001, shall be used for surface structures, and general underground
structures.

The minimum imposed floor load defined by DLS shall be used for shaft structures.

AA_SPEC_114005 2014-06-11 June 2014 Page 15 of 61

6.4.2 Storage and Maintenance Loads

Where it is intended that any spares or equipment are to be stored on steel or FRP flooring, or placed on
steel or FRP flooring during maintenance, the steel or FRP flooring and its supports shall be specifically
designed for this purpose. Any area designed for storage purposes or load carrying during maintenance
shall be specifically and clearly marked with the design load.

6.5 DESIGN DRAWINGS

Design drawings shall comply with the requirements of AA SPEC 114001.

In addition, the design drawings shall provide the following information:

• The span direction of all floor grating

• The size and location of any load bearing toeboards

• All cut-outs greater than 150 mm x 80 mm

• Guardrail locations, section sizes, material and maximum standard spacing

6.6 LAYOUT OF FLOOR GRATING

6.6.1 Modular Design

The components shall be designed in such a manner as to facilitate modular manufacturing.

6.6.2 Type of Grating

Open grid grating made of steel or FRP may be used in any appropriate application.

Expanded metal grating shall not be used, except on access walkways, where the walkway width does not
exceed 750 mm, and the applied load does not exceed 2,5 kPa.

Important note: From the scope definition (clause 1), the use of cat ladders, FRP products and expanded
metal flooring is prohibited on all Anglo American Thermal Coal operations.

6.6.3 Span of Grating

Walkway grating shall be supported along both ends. The maximum span of walkway grating shall be based
on the Supplier’s recommendations, usually contained in a table in their catalogues. The Supplier’s
recommended maximum safe span shall not be exceeded.

AA_SPEC_114005 2014-06-11 June 2014 Page 16 of 61

Walkway grating panels may extend over more than one span, up to a maximum of three spans, to improve
load distribution and deflection performance.

Where it is necessary to cantilever grating, the length of the cantilever shall not exceed 10 % of the tieback
length or 100 mm, whichever is the lesser. The Design Engineer shall provide design calculations
demonstrating the adequacy of the selected grating strength for this cantilever portion, taking cognizance of
possible buckling of the bearer bars.

6.6.4 Seating of Grating

The seating of grating on supporting steelwork shall not be less than 50 mm. Where a beam supports two
adjacent floor grating panels, but its flange is less than 100 mm wide, a detail shall be derived to ensure
compliance with this requirement. In the case of panels supported on channels, a ledge seating angle may
be necessary.

The entire width of both ends of all steel floor grating panels shall be supported on beams, except that small
openings are permitted where the size of the opening does not exceed:

• Openings not exceeding 100 mm long and 50 mm wide. These openings shall have banding
around the edges of the opening.

• Openings not exceeding 500 mm long and 100 mm wide. These openings shall have load bearing
toeboards around the edges of the opening.

• Gap in the support beam not exceeding 1000 mm in width, or half the width of the panel. The steel
floor grating panels over these gaps shall have a load bearing toeboard along the edge.

The entire width of both ends of all FRP floor grating panels shall be supported on beams, except that small
gaps not exceeding 100 mm in width are permitted in the beams, provided that there is not more than one
gap along any one side of a panel.

6.6.5 Floor Panel Clearance

To facilitate erection, clearances shall be allowed around floor grating panels as follows:

• 10,0 mm between adjacent floor panel sections

• 10,0 mm between the edge of the flooring panel and any adjacent structure

AA_SPEC_114005 2014-06-11 June 2014 Page 17 of 61

6.6.6 Toeboards

(a) General

Toeboards shall not be less than 130 mm high x 8 mm thick.

Toeboards shall be provided at all open edges of flooring including stair wells and equipment openings.

Toeboards shall project a minimum height of 100mm above the flooring.

(b) Load bearing toeboards

Load bearing toeboards shall only be used where all of the following conditions are met:

• A straight load bearing toeboard shall not exceed 1000 mm in width.

• A cranked load bearing toeboard shall not exceed 500 mm in width by 100 mm offset.

• No more than one section of load bearing toeboard shall be used on any one flooring panel.

• The load bearing toeboard shall have a ratio of depth to thickness which does not exceed 200/√f y,
where fy is the yield strength of the steel used.

The Design Engineer shall provide design calculations demonstrating the adequacy of load bearing
toeboards.

6.6.7 Bar Spacing and Size

(a) Steel floors

• Bearer bar centres shall not exceed 50 mm

• Transverse bar centres shall not exceed 100mm

• The depth of bearer bars shall not be less than 30 mm

• The thickness of bearer bars shall not be less than 4,5 mm

• The diameter of transverse bars shall not be less than 8,0 mm

(b) FRP floors

• Bearer bars and transverse bars are typically the same size

• Bearer bar centres shall not exceed 40 mm

AA_SPEC_114005 2014-06-11 June 2014 Page 18 of 61

• Transverse bar centres shall not exceed 100 mm

• The depth of bars shall not be less than 30 mm

• The thickness of bars shall not be less than 4,5 mm

6.6.8 Walking surfaces to be Non-Slip

All grating shall have a non-slip walking surface, preferably utilizing either serrated or pinched bearer-bar
profiles for steel grating, and meniscus top for FRP grating.

All stair treads shall be equipped standard with fabricated non-slip nosing.

The Purchaser shall approve the non-slip finishes at tender stage.

6.6.9 Inclined Walkways

The slope of inclined walkways, along conveyor gantries or where inclination of the walkway is required for
any reason shall not exceed 20°. Where the inclination exceeds 10°, full width square bars (or full width
stepping laths) shall be fixed across the surface, or some other means shall be used in addition to the non-
slip surface to prevent slipping. A concession is given for Anglo American Thermal Coal operations to
increase the abovementioned 10o to 13o.

On all inclined walkways specific positive provision shall be made to permanently secure panels against
sliding down the walkway.

6.6.10 Lateral Location of Grating

All grating shall where possible be designed to be located between guardrail standards or toeboards, or
seated into a recess to prevent lateral movement. Where this is not possible, the use of temporary “locating
pins” during installation is required.

6.7 LAYOUT OF FLOOR PLATING

6.7.1 Modular Design

The floor plating shall be designed in such a manner as to facilitate modular manufacture.

AA_SPEC_114005 2014-06-11 June 2014 Page 19 of 61

6.7.2 Span of Plating

The maximum span of floor plating shall be based on calculations in accordance with LSD. The deflection of
floor plating shall not exceed span/100.

Walkway floor plates may extend over more than one span, up to a maximum of three spans, to improve
load distribution and deflection performance.

Where it is necessary to cantilever floor plating, the length of the cantilever shall not exceed 10 % of the
tieback length or 50 mm, whichever is the lesser.

6.7.3 Seating of Plating

Seating of plating on supporting steelwork shall not be less than 25 mm where plating is welded to support
beams, and sufficient to allow an edge distance of not less than 1,5 times the bolt diameter where plating is
bolted to support beams.

The entire width of both ends of all steel floor plating panels shall be supported on beams, except that small
openings are permitted where the size of the openings does not exceed:

(a) Openings not exceeding 25 mm long and not exceeding the length of the support beam.

(b) Openings not exceeding 300 mm long and 50 mm wide. These openings shall have load bearing
toeboards around the edges of the opening.

(c) Gap in the support beam not exceeding 1000 mm in width, or half the width of the panel. The steel
floor plating panels over these gaps shall have a load bearing toeboard along the end.

There shall not be more than one gap along any one side of a panel.

6.7.4 Flooring Clearance

To facilitate erection, clearances shall be allowed around floor plating panels as follows:

• 5,0 mm between adjacent floor panel sections

• 5,0 mm between the edge of the flooring panel and any adjacent structure

6.7.5 Load-bearing Toeboards

Load bearing toeboards shall be as required for floor grating (see 6.6.6).

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6.7.6 Walking surfaces to be Non-Slip

All floor plating shall be vastrap plating to provide a non-slip surface.

