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AA - SPEC - 114005 - Flooring, Stairs, Ladders & Handrails
AA - SPEC - 114005 - Flooring, Stairs, Ladders & Handrails
CONTENTS PAGE
1 SCOPE 2
2 TECHNICAL REQUIREMENTS 2
2.1 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 2
3 DEFINITIONS 2
4 GENERAL REQUIREMENTS 5
4.1 SAFETY AND RISK 5
4.2 GENERAL REQUIREMENTS 6
4.3 REQUIREMENTS FOR DESIGN 7
4.4 REQUIREMENTS FOR FABRICATION AND SUPPLY 20
4.5 REQUIREMENTS FOR INSTALLATION 25
4.6 REQUIREMENTS FOR USE 30
4.7 REQUIREMENTS FOR MAINTENANCE AND REPAIR 36
5 QUALITY ASSURANCE PROVISIONS 41
5.1 QUALITY MANAGEMENT 41
5.2 QUALITY PLAN 41
5.3 TEST FACILITIES 42
5.4 INSPECTION 42
APPENDIX A: RELATED DOCUMENTS 43
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 vastrap 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 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.
2 TECHNICAL REQUIREMENTS
3 DEFINITIONS
For the purpose of this specification the following definitions shall apply:
AT : Anglo Technical
BANDING : A bar of equal depth and thickness to the bearer bars which
is welded to the grating around the outer ends and edges of
the panel.
BS : British Standard
DESIGN DRAWINGS : As defined by AA SPEC 114001
DESIGN ENGINEER : As defined by AA SPEC 114001
DESIGNATED : A Foreman who is appointed in writing by the Mine
FOREMAN Engineer as having responsibility for steel and FRP flooring,
stairs and guardrails. The Designated Foreman should
have specific training and experience in the use and
inspection of steel and FRP flooring, stairs, ladders and
guardrails
SS : Stainless steel
4 GENERAL REQUIREMENTS
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 AFRS 07 “Working at Heights”.
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.
• 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.
• Minimum Requirements
1. 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.
2. 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.
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.
4. 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.
5. 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.
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 (AA AFRS 07) “Working at Heights”.
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
Engineering Manager: Structures of Anglo Technical for written approval.
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
Engineering Manager: Structures of Anglo Technical Division for a ruling. The decision of
the Engineering Manager: Structures shall be final.
In the event of any conflict between the technical requirements of relevant documents, the
order of precedence shall be:
• This specification
The design shall comply with the requirements of AA SPEC 114001, as amended by this
specification.
This specification defines the minimum prescribed standards. Alternative designs that
represent an improved or equivalent standard may be proposed and presented to the
Engineering Manager: Structures of AT for approval. Alternative designs may only be
used after they have been approved in writing.
4.3.3 Materials
All materials used shall comply with the requirements below. All materials shall be clearly
specified on the Design Drawings.
• Condition of Material
Pitting or rusting of steel surfaces shall not be more severe than grade C of
ISO 8501 unless otherwise agreed by the Design Engineer.
• Structural Carbon Steel
1. Steel sections
All materials shall be graded hot formed steel, complying with the relevant GWS,
with guaranteed yield strength not less than 350MPa. No commercial quality or
ungraded steel shall be used.
Surface defects shall not exceed the extent allowed by the relevant GWS.
2. 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 16mm and shall be graded high strength structural bolts.
Bolts for clips and attachment of flooring and toeboards shall have a diameter of not
less than 8mm and shall be graded standard strength structural bolts.
• Stainless Steel
1. 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 200MPa
Have a guaranteed minimum yield stress, achieved by cold working before
manufacture, of not less than 220MPa and not more than half the minimum
tensile strength
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.
3. Fasteners
The dimensions of stainless steel fasteners shall comply with an approved national
or international standard.
4. Surface finish
All materials shall comply with the following specifications, whichever is applicable:
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.
• FRP
5. 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 0.25mm thick
Any drilled hole or cutting area shall be resin sealed to a minimum thickness of
0.25mm.
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%.
