Monorails

ES-14-403-20

This is a Controlled Document that complies with

Wesfarmers Chemicals, Energy & Fertilisers formatting and Quality Control standards.
Please check that this is the latest available version before use.

Title: MONORAILS

Number: ES-14-403-20

Version Number: 5.0

Date Revised: 30 June 2014

Owner: Harish Chopra

Authoriser: Manoj Thakur

Reasons for Creating

or Amending Full Review of Document
Document

Actual Change Details: Standards Association of Australia list updated.

The word 'Superintendent' replaced with 'Responsible Officer'.

Section 7.4 and 18 has been updated.

TABLE OF CONTENTS
1. SCOPE ....................................................................................................................................... 4

2. PURPOSE .................................................................................................................................. 4

3. RESPONSIBILITY ................................................................................................................... 4

4. DEFINITION OF TERMS ....................................................................................................... 4

5. STANDARDS ............................................................................................................................ 5

6. OVERVIEW .............................................................................................................................. 9
6.1 DESIGN PHASE – FIGURE 1 (3 SHEETS) ...................................................................... 9
6.2 INSTALLATION PHASE – FIGURE 2 ............................................................................... 9
6.3 OPERATIONAL PHASE – FIGURE 3 .............................................................................. 10
7. BASIS OF DESIGN ................................................................................................................ 16
7.1 EXISTING MONORAIL OF UNKNOWN CAPACITY ................................................... 16
7.2 CONDITION OF EXISTING STEELWORK .................................................................... 16
7.3 DESIGN STANDARDS ..................................................................................................... 16
7.4 DESIGN .............................................................................................................................. 16
7.5 INDEPENDENT DESIGN REVIEW ................................................................................. 17

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7.6 STATUTORY AUTHORITY APPROVAL ....................................................................... 17

8. DESIGN METHODS .............................................................................................................. 17
8.1 WORKING STRESS DESIGN METHOD ......................................................................... 17
8.2 LIMIT STATES METHOD ................................................................................................ 17
9. MONORAIL SECTION SIZE ............................................................................................... 17
9.1 SAFE LOAD / CAPACITY TABLES ................................................................................ 17
9.2 FLANGE THICKNESS ...................................................................................................... 17
9.3 WEB THICKNESS ............................................................................................................. 18
9.4 DEFLECTION LIMITS ...................................................................................................... 18
9.5 LONG SPAN MONORAIL BEAMS .................................................................................. 18
10. END STOP DESIGN............................................................................................................... 18

11. INDEPENDENT DESIGN REVIEW .................................................................................... 20

12. CALCULATIONS................................................................................................................... 20
12.1 DESIGN CALCULATIONS ............................................................................................... 20
12.2 INDEPENDENT DESIGN REVIEW ................................................................................. 20
13. APPROVAL BY STATUTORY AUTHORITY ................................................................... 21

14. MATERIALS AND EQUIPMENT SELECTION ............................................................... 21

15. ELECTRICAL CONTROLS ................................................................................................. 21

16. HANDLING OF STRUCTURAL STEELWORK & EQUIPMENT ................................. 21

17. FABRICATION ...................................................................................................................... 21

18. WELDING ............................................................................................................................... 22

19. BOLTING ................................................................................................................................ 22

20. SITE MODIFICATIONS ....................................................................................................... 22

21. PROTECTIVE COATINGS .................................................................................................. 22

21.1 STRUCTURAL STEEL ...................................................................................................... 22
21.2 HOIST AND TROLLEY..................................................................................................... 22
21.3 BOLTS ................................................................................................................................ 23
22. INSTALLATION .................................................................................................................... 23
22.1 CIVIL / STRUCTURAL / MECHANICAL ........................................................................ 23
22.2 ELECTRICAL ..................................................................................................................... 23
23. IDENTIFICATION................................................................................................................. 23
23.1 BEAMS ............................................................................................................................... 24
23.2 HOIST AND TROLLEY..................................................................................................... 25
24. INSPECTION AND TESTING .............................................................................................. 25
24.1 WELD TESTING AND INSPECTION .............................................................................. 25
24.2 EXISTING STRUCTURAL STEELWORK INSPECTION .............................................. 25
24.3 NEW FABRICATED STEELWORK INSPECTION ......................................................... 26
24.4 INSPECTION DURING ERECTION ................................................................................. 26

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24.5 COMMISSIONING ............................................................................................................ 26

24.6 INSPECTION DURING OPERATIONAL PHASE ........................................................... 27
25. RECORDS MANAGEMENT ................................................................................................ 29
25.1 AS - BUILT DRAWINGS .................................................................................................. 29
25.2 ENGINEERING PROJECT FILES ..................................................................................... 29
25.3 MAINTENANCE WORK ORDERS .................................................................................. 29
25.4 MONORAIL SYSTEM ANNUAL INSPECTION ............................................................. 29

FIGURES
Figure 1 Monorail Design Process Flow Diagram Sheet 1 of 3 11
Figure 2 Monorail Installation Process Flow Diagram 14
Figure 3 Monorail Maintenance Process Flow Diagram 15
Figure 4 Minimum Interference between Monorail and Trolley End Stops 19

TABLES
Table 1 Size of Monorail Beam Identification Markings 24

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1. SCOPE
This Standard covers the minimum technical requirements for the design, approval, fabrication,
installation, testing and commissioning, preventative maintenance and inspection, and record
keeping of new and upgrades to existing monorails.

