INSTALLATION MANUAL & OPERATIONS GUIDE TOWERS & CATWALK Edition

Transcription

1 INSTALLATION MANUAL & OPERATIONS GUIDE TOWERS & CATWALK 2019 Edition

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3 TABLE OF CONTENTS CONTENTS CHAPTER ONE INTRODUCTION. General Information... 6 General Safety Replacement Parts CHAPTER TWO SAFETY Safety Guidelines Safety Sign-Off Form Cautionary Symbols Definitions CHAPTER THREE PRE-INSTALLATION Receiving Inspection Pre-Installation Weep Holes CHAPTER FOUR: PART ONE GENERAL INSTALLATION Bolt Length Pretension Chart Reuse of A325 Galvanized Bolts Bolt Length Washer Use Non Pretensioned Bolts CHAPTER FOUR: PART TWO TOWER INSTALLATION Receiving Inspection Pre-Installation Preparation CHAPTER FOUR: PART THREE CATWALK INSTALLATION Receiving Inspection Pre-Installation Preparation CHAPTER FIVE MAINTENANCE, REPAIR, & TROUBLESHOOTING Maintenance, Repair, & Troubleshooting CHAPTER SIX WARRANTY Warranty Replacement Parts TOWER & CATWALK

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5 TOWER & CATWALK MANUAL & OPERATION GUIDE Chapter One INTRODUCTION 2018 Edition

6 CHAPTER ONE INTRODUCTION GENERAL INFORMATION Mid-States Support Towers are a great choice for supporting bucket elevators. Our robust, custom engineered designs give our customers a heavy-duty product specifically designed for their specification. At Mid-States, custom is standard, so our towers are also able to support bulk weighers, cleaners, distributors, and anything else our customer specifies. Our Catwalk Support Towers stand alone with their solid design. Mid-States Catwalk Support Towers are custom engineered to any height, wind speed or seismic zone. With our in-house design, you can be sure Mid-States is your partner when choosing Catwalk Support Towers. Mid-States Catwalk is one of the most economical and heavy built catwalk in the industry. With our heavy-duty design and factory welded sections, you can be sure to save installation time. Our handrail truss are uniquely custom designed and engineered for every project to meet our customers specifications and need. You can contact us with these requests at This manual covers the guidelines for installation and operation. We recommend a qualified contractor to provide on-site expertise. GENERAL SAFETY STATEMENTS 1 Modifications to equipment may cause extremely dangerous situations that could result in damage to the equipment as well as serious injury or death to the operator. Never modify the equipment. Modification of the MMF equipment will void any warranty. 3 Mid-States Material Handling and Fabrication recommends that you contact your local power company to survey the installation to ensure compatible wiring and adequate power is supplied to the unit. REPLACEMENT PARTS Mid-States Material Handling and Fabrication Structures are built to last. However, it is Mid-States Material Handling and Fabrication s recommendation that a small supply of spare parts be kept on hand to cover any minor breakdowns. A separate Spare Parts/Price List will be sent identifying the suggested spare parts. It is also necessary to check the certified drawings, which will list any special or custom components utilized on this equipment. The certified drawings furnished with the conveyor list the components which are likely to require replacement. Replacements for any other components, including structural members can be supplied upon request. For direct parts orders or requests for technical assistance to your sales representative or to: MID-STATES MATERIAL HANDLING AND FABRICATION 1280 SOUTH D AVE, NEVADA, IA PHONE: FAX: PLEASE HAVE THE MODEL/SERIAL NUMBER, CUSTOMER ORDER NUMBER & INSTALLATION LOCATION OF THE EQUIPMENT AVAILABLE. 6

