PRAIRIE ENTERPRISES PTY. LTD Trading as INDUSTRIAL …

PRAIRIE ENTERPRISES PTY. LTD

Trading as

INDUSTRIAL STEPS & LADDERS

ADD-A-STEP

MODULAR LADDER SYSTEM

PRODUCT APPRAISAL 05/11

25 JULY 2006

This report consists of cover pages, a table of contents, 21 pages of report, a disclaimer and 3 Appendices.

Sydney Office: Suite 21, L5, 321 Pitt Street, Sydney, NSW, Australia PO Box A812, Sydney South, NSW, 1235, Australia

Telephone (02) 9283 0725, Facsimile (02) 9283 0799, Email: [email protected]

WSAA Product Appraisal 05/11 Industrial Steps & Ladders – Add-A-Step

Note 1

This appraisal applies to the product(s) as submitted. Any changes to the product(s) either minor or major shall void this appraisal. To maintain the recommendations of this appraisal any such changes shall be detailed and notified to the National Codes Manager for consideration and review of the appraisal report and appropriate action. Appraisals and their recommendations will be the subject of continuous review dependent upon the satisfactory performance of products. WSAA reserves the right to undertake random audits of product manufacture and installation. Where products fail to maintain appraised performance requirements the appraisal and its recommendations may be modified and reissued. Appraisal reports will be reviewed and reissued at regular intervals not exceeding five (5) years.

Note 2 Disclaimer

The Disclaimer on page 26 explains a number of very important limits on your ability to rely on the information in this Product Appraisal Report.

Please read it carefully and take it into account when considering the contents of this Product Appraisal Report.

This appraisal was carried out by Leith Forbes & Associates Pty. Ltd. on behalf of WSAA.

The report was peer reviewed by Ian Wight - Coliban Water, Killian Roddy – Water Corporation WA, Terry Scott – Melbourne Water and David Cox - WSAA

Any technical inquiries regarding this report should be directed to the Appraisal Project Manager, Leith Forbes.

Tel/Fax (03) 9803 2313. E-mail [email protected]

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mailto:[email protected]


CONTENTS

Page

1 EXECUTIVE SUMMARY 5 1.1 RECOMMENDATION 6

2 THE COMPANY 7

3 THE PRODUCT 7

4 SCOPE OF THE APPRAISAL 9

5 APPRAISAL CRITERIA 9 5.1 QUALITY ASSURANCE REQUIREMENTS 9 5.2 PERFORMANCE REQUIREMENTS 10

6 COMPLIANCE WITH APPRAISAL CRITERIA 10 6.1 COMPLIANCE WITH QUALITY REQUIREMENTS 10 6.2 COMPLIANCE WITH APPRAISAL REQUIREMENTS 10 6.2.1 Performance requirements 10

6.2.1.1 Prototype testing 10 6.2.1.2 WSA 108 test results for PBT 11 6.2.1.3 WSA 108 test results for FRN 14

6.2.2 Dimensional requirements 16 6.2.3 Contact with drinking water 16 6.3 WSAA AGENCY NETWORK REQUESTS 17

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION 22

8 PRODUCT MARKING 22

9 PACKAGING AND DELIVERY 23

10 WATER AGENCIES EXPERIENCE / FIELD TESTING REPORT 23

11 PRODUCT WARRANTY 23

12 DISCUSSION 23

13 SUMMARY 24

14 LIFE EXPECTANCY RATING 24

15 FUTURE WORK 24

16 RECOMMENDATION 25

17 DISCLAIMER 26 17.1 ISSUE OF REPORT 26 17.2 LIMITS ON RELIANCE ON INFORMATION AND RECOMMENDATIONS 26 17.2.1 Disclaimer of liability 26 17.2.2 Need for independent assessment 26 17.2.3 No updating 26 17.2.4 No warranty 26



APPENDIX A TECHNICAL MANUAL/BROCHURES 27

APPENDIX B QUALITY ASSURANCE CERTIFICATES 33

APPENDIX C SUPPLIER CONTACT DETAILS 34



1 EXECUTIVE SUMMARY

The ADD-A-STEP modular ladder system, which is manufactured by Industrial Steps & Ladders in Western Australia, has stiles rungs and brackets manufactured from either:

• Fibre reinforced polybutelene terephthalate partially crystalline polyester (known as PBT [Yellow] ladder and recommended for use in chemically aggressive locations such as sewer MH’s), or

• Fibre reinforced nylon (known as FRN [Blue] ladder and recommended for use with water immersion situations such as water towers and tanks).