Existing structures shall be analysed in accordance with the criteria established in this Standard and
appropriate action taken, before upgrades to existing monorails are carried out or a new monorail is
installed in an existing structure.

Note: For electric hoists and motorised trolleys, this Standard is to be read in conjunction with
CSBP Engineering Standard Electric Hoists (ES-14-403-21).

2. PURPOSE
To ensure that all monorails in CSBP facilities are in compliance with WorkSafe WA regulations
and other relevant codes and practices and that the company’s requirements for operability, safety
and reliability are assured at all times.

3. RESPONSIBILITY
During the development phase it is the responsibility of the Responsible Officer to ensure that all
approvals have been obtained before the Works are carried out and that the requirements of this
Standard are adhered to.

Following completion of project handover, it is the responsibility of each business unit to ensure
that their monorails remain compliant with this Standard and are safe to use.

4. DEFINITION OF TERMS
Contractor/Vendor
The company that provides the equipment and services needed.

Sub-Contractor
A third party to be employed by the Contractor/Vendor, who has been approved by the Responsible
Officer.

Responsible Officer
Functional title for the Wesfarmers CSBP Limited Officer, or authorised representative,
responsible for the development and implementation of the Works, including liaison with and
obtaining internal and external approvals from appropriate personnel, statutory authorities etc.

CSBP
Wesfarmers CSBP Limited.

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Works
The scope of work that a Contractor is or may be required to execute under an agreement including
variations and remedial work.

Monorail
Light industrial crane comprising a beam, a trolley and a hoisting device. The trolley travels along
the bottom flange of the beam.

Jib Crane
A cantilevered monorail, that is pivoted about a vertical axis at the supported end.

Verification
Examination of objective evidence to determine conformity with stated requirements for that
activity.

5. STANDARDS
The Contractor shall perform the Works in accordance with this Standard, the latest issue of
referenced standards and Contractor regulations for on-site work. Should there be a conflict
between the Works, Statutory Requirements and the Standards, the Contractor shall notify the
Responsible Officer in writing for resolution. In general, the most stringent requirement will
prevail.

CSBP Engineering Standards

ES-14-101-02 Drawing Management
ES-14-101-03 Drawing Preparation
ES-14-101-04 Drawing Numbering
ES-14-101-06 Equipment Numbering System
ES-14-102-09 Labels & Signs: Plant and Equipment
ES-14-102-12 Protective Coatings
ES-14-202-10 Concrete
ES-14-202-14 Grouting

ES-14-302-01 Fabrication of Structural Steelwork

ES-14-302-02 Erection of Structural Steelwork
ES-14-401-01 Mechanical Preferred Equipment
ES-14-402-01 Mechanical Equipment Design, Supply and Installation
ES-14-402-02 Testing and Commissioning of Mechanical Equipment
ES-14-403-21 Electric Hoists
ES-14-701-01 Electrical/Instrument Preferred Equipment
ES-14-902-01 Materials and Workmanship for Electrical Installations
ES-14-902-02 Testing and Commissioning of Electrical Installations

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CSBP Procedures
DP-05-011-03 Maintenance Daily Schedule
DP-05-013-01 Work Order Entry and Approval
DP-05-013-04 Closing Maintenance Work Orders
DP-05-013-05 Developing Maintenance Strategies
DP-05-014-01 Maintenance Breakdown Repairs
EP-08-030-05 Engineering Project Files
EP-08-030-19 Engineering Project Design Review
EP-08-030-38 Engineering Project Handover
CSBP Guides
GM-05-043-01 Technical Data Requirements for Plant and Equipment
GM-05-050-01 Engineering Modification
GM-10-020-04 Contractor’s Site Instructions
GM-11-035-02 Basic Safety Rules
GM-11-038-02 Slings, Rigging and Lifting Equipment Safety

CSBP Standard Forms

ES-14-101-12 Technical Data Sheets – Mechanical, Electrical and Instrument
IF1463 Technical Data Sheets – Hoist, Winch, Crane
Stage 1 Commissioning Inspection Reports
M101 General Mechanical
M152 Hoist, Monorail and/or Monorail Jib Crane
Stage 2 Commissioning Test Reports
M201 General Mechanical
M252 Hoist, Monorail and/or Monorail Jib Crane

CSBP Standard Drawings

9900-3-0005/001 Standard Beam and Bracing Connection Details
9900-3-0005/002 Standard Beam Connection Details & Member Schedule
9900-3-0005/003 Structural Base Plates
9900-3-0005/004 Standard Column & Beam Bolted Splice Connection Details

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Standards Association of Australia