All stair treads shall be equipped standard with fabricated non-slip nosing.

The Purchaser shall approve the non-slip finishes at tender stage.

6.7.7 Inclined Walkways

The slope of inclined walkways, along conveyor gantries or where inclination of the walkway is required for
any reason shall not exceed 10°.

On all inclined walkways specific positive provision shall be made to permanently secure plate panels
against sliding down the walkway, and against sliding over one another.

6.8 OPENINGS IN FLOORING

The following specific details shall be implemented for all steel and FRP flooring.

(a) Large cut-outs or openings with dimensions greater than 500 mm x 200 mm shall be protected by:

• Either providing guardrails all around the cut-out or opening or

• Providing a removable cover which is designed to carry the same load as the surrounding floor

(b) Where a cover is constructed of the same steel or FRP flooring as the surrounding floor, the
removable panel shall be colour coded in a high visibility colour. The edge of the floor grating
around the removable panel shall also be colour coded in a high visibility colour.

(d) Banding shall be provided around all cut-outs which do not have toeboards.

The following specific details are recommended for all steel and FRP flooring.

(a) Any cut-out smaller than 150 mm across should be square or rectangular rather than circular.

(b) Circular panels should have load bearing toeboards along unsupported curves. These load bearing
toeboards should not exceed 1000 mm in length. The overhang of curved panels should not exceed
10 % of the tieback span, or 100 mm, whichever is the lesser.

(c) Where the distance from the edge of any cut-out to the edge of the flooring panel is less than 100
mm or half the size of the cut-out, the cut-out should extend right to the edge of the panel.

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(d) Where panels or cut-outs are alongside concrete columns or walls, a gap of at least 20 mm should
be left to allow for tolerance on the concrete construction.

(e) Where panels have cut-outs to allow for steel columns or bracing, adequate allowance should be
made for the projections of bolts beyond the steel face.

(f) The distance between two adjacent cut-outs should not be less than 250 mm. Where cut-outs are
required closer together, they shall be combined into a single cut-out.

6.9 LAYOUT OF GUARDRAILS

All Guardrails shall consist of a hand rail, a knee rail, and a toeboard or bund wall. Recommended structural
sections are listed in Table 6.2.

6.9.1 Guardrail Sections

The guardrail sections shown in Table 6.2 shall be used as minimum sizes for all guardrails. The sections
used for hand rails shall not exceed 75 mm diameter for round sections, or 80 mm leg length for angle
sections. The adequacy of all guardrail sections shall be checked by the Supplier, or a Structural Engineer,
taking cognizance of the applied loads and material grade.

Table 6.2: Recommended Minimum Sections for Steel Guardrails

Description Guardrail Hand rail Knee rail Toeboard

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Description Guardrail Hand rail Knee rail Toeboard

Poorly ventilated or wet

underground areas. 60 x 60 x 6 L 50 x 50 x 5 L 50 x 5 F
or or
Wet or dry plant areas where
chloride liquid, fumes or dust is 25  Round 25  Round
present.

3 Flash drier area. 38  x 1.6 HCS 32  x 1.6 32  x 1.6 130 (to 150)
HCS HCS x8F
Wet or dry areas where
sulphurous (SO3/SO2) fumes or
dust is present.
Areas where sulphuric acid
(H2SO4) is present.

4 Special requirements for all 60 x 60 x 6 L 50 x 50 x 5 L 50 x 5 F 130 (to 150)

Anglo American Thermal Coal x8F
operations. Standard drawings
are available from the Anglo
American Thermal Coal Principal
Mechanical and Structural
Engineer.

Notes:

1. All sizes and dimensions indicated depict the minimum acceptable size.

2. Use of Category 1 sections is not permitted on any Anglo Thermal Coal site.

6.9.2 Guardrail Dimensions

The following dimensions should be used for all guardrails:

• The top of hand rails around horizontal platforms should be not less than 1000 mm (this is
increased to 1100 mm for all Anglo American Thermal Coal operations) and not more than 1150
mm above the top of steel level. The top of hand rails on stairs should be not less than 850 mm
and not more than 950 mm above the sighting edge of the stairs. Where the maximum
recommended heights are exceeded for any reason, the adequacy of the guardrail standard
sections in Table 6.2 shall be checked by the Supplier or a Structural Engineer.

• The top of knee rails around horizontal platforms should be 500 mm above the top of steel level.
The top of knee rails on stairs should be 500 mm above the sighting edge of the stairs.

• Toeboards around horizontal platforms should protrude a minimum of 100 mm above the top of
floor grating or floor plating.
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6.9.3 Hand rails

Wherever possible, hand rails should be continuous. Hand rails on stairs shall be continuous.

Hand rails should not have any obstruction on, above or near them that might obstruct movement of a hand
along the hand rail.

The recommended clearance between a hand rail and any wall or other obstruction behind or below it is 65
mm.

Where angle hand rail sections are used, the horizontal leg shall project outwards.

6.9.4 Guardrail standards

Guardrail standards shall be attached to structural steel or structural concrete, and not to toeboards. All
standards shall be bolted to steelwork or concrete kerbs using bolts not smaller than M16.

6.9.5 Other Requirements

Wherever possible, flooring should be located between hand guardrail standards, columns, or toeboards
attached to the supporting structures, so that in the event of fastening clips loosening the flooring cannot slip
outwards over the end or the edge of supporting structures.

Guardrails shall be at the edge of, or within, the extent of the walking surface. No Guardrails shall be outside
of the walking surface for any reason whatsoever.

Toeboards and bund walls shall be provided around the entire outer perimeter of floors, except at stairs.
Toeboards and bund walls shall be provided around all cut-outs of floors.

Wherever possible, off-set or gooseneck guardrail stanchions are to be avoided for safety reasons.

6.10 LAYOUT OF STAIRS AND LADDERS c

g
b

6.10.1 Stairs

Stairs shall have an angle of inclination, α, of not less than 22° and not
h
more than 45°.

The step rise, h, shall be not less than 180 mm and not more than 220 α
mm. The step rise shall remain constant throughout the length of any
one flight of stairs.

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The tread length shall be a minimum of 750 mm.

The going of any tread, g, shall be a minimum of 250 mm.

The horizontal overlap between any two consecutive steps, c, shall be not less than 25 mm and not more
than 50 mm.

The maximum height of any stair between landings shall not exceed 3 m.

The minimum headroom above stairs shall not be less than 2,1 m.

6.10.2 Stair Treads

A rectangular pattern bar grating with bearer bars running across the length of the stair, and with an abrasive
nosing and side plates shall be provided.

All stair treads shall be drilled for bolting to the stair stringers using a minimum of 4 Class 4.8 M16 bolts with
self-locking nuts.

Side plates shall have a minimum thickness of 4,5 mm and shall be welded to the ends of all the bearer bars
with a continuous 4 mm fillet weld on both sides.

6.10.3 Inclined Steel Ladders

Inclined Steel Ladders shall have an angle of inclination, α, of not less than 65° and not more than 75°.

The step rise, h, shall be not less than 230 mm and not more than 260 mm. The step spacing shall remain
constant throughout the length of any one ladder.

The step length shall be a minimum of 450 mm.

The step depth, b, shall be a minimum of 80 mm.

The maximum length of any ladder between landings should preferably be not exceed 3,0 m, but shall not
exceed 5,0 m.

Inclined ladders shall have a single hand rail on each side, at a vertical height above the nosing of not less
than 400 mm and not more than 600 mm.

6.10.4 Guardrails and Handrails on Stairs and Inclined Ladders

Any stair or inclined ladder which has a height exceeding 750 mm, or from which any person could fall more
than 750 mm, shall have barricading (i.e. a wall or guardrails) on both sides.

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All stairs and inclined ladders shall have hand rails along both sides, either as the top rail of guardrails, or
attached to the wall.

6.10.5 Vertical Steel Ladders

The step spacing, h, shall be not less than 230 mm and not more than 255
mm. The step spacing shall remain constant throughout the length of any
one ladder.

The step length shall be a minimum of 450 mm.