7 TOWER & CATWALK MANUAL & OPERATION GUIDE Chapter Two: SAFETY 2018 Edition

8 CHAPTER TWO SAFETY & DECALS SAFETY GUIDELINES These safety guidelines range from broad to specific safety rules. This manual exists to help you, the user, understand safe operating procedures and problems that can be encountered by the operator and other personnel when using this equipment. Save these safety guidelines in a secure place for future reference. GENERAL SAFETY PRECAUTIONS AND NOTES 1 It is the responsibility of the buyer to inform, educate and share this manual with all personnel that are involved with operation or maintenance of this equipment. Personnel operating or working around equipment must read this manual and follow all safety, installation, and operating procedures. Failure to read this manual and its safety instructions is a misuse of the equipment. 2 Power lockout of any accompanying equipment is very important prior to installation, adjustment, and maintenance of the product. 3 Safety labels and guards have been installed by the manufacturer and/or the installer. These devices shall remain intact with the unit and should never be removed, altered, or tampered with. Doing so will void all liability and warranty of the manufacturer. It is the responsibility of the owner and or user to inspect the conveyor for proper safety stickers. If the stickers somehow become missing, it is the responsibility of the owner to provide and replace the safety stickers. 4 The covers and guards on our products create a barrier to prevent others from entering, reaching, or falling into the machinery contained. Operating the product with guards and covers missing or improperly installed to structural products may result in serious injury or death. 5 MMF recommends the buyer train all affected employees in the safe use of catwalks and towers. 6 As owner or operator, you are responsible for understanding the requirements, hazards, and precautions that exist and to inform others as required. Unqualified persons must always keep out of the work area. 7 Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in serious injury or death. Any alterations made will immediately void any warranty on the product. 8 This equipment must be installed in accordance with the current installation codes and applicable regulations. Authorities having jurisdiction must be consulted before installations are made. 9 When it is applicable, you must consider the installation location relative to electrical, fuel and water utilities. COMPLIES WITH OSHA & ANSI Z535 8

9 CHAPTER TWO SAFETY & DECALS SAFETY SIGN-OFF FORM Below you will find a safety sign-off form that can be used to track and verify that all personnel have read and comprehend the safety instructions. This is provided solely for your own record keeping. STRUCTURAL SAFETY SIGN-OFF SHEET DATE EMPLOYEE SUPERVISOR 9 TOWER & CATWALK

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11 TOWER & CATWALK MANUAL & OPERATION GUIDE Chapter Three: PRE-INSTALLATION 2018 Edition

12 RECEIVING INSPECTION Carefully inspect the shipment upon reception for damage. Verify all necessary parts are included and correspond with the packing slip. Report any damage or missing parts to the carrier on arrival. Any damage to the equipment is the fault of the delivering party as per the bill of ladling. Save all paperwork related to the tower s delivery, its parts and its operation. There are multiple models & configurations of MMF towers, catwalk, and structures. Upon delivery, be sure that you have received the correct model. PRE-INSTALLATION Make sure to read this entire manual prior to installation to ensure that you are compliant to all OSHA/ ANSI, electrical and other applicable codes. Only qualified millwrights or contractors should install tower and its accompanying equipment. Retention of a licensed engineer is essential for planning the installation of this tower. No responsibility is assumed by MMF for the installation of this tower. The directions of this manual are simply the manufacturer s considerations. The end user or installer of this MMF catwalk should consult a structural/civil engineer about this tower design, construction and installation. HOLE PREPARATION Galvanized product may result in smaller hole sizes due to buildup of galvanizing material. Bolt holes are manufactured at 1/16 larger than the recommended bolt size. If a bolt will not fit, due to galvanizing buildup, carefully de-burr the hole with proper equipment until the bolt fits. WEEP HOLES Weep holes are cut into the bottom of the columns to properly shed water. Check that weep holes are clear of any blockage so that moisture can flow out of the columns. 12

13 TOWER & CATWALK MANUAL & OPERATION GUIDE Chapter Four: Part One GENERAL ASSEMBLY, INSTALLATION & SPECIFICATIONS 2018 Edition

14 BOLT LENGTH AND TIGHTENING All bolt holes shall be aligned to permit insertion of the bolts without undue damage to the threads. Bolts shall be placed in all holes with washers positioned as required and nuts threaded to complete the assembly. Compacting the joint to the snug-tight condition shall progress systematically from the most rigid part of the joint. Snug tight is the condition that exists when all the plies in a connection have been pulled into firm contact by the bolts in the joint and all the bolts in the joint have been tightened sufficiently to prevent the removal of the nuts without the use of a wrench. Do not substitute any other bolts, only use the supplied ASTM A325 bolts. All MMF bolts are ASTM A325 bolts and shall be installed according to the AISC s structural joint specifications. PRETENSIONED BOLTS Columns of tower are to be connected using pretensioned bolts. Using a calibrated wrench, or by turning the nut, pretension the bolts according to your bolt diameter and required tension in the chart below. BOLT PRETENSION CHART MINIMUM BOLT PRETENSION FOR A325 BOLTS BOLT DIAMETER (IN.) PRETENSION (KIPS) 1/2 12 5/8 19 3/4 28 7/ / / /2 103 REUSE OF A325 GALVANIZED BOLTS Galvanized ASTM A325 bolts cannot and should not be reused after they have been initially tightened with a nut. Turning the nut is another option if you do not have access to a calibrated wrench. Use the chart below to distinguish how much of a turn to apply to the nut for proper pretension. Tighten the bolts into the joint snugly, match mark the nut with its complementary end of the bolt and rotate to tension. 14