AS 1111 (all parts) ISO Metric Hexagon Bolts and Screws
AS 1112 (all parts) ISO Metric Hexagon Nuts Cold Formed
AS 1163 Structural Steel Hollow Sections
AS 1170 SAA Loading Code
AS 1214 Hot-Dip Galvanised Coatings on Threaded Fasteners
AS 1237 (all parts) Plain Washers for Metallic Bolts, Screws and Nuts for General
Purposes
AS 1252 High-Strength Steel Bolts with Associated Nuts and Washers for
Structural Engineering
AS 1418.1 Cranes - General Requirements
AS 1418.2 Cranes - Serial Hoists and Winches
AS 1554.1 Welding of Steel Structures
AS 1594 Hot Rolled Steel Flat Products
AS 1666.2 Wire Rope Slings - Care and Use
AS 1674 Safety in Welding and Allied Processes
AS 1796 Certification of Welders and Welding Supervisors
AS 1858.1 Electrodes and Fluxes for Submerged-Arc Welding – Carbon Steel
and Carbon Manganese Steels.
AS 1939 Degrees of Protection Provided by Enclosures of all Electrical
Equipment
AS 2053 Conduits and Fittings for Electrical Installations
AS 2214 Certification of Welding Supervisors – Structural Steel Welding
AS 2550 Cranes – Safe Use
AS 2700 Colour Standards for General Purposes
AS 3600 Concrete Structures
AS 3678 Structural Steel Hot Rolled Plates, Floor Plates and Slabs
AS 3679.1 Structural Steel Hot Rolled Bars and Sections
AS 3679.2 Structural Steel Welded I Sections
AS 3990 Mechanical Equipment – Steelwork
AS 3992 Welding and Brazing Qualifications
AS 4024 Safe Guarding of Machinery
AS 4100 Steel Structures
AS 4600 Cold-Formed Steel Structures
AS 4680 Hot-Dip Galvanised (Zinc) Coatings on Fabricated Ferrous Articles
AS 4855 Welding Consumables – Covered Electrodes for Manual Metal Arc
Welding of Non-Alloy and Fine Grain Steels.
AS/NZS ISO 9002 Quality Systems – Model for Quality Assurance in Production,
Installation and Servicing

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Other Engineering Standards and Publications

AISC Design Capacity Tables for Structural Steel
AISC Design of Structural Connections
AISC Safe Load Tables 6th Edition 1987

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6. OVERVIEW
Flow diagrams Figure 1, Figure 2 and Figure 3 show the high level activities involved in the
management of monorail systems through design, installation and operational phases.

6.1 DESIGN PHASE – FIGURE 1 (3 SHEETS)

The process commences with an engineering project request to either upgrade an existing monorail
system, or design and install a new one.

If the Safe Working Load (SWL) of an existing monorail is unknown it is necessary to check
through maintenance records, archived project files etc, to determine the monorail’s history, initial
usage and whether design calculations are available.

The condition of the existing monorail, connections and support structure shall be checked for
corrosion, deformation etc as this could impact the design and consequently the Works.

Based on findings, the SWL of existing monorail and loads on existing support structure shall be
determined, enabling engineering design modifications to monorail and/or support structure to be
established.

ALL design work for monorail systems with a SWL of ten (10) tonne or greater shall be carried out
and checked by an external engineering company / consultant. Monorail systems less than ten (10)
tonne shall be either designed / checked externally or, designed internally by CSBP and checked
externally by a suitably qualified and experienced structural engineer.

An Independent Design Review shall be carried out on ALL monorail systems with a SWL of ten
(10) tonne or greater, to ensure proposed modifications and loading conditions comply with
relevant standards and regulations. Independent Design Review of monorail systems less than ten
(10) tonnes shall ONLY be carried out if specified in the Works by the Responsible Officer.

Monorail systems with a SWL of ten (10) tonne or greater shall be reviewed and approved by
WorkSafe or their authorised agency, prior to commencement of fabrication or remedial work.

A new monorail in an existing plant basically has the same design steps as previously outlined,
whilst a new monorail with a new support structure follows normal design activities as indicated in
the flow diagram.

Reference to relevant clauses in this Standard and other CSBP and Australian Standards are made
in Figure 1, covering design phase activities.

6.2 INSTALLATION PHASE – FIGURE 2

This process commences with an approved monorail design and includes design modifications and
structural strengthening of existing structural steelwork where required.

Normal project development sequence activities are followed through to Customer handover and
project file close out.

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Reference to relevant clauses in this Standard and other CSBP Engineering Standards are made in
Figure 2, covering installation phase activities.

6.3 OPERATIONAL PHASE – FIGURE 3

This process commences with a commissioned monorail system that has been handed over to the
Customer.

The maintenance strategy, monorail system technical details and the inspection and preventative
maintenance requirements are finalised and recorded in the JDE Maintenance System, (activities
commenced in the design / installation phases).

Based on inspection findings, maintenance work is carried out in accordance with work priority or
if an engineering modification is required, changes are implemented in accordance with Figure 1
and Figure 2. Closure details are recorded in the JDE System. Reference to relevant clauses in this
Standard and other CSBP Engineering Standards and Departmental Procedures are made in Figure
3, covering operational phase activities.

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No Eng Project MONORAILS

AS3990 Source historical info /
AS1418 Calculate SWL.

7.1 Upgrade
Exit SWL New or New Exit No
7.3 A
8. known? Upgrade? struct?
9. Yes
Yes
9.
Cals for exist No Calculate AS4100
8.
Structure? existing loads AS3990
7.3
Yes

24.2 Inspect existing 24.2

7.2 Inspect existing
Monorail. 7.2
structure

Extent of corrosion.
No Condition Condition of bolts.
Extent of corrosion. OK? Extent of Structural
Condition of end stops deformation etc..
and connection to Yes
structure. ES-14-101-02
Prepare layout/detail ES-14-101-03
drawings. ES-14-101-04
ES-14-101-06

10.
Carry out monorail 9. AS4100 / AS3990
calculations. 8. AS1418
7.4
7.3

Check existing 8.
structure imposed 7.4
loads. 7.3

Within Yes SWL No

Condition of existing 24.2 ≥ 10t? End
7.2 code?
structure and monorail
to be factored into No Yes
design.
Design structural
B
stiffening.