Round steps shall be used. The step diameter shall be not less than 20 mm
h
and not more than 50 mm.

The maximum length of any ladder between landings should preferably be b

not more than 3,0 m, but shall not exceed 6,0 m.

Any vertical ladder which has a height of more than 4,0 m shall have a safety
cage, extending from 2,5 m above the lower end of the ladder to at least 1,0 α
m above the floor or landing at the top of the ladder.

6.10.6 Landings

The length of landings shall be not less than the length of the stair tread, or the diameter of the ladder cage.

The width of landings shall be not less than 900 mm.

6.11 USE OF STAIRS OR LADDERS

Where access between higher and lower levels is required, it is recommended that stairs should be provided
in preference to ladders wherever possible.

Stairs shall be provided, and ladders shall not be used, under the following conditions:

• The use of cat ladders is prohibited on all Anglo American Thermal Coal operations

• Where a risk assessment shows the use of ladders to be unsafe for any reason

• Where emergency egress for more than 3 people is required

• Where daily access for more than 10 people is required

• Where any injured persons may have to be evacuated

• Where heavy, or large, tools or toolboxes must be carried

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6.12 ROOF ACCESS AND EDGE PROTECTION

Where maintenance is required on any roof, access shall be provided. All platforms, walkways and stairs on
roofs shall comply in all respects with the requirements of this specification.

Guardrails shall be installed along the edges of all platforms, walkways and stairs on roofs where any of the
following applies:

• Where the roof has a slope exceeding 15º guardrails shall be installed along the down slope edge

• Where any edge is less than 2,0 m from the edge of the roof guardrails shall be installed along that
edge

• As a rule, the use of translucent or brittle cladding is limited to vertical applications only. However,
where translucent or brittle roof cladding exists and until it is replaced, guardrails shall be installed
along all edges to avoid access to such sheeting.

• Where gutters are accessible and may be used as walkways guardrails shall be installed along the
outer edge of the gutters

7 REQUIREMENTS FOR FABRICATION AND SUPPLY

7.1 M ATERIALS

The Supplier shall ensure that all material used in the fabrication of steel or FRP flooring and walkways,
stairs and handrails complies with the requirements of this specification and is as specified on the relevant
design drawings. Materials conforming to standards other than those covered by this specification shall be
tested in order to demonstrate their conformance to the relevant standards specified herein, and their use
shall be approved in writing by the Design Engineer.

Additional costs incurred in obtaining approval and using approved substitutions shall be borne by the
Supplier.

7.2 COMPLIANCE WITH DESIGN DRAWINGS

All work shall comply in all respects with the design drawings. If the Supplier requires clarification of any
information on the design drawings, such clarification shall be obtained from the Design Engineer.

If the Supplier has good reason to modify or change any part of the work specified on the design drawings,
this shall be agreed with the Design Engineer, who shall revise the design drawings accordingly, and issue
the revised drawings for fabrication.
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7.3 MODULAR DESIGN

The components shall be manufactured on a modular basis and shall utilise readily available standard sub-
components where possible to facilitate the procurement of spares and replacement parts for maintenance
purposes and to facilitate inter-changeability.

The Supplier shall prepare modular layout drawings which shall be submitted to the Project Engineer for
approval. The Project Engineer shall review and approve the modular design and layout prior to the
commencement of fabrication to ensure it complements the design intent. Such approval shall be defined as
a “Hold” point in the fabrication Quality Control Plan.

7.4 CONSTRUCTION DETAILS

7.4.1 Banding Bars

All steel or FRP grating panels shall be banded around the entire perimeter, except where:

• Toeboards are fixed to the grating panel

• The bearer bar forms the banding bar

• Specified otherwise by the Purchaser

Banding bars shall be 10 mm shallower than the bearer bars. All banding bars shall be flush with the top of
the grating panel, allowing a 10 mm gap below for drainage of water or spillage.

7.4.2 Welding of Bars in Steel Grating

Welding of bars in steel grating panels shall comply with the requirements listed in Table 7.1.

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Table 7.1: Welding of bars

Description Welding Required

Transverse bars to Bearer bars to Bearer bars to

bearer bars and banding or load bearing
banding or toeboards toeboards
toeboards

General dry areas. Weld one bar in Weld one bar in Weld all bars.
three. three.
Crushing and screening. 5 mm continuous
3 mm continuous 3 mm continuous fillet weld on both
Conveyor gantries.
fillet weld all round. fillet weld on one sides.
Headgears. side only.
Well ventilated, dry underground areas.

Wet plant area with no acid present. Weld all bars. Weld all bars. Weld all bars.

High temperature furnace area. 3 mm continuous 3 mm continuous 5 mm continuous

fillet weld all round. fillet weld all round. fillet weld all round.
Converter area.

Poorly ventilated or wet underground

areas.

Wet or dry plant areas where chloride

liquid, fumes or dust is present.

Flash drier area. Weld one bar in Weld one bar in Weld all bars.
three. three.
Wet or dry areas where sulphurous 5 mm continuous
(SO3/SO2) fumes or dust is present. 3 mm continuous 3 mm continuous fillet weld on both
fillet weld all round. fillet weld on one sides.
Areas where sulphuric acid (H2SO4) is
side only.
present.

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7.5 WELDING

7.5.1 General

All welding shall comply with the design drawings, and be done in accordance with the requirements of AWS
D1.1

7.5.2 Welding Consumables

All welding consumables shall comply with the requirements of SSC.

7.5.3 Qualification of Welders

All welders shall be suitably qualified and coded to the requirements of AWS D1.1.

7.6 PAINTING AND PROTECTIVE COATING

7.6.1 Protective Coating to be Applied

Painting and protective coating shall be in accordance with the design drawings or Section 6.3 of this
specification.

7.6.2 Repair of Corrosion Protection

(a) Paint Systems

Paint systems shall be made good by wire brushing of the affected area to remove any loose material and
hand painting with the specified paint system.

(b) Hot Dip Galvanising

Should any shaping of the panel be carried out after hot dip galvanising, the appropriate area shall be made
good in accordance with AA CPS 41A.

If the panel also had a coat of bitumen before shaping, the repair procedure of AA CPS 41A shall be followed
by one coat of bitumen.

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7.7 CERTIFICATION

All materials used shall be traceable.

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

7.8 TOLERANCES

All tolerances shall be measured after completion of manufacture (including galvanising or painting and
banding where appropriate) of steel and FRP flooring, stairs and guardrails.

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7.8.1 Floor Grating Tolerances

Table 7.2: Floor Grating and Stair Tread Tolerances

Description Steel Grating FRP Grating

Overall panel length ± 5,0 mm ± 5,0 mm

Overall panel width ± 5,0 mm ± 5,0 mm

Overall panel squareness ± 5,0 mm ± 5,0 mm

Stair tread length ± 2,0 mm ± 2,0 mm

Stair tread width ± 5,0 mm ± 5,0 mm

Cut-out size (width and length) ± 5,0 mm ± 5,0 mm

Panel camber (upward or downward bow) before Lesser of: Lesser of:
fixing
± 10,0 mm ± 10,0 mm
Width/200 Width/200
Length/200 Length/200

Panel curve (lateral bow) before fixing Lesser of: Lesser of:
± 5,0 mm ± 5,0 mm
Width/200 Width/200
Length/200 Length/200

Bearer bar and banding depth Lesser of: Lesser of:

± 1,0 mm ± 1,0 mm
2 % of depth 2 % of depth

Bearer bar and banding thickness ± 0,3 mm ± 0,3 mm

Bearer bar and banding twist ± 4° ± 4°

Bearer bar spacing Lesser of: ± 2,0 mm

± 2,0 mm
4 % of nominal spacing

Transverse bar spacing ± 3,0 mm ± 2,0 mm

Transverse bar size ± 0,5 mm As bearer bar

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7.8.2 Guardrail Tolerances

All guardrail components shall be manufactured to the tolerances for structural steelwork specified by SSC.

7.8.3 Stair Tolerances

All stairs shall comply with the tolerances for structural steelwork specified by SSC.