15 BOLT LENGTH The length of the bolt should exceed or at a minimum come flush with the nut when properly tightened. WASHER USE Slotted holes are machined into multiple locations of the catwalk s outer ply. When these slots occur, be sure to use a washer with the bolt to cover the slot. TOWER CONNECTION POINTS NON-PRETENSIONED BOLTS All bolts in the assembly might not need to be pretensioned. These bolts, as called out on the print, will need to be snug tightened. Snugness is defined as the tightness attained by either a few impacts of an impact wrench or the full effort of a worker with an ordinary spud wrench that brings the connected plies into firm contact (AISC J3.1 pg ). 15 TOWER & CATWALK

16 SLIP VERSUS FIXED CONNECTIONS FUTURE EXPANSIONS & ADDITIONAL WIND LOAD If you plan to support any additional equipment with this tower that wasn t discussed in the quoting process, contact MMF to make sure your tower is equipped for the wind load. For any additional needs, please contact MMF directly. Any alterations without MMF authorization are strictly prohibited and dangerous to perform. 16

17 PANEL POINT SUPPORT If the condition arises when the catwalk support beam does not sit directly beneath a panel point of the catwalk, a heavy channel (shown below with C10 Channel) should be used to pick up the extra moment. Please contact MMFs office for additional parts that may be needed. 17 TOWER & CATWALK

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19 TOWER & CATWALK MANUAL & OPERATION GUIDE Chapter Four: Part Two CATWALK ASSEMBLY, INSTALLATION & SPECIFICATIONS 2018 Edition

20 ASSEMBLY MMF catwalk is designed in 20 sections. Organize the sections from end to end on the ground to ensure you have the proper measurements and hardware required to assemble. Attach end to end by crane. HANDRAILS TRUSS PANEL CONNECTIONS MMF catwalk sections are connected end to end by a bolt together connection. Ensure all bolt holes are filled with the included bolts for intended load capacity. CONVEYOR SUPPORT If you are planning to use this MMF Catwalk with MMF Conveyor, be sure the conveyor is supported every 10 feet from the bottom struts. BEARING CONNECTIONS Points of support are located along the catwalk at strategic points for OSHA compliance. Make sure that these are installed according to the official schematics to ensure safety. GRATING DIRECTION Grating, if not pre-installed, is to run perpendicularly to the support beams on the structure. 20

21 TOWER & CATWALK MANUAL & OPERATION GUIDE Chapter Four: Part Three TOWER ASSEMBLY, INSTALLATION & SPECIFICATIONS 2018 Edition

22 GENERAL TOWER ASSEMBLY MMF tower sections are designed to be installed vertically. Assemble each stage by first loosely tightening the bolts and later fully tightened to a proper tension. TOWER BRACING Bracing on tower typically is designed in an X formation. Another common bracing in our tower is the K formation. Bracing formations can be customized by request to meet your needs. Do not modify the bracing formations without first consulting MMF s design team. They will consult with you how to best modify the bracing in the field. MMF uses a few different variations of tower bracing depending on the application: K BRACE K bracing allows the tower to be structurally sound, while also allowing for spouting to exit the structure or to allow a more accessible entrance to the tower for maintenance on machinery contained within the structure. X BRACE This is the generic bracing structure. X bracing still allows a great amount of accessibility. Our engineers can also design a unique bracing configuration to match individual needs. If this was the case, please adhere to the specific instructions that were included in your final drawings. TOWER ANCHORING Contact a foundation engineer through your millwright or soils service to design a plan specific to your location and the planned structure. This support plan will give you the required anchor bolt grade, diameter and length. Do not heat high strength bolts as it will alter the structural strength of the anchor bolt. Double nut the anchor bolts for your tower to prevent loosening. TOWER ERECTION Always assemble MMF Tower vertically, as shown below, do not assemble the tower on it s side. Also consider the staging of the tower during assembly. 22 CORRECT INCORRECT