12.
10.
Recheck design 9. B
calculations 8.
7.4
7.3 Yes

No Within Yes SWL No

≥ 10t? End
code?

Figure 1 Monorail Design Process Flow Diagram Sheet 1 of 3

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Intergrated design
monorail and
structure

ES-14-101-02
ES-14-101-03
Prepare layouts and
detail drawings ES-14-101-04
ES-14-101-06

12.
10.
Carry out design AS4100
9.
8. calculations AS1418
7.4
7.3

Yes SWL No
Within
code? ≥ 10t? End

No Yes

Revise design B

12.
10.
9. Recheck design
8. calculations
7.4
7.3

No Yes SWL No
Within
code? ≥ 10t? End

Yes

Figure 1 Monorail Design Flow Diagram Sheet 2 of 3

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7.5
Independent 11.
Design Review 12.

Within No
Advise
code? Superintendent

Yes
Action as
required

Statutory 7.6
Authority 13.
review/approval

Within No Advise
code? Superintendent

Yes

File approvals in Action as

project file required

End

Figure 1 Monorail Design Process Flow Diagram Sheet 3 of 3

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Approved monorail
design.

Tender, evaluate,
approval to proceed,
award.

ES-14-101-02
Prepare shop/ vendor ES-14-101-03
drawing and ES-14-101-04
documents. Submit ES-14-402-01
and review/ approve. ES-14-902-01

24.3 ES-14-302-01
24.1 ES-14-401-01
Fabricate/
23. ES-14-402-01
manufacture, inspect.
21. ES-14-701-01
14. ---> 19. ES-14-902-01
24.4
24.1 ES-14-302-02
Install ES-14-402-01
. 22.
14. ---> 19. ES-14-902-01

Test / Commission 24.5 ES-14-402-02

ES-14-902-02

Remedial work No
Accepted?
as
required.
Yes

Finalise handover
and close out
documentation,

As built Drawings
Remedial work as No Customer MDR's
required accept? Data Sheets
. H/O Certificate
Yes

File project
documentation
25.2

End

Figure 2 Monorail Installation Process Flow Diagram

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Commissioned
monorail system.

Finalise maintenance DP-05-013-05

Activities commence in strategy. GM-11-038-02
the design and
installation phases as
information becomes Equipment number
available. Complete recording SWL
details in JDE Registration numbers
Maintenance System. Hoist details
Inspection Reqts etc.

25.4
24.6 Carry out inspection GM-11-038-02
according to plan.

Yes Record details in

Accepted? End
JDE system.
No

MAINTENANCE Identify remedial ENGINEERING

WORK work required. MODIFICATION

DP-05-011-03 Initiate maintenance Initiate engineering

GM-05-050-01
DP-05-013-01 work work
DP-05-014-01 . .

Carry out design

work. Fig 1
Carry out
maintenance work.

Carry out
engineering work. Fig 2

Close out - record

DP-05-013-04 details in JDE
system. Close out - record
details in JDE
25.3 system. 25.2
25.1

End

Figure 3 Monorail Maintenance Process Flow Diagram

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7. BASIS OF DESIGN
7.1 EXISTING MONORAIL OF UNKNOWN CAPACITY

The safe working load of an existing monorail of unknown capacity shall be established by a search
through existing records and/or a design check, dependant on results of search.

This information search will include archived project records, maintenance, inspection and testing
records in order to determine equipment history, initial and current usage and availability of
original calculations.

If required, design calculations shall be carried out in accordance with applicable standards and
based on the properties and condition of existing structural steelwork members and the current
loading requirements. Refer Sections 7.2 to 7.4, 12 and 24.2.

Note: Where the strength or serviceability of an existing monorail or structure is to be

evaluated, the actual properties of the existing structural steelwork shall be used, NOT the
properties of sections currently available, which have replaced superseded sections.

7.2 CONDITION OF EXISTING STEELWORK

Existing structural steelwork, including monorails to be rated or upgraded, shall be inspected prior
to commencement of design work for structural adequacy, as condition could impact on the extent
of remedial and strengthening work that may be required. Refer to Section 24.2.

7.3 DESIGN STANDARDS

Monorails and supporting structures, including strengthening of existing steelwork members where
required, shall be designed in accordance with this Standard and Australian Standards AS3990,
AS4100 and AS1418.1 as applicable. Refer to Sections 8, 9, 10 and 12 for details.

For free standing monorail structures concrete footings shall be designed in accordance with
AS3600 and CSBP Engineering Standard Concrete (ES-14-202-10).

7.4 DESIGN

All Design work shall be performed in accordance with applicable CSBP specifications and
relevant Australian Standards. All loading including impact effect shall be considered as per
Australian Standards.

ALL design work for monorail systems with a SWL of ten (10) tonne or greater shall be carried out
and checked by an external engineering company / consultant. Monorail systems less than ten (10)
tonne shall be either designed / checked externally or, designed internally by CSBP and checked
externally by a suitably qualified and experienced structural engineer.

Note: Externally produced designs can be checked within the same organisation provided that
the company has in place a QA checking process. If not, design shall be checked by a
suitably qualified and experienced structural engineer from a different company.