7.9 TEST AND INSPECTION METHODS

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

7.10 PACKING AND M ARKING

7.10.1 Packaging

Packing shall be such as to ensure adequate protection in transit and to prevent deterioration for a period of
two months after delivery to site. Packing shall be on the basis that the there will be no additional protection
from transport damage or from the site environment during that period.

Any damage as a result of inadequate packaging and marking shall be for the Supplier’s account.

Each consignment shall include a complete packing list identifying each loose item, component or part and
shall reference the relevant order number and equipment number.

7.10.2 Marking

(a) Marking drawings

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

(b) Item marking

Each item shall be clearly marked in accordance with the requirements of the design drawings.

Where necessary, match marking shall be used to facilitate site assembly.

Marking shall include:

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• Identifying number or mark

• Manufacturer's name or logo

• Batch number or date of manufacture

Grating panels shall be marked on the banding or toeboards, or on metal tags. Hand rails, knee rails and
standards shall be marked on metal tags. All metal tags shall be securely fastened with wire.

7.11 PERFORMANCE AND GUARANTEE

The performance of the items supplied in terms of this specification, as defined by the order, shall be
warranted by the Supplier and, if specified, be tested in accordance therewith.

The Supplier shall warrant that the goods supplied will perform for the purpose for which they are intended.

The Supplier shall not be required to conduct a performance test on site.

A minimum guarantee period of 12 months is required.

8 REQUIREMENTS FOR INSTALLATION

8.1 SAFETY

Installation of steel and FRP flooring, stairs and guardrails requires that workers work at heights. All work
shall be done in compliance with the AA GTS 07 “AFRS Working at Heights”.

Installation shall be done by workers who are secured to steelwork or a lifeline system via a full fall restraint
system. Full fall restraint shall be used by all workers on the flooring, until it has been inspected and
approved for use.

The work area shall be closed off to all other Contractors and site personnel until it has been inspected and
approved for use.

The area beneath the working area shall be barricaded or demarcated to prevent access.

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8.2 INSTALLATION PROCEDURE

8.2.1 Method Statement

The Contractor shall prepare an installation method statement giving details of the proposed installation
method to ensure that nothing about the manner in which it is to be installed makes it unsafe, or creates a
risk to health and safety. The installation procedure shall also be such as to ensure that components are not
damaged in any way. Such method statement shall be issued to the Project Engineer for information and
acceptance prior to the commencement of installation and shall form part of the Contractors Risk
Assessment for the execution of the works.

8.2.2 Inspection and Acceptance

The Contractor shall inspect and accept the structures for access to commence installation. Discrepancies
shall be made known to the Project Engineer in writing prior to commencement of installation. The Project
Engineer shall be notified of any further faults in the work area, which are revealed during the installation of
flooring, stairs or guardrails in the area.

8.2.3 Installation of flooring

Locating pins, or some other means of holding loose panels in position, shall be progressively installed
during placement of panels, to avoid individual panels or assemblies of panels sliding off the supporting
steelwork. These may only be removed after the proper alignment and fixing of flooring panels in
accordance with an approved fixing method hereafter.

Temporary location of flooring panels on inclined floors shall be subject to specific risk assessment, to
ensure they do not slip or fall off.

Each part of the flooring shall be aligned and fixed as soon as it is practicably possible. Members shall not be
permanently fastened until enough of the flooring has been aligned and temporarily connected to ensure that
they will not be displaced during the placement or alignment of the remainder of the floor. Modular group
installations shall be restricted to the area that temporary locating devices have been provided for. Should
the secured panels require removal, a new risk assessment shall be done to suit.

All workers installing flooring shall use fall arrest systems.

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8.2.4 Installation of Stairs

Stairs should be installed from the ground level, working upward.

All stair treads should be properly fastened as soon as they are installed.

All workers installing stairs shall use fall arrest systems.

8.2.5 Installation of Guardrails

The installation procedures recommended by the Suppliers should be followed.

All guardrails should be installed as soon as possible after installation of flooring and stairs. All guardrails
should be properly and securely fastened as soon as possible after they have been located in position.

All workers installing guardrails shall use fall arrest systems.

8.3 FASTENING OF FLOORING, STAIRS AND GUARDRAILS

8.3.1 Location of Fasteners

Panels shall be securely fastened to the supporting structure at each corner, or as close as possible to each
corner.

A minimum of four fasteners shall be used per panel. Where large panels are used, additional fasteners
shall be utilised to secure the panels at intervals not exceeding 1,5 m along each end and edge.

Where any floor vibration is present, the preferred method of fastening steel grating or plating is welding.

8.3.2 Floor Grating Fasteners

(a) Top fixing of fasteners

Fasteners should be of a type that can be inserted and fastened from above. Where access below grating is
required to insert or fasten any fasteners, a specific risk assessment shall be conducted to address how this
will be accomplished safely.

(b) Non-loosening fasteners

Fasteners shall be of a type that will not loosen with use of the floor. Nuts shall be non-loosening type.

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(c) Fasteners to be flush with floor

Fasteners shall be of a type that is flush with the floor surface, or is set below the floor surface. Fasteners
shall not protrude above the floor surface by more than 2 mm. Bolts for floor plating shall have countersunk
heads.

(d) Specific recommended fasteners

Two-bolt continuity clips must be used where needed to avoid relative deflection and tripping hazards. The
Vital Vitaclamp, Saddle clamp with 8 mm diameter bolt (or similar clamping arrangement) is recommended.

(e) Proprietary bolt and clamp or clip systems

The Supplier of any proprietary fastening system shall provide a written performance guarantee for use of
the fastening system in the specific environment in which it is to be used. The description of the specific
environment shall include at least the following:

• whether there is any vibration of the floor

• corrosive chemicals to which the floor may be exposed

• exposure to washing or process water

• whether there is exposure to direct sunlight

• duty usage of the floor

• whether the floor is flat or inclined, in which case the angle of inclination shall be included

(f) Bolts

Securing bolts shall not be smaller than 8mm diameter, and shall use locking nuts or a double-nut
arrangement for locking.

(g) Materials

The bolt and saddle clamp materials shall be selected to complement the grating material specified in order
to avoid bi-metallic corrosion. Where steel or stainless steel grating is used, fasteners shall be of the same
material, and shall have the same corrosion protection system.

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8.3.3 Floor Grating Welding

Field welding shall only be performed where specified by the Design Engineer or on approval by written
consent from the Business Unit Principal Engineer responsible for the Structural discipline.

The location of welds shall comply with the Location of Fasteners in Section 8.3.1.

The size of welds shall be:

• 5mm fillet weld

• Minimum length to be 25 mm

Galvanized steel:

Suitable welding consumables must be used.

Inspection of welds shall include:

• The fastening welds of the first three floor panels fixed are to be 100% visually inspected and 100%
dye penetrant tested. If satisfactory, the welds on subsequent floor panels are to be 100% visually
inspected and 10% dye penetrant tested. If not satisfactory the welds on subsequent floor panels
shall be 100% visually inspected and 100% dye penetrant tested until satisfactory results are
achieved. Thereafter subsequent floor panels are to be 100% visually inspected and 10% dye
penetrant tested.

• The inspection standard for the above inspection shall be as per AWS D1.1 Table 8.1

Corrosion protection:

• All welds shall be corrosion protected after inspection. Care shall be taken to ensure that all
damaged paintwork on the grating as well as the supporting structural steelwork is corrosion
protected

• Where the grating is painted, the weld damaged areas shall be repaired using the same paint
system

• Where the grating is galvanised, remedial work is to be done, in compliance with AA CPS 41A

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Qualification of welders:

• All welding shall be carried out by suitably qualified welders coded to the minimum requirements of
AWS D1.1.

Where welding takes place there is to be good ventilation in the vicinity of the welding operation, where
possible suction tube gun nozzles, facemasks and respirators are to be used. Welders are to position
themselves so as not to be overexposed to the weld fumes. Note that zinc fumes are not toxic and the
symptoms of overexposure (fever, headaches) will disappear within a few hours.