7. Fire Resistance
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.
8. Approval
The Mine Engineer shall approve the proposed resin system before use.
• Specific Material and Corrosion Protection Applications
The specific materials and corrosion protection systems listed in Table 4.1 shall be
used in different areas of plants and mines.
1. Wet plant area with no Structural carbon steel hot Structural carbon steel hot
acid present. dip galvanised. dip galvanised.
1. Poorly ventilated or wet Structural carbon steel hot Structural carbon steel hot
underground areas dip galvanised. dip galvanised or 3CR12.
Hand rails.
Floor grating
Description Knee rails.
Stair treads
Stanchions.
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.
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. Anglo Technical shall approve the coating system
before use.
4.3.4 Loads
• General
The minimum imposed floor and stair loads defined by SLO, as modified and
supplemented by the 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.
• 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.
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 750mm and the applied load does not exceed
2.5kPa.
• 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.
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 100mm, 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.
• Seating of Grating
The seating of grating on supporting steelwork shall not be less than 50mm. Where
a beam supports two adjacent floor grating panels but its flange is less than 100mm
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 100mm long and 50mm wide. These openings shall
have banding around the edges of the opening.
Openings not exceeding 500mm long and 100mm wide. These openings
shall have load bearing toeboards around the edges of the opening.
Gap in the support beam not exceeding 1000mm 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 100mm in width are permitted in the
beams, provided that there is not more than one gap along any one side of a panel.
• Floor Panel Clearance
1. General
Toeboards shall be provided at all open edges of flooring including stair wells and
equipment openings.
Load bearing toeboards shall only be used where all of the following conditions are
met:
A straight load bearing toeboard shall not exceed 1000mm in width.
A cranked load bearing toeboard shall not exceed 500mm in width by 100mm
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/√fy, where fy is the yield strength of the steel used.
The Design Engineer shall provide design calculations demonstrating the adequacy
of load bearing toeboards.
• Bar Spacing and Size
1. Steel floors
Bearer bar centres shall not exceed 50mm
2. FRP floors
Bearer bars and transverse bars are typically the same size
Bearer bar centres shall not exceed 40mm
Transverse bar centres shall not exceed 100mm
The depth of bars shall not be less than 30mm
The thickness of bars shall not be less than 4.5mm
• 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 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°, square bars shall be fixed across the surface or some other means
shall be used in addition to the non-slip surface to prevent slipping.
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 50mm, whichever is the lesser.
• Seating of Plating
Seating of plating on supporting steelwork shall not be less than 25mm 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:
1. Openings not exceeding 25mm long and not exceeding the length of the support
beam.
2. Openings not exceeding 300mm long and 50mm wide. These openings shall have
load bearing toeboards around the edges of the opening.
3. Gap in the support beam not exceeding 1000mm 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.
• Flooring Clearance
All stair treads shall be equipped standard with fabricated non-slip nosing.
The slope of inclined walkways, along conveyor gantries or where inclination of the
walkway is required for any reason shall not exceed 10°.
The following specific details shall be implemented for all steel and FRP flooring.
1. Large cut-outs or openings with dimensions greater than 500mm x 200mm 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
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.
2. Toeboards shall be provided around all cut-outs with dimensions greater than
150 mm x 80mm.
3. 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.
4. Any cut-out smaller than 150mm across should be square or rectangular rather than
circular.
5. Circular panels should have load bearing toeboards along unsupported curves.
These load bearing toeboards should not exceed 1000mm in width. The overhang
of curved panels should not exceed 10% of the tieback span, or 100mm, whichever
is the lesser.
6. Where the distance from the edge of any cut-out to the edge of the flooring panel is
less than 100mm or half the size of the cut-out, the cut-out should extend right to
the edge of the panel.
7. Where panels or cut-outs are alongside concrete columns or walls, a gap of at least
20mm should be left to allow for tolerance on the concrete construction.
8. 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.
9. The distance between two adjacent cut-outs should not be less than 250mm.
Where cut-outs are required closer together, they shall be combined into a single
cut-out.