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For requirements on design calculations refer to Section 12.1.

7.5 INDEPENDENT DESIGN REVIEW

Completed design work for monorail systems with SWL of ten (10) tonne or greater shall be
subject to an Independent Design Review. Refer to Section 11and 12 for details.

7.6 STATUTORY AUTHORITY APPROVAL

WorkSafe WA or their authorised agency shall approve all CSBP monorail systems with a ten (10)
tonne or greater safe working load prior to commencement of any fabrication or remedial work.
Refer to Section 13 for details.

8. DESIGN METHODS
8.1 WORKING STRESS DESIGN METHOD

Unless directed otherwise by the Responsible Officer, design-involving plants installed during or
before 1990 shall be carried out using the working stress design method. This shall be in
accordance with the provisions of AS3990 except where specified otherwise in AS1418.1.

8.2 LIMIT STATES METHOD

Unless directed otherwise by the Responsible Officer, design - involving new plants, or operating
plants installed after 1990 - shall be carried out using the limit states method. This shall be in
accordance with the provisions of AS4100, except where specified otherwise in AS1418.1.

9. MONORAIL SECTION SIZE

9.1 SAFE LOAD / CAPACITY TABLES

Subject to flange and web thickness and deflection checks (Sections 9.2 to 9.4 inclusive) monorail
section size may be designed using:

a. AISC Safe Load Tables 6th Edition 1987, for plants installed during or before 1990 using
‘old’ steel grades (e.g. Grade 250) and following the working stress design method of
AS3990.

b. AISC Design Capacity Tables for structural steel, for new and existing plants installed after
1990 and following the limit states method of AS4100.

9.2 FLANGE THICKNESS

Flange thickness of proposed beam section; shall be checked for local buckling in accordance with
AS1418.1 Clause 5.7.1.

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9.3 WEB THICKNESS

Web thickness of proposed beam section shall be checked in accordance with AS1418.1 Clause
5.7.2.

9.4 DEFLECTION LIMITS

The calculated deflection of the beam shall satisfy the requirements of AS1418.1 Clause 5.6.

9.4.1 Cantilever Monorails

Calculations for the deflection of cantilever monorails shall include the effects of adjacent spans.

9.4.2 Jib Cranes

Jib Cranes that can rotate through 90ο or more will impose torsional stresses in supporting building
columns.

Deflections due to torsional and other loading on building columns or structure shall be considered
when calculating total effects.

9.5 LONG SPAN MONORAIL BEAMS

Strengthening of long span monorail beams, to increase lateral buckling strength and stability, can
be achieved by the addition of bracing or ties to the top flange of the beam. Design shall be in
accordance with Section 8.

10. END STOP DESIGN

End stop connection to monorail beam, shall be designed to withstand dynamic loads transmitted
by hoist trolley, in accordance with applicable standards.

End stop shall be sized and positioned to suit the actual hoist trolley to be used, such that the
calculated vertical and horizontal interference dimensions, between monorail and trolley end stops,
shall not be less than those specified in Figure 4.

Note: If original hoist trolley is to be replaced a verification check shall be carried out, to ensure
minimum interference dimensions are maintained, PRIOR to putting the new trolley into
service. End stops shall be replaced if needed. Refer to Section 24.5 for commissioning
requirements.

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MONORAIL
WHEELS

MONORAIL

L
END STOP

HOIST TROLLY MONORAIL TROLLY

END STOP

MONORAIL HORIZONTAL
END STOP INTERFERENCE >15mm
(BOTH SIDES)

VERTICAL
INTERFERENCE >15mm
(BOTH SIDES)

TROLLY
END STOP

MANUFACTURERS RECOMENDED
WHEEL FLANGE CLEARANCE
(BOTH SIDES)
TYPICAL CROSS SECTION THROUGH MONORAIL

Figure 4 Minimum Interference between Monorail and Trolley End Stops

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11. INDEPENDENT DESIGN REVIEW

On completion of design and checking of calculations, including details of remedial work and
strengthening of existing structural steelwork where required, as per Section 7.3 and 7.4, an
Independent Design Review shall be carried out for ALL monorail systems with a SWL ten (10)
tonne or greater. Independent Design Review of monorails with SWL less than ten (10) tonne shall
ONLY be carried out when specified in the Works by the Responsible Officer.

The Responsible Officer shall nominate the type and extent of Independent Design Review
activities to be carried out, on a case by case basis. For example:
a. Methodology checks.
b. Conformance with Australian Standards and good engineering practices.
c. Analysis of design by carrying out alternative calculations or analysis methods.
d. Engineering check of prepared design drawings and calculations.
e. Comparison with a proven similar design.
Outcome of the Independent Design Review will enable the Responsible Officer to:
a. Initiate review / approval process with WorkSafe, or their authorised agency, if review
outcome is satisfactory.
b. Initiate appropriate action, if the Independent Design Review identifies problem areas such
as non-conformance to standards and incorrect analysis.

12. CALCULATIONS
12.1 DESIGN CALCULATIONS

Copies of the checked structural design calculations for the monorail and supporting structure, and
where required: concrete footing design - for free standing monorail structures; and the
strengthening of existing steelwork members, shall be submitted to the Responsible Officer in
accordance with the requirements of the Works.

Calculation sheets shall reference preliminary drawings, sketches and layouts by drawing and
revision number, and standards and other publications referred to in the calculations by title,
author, date and publisher.