8.3.4 Protection from Corrosion

(a) Bearing area

Except in the case of FRP grating, when the material of construction of the grating is different to the material
of construction of the supporting structure, the bearing area on the supporting structure should be covered
with a 3 mm thick Bitumen or Neoprene strip equal in length to that of the minimum bearing length. The strip
should be laid before the grating is installed.

(b) Anti-seize paste

All bolts and bolt holes (required for FRP grating installation) shall be coated with a Depac anti-seize paste
before assembly. Depac paste is a non metallic based paste and can be used on carbon steel and stainless
steel bolts and nuts up to a temperature of 14000C. The use of metallic based paste is not recommended
due to the associated health risk and relative low chemical resistance to acids.

8.4 INSTALLATION TOLERANCES

8.4.1 Maximum clearance

The clearance between adjacent flooring panels after erection shall not exceed 10,0 mm.

8.5 INSPECTION AND ACCEPTANCE

Prior to the barricading being removed and general access being allowed, the area shall be inspected by the
Project Engineer to ensure that the area is safe. This inspection shall cover at least the following:

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• All components (flooring, stairs and guardrails) shall be in place. All floor grating shall be spanning
in the correct direction.

• All components shall be properly fastened.

• Any openings shall be safe, i.e. they shall be properly covered, or guardrails or toeboards as
required shall be in place.

9 REQUIREMENTS FOR USE

9.1 SUPPORT OF EQUIPMENT

9.1.1 Equipment on Floors

No pipes resulting in a load greater than 0.3 kN/m or 2 kN point load or of diameter greater than 50 mm may
be laid across nor supported from any floor grating, floor plates or walkway grating, unless specifically
requested and approved in writing by a structural engineer.

Floor grating and floor plating shall not permanently support any form of heavy equipment. Light equipment,
cabinets or switchgear, with a mass not exceeding 500 kg on floor grating, and not exceeding 250 kg on floor
plating, may be supported providing the following precautions are taken:

• Each leg shall have a steel plate foot, at least 8 mm thick, and at least 150 mm x 150 mm in size.

• No cut-outs shall be made in the grating to accommodate the equipment.

• The equipment shall not have any vibrating or moving components.

Walkway grating shall not support any equipment of any kind, which weighs in access of 500 kg.

9.1.2 Equipment on Guardrails

No equipment having a mass exceeding 100 kg shall be supported on guardrails. Light equipment, with a
mass not exceeding 100 kg may be supported on guardrails, provided the following precautions are taken:

• The cumulative mass of several small items of equipment along one length of guardrail shall not
exceed 30 kg/m.

AA_SPEC_114005 2014-06-11 June 2014 Page 40 of 61

• The fixing of the equipment shall be such that, should a person run their hand along the hand rail,
no part of their hand or fingers can get stuck between the hand rail and the equipment.

• Any projection of the equipment in front of the guardrail shall be limited so that it does not cause
any obstruction to people moving along the floor area. No equipment whatsoever shall project in
front of any guardrail along the edge of an emergency escape route.

• Electrical cable racks are not permitted on guardrails for conveyor walkways.

9.1.3 Equipment on Stairs

No equipment of any kind shall be supported on stairs.

No equipment of any kind shall be supported on or attached to the guardrails on stairs.

9.2 STORAGE

Steel flooring shall not be used for the permanent storage of any spares or equipment, unless the area has
been specifically designed and marked for this purpose. Where it is necessary during maintenance for small
items of equipment to be temporarily placed on floor grating or floor plating, this shall be risk assessed giving
due cognizance to the design load for the specific floor. Where there is any doubt, a Structural Engineer
shall be consulted.

9.3 LIFTING

No attachments shall be made to any guardrail, flooring, or stair to hoist or lower any goods or heavy
equipment.

Guardrails may only support fibre or nylon ropes used for lifting hand tools and small equipment with a mass
not exceeding 20 kg.

No chain block, slings, or any other lifting equipment shall be attached to any walkway grating or stairs.

9.4 OPENINGS

9.4.1 Risk Assessment

When it is necessary to make any openings in any flooring, a risk assessment shall be carried out. The risk
assessment shall include the use of the floor after the opening has been made, as well as the process of
making and protecting the opening.

AA_SPEC_114005 2014-06-11 June 2014 Page 41 of 61

9.4.2 New Openings in Flooring

New openings shall not be made in flooring, unless all other options have been considered and shown to be
impractical or not feasible. Where it is necessary to make new openings in flooring, this shall be done in
compliance with the following requirements:

(a) Forming temporary openings

Where any new temporary opening is required for maintenance or any other purposes, only complete grating
panels shall be removed. Grating panels shall not be cut and repaired. Any grating panel temporarily
removed shall be marked, so that it can be replaced in exactly the same orientation as prior to its removal.

Immediately on completion of the work for which the grating panel was removed, the panel shall be replaced
and securely fastened.

(b) Support of floor panels

All floor grating panels or floor plates surrounding the new opening shall be supported as required for Design
in the section above. Where new floor support beams are required to provide adequate support around the
ends or edges of a new opening, these shall be specified by a Design Engineer.

(c) Protection of permanent openings

All new permanent openings shall be protected as required for Design in the section above.

(d) Protection of temporary openings

All temporary openings in the floor grating or floor plating panels, where the length does not exceed 1,0 m,
shall be closed-up using scaffolding planks which shall be securely attached to the surrounding steelwork.
No loads from any spares or equipment shall be placed on scaffolding plank covers.

All temporary openings in the floor grating or floor plating panels, where the length exceeds 1,0 m, shall be
closed-up using a cover specified by a Design Engineer which shall be securely attached to the surrounding
steelwork. This cover shall be designed to carry the same floor loads as the surrounding flooring.

Alternatively, the temporary opening shall be barricaded by means of guardrails.

AA_SPEC_114005 2014-06-11 June 2014 Page 42 of 61

(e) Precautions during installation work

Whilst work of making new openings is in progress, the precautions required for Installation in the section
above shall apply.

9.4.3 Closing of Existing Redundant Equipment Openings

Where openings have been left in floors due to equipment having been removed and not replaced, the
opening shall be protected as follows:

• Redundant openings should be closed using the same flooring as is used for the surrounding floor
areas. New floor support beams, the same size and at the same spacing as the surrounding floor
shall be installed to support the new flooring. A Design Engineer shall be consulted if there is any
doubt as to the size, spacing and end fastenings for the new beams. Layout and design of the new
flooring shall comply with the requirements of this specification for design, as listed in the section
above.

• Where the redundant opening is to remain open, the preferred method of protection is to place a
guardrail around the opening. This is the preferred method as it eliminates steps in flooring and
tripping hazards. This method shall be used wherever possible.

• Alternatively if the opening is to remain open, removable covers may be placed over the opening.
The covers shall be designed by a Design Engineer, and shall be designed to carry the loads for
which the surrounding floor areas are designed. This method shall only be used on openings
smaller than 1500mm square.

9.5 COVERING OF FLOOR

Instances have been encountered where flooring is covered by off-cuts of conveyor belting or steel plates.
The following shall be observed in respect of these floor coverings:

(a) Where off-cuts of conveyor belting or steel plates are used to provide a smooth working surface or to
prevent small objects such as bolts, nozzles, etc falling through the floor during maintenance, the
floor covering shall be removed as soon as the maintenance task has been completed.

(b) Where off-cuts of conveyor belting or steel plates are used to prevent spilled oil or dust to penetrate
the floor, the cause of the spilled oil of dust shall be rectified as soon as possible, and the floor
covering shall be removed as soon as this has been completed.

AA_SPEC_114005 2014-06-11 June 2014 Page 43 of 61

(c) Off-cuts of conveyor belting or steel plates shall not be used to cover holes. Any holes in the flooring
shall be protected as specified above.

(d) Off-cuts of conveyor belting or steel plates shall not be used to cover deteriorated portions of
flooring. Any deterioration in the flooring shall be repaired as specified in the Section “Requirements
for Maintenance and Repair”.