All Guardrails shall consist of a hand rail, a knee rail and a toeboard or bund wall.
Recommended structural sections are listed in Table 4.2.
AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 15 of 45
• Guardrail Sections
The guardrail sections shown in Table 4.2 shall be used as minimum sizes for all
guardrails. The sections used for hand rails shall not exceed 75mm diameter for
round sections, or 80mm 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.
• Guardrail Dimensions
The top of hand rails around horizontal platforms should be not less than
1000mm and not more than 1150mm above the top of steel level. The top of
hand rails on stairs should be not less than 850mm and not more than 950mm
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 4.2 shall be checked by the Supplier or a Structural
Engineer
The top of knee rails around horizontal platforms should be 500mm above the
top of steel level. The top of knee rails on stairs should be 500mm above the
sighting edge of the stairs
Toeboards around horizontal platforms should protrude a minimum of 100mm
above the top of floor grating or floor plating.
• 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 65mm.
Where angle hand rail sections are used, the horizontal leg shall project outwards.
• Guardrail standards
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.
• 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 8.8 M12 bolts with self-locking nuts.
Side plates shall have a minimum thickness of 4.5mm and shall be welded to the
ends of all the bearer bars with a continuous 4mm fillet weld on both sides
Any stair or inclined ladder which has a height exceeding 750mm or from which any
person could fall more than 750mm shall have barricading (i.e. a wall or guardrails)
on both sides.
All stairs and inclined ladders shall have hand rails along both sides, either as the
top rail of guardrails, or attached to the wall.
• Vertical Steel Ladders
The step spacing, h, shall be not less than 230mm and not more than 300mm. The
step spacing shall remain constant throughout the length of any one ladder.
Round steps shall be used. The step diameter shall be not less than 20mm and not
more than 50mm.
The maximum length of any ladder between landings should preferably be not more
than 6.0m but shall not exceed 8.0m.
Any vertical ladder which has a height of more than 4.0m shall have a safety cage,
extending from 2.5m above the lower end of the ladder to at least 1.0m above the
floor or landing at the top of the ladder.
• Landings
The length of landings shall be not less than the length of the stair tread or the
diameter of the ladder cage.
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:
• 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
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 2.0m from the edge of the roof guardrails shall be
installed along that edge
• Where translucent or brittle roof cladding is used guardrails shall be installed along
all edges
• Where gutters are accessible and may be used as walkways guardrails shall be
installed along the outer edge of the gutters
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.
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.
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
compliments the design intent. Such approval shall be defined as a “Hold” point in the
fabrication Quality Control Plan.
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 10mm shallower than the bearer bars. All banding bars shall
be flush with the top of the grating panel, allowing a 10mm gap below for drainage
of water or spillage.
• Welding of Bars in Steel Grating
Welding of bars in steel grating panels shall comply with the requirements listed in
Table 4.3.
1. General dry areas. Weld one bar in Weld one bar in Weld all bars.
three. three.
5mm continuous
2. Crushing and screening. 3mm continuous 3mm continuous fillet weld on
fillet weld all fillet weld on one both sides
3. Conveyor gantries. round side only
4. Headgears.
1. Wet plant area with no acid Weld all bars. Weld all bars. Weld all bars.
present. 3mm continuous 3mm continuous 5mm continuous
fillet weld all fillet weld all fillet weld all
2. High temperature furnace
round round round
area.
3. Converter area.
1. Flash drier area. Weld one bar in Weld one bar in Weld all bars.
three. three.
5mm continuous
2. Wet or dry areas where
3mm continuous 3mm continuous fillet weld on
sulphurous (SO3/SO2) fumes
fillet weld all fillet weld on one both sides
or dust is present.
round side only
3. Areas where sulphuric acid
(H2SO4) is present.
4.4.5 Welding
• General
All welding shall comply with the design drawings, and be done in accordance with
the requirements of AWS D1.1
• Welding Consumables
All welders shall be suitably qualified and coded to the requirements of AWS D1.1.