All calculations shall be checked in accordance with Section 7.4, for accuracy and confirmation of
technical detail. Each sheet shall have the company name and the printed name and signature of the
checking engineer, and be dated.

Copies submitted shall be clearly referenced legible hard copies. If calculations are computer
generated, electronic copies shall be supplied in addition to the hard copy if specified by the
Responsible Officer in the Works.

12.2 INDEPENDENT DESIGN REVIEW

Report and copy of analysis and any calculations prepared by the Independent Design Review shall
be submitted to the Responsible Officer in accordance with the requirements of the Works.
Documentation shall reference drawings and publications and shall be submitted in a similar
manner as Section 12.1.

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13. APPROVAL BY STATUTORY AUTHORITY

All new, re-rated or modified monorail systems, ten (10) tonne or greater safe working load shall
be reviewed and approved by WorkSafe, or their authorised agency.

No fabrication or remedial work shall commence until the Responsible Officer has received written
approval from WorkSafe, or their authorised agency.

14. MATERIALS AND EQUIPMENT SELECTION

All materials shall be new unless approved by the Responsible Officer.

Unless otherwise noted on the drawings or approved by the Responsible Officer, materials and
equipment shall comply with the requirements of CSBP Engineering Standards:
• ES-14-302-01 Fabrication of Structural Steelwork
• ES-14-401-01 Mechanical Preferred Equipment
• ES-14-701-01 Electrical/Instrument Preferred Equipment
• ES-14-902-01 Materials and Workmanship for Electrical Installations
Manual lifting equipment shall be designed and comply with the relevant section of AS 1418.1 and
AS 1418.2.

Power operated lifting equipment shall be designed and comply with the relevant section of AS
1418.1 and AS 1418.2, and CSBP Engineering Standard Electric Hoists (ES-14-403-21).

15. ELECTRICAL CONTROLS

Where required, electrical controls shall comply with CSBP Engineering Standard Electric Hoists
(ES-14-403-21).

16. HANDLING OF STRUCTURAL STEELWORK & EQUIPMENT

Care shall be taken at all times during the fabrication, transportation, storage and erection of
monorails, supports and equipment and where applicable the modification and strengthening of
existing structures, to prevent steelwork deformation and/or damage to protective coatings.

Damaged steelwork, equipment and protective coatings shall be repaired to the satisfaction of the
Responsible Officer or replaced.

17. FABRICATION
Unless otherwise specified, fabrication of monorails, supports and strengthening components for
existing structures, shall be in accordance with CSBP Engineering Standard Fabrication of
Structural Steelwork (ES-14-302-01).

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18. WELDING
Unless otherwise specified, all structural welding shall conform to AS 1554.1 Category SP and
CSBP Engineering Standard Fabrication of Structural Steelwork (ES-14-302-01). All welding
procedures shall be submitted to the Responsible Officer for approval.

19. BOLTING
Unless otherwise specified all structural bolted connections shall be torqued bearing type AS 1252
Grade 8.8/TB bolts, installed in accordance with CSBP Engineering Standard Erection of
Structural Steelwork (ES-14-302-02).

20. SITE MODIFICATIONS

No site modification or correction to structural steelwork, mechanical or electrical work, other than
those specified on drawings or in the Works, shall be made without the approval of the Responsible
Officer.

Note: Any proposed site change shall be assessed for potential impact on the structural integrity
of the monorail system, or breach of the WorkSafe license agreement.

Where necessary, proposed changes shall be submitted to relevant parties for review and
approval before implementing proposed changes. Refer to Sections 11, 12 and 13.

21. PROTECTIVE COATINGS

21.1 STRUCTURAL STEEL

Surface preparation and protective coating, shall be in accordance with CSBP Engineering
Standard Protective Coatings (ES-14-101-12).

The monorail shall be painted Golden Yellow to AS 2700-colour code Y14.

Support steelwork shall be:

a. Light Grey Blue, AS 2700 - B44 in Chemical Process Plants
b. Cream, AS 2700 – Y34 in other areas such as fertiliser plants, storage and despatch.

Note: If supporting structural steelwork has torqued friction type connections (bolts denoted as
8.8/TF), contact surfaces shall be clean “as-rolled” or equivalent, free from paint or any
other applied finish, which will impact on the effectiveness of the friction developed
between the contact surfaces.

21.2 HOIST AND TROLLEY

Protective coating and finish of mechanical and electrical trolleys and hoists shall be to the
manufacturer’s standard unless specified otherwise by the Responsible Officer.

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21.3 BOLTS

Unless otherwise specified all bolts, nuts and washes shall be hot-dip galvanised in accordance
with AS 1214.

22. INSTALLATION
22.1 CIVIL / STRUCTURAL / MECHANICAL

As applicable, all monorail installation activities including setting out, concrete footings,
modification and strengthening of existing structures, steelwork erection, bolting, field welding and
grouting of structure base plates shall be carried out in accordance with:
a. the drawings;
b. Responsible Officer approved Contractor installation procedures;
c. CSBP Engineering Standards:
• Concrete (ES-14-202-10)
• Erection of Structural Steelwork (ES-14-302-02)
• Grouting (ES-14-202-14)
• Mechanical Equipment Design, Supply and Installation (ES-14-402-01)
d. Statutory Authorities having jurisdiction over the work site.