9.6 REINSTATEMENT FOLLOWING REMOVAL FOR M AINTENANCE

When any maintenance work has required the temporary removal of any steel or FRP floor panels, stair
components or guardrail components, the Designated Foreman shall carry out an inspection following
reinstatement of what was removed.

No workers other than those specifically required to perform the maintenance tasks shall use the floor until
the Designated Foreman has completed this inspection and declared the floor to be safe for use.

9.7 REGULAR INSPECTIONS

9.7.1 Inspection Intervals

All steel and FRP floors and walkways, stairways and guardrails shall be visually inspected at intervals not
exceeding the intervals defined in Table 9.1.

Table 9.1: Visual Inspection Intervals for Steel flooring, Stairs and Guardrails

Inspector Inspection Interval

Designated Foreman 6 months

Professional Structural Engineer 3 years

In addition, an inspection shall be carried out immediately following any significant event that affects the steel
or FRP flooring, stairs and guardrails. Examples of significant events include: vehicle impact leading to
structural damage; smelter runout; large item dropped on the flooring or stairs; accumulation of spillage
exceeding 0,5 m deep; or earthquake.

AA_SPEC_114005 2014-06-11 June 2014 Page 44 of 61

9.7.2 Inspection Requirements

A checklist shall be prepared and used for every inspection to ensure that all important items are covered.
Every inspection of steel and FRP flooring, stairs and guardrails shall include at least the items listed in

Table 9.2. A separate checklist should be completed for each different floor level or area.

Table 9.2: Items to be inspected

ITEM CHECKS TO BE DONE

All edges shall have guardrails.

Safety All holes shall be covered or protected by toeboards or guardrails as required.

Flooring shall be level without tripping hazards.

There shall not be loose hoses, spares, pipes, etc lying on floors or against guardrails.

Housekeeping There shall not be excessive spillage lying on flooring.

There shall not be heavy piping or other equipment supported on flooring.

Steel floor FRP floor Stair

Guardrails Floor plates Ladders
grating grating treads

Joints and fixings Check Check Check Check Check Check

Seating on beams N/A Check Check Check N/A N/A

Damage Check Check Check Check Check Check

Wear of surface N/A Check Check Check Check Check

Corrosion Check Check Check N/A Check Check

Nosing secure and

N/A Check Check Check Check N/A
visible

Ladder cage N/A N/A N/A N/A N/A Check

Spillage N/A Check Check Check N/A N/A

No cutting and
Check Check Check Check Check Check
modifications

AA_SPEC_114005 2014-06-11 June 2014 Page 45 of 61

9.7.3 Inspection Records

The results of all inspections shall be recorded and kept on file, either electronically or in hard copy form.

Inspection findings should be reported as described in AA BPG S03. As a minimum, the inspection findings
shall include problems identified, remedial work required, and the urgency of remedial work. The section
dealing with maintenance below provides guidance as to what remedial work is appropriate under different
conditions.

Where any remedial work is required following an inspection, the inspection record shall be signed off after
completion of the work, by the person allocated to do the work.

9.8 RETROFIT REQUIREMENTS FOR NON-COMPLIANT ITEMS

There are likely to be situations where existing steel or FRP flooring, stairs, ladders or guardrails do not
comply with this specification, either because the plant was constructed prior to approval of this specification,
or because the plant was purchased from an owner with a different specification.

All replacements shall comply with the requirements of this specification.

Where any items do not comply with this specification, the actions listed below should be implemented within
the time frame specified.

9.8.1 Non-Compliant Material

Actual Material Specified Material Action Required

Structural steel Stainless steel Material ≥ 2,5 mm thick – replace when required
Material < 2,5 mm thick – replace within 3 years

Structural steel FRP Replace within 2 years

Structural steel 3CR12 Replace when required

Stainless steel Any No action required

FRP Any No action required

3CR12 Any Replace when required

Wrong grade bolts Any Replace bolts within 6 months

AA_SPEC_114005 2014-06-11 June 2014 Page 46 of 61

Note: Where action is given as replace when required, replacement is only necessary when regular
inspections indicate that it should be done.

9.8.2 Non-Compliant Corrosion Protection

Actual Corrosion Specified Corrosion Action Required

Protection Protection

Any paint system Hot dip galvanised Material ≥ 2,5 mm thick – replace when required
Material < 2,5 mm thick – replace within 3 years

Other paint system Epoxy coal tar Replace when required

Note: Where action is given as replace when required, replacement is only necessary when regular
inspections indicate that it should be done.

9.8.3 Non-Compliant Section or Grating Sizes

Actual Section Specified Section Action Required

Hollow sections Solid or angle sections Material ≥ 2,5 mm thick – replace when required
Material < 2,5 mm thick – replace within 2 years

Bearer bars < 4,5 Bearer bars ≥ 4,5 mm Replace when required
mm thick

Note: Where action is given as replace when required, replacement is only necessary when regular
inspections indicate that it should be done.

9.8.4 Non-Compliant Construction Details

Non-Compliant Detail Action Required

Stairs and ladders

Stair angle too steep Place warning signage

Replace within 5 years

Ladder cage missing Cordon off area

Replace within 1 month

AA_SPEC_114005 2014-06-11 June 2014 Page 47 of 61

Non-Compliant Detail Action Required

Stair treads too small, too far apart or too Place warning signage
close together
Replace within 5 years

Stair or walkway too narrow No action required, unless deemed necessary for safe
access

Floor panels and plates

Floor panel seating < 50 mm but > 10 mm Inspect for safety at 3 monthly intervals

Floor panel off support beams or seating < 10 Cordon off area
mm
Repair within 1 month

Floor grating panels span wrong direction Inspect for safety at 3 monthly intervals
Replace panels within 2 years

Floor grating panels not adequately supported Inspect for safety and damage at 3 monthly intervals
along full width of sides
Implement remedial work within 2 years

Floor grating or plating surface smooth Place warning signage

Replace within 1 year

Guardrails

Hand rail missing Cordon off area

Replace within 1 month

Knee rail missing Place warning signage

Replace within 3 months

Toeboard missing Place warning signage

Replace within 3 months

Guardrails outside of working surface Place warning signage

Replace within 1 year

AA_SPEC_114005 2014-06-11 June 2014 Page 48 of 61

10 REQUIREMENTS FOR MAINTENANCE AND REPAIR

10.1 FABRICATION AND SUPPLY

The fabrication and supply of replacement steel and FRP grating, stairs, ladders and guardrails shall comply
in all respects with the requirements for new steel and FRP grating, stairs, ladders and guardrails in the
section above.

Wherever possible, replacement steel and FRP grating, stairs, ladders and guardrails should be in
accordance with the drawings for the existing steel and FRP grating, stairs, ladders and guardrails. Where
the existing layout or design does not comply with this specification, or changes to the layout are required for
any other reason, the drawings shall be updated and approved prior to fabrication commencing. The original
Supplier should be the preferred Supplier of replacements in all cases.

10.2 INSTALLATION

10.2.1 Installation of Large Areas

Where large areas of flooring, entire stairs or ladders, or long lengths of guardrails require replacement, the
installation of such replacement steel and FRP grating, stairs, ladders and guardrails shall comply in all
respects with the requirements for new steel and FRP grating, stairs, ladders and guardrails in the section
above.

10.2.2 Installation of Isolated Components

Where isolated components of flooring, stairs, ladders, or guardrails require replacement, the installation
may be done in compliance the requirements for new steel and FRP grating, stairs, ladders and guardrails in
the section above, or a specific installation procedure may be prepared. If a specific installation procedure is
prepared, this shall be based on a risk assessment to determine the safety and other requirements of the
installation project.

The Section Engineer shall ensure the proper reinstatement of the flooring, stairs, ladders or guardrails. On
completion the Section Engineer shall inspect and accept the work as required for new installations in the
section above.