Painting and protective coating shall be in accordance with the design drawings or
Section 4.3.3 of this specification.
• Repair of Corrosion Protection
1. 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.
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.
4.4.7 Certification
4.4.8 Tolerances
• Guardrail Tolerances
All stairs shall comply with the tolerances for structural steelwork specified by SSC.
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.
• Marking
1. Marking drawings
The Contractor shall prepare marking drawings and supply one print to the Project
Engineer for approval. An electronic file shall also be supplied to the Project
Engineer on request
2. 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:
Identifying number or mark
Manufacturer's name or logo
Batch number or date of manufacture
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.
Installation of steel and FRP flooring, stairs and guardrails requires that workers work at
heights. All work shall be done in compliance with the Anglo Fatal Risk Standard
AA AFRS 07 “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.
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.
• 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.
• 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.
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 stair treads should be properly fastened as soon as they are installed.
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
1.5m along each end and edge.
Where any floor vibration is present, the preferred method of fastening steel grating
or plating is welding.
• Floor Grating 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.
2. Non-loosening fasteners
Fasteners shall be of a type that will not loosen with use of the 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
2mm. Bolts for floor plating shall have countersunk heads.
whether the floor is flat or inclined, in which case the angle of inclination shall
be included
5. Bolts
Securing bolts shall not be smaller than 8mm diameter and shall use locking nuts or
a double-nut arrangement for locking.
6. 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.
• Floor Grating Welding
Field welding shall only be performed where specified by the Design Engineer.
The location of welds shall comply with the Location of Fasteners in Section 4.5.3.
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, cold galvanising shall be applied, in
compliance with AA CPS 41A
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.
Protection from Corrosion
1. 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 3mm 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.
2. 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 past 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.
3. Repair of galvanising
The clearance between adjacent flooring panels after erection shall not exceed
10.0mm.
• Minimum seating
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:
• 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
No pipes of diameter greater than 50mm may be laid across nor supported from
any floor grating, floor plates or walkway grating.
Floor grating and floor plating shall not permanently support any form of heavy
equipment. Light equipment, cabinets or switchgear, with a mass not exceeding
500kg on floor grating, and not exceeding 250kg on floor plating, may be supported
providing the following precautions are taken:
Each leg shall have a steel plate foot, at least 8mm thick, and at least
150mm x 150mm 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.
4.6.2 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.
Guardrails shall not be used as a support to which goods or articles may be secured for
any reason whatsoever.
4.6.3 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 20kg.
No chain block, slings or any other lifting equipment shall be attached to any walkway
grating or stairs.
4.6.4 Openings
• 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.
• 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:
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.
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.
All new permanent openings shall be protected as required for Design in the section
above.
All temporary openings in the floor grating or floor plating panels, where the length
does not exceed 1.0m, 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 1.0m, 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.
Whilst work of making new openings is in progress, the precautions required for
Installation in the section above shall apply.
• 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.
1. 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.
2. 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.
3. 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.
4. 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”.
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.
All steel and FRP floors and walkways, stairways and guardrails shall be visually
inspected at intervals not exceeding the intervals defined in Table 4.5.
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 4.6. A separate checklist
should be completed for each different floor level or area.
• Inspection Records
The results of all inspections shall be recorded and kept on file, either electronically
or in hard copy form.
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.
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.
Where any items do not comply with this specification, the actions listed below should be
implemented within the time frame specified.
• Non-Compliant Material
Actual Material Specified Material Action Required
Material ≥ 2.5mm thick – replace when required
Mild steel Stainless steel
Material < 2.5mm thick – replace within 3 years
Mild steel FRP Replace within 2 years
Mild 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
Note: Where action is given as replace when required, replacement is only necessary when regular
inspections indicate that it should be done.
• Non-Compliant Corrosion Protection
Actual Corrosion Specified Corrosion
Action Required
Protection Protection
Material ≥ 2.5mm thick – replace when required
Any paint system Hot dip galvanised
Material < 2.5mm thick – replace within 3 years
Other paint Epoxy coal tar Replace when required
system
Note: Where action is given as replace when required, replacement is only necessary when regular
inspections indicate that it should be done.