22.2 ELECTRICAL

Where an electric trolley and /or hoist is fitted, all electrical installation activities shall be in
accordance with CSBP Engineering Standard Electric Hoists (ES-14-403-21).

23. IDENTIFICATION
Monorail beam, hoist and trolley shall be clearly marked with their safe working load, equipment
number, Statutory Authority registration number if applicable, and other identification markings in
accordance with Sections 23.1 and 23.2.

Note: When the safe working load of a trolley and / or hoist is not matched to that of the beam,
the trolley, hoist and beam shall be marked with the lesser safe working load as
appropriate.

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23.1 BEAMS

All monorail beams shall be identified with the following information:

a. Safe Working Load (SWL) shall be specified in metric units as follows:
• kilograms where SWL is less than 1 tonne e.g.; SWL 700kg
• tonnes where SWL is equal to or greater than 1 tonne e.g.; SWL 9t or SWL 9 tonne
b. Equipment number, assigned in accordance with CSBP Engineering Standard Equipment
Numbering System (ES-14-101-06) e.g.; 1121L0221

Note: For a hoist and trolley that is ‘permanently attached’ to a specific monorail beam the
equipment number shall cover the beam, hoist and trolley.

For a hoist and trolley that is ‘portable’, the beam shall have a different equipment
number to that of the hoist and trolley.

c. Statutory Authority registration number for all monorails 10 tonne SWL or greater.
d. Beam orientation (i.e. either north-south OR east-west, as applicable) shall be clearly
marked on the beam. For corresponding markings on electric control switches for
motorised trolleys refer to CSBP Engineering Standard Electric Hoists (ES-14-403-21).

Note: For curved monorails, marking shall be as directed by the Responsible Officer.

Identification labelling shall be black paint stencilled lettering and numerals on both sides of the
monorail.

Markings shall be of sufficient size to be clearly visible and legible from the working area below
the beam. The following minimum sizes specified in Table 1 shall be adhered to wherever
possible.

MINIMUM HEIGHT of MARKINGS in mm

NOMINAL DEPTH of BEAM in mm
(see note)
150 75
200 100
250 125
300 150
350 200
400 200
450 and larger 250

Note: For short span beams, height of markings may be reduced where they cannot be
accommodated over monorail length with standard size text specified above.

Table 1 Size of Monorail Beam Identification Markings

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23.2 HOIST AND TROLLEY

All hoists and trolleys shall be identified by the following information:

a. Equipment number assigned in accordance with CSBP Engineering Standard Equipment

Numbering System (ES-14-101-06) e.g. 1121L0221.

Note: For a hoist and trolley that is ‘permanently attached’ to a specific monorail beam
one (1) equipment number shall be assigned to cover the beam, hoist and trolley
as per Section 23.1.

Hoists and trolleys that are ‘portable’ i.e. they are not attached permanently to a
specific monorail beam, shall be assigned one (1) number for the hoist and trolley
and one (1) number for the beam, specific to the plant area responsible for that
equipment.

For identification and labelling of electric hoists and trolleys refer to CSBP
Engineering Standard Electric Hoists (ES-14-403-21).

b. Labelling details shall be in accordance with CSBP Engineering Standard Labels & Signs:
Plant and Equipment (ES-14-102-09).

24. INSPECTION AND TESTING

24.1 WELD TESTING AND INSPECTION

Weld inspection and testing shall be in accordance with AS 1554.1 and CSBP Engineering
Standards:
• ES-14-302-01 Fabrication of Structural Steelwork
• ES-14-302-02 Erection of Structural Steelwork.
24.2 EXISTING STRUCTURAL STEELWORK INSPECTION

The following areas shall be inspected and results recorded during the design/development phase to
establish the extent of remedial and strengthening work that may be required to existing structural
steel.

Monorail (if fitted)

a. Extent of corrosion and condition of protective coating on monorail steelwork and end
connection bolts.
b. Type, size, connection details and adequacy and condition of existing monorail end stops.
c. Monorail identification markings are on both sides of beam, are correct and clearly visible
from ground level, or operating level in a multi-level situation. Required markings in
accordance with Section 23 to be displayed are:
• Safe Working Load (SWL)
• CSBP equipment numbers
• Statutory Authority registration number where applicable

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Structure
a. Extent of corrosion and condition of protective coating on existing monorail support
structure and connection bolts.
b. Bolted connections are secure in areas subject to vibration.
c. Supporting structure above a proposed monorail does not have excessive deflection or that
supporting columns are not noticeably distorted.
d. Extent of corrosion and condition of protective coating on existing structure that is to be
used to support a proposed monorail.

24.3 NEW FABRICATED STEELWORK INSPECTION

All new fabricated structural steelwork shall be inspected in accordance with the requirements of
CSBP Engineering Standard Fabrication of Structural Steelwork (ES-14-302-01).

24.4 INSPECTION DURING ERECTION

The following areas shall require inspection and approval by the Responsible Officer:
a. Surface preparation of concrete footing prior to erection of structural support steelwork.
b. Setting out and alignment tolerances.
c. Cutting, drilling and welding of existing steelwork.
d. Surface preparation and protective coating of remedial works, modifications and
strengthening existing steelwork and field welds.
e. Cleaning and surface preparation of the underside of support column base plate, holding
down bolts and concrete foundation prior to grouting.