AA_SPEC_114005 2014-06-11 June 2014 Page 49 of 61

10.3 GRATING

10.3.1 Replacement of Grating

Steel and FRP grating shall not be repaired by welding or any other means. Grating panels shall be
replaced under any of the following conditions:

(a) Corrosion

• Where corrosion has reduced the bearer bar thickness, resulting in a condition category of 4 or 5
as defined in AA BPG S003, SIMM guidelines for plant structures. A condition category 4 is defined
as a condition where the structural element has retained 50 % to 75 % of its original strength. For a
condition category 5, the element has retained less than 50 % of its original strength.

• Where corrosion has reduced the area of the transverse bars by more than 35%

(b) Bending of bearer bars

• Where bearer bars, banding or toeboards have been twisted through more than 15°

• Where a single bearer bar has been bent laterally by more than the spacing between bearer bars,
or where several bearer bars, banding or toeboards have been bent laterally by more than half the
spacing between bearer bars

• Where the panel has been bent upwards or downwards by more than the depth of the bearer bars

(c) Cutting of bars or panel

• Where any of the bearer bars have been cut so that they are no longer seated on the supporting
structure

• Where any portion of the panel has been cut out and it is not possible to comply with the
requirements for new openings in the section above. This shall apply even where the cutout has
been re-welded in place. Patch repairs of this nature are not allowed.

(d) Connection between bars

• Where the connection between the transverse bars and the bearer bars has broken or loosened at
more than 3 locations along a single bearer bar, or at more than 10 locations within a single panel

• Where the welding between more than one bearer bar and a load bearing toeboard has broken
AA_SPEC_114005 2014-06-11 June 2014 Page 50 of 61

• Where the welding of bearer or transverse bars to the banding or toeboard has cracked or broken
at more than 2 locations along a single side, or at more than 5 locations around one panel.

(e) Fire damage

• Where FRP components have been exposed to any fire

• Where steel components subjected to a fire have distorted to the extent that the distortion is clearly
visible

Where the existing grating panels have bearer bars with a depth of less than the minimum requirement of
this specification, new grating panels with deeper bearer bars shall be used. In this event, sufficient grating
panels shall be replaced to blend smoothly into the grating panels with shallower bearer bars. By this it is
intended that all grating panels shall be replaced up to a natural break in the floor where a change in grating
panel depth will not be noticed.

10.3.2 Dimensions

Dimensions and layout of replacement panels should be as specified on the approved drawings. If it is
necessary to change the panel dimensions for any reason, the Supplier shall prepare revised drawings
showing the new panel layout, and have these drawings approved.

10.4 FASTENERS

10.4.1 Tightening of Fasteners

All loose fasteners shall be tightened as soon as possible, but never more than one month after the
inspection.

Any fasteners that loosen again within six months of being tightened shall be replaced with different
fasteners that have improved resistance to loosening.

10.4.2 Replacement of Fasteners

Where any of the following conditions apply, the relevant fasteners shall be replaced:

• Any missing fasteners

• Any broken fasteners

AA_SPEC_114005 2014-06-11 June 2014 Page 51 of 61

• Any fasteners that have corroded, bent or been damaged in any way

• Any fasteners where the heads project above the top surface of the flooring

Replacement fasteners shall be the same as, or better than, those specified on the drawings in all respects.

10.5 STAIRS

10.5.1 Replacement of Stair Treads

Where any of the following conditions apply, the relevant stair treads shall be replaced:

• Any missing stair treads

• Any broken stair treads

• Any stair treads that have corroded to a condition category of 4 or 5 as defined in AA BPG S003,
SIMM guidelines for plant structures. A condition category 4 is defined as a condition where the
structural element has retained 50 % to 75 % of its original strength. For a condition category 5, the
element has retained less than 50 % of its original strength.

• the extent that the bearer bars have lost more than 1,0 mm of their thickness

• Any stair treads that have been bent upwards or downwards by more than the bearer bar depth

• Any stair treads where the non-slip surface has come off the nosing so that it has become slippery

Replacement stair treads shall be the same as those specified on the drawings in all respects.

10.6 LADDERS

10.6.1 Replacement of Ladders

Where any of the following conditions apply, the relevant ladder shall be replaced in its entirety:

• Either of the ladder stringers has corroded to a condition category of 4 or 5 as defined in AA BPG
S003, SIMM guidelines for plant structures. A condition category 4 is defined as a condition where
the structural element has retained 50 % to 75 % of its original strength. For a condition category 5,
the element has retained less than 50 % of its original strength.

• the extent that its thickness has reduced by more than 1,0 mm
AA_SPEC_114005 2014-06-11 June 2014 Page 52 of 61

• Either of the ladder stringers is broken, or both ladder stringers are bent by more than 100 mm

• More than 20 % of the rungs are corroded to the extent that their diameter has reduced by more
than 2,0 mm

• More than 20 % of the rungs are broken or bent by more than 40 mm

• The cage is generally corroded to the extent that thicknesses have reduced, resulting in a condition
category of 4 or 5 as defined in AA BPG S003, SIMM guidelines for plant structures. A condition
category 4 is defined as a condition where the structural element has retained 50 % to 75 % of its
original strength. For a condition category 5, the element has retained less than 50 % of its original
strength.

• The cage is broken or bent by more than 75 mm at more than 3 places

• Where damage cannot be repaired for any reason

Replacement ladders shall be the same as, or better than, those specified on the drawings in all respects.

10.6.2 Repair of Ladders

Where any of the following conditions apply, the damage to the ladder shall be repaired as described:

• Where less than 20 % of the rungs are corroded to the extent that their diameter has reduced by
more than 25 % of the cross section area, the corroded rungs shall be cut out and new rungs shall
be welded in place.

• Where less than 20 % of the rungs are broken or bent by more than 40 mm, the broken or bent
rungs shall be cut out and new rungs shall be welded in place.

• Where the cage is locally corroded to the extent that thicknesses have reduced by more than 25 %
of the cross section area, the corroded areas shall be cut out and new sections welded in place

• Where the cage is broken or bent by more than 75 mm at less than 3 places the bent sections shall
be cut out and new sections welded in place

Corrosion protection shall be made good after welding.

AA_SPEC_114005 2014-06-11 June 2014 Page 53 of 61

10.7 GUARDRAILS

10.7.1 Replacement of Guardrails

Where any of the following conditions apply, the guardrails shall be replaced in their entirety:

• Where any length of guardrail is missing

• Any general corrosion of components with corrosion extending past 25% of the original cross
section area

• General damage, where the standards, hand rails and knee rails are all bent to the extent of more
than 100 mm

Replacement guardrails shall be the same as, or better than, those specified on the drawings in all respects.

10.7.2 Repair of Guardrails

Where any of the following conditions apply, the guardrails shall be repaired as described:

• Where any length of hand rail or knee rail is missing this shall be replaced by welding in a new
section. All welds on hand rails shall be ground smooth after welding

• Any local corrosion of components with thickness greater than 5,0 mm to the extent that the
thickness has reduced by more than 1,0 mm. The corroded portion shall be cut out, and a new
section welded in place

• Any local corrosion of components with thickness less than or equal to 5,0 mm to the extent the
thickness has reduced by more than 0,5 mm. The corroded portion shall be cut out, and a new
section welded in place

• Local damage, where only a standard is bent to the extent of more than 100 mm. Damaged
standards shall be removed and replaced by new standards

• Local damage, where only a hand rail or a knee rail is bent to the extent of more than 100 mm.
The damaged portion of hand rails or knee rails shall be cut out and a new section welded in place

• Cracked hand rails or knee rails shall be welded

All welds on hand rails shall be ground smooth after welding. Corrosion protection shall be made good after
welding.

AA_SPEC_114005 2014-06-11 June 2014 Page 54 of 61

11 QUALITY ASSURANCE PROVISIONS

11.1 QUALITY M ANAGEMENT

The requirements of ISO 9001 shall apply. All optional requirements in ISO 9001 shall be compulsory
requirements for material supplied against this specification.

Quality management and quality assurance arrangements shall be in accordance with AA STD 100 “Quality
Requirements for Critical and Major Products and Services”.