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.
AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 36 of 45
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.
4.7.2 Installation
• 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.
• Installation of Isolated Components
The Mine Engineer shall ensure the proper reinstatement of the flooring, stairs,
ladders or guardrails. On completion the Mine Engineer shall inspect and accept the
work as required for new installations in the section above.
4.7.3 Grating
• 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:
1. Corrosion
Where corrosion has reduced the bearer bar thickness by more than 1.0mm
Where corrosion has reduced the area of the transverse bars by more than
35%
5. 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.
• Dimensions
4.7.4 Fasteners
• 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.
• Replacement of Fasteners
Where any of the following conditions apply, the relevant fasteners shall be
replaced:
Any missing fasteners
Any broken fasteners
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.
4.7.5 Stairs
• 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 the extent that the bearer bars have lost
more than 1.0mm 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.
4.7.6 Ladders
• 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 the extent that its thickness has
reduced by more than 1.0mm
Either of the ladder stringers is broken, or both ladder stringers are bent by
more than 100mm
More than 20% of the rungs are corroded to the extent that their diameter has
reduced by more than 2.0mm
More than 20% of the rungs are broken or bent by more than 40mm
The cage is generally corroded to the extent that thicknesses have reduced by
more than 1.0mm
The cage is broken or bent by more than 75mm 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.
• 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 2.0mm, 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 40mm,
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 1.0mm, the corroded areas shall be cut out and new
sections welded in place
Where the cage is broken or bent by more than 75mm at less than 3 places
the bent sections shall be cut out and new sections welded in place
4.7.7 Guardrails
• 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 thickness greater than 5.0mm to
the extent that the thickness has reduced by more than 1.0mm
Any general corrosion of components with thickness less than or equal to
5.0mm to the extent the thickness has reduced by more than 0.5mm
General damage, where the standards, hand rails and knee rails are all bent
to the extent of more than 100mm
Replacement guardrails shall be the same as or better than, those specified on the
drawings in all respects.
• 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 5.0mm to the
extent that the thickness has reduced by more than 1.0mm. 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 5.0mm
to the extent the thickness has reduced by more than 0.5mm. 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
100mm. 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 100mm. 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
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.
The quality plan shall be approved by the Project Engineer prior to commencement of
manufacture.
5.4 INSPECTION
The QAR shall have access at all reasonable times to those parts of the manufacturing
facilities engaged in the manufacture of articles to this specification. The QAR is
authorised to witness any stage of manufacture, tests and to inspect documentation. The
QAR is authorised to reject any items not complying with the requirements of this
specification. In the event of a dispute arising regarding the interpretation of test results
the decision of the Project Engineer shall be final.
Unless otherwise stated the latest issue of the following documents shall be deemed to form part
of this specification.
AA BPG S06 : Guidelines for Layout and Inspection of Steel and FRP Floors, Stairs
and Guardrail
AA CPS 41A : Galvanised Iron and Steel Repair Procedure (Single Pack Zinc Rich)
AA CPS 000124 : New Work, Non-Immersion Two Coat Epoxy Coal Tar
ISO 1461 : Hot dip galvanised coatings on fabricated iron and steel articles
Issue 0 New document based on AAC Specification 114005 Rev 5 with a complete re-write
LSD AS 4100 “Steel Structures”. SANS 10162-1 “The use of structural steel. Part 1:
Hot Rolled Steelwork”.
AS/NZS 1554 “Structural Steel
Welding”.
STS ASTM 269 for tubing. ASTM 240 for plate and strip.
ISO Standard Australia Canada South Africa Europe
ISO 834 “Fire Resistance Tests – AS 1530 “Methods for Fire Tests SANS 10177 “Fire testing of materials, components
Elements of Building Construction”. on Building Materials”. and elements used in building”.
Description Australia Canada South Africa Europe
Graded high strength structural bolts Class 8.8 bolts
Graded standard strength structural bolts Class 4.8 bolts