Inspection shall be carried out in accordance with relevant Australian Standards and the following
CSBP Engineering Standards:
• ES-14-102-12 Protective Coatings
• ES-14-202-14 Grouting
• ES-14-302-02 Erection of Structural Steelwork
24.5 COMMISSIONING

Prior to being placed into service the monorail shall comply with the commissioning requirements
of AS1418.

24.5.1 Stage 1 Commissioning

All components within the monorail system shall be inspected to verify that they have been
fabricated / manufactured, supplied and installed in accordance with:

• Contract drawings and documentation;

• Standards and Codes specified in this Standard;
• Statutory Regulations;
• Manufacturer’s requirements.

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Movement of hoist and trolley shall be checked throughout their complete range in all directions
under no-load condition.

Stage 1 Commissioning Inspection Reports General Mechanical (M101) and Hoist, Monorail
and/or Monorail Jib Crane (M152) shall be used to verify equipment details.

Note: Stage 2 Commissioning, shall not commence until the Responsible Officer has accepted
and signed off the Stage 1 Commissioning Inspection Reports, as being successfully
completed.

24.5.2 Stage 2 Commissioning

Monorail and hoist shall be tested in accordance with the requirements of AS1418. Results shall be
recorded in the Stage 2 Commissioning Test Reports; General Mechanical (M201) and Hoist,
Monorail and/or Monorail Jib Crane (M252).

Note: Monorail system shall not be put into service until the Responsible Officer has accepted
and signed off the Stage 2 Commissioning Test Reports, as being successfully completed.

24.5.2.1 Beam Load Testing

Unless otherwise directed by the Responsible Officer, beam load testing shall be carried out with:

a. Test load equivalent to SWL + 10%

b. Test locations at:
• centre of span or
• end of cantilever (if applicable).
Beam deflection shall be measured at location of test load.

Note: ALL beams shall be load-tested as above, regardless of the monorail safe working load.

ONLY suitably qualified and experienced personnel shall carry out load testing.

Test load shall be kept as close as practical to ground or operating level. The stability and
deformation of supporting structure shall be monitored during testing.

24.6 INSPECTION DURING OPERATIONAL PHASE

In accordance with CSBP Guide Slings, Rigging and Lifting Equipment Safety (GM-11-038-02)
and AS 2550 the monorail system, including all mechanical, electrical and structural components
shall be subject to a complete and documented annual inspection. Dependant upon the
environmental conditions and the type of equipment being used more frequent safety checks shall
be carried out as directed by the applicable business unit.

Note: The person using lifting equipment shall inspect it for safety, before each use. Any lifting
equipment found to be defective, damaged or suspect shall not be used.

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24.6.1 Inspection Plan

In accordance with the Inspection Plan, the following areas shall be inspected and results recorded,
to establish whether any remedial work is required.

Monorail
a. Extent of corrosion and condition of protective coating on monorail steelwork and end
connection bolts.
b. Condition of monorail end stops.
c. Monorail identification markings are clearly visible from ground level, or operating level in
a multi level situation.

Structure
a. Extent of corrosion and condition of protective coating on monorail support structure and
connection bolts.
b. Bolted connections are secure in areas subject to vibration.
c. Supporting structure above monorail does not have excessive deflection or the supporting
columns are not noticeably distorted.

Hoist and Trolley

a. Mechanical
1. Extent of corrosion and condition of protective coating on trolley, end stops, wheels
and connection bolts.
2. Clearance between monorail bottom flange outside face and trolley wheel flange is
within manufacturer’s limits.
3. Actual vertical and horizontal interference dimensions, between monorail and
trolley end stops are not less than those specified in Figure 4.
4. Condition of chains, wire ropes, slings, sheaves, hook and safety latch as applicable.
Refer to CSBP Guide Slings, Rigging and Lifting Equipment Safety (GM-11-038-
02) for requirements.
5. Wear and clearances on all movable components are within manufacturer’s limits.

b. Electrical

Condition and operation of electrical equipment as defined in CSBP Engineering Standard

Electric Hoists (ES-14-403-21).

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25. RECORDS MANAGEMENT

25.1 AS - BUILT DRAWINGS

On completion of site modifications and installation, testing and commissioning of the monorail
system, drawings shall be upgraded to reflect any as-built design deviations.

Drawings recording the as-built details shall be prepared/revised, numbered, approved and handed
over in accordance with CSBP Engineering Standards:

• ES-14-101-02 Drawing Management

• ES-14-101-03 Drawing Preparation
• ES-14-101-04 Drawing Numbering

25.2 ENGINEERING PROJECT FILES

On completion of the project all relevant hard-copy documentation, in numbered project files, shall
be archived in the designated work area.

Records in electronic format (such as drawings and JDE data) shall be stored in the appropriate
databases and designated work area.

Refer to CSBP Guide Engineering Modifications (GM-05-050-01) for type of documents to be

retained for historical purposes.

25.3 MAINTENANCE WORK ORDERS

On completion of the maintenance work order, details shall be recorded in accordance with CSBP
Departmental Procedure Closing Maintenance Work Orders (DP-05-013-04).

25.4 MONORAIL SYSTEM ANNUAL INSPECTION

On completion of the annual inspection (or more frequently as determined by each business unit),
results shall be recorded in accordance with CSBP Guide Manual Slings, Rigging and Lifting
Equipment Safety (GM-11-038-02).

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