Both materials are injection moulded using a purpose made set of dies. The green coloured rung retaining clip is injection moulded from acetyl material.

Each module of the ADD-A-STEP ladder consists of two stiles, one rung and two retaining clips. Each stile measures 360 mm long, 80 mm wide and 32 mm thick maximum dimension. The ladder width outside the stiles (uprights) is 435 mm and it weighs approximately 5 kg per lineal metre. The ADD-A-STEP ladder has 30 mm diameter rungs at 300 mm centre spacings, and the width or foot space inside the stiles is 375 mm. The ladder is assembled on site using the number of modules required to achieve any length requirement.

Each module is packed into a purpose made box 425 mm x 80 mm x 80 mm. Up to 400 boxes containing a total of 120 lineal ladder metres can be packed onto a pallet for delivery. Any number of modules can be purchased. The ADD-A-STEP modular ladder system offers supply off the shelf for a next day delivery.

The ADD-A-STEP ladder has the following benefits:

• It is modular and can be transported over long distances more economically than fully assembled ladders.

• It does not have to be measured prior to order and can be made up to any length on site as required.

• The ADD-A-STEP ladder packs can be transported in a lift or by crane and assembled on top of a structure where a ladder may be required for say inside a water reservoir (tank).

• The ADD-A-STEP ladder has excellent insulation properties so it can be used in applications where electrical cables are present.

• The fibre reinforced plastic materials used are UV tolerant and non-corrosive.

• The FRN product is suitable for contact with drinking water.

• There is no maintenance required other than occasional cleaning with a pressure hose if desired.

WSA 108-2001 Industry standard for fibre reinforced plastic ladders has been used as the appraisal criteria along with the requirements of WSA 02-2002. WSA 108 was developed from other available standards for the appraisal of the Myiama ladder (PA 99/12) and has been shown to be limiting and too prescriptive for this product. The recent release of the European Standard EN 14396 for manhole ladders may offer more appropriate appraisal criterion for the Add-A-Step modular ladder. WSAA is to review WSA 108 in light of EN 14396 and consider whether WSA-108 should be replaced in part or full by EN 14396.



All questions of the WSAA Product Appraisal Network have also been adequately satisfied. The ADD-A-STEP modular ladder system has satisfied the requirements of WSA 108 (apart from one test requirement representing a loading circumstance of low probability) and WSA 02-2002.

The ADD-A-STEP modular ladder system offers the water industry a new and innovative product with many benefits and is seen as ‘fit for purpose’.

Industrial Steps & Ladders is required to arrange for corrosion testing and deterioration resistance in the highly aggressive sewer environment at the sewage test chamber at SA Water. This test will take some time and a progress report including testing the exposed ladder section to the performance requirements specified in WSA 108, should be added to this Appraisal Report before July 2008.

A life expectancy for this product is very subjective as the information available for this product to establish long term performance is limited. No data has been presented for long term performance in aggressive sewage environments, immersion in heavily chlorinated waters or exposure to a heavily (gaseous) chlorinated environment above water in an enclosed tank. The general knowledge of the Product Appraisal Network has accepted a ‘B’ rating with a suggested life expectancy in excess of 50 years. This rating is only a general guide to life expectancy and may increase or decrease as a result of the system operating conditions, preventative maintenance programs, operating environment and other geographical and site specific factors.

1.1 RECOMMENDATION

It is recommended that, subject to the cautions noted in the report for extreme exposure situations and only vertical installation, WSAA members and associates accept/authorise the Industrial Steps & Ladders ADD-A-STEP modular ladder system in PBT and FRN as required.



2 THE COMPANY

Prairie Enterprises Pty Ltd was purchased by the present owners in 1993 and has been trading as Industrial Steps & Ladders since October 2001.

