Installation | Four Step System | Brass Edge Installation | Installation of Greasetrap Lids | Rebate Drawing
19.1
Installation of Access Covers & Grates ~ General
The actual installation of cast iron and mild steel access covers and grates is relative to the specific use of the product.
1. Light Duty Applications - Class A & B - can be either cast in-situ or a rebate left in the base work and the product built in later using non-shrink grout.
2. Where, however, product will be subjected to heavy loads - Class C, D, E, etc. - it is necessary that the product is cast into the base concrete.
- Care should also be taken to ensure that concrete is vibrated, particularly under the frame and that concrete both under the frame and inside the cellular frame structure reaches the same Mpa as the base concrete.
- Clear Opening of the pit must not be larger than the frame opening.
3. In terms of extra heavy duty loadings - Class D, E, F - the frame of the product must be built into the base concrete and the base concrete must include sufficient reinforcing under and around the frame and in some cases reinforcing must be attached to the frame (i.e. case of high back pressure head).
4. Where product is to be used in conjunction with precast pits, the same general action must be taken and in terms of heavy duty application, bedding concrete must be of the same strength as the precast pit and include all necessary reinforcement.
5. In the case of Class D,E,F and G Units, these can be used with Precast
Rebates only where High Levels of Supervision are
provided and to ensure that:-
- Rebate fully supports frame
- Concrete or grout bedding and back fill is of sufficient Mpa to fully support the frame under High Load and impact conditions
6. All gastight covers and frames are individually manufactured making each cover unique to it's frame. Covers and frames can not be inter-changed and covers must be assembled into frame during installation.
Where frames are installed without covers being assembled, out of square conditions will effect the re-installation of the cover and the gas tightness of the finished product.
After installation, covers and frames shall be smeared with grease on the mating surfaces.
For Brass Edged, Two and Three part covers and frames and Multi-part covers, a system of installation bolts and numbering, ensure this individuallity of covers and frames is maintained.
As the manufacturer of the cast iron product, we advise that whilst our product is tested to AS3996 in terms of Design Load, the frames are designed to be fully encased in concrete of sufficient Mpa to hold the loads indicated.
Havestock do not take any responsibility for the integrity of the product in service where it has not been installed as described in this document. Inadequate installation will void the product warranty.
***Important - read before installing products***
The installation of a Havestock unit is crucial to the future life of the product.
STEP 1 - PREPARATION
Ensure the Class of product suits the
traffic application.
Products can be cast in-situ or rebated in.
Prepare internal boxing so it is internal to the frame.
Frame sits around boxing and may be held in place by either :
nail supports
by the cover (if it is clamped to the frame).
Clear Opening of the pit must not be larger than the frame opening.
STEP 2 - POSITION COVER IN FRAME
Covers and frames are unique and must not
be interchanged.
- Clean all cover and frame matching surfaces to ensure they are free of dirt.
- Cover and frame edges must be level.
- Installation bolts (pre-tagged) must be identified and removed just prior to infilling the covers.
- Ensure frame is flat and level with the finished surface level required.
- Ensure frame is in square around the cover and that the cover does not rock.
- Fit plastic plugs into keyholes.
STEP 3 - POUR CONCRETE
Concrete must FULLY support the frame all the way to the inside edge of the frame.
- Concrete must be of at least 32mpa.
- Ensure all concrete is free of voids.
- Ensure that concrete is vibrated, particularly under the frame and that concrete both under the frame and inside the cellular frame structure reaches the same Mpa as the base concrete.
- Screed off excess concrete to a neat finish (cover ribs and edges should be visible).
- Allow to cure before attempting to remove cover as early movement may distort the frame and jeopardise the gastight seal and the frame remaining in square.
STEP 4 - STRIP & SEAL
- After curing period, remove cover.
- Strip out formwork.
- Ensure concrete FULLY supports the frame and is free from all voids.
- Clean and apply heavy grease to all
mating surfaces before returning cover to it’s
original position.
Installation Guide
Brass edged units are supplied with closed level frames and an installation bolt which is fitted to ensure the unit is secure for transportation and is installed correctly on site.
Install the cover and frame so that the top edge of the brass edge is at the same height as the finished flooring.
Concrete or grout the cover and frame into position and allow the compound to cure. Do not fill the lid at this stage.
Once the compound has cured remove the installation bolt and then fill the cover.
The cover may now be removed when necessary. When replaced into the frame, the complete unit will be gas-tight.
Remember :
Installation bolts must be removed before filling the
cover or else you will not be able to remove the cover.
Covers must not be removed from the frame prior to installation.
The units must be treated with respect on site.
Do not mix covers and frames.
Do not leave the brass edges exposed before finishing the flooring - pack around the brass to protect them from excavators & heavy tools.
- Once installed into position, all surfaces should be cleaned and heavy grease applied to the mating surfaces before returning the covers to their original position.
19.4 Installation of Greasetrap Lids
It is important to install greasetrap lids so that the unit is gas-tight when
complete. This is achieved with the following recommended installation method.
Option 1 - Lid fitted directly to the top of the tank or riser.
This method can only be used with full width lids that sit on or past the precast walls of the trap.
Allow 50mm for grouting into the precast rebate.
Option 2 - Cast into a concrete collar which in turn sits on top of the tank or riser.
This method is used on covers with are less than the full width of the trap.
Concrete collar to be made to the following specifications :
Collar to 100mm all around larger than the lid.
Class A lids - collar must be 100mm deeper than the frame.
Class C lids - collar must be 150mm deeper than the frame and must have 12R deformed bar reinforcing at 150mm centres.
Installation Steps
- All lids are manufactured in our Northgate factory and during production are fitted with installation bolts .
- Installation bolts are identified by way of an attached white tag with the words "Remove bolt before filling lid".
- These bolts hold the covers together and in line as well as holding the lid secure for transportation to site.
Install the lid and/or collar to the tank, making sure the lid is laying flat and square to the tank ~ do not remove installation bolts or covers at this stage.
Important ~ Ensure the frame is fully supported underneath with concrete.
Concrete or grout the frame into position and allow to cure ~ do not fill the lids yet.
After curing, remove installation bolts and fill the covers with concrete.
At least 32 Mpa concrete should be used for the lid to realise it's full strength potential.
Remember :
· Lids must be installed flat and straight and should be full width or fitted with a concrete collar.
Installation bolts must not be removed until the frame has been concreted into position and the concrete cured. Installation bolts must be removed prior to filling the covers or else the lids will be permanently fixed to the frame.
- Once the covers have been filled,
all surfaces should be cleaned and heavy grease applied to the mating
surfaces before returning the covers to their original position.
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Rebate drawings are enclosed on the following pages to allow for early site preparation.
Please contact the Technical Sales Department for any futher information.