23 LEG POSITIONING Grain legs distribute wind load equally throughout the tower. Make sure these legs are centered within the tower to achieve maximum capacity. Legs outside of the tower should be centered between the two nearest towers. Grain legs should be braced, see the attached figure for proper and improper examples of tower leg bracing. LEG ATTACHMENT Leg attachments help brace the tower and grain leg on the horizontal plane. Brace the leg to the tower in a way that frames it to the tower in a complimentary way. If more than one leg is to be braced to the tower, brace them to their corresponding corners of the tower. See a grain leg bracket and the x-bracing below. TOWER PANEL POINTS OF X-BRACING 23 TOWER & CATWALK

24 GRAIN LEG BRACKET POSITIONING Be sure that you are installing the grain leg brackets in the correct location. Below, the illustrations will teach you what is and isn t a proper location for your grain leg brackets. CORRECT CATWALK POSITIONING INCORRECT The tower is designed to support catwalk in the middle of the tower. This utilizes the support provided by the tower in the most efficient way. WEB STIFFENERS Web stiffeners are to be placed on wide flanged beams at load points for increased support. See the highlights on the illustration below for further description of the web stiffeners locations. 24

25 EXAMPLE OF STIFFENER LOCATION 25 TOWER & CATWALK

26 26 GRAIN LEG BRACING RECOMENDATIONS

27 TOWER & CATWALK MANUAL & OPERATION GUIDE Chapter Five MAINTENANCE, REPAIR, & TROUBLESHOOTING 2018 Edition

28 GENERAL MAINTENANCE DISCLOSURE STATEMENT It is up to the owner/operator of this MMF catwalk to seek manufacturer advice on how to maintain their device as necessary. GENERAL REPAIR DISCLOSURE STATEMENT It is the recommendation of Mid-States Material Handling & Fabrication that any part that becomes damaged is to be repaired or replaced immediately. Not repairing problems in your towers can cause catastrophic failure and is extremely dangerous. Be sure to keep up maintenance on your MMF catwalk so that you can identify potential problems early. 28

29 TOWER & CATWALK MANUAL & OPERATION GUIDE Chapter Six: WARRANTY 2018 Edition

30 WARRANTY MMF warrants all products manufactured to be free of defects in material and workmanship under normal usage for a twelve-month period after retail sale to the original end buyer of such products. MMF has the obligation to repair or replace, at MMF s sole judgment, defect due to materials or workmanship. Except for the above stated express limited warranties MMF makes no warranty of any kind, expressed or implied, including, without limitation, warranties or merchantability of fitness for a purpose or use in the connection with the product manufactured or sold by MMF, any advice, instruction, recommendation, or suggestion by MMF regarding, configuration, installation, layout, suitability for a purpose, or design of such product or products. In no event shall MMF be liable for any direct, indirect, incidental or consequential damages, including, without limitation, loss of anticipated profit or benefits. MMF assumes no responsibility for field modifications or erection defects, which may create structural problems. Modifications to the product not specifically covered by this manual will nullify any product warranty that might have been otherwise available. The foregoing warranty shall not cover product or parts which have been damaged by negligent use, misuse, alteration or accident. This warranty covers only the products manufactured by MMF. This warranty is exclusive and in lieu of all other warranties express or implied, MMF reserves the right to make design or specification changes at any time. It is the responsibility of the buyer to research and comply with all federal, state and local codes, which may apply to the location and installation of our products. 30

31 REPLACEMENT PARTS The MMF catwalk is built to our highest standards, a heavy-duty construction ensures a high lifespan. It is MMF s recommendation that a small supply of spare parts be kept on hand to cover any minor part wear or damage. It is also necessary to check the certified drawings, which will list any special or custom components utilized in the tower. The engineer-certified drawings furnished with the tower list out the components which are most likely to require replacement. Replacements for any other parts can be ordered upon the customer s request. To reorder parts, contact your sales representative or contact us directly at: MID-STATES MATERIAL HANDLING AND FABRICATION 280 SOUTH B AVE, NEVADA, IA NEVADA, IOWA PHONE: FAX: PLEASE HAVE THE MODEL/SERIAL NUMBER, CUSTOMER ORDER NUMBER & INSTALLATION LOCATION OF THE EQUIPMENT AVAILABLE. FINAL DISCLOSURES Mid-States Material Handling and Fabrication reserves the right to improve our product whenever possible and practical to do so. We reserve the right to change, improve and modify our products at any time without obligation to make changes, improvements and modifications on equipment sold prior to the improvements. MID-STATES MATERIAL HANDLING AND FABRICATION (MMF) IS NOT RESPONSIBLE FOR THE INSTALLATION OF THIS PRODUCT. 31 TOWER & CATWALK