Prairie Enterprises Pty Ltd has supplied step irons to Humes Welshpool (WA) concrete pipe plant since May 1994. Humes was approved to supply precast concrete sewer manholes fitted with Prairie Enterprises Pty Ltd polypropylene covered galvanised steel step irons to the Water Corporation of Western Australia in mid 1998. These step irons are now supplied for many applications in Western Australia, including sewer and storm water drainage pits, underground pits for the mining industry and Perth rail system.

In February 2000 Prairie Enterprises Pty Ltd purchased its first plastic injection moulding machine and in December 2001 a second machine was purchased. With encouragement from the Water Corporation of Western Australia a project was commenced to develop a modular plastic ladder that could be purchased ex stock for next day delivery. The injection moulding machines produce the modular components for an ‘off the shelf’ ladder that provides delivery advantages over continuous length ladders. The design and testing of a modular ladder system began in November 2002 and manufacture of the ADD-A-STEP ladder commenced in 2004.

3 THE PRODUCT

The ADD-A-STEP modular ladder system has stiles rungs and brackets manufactured from either

• ‘Fibre reinforced polybutelene terephthalate partially crystalline polyester’ (known as PBT [Yellow] ladder and recommended for use in chemically aggressive locations such as sewer MH’s), or

• ‘Fibre reinforced nylon’ (known as FRN [Blue] ladder and recommended for use with drinking, recycled and raw water immersion situations such as water towers and tanks).

Both materials are injection moulded using a purpose made set of dies. The rung retaining clip is injection moulded from acetyl material. For larger size orders the ladder can be manufactured in any colour.

The ADD-A-STEP modular ladder system was designed to provide a product that could be supplied off the shelf for a next day delivery. Each module is packed into a purpose made box 425 mm x 80 mm x 80 mm and some 400 boxes can be packed onto a pallet. Each pallet can contain 120 lineal ladder metres. Any number of modules can be purchased. The final ladder is assembled on site using the number of modules required to achieve any length requirement.

Each module of the ADD-A-STEP ladder consists of two stiles, one rung and two green coloured retaining clips (see Figure 1.). Extra retaining clips are provided in case they become lost.

Each stile measures 360 mm long, 80 mm wide and 32 mm thick maximum dimension. The ladder width, outside the stiles (uprights), is 435 mm and it weighs approximately 5 kg per lineal metre.

The ADD-A-STEP ladder has 30 mm diameter rungs at 300 mm centre spacings, and the width or foot space inside the stiles is 375 mm. The ladder is assembled on site using the number of modules required to achieve any length requirement.



Figure 1 – Module components

The ladder joint design locks the rung into the stile and the green coloured retaining clips fit into slots in the rung adjacent to the stiles. The rung has a collar on each end, which can only fit one way into the top of the stile. The legs on the female end of the stile joint are made with a clip shape to resist a tensile load. The joint has a taper fit, and with the retaining clips locked into the rung, an ultimate tensile test load of 16 kN (1.6 tonne) has been achieved with FRN. The joint has been designed for the assembly process to be simple and assembled only in the correct way. (See Figures 2, 3, 4 & 5)

Figure 2 – Assembling stile and rung. Figure 3 – Assembled stile and rung

Figure 4 – Placing the retaining clip. Figure 5 – A single rung assembly.



Figure 6 – Wall bracket assembly. Figure 7 – Floor mount assembly.

Industrial Steps & Ladders manufacture two types of bracket; one to suit the cylindrical access chamber (MH) wall (1050-1500 mm dia.), and the other for a flat wall or floor mount (See Figures 6 and 7). The ADD-A-STEP ladder is mounted using brackets supporting the ladder at a maximum spacing of 2400 mm. The ladder bracket is attached to the ladder using a 12 mm x 50 mm Grade 316 stainless steel bolt assembly. Industrial Steps & Ladders recommend the ladder be secured to the access chamber wall using HILTI 10 mm x 40 mm grade 316 stainless steel drop-in anchors. HILTI anchors are guaranteed to resist a pullout force of 7.5 kN.

Figure 8 – MH configuration. Figure 9 – MH installation

4 SCOPE OF THE APPRAISAL

The scope of this appraisal is the ADD-A-STEP ladder system comprising of either PBT or FRN composite materials as described in Section 3 above.

5 APPRAISAL CRITERIA

5.1 QUALITY ASSURANCE REQUIREMENTS

The WSAA product appraisal network accepts system (ISO 9000) and product certification by