All test and inspection reports shall be suitably signed off by the responsible parties and included in a Quality
Data Pack, which shall be submitted prior to the issuing of an Acceptance Certificate at completion of the
works.

11.2 QUALITY PLAN

Suppliers and Contractors shall compile and submit a quality plan for the design and installation of all steel
and FRP flooring, stairs and guardrails. This quality plan shall:

• Be separate from the quality plan for design and installation of structural steelwork or other
structures

• List all major works, specifications, tests, methods of test, equipment to be used and
acceptance/rejection criteria

• All areas of flooring, stairs and guardrails to be inspected and signed off separately from any other
structures

• Provide proof of qualification of all welders

The quality plan shall be approved by the Project Engineer prior to commencement of manufacture.

11.3 TEST FACILITIES

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

AA_SPEC_114005 2014-06-11 June 2014 Page 55 of 61

11.4 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 Project Engineer shall be final.

AA_SPEC_114005 2014-06-11 June 2014 Page 56 of 61

APPENDIX A: RECORD OF AMENDMENTS

Issue Notes Author Date

1 Completely re-written document Kurt Waelbers 09/09/2014

AA_SPEC_114005 2014-06-11 June 2014 Page 57 of 61

Anglo American Group Engineering accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
Country
Code
Australia Canada South Africa Europe
Letters

GWS AS/NZS 3678 “Structural SANS 1431 “Weldable

Steel”. structural steels”.

AA_SPEC_114005 2014-06-11
AS/NZS 3679 “Structural

SLO Steel”.
AS/NZS 1170 “Minimum SANS 10160 “The General
Design Loads on Procedures and Loadings to
APPROPRIATE NATIONAL STANDARDS

Structures”. be Adopted in the Design of

Buildings”.
APPENDIX B : RELATED DOCUMENTS

June 2014
DLS SANS 10208-4 “Design of
Structures for the Mining
Industry – Part 4: Shaft
System Structures”.

information contained therein, irrespective of the cause and quantum thereof.

SSC AS 4100 “Steel SANS 2001 CS1
Structures”. “Construction works Part
AA SPECIFICATION

CS1: Structural steelwork”.

LADDERS AND GUARDRAILS

LSD AS 4100 “Steel SANS 10162-1 “The use of

Structures”. structural steel. Part 1: Hot
STEEL AND FRP FLOORING, STAIRS,

Rolled Steelwork”.
AS/NZS 1554 “Structural
Steel Welding”.

STS ASTM 269 for tubing.

ASTM 240 for plate and

Page 58 of 61
114005

strip.
ISSUE 00

Anglo American Group Engineering accepts no liability for any damage whatsoever that may result from the use of this material or the
AA SPECIFICATION 114005
ISSUE 00
STEEL AND FRP FLOORING, STAIRS,
Europe LADDERS AND GUARDRAILS COPYRIGHT

testing of materials,
SANS 10177 “Fire

elements used in
components and
South Africa

building”.
Country

Canada

AS 1530 “Methods for

Fire Tests on Building
Materials”.
Australia

Elements of Building
Resistance Tests –

Construction”.
ISO Standard

ISO 834 “Fire

AA_SPEC_114005 2014-06-11 June 2014 Page 59 of 61

Class 8.8 bolts

Class 4.8 bolts

South Africa
Canada
Country

AS 1530 “Methods for

Fire Tests on Building
Materials”.
Australia

strength structural bolts

Graded high strength

Graded standard
structural bolts
Description

AA_SPEC_114005 2014-06-11 June 2014 Page 60 of 61

BS 1449 : Steel plate and strip

BS 4592 : Specification for industrial flooring and stair treads

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

SANS 10400 : The Application of the National Building regulations

SANS 1137 : Hot applied bitumen for steel pipeline protection

AA_SPEC_114005 2014-06-11 June 2014 Page 61 of 61

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AA SPEC 114005 Stairs, Platforms and Handrails

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AA SPEC 114005 Stairs, Platforms and Handrails

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AA SPECIFICATION 114005

2 SAFETY AND RISK 4

2.1 ANGLO FATAL RISK STANDARDS 4

2.2 RISK ASSESSMENT 4

3.1 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 6

3.2 REFERENCE STANDARDS AND SPECIFICATIONS 6

5.1 COMPLIANCE WITH LEGISLATION AND AA PLC REQUIREMENTS 10

5.2 DEVIATION FROM THIS SPECIFICATION 10

5.3 MEANING AND PRECEDENCE OF INFORMATION 10

6 REQUIREMENTS FOR DESIGN 11

6.2 ALTERNATIVE DESIGNS 11

6.5 DESIGN DRAWINGS 16

6.6 LAYOUT OF FLOOR GRATING 16

6.7 LAYOUT OF FLOOR PLATING 19

6.8 OPENINGS IN FLOORING 21

6.9 LAYOUT OF GUARDRAILS 22

6.10 LAYOUT OF STAIRS AND LADDERS 24

6.11 USE OF STAIRS OR LADDERS 26

6.12 ROOF ACCESS AND EDGE PROTECTION 27

AA_SPEC_114005 2014-06-11 June 2014 Page 1 of 61

7 REQUIREMENTS FOR FABRICATION AND SUPPLY 27

7.2 COMPLIANCE WITH DESIGN DRAWINGS 27

7.3 MODULAR DESIGN 28

7.4 CONSTRUCTION DETAILS 28

7.6 PAINTING AND PROTECTIVE COATING 30

7.9 TEST AND INSPECTION METHODS 33

7.10 PACKING AND M ARKING 33

7.11 PERFORMANCE AND GUARANTEE 34

8 REQUIREMENTS FOR INSTALLATION 34

8.2 INSTALLATION PROCEDURE 35

8.3 FASTENING OF FLOORING, STAIRS AND GUARDRAILS 36

8.4 INSTALLATION TOLERANCES 39

8.5 INSPECTION AND ACCEPTANCE 39

9 REQUIREMENTS FOR USE 40

9.1 SUPPORT OF EQUIPMENT 40

9.5 COVERING OF FLOOR 43

9.6 REINSTATEMENT FOLLOWING REMOVAL FOR M AINTENANCE 44

9.7 REGULAR INSPECTIONS 44

9.8 RETROFIT REQUIREMENTS FOR NON-COMPLIANT ITEMS 46

10 REQUIREMENTS FOR MAINTENANCE AND REPAIR 49

10.1 FABRICATION AND SUPPLY 49

11 QUALITY ASSURANCE PROVISIONS 55

11.1 QUALITY M ANAGEMENT 55

11.2 QUALITY PLAN 55

11.3 TEST FACILITIES 55

APPENDIX A: RECORD OF AMENDMENTS 57

APPENDIX B : RELATED DOCUMENTS 58

APPROPRIATE NATIONAL STANDARDS 58

OTHER RELATED DOCUMENTS 61

AA_SPEC_114005 2014-06-11 June 2014 Page 3 of 61

2 SAFETY AND RISK

2.1 ANGLO FATAL RISK STANDARDS

2.2 RISK ASSESSMENT

2.2.1 New Installations

AA_SPEC_114005 2014-06-11 June 2014 Page 4 of 61

2.2.2 Existing Installations

2.2.3 Minimum Requirements

The risk assessment shall consider at least the following:

(c) Access and Escape

(d) Falling objects

3.1 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

• Number, title, date and issue of this specification

• Number, title and issue of the relevant drawings

• Type of material to be used in the manufacturing of flooring, stairways and handrails

• Corrosion protection requirements

• Fire rating and fire protection requirements

• Panel fastening methods

3.2 REFERENCE STANDARDS AND SPECIFICATIONS

AA_SPEC_114005 2014-06-11 June 2014 Page 6 of 61

3.2.1 International Standards

• ISO 834 “Fire resistance tests. Elements of building construction”

• ISO 9001 “Quality management systems”.

3.2.2 National Standards

• SLO – The appropriate national standard for structural loading.

• SSC – The appropriate national standard for structural steel construction.

• STS – The appropriate national standard for stainless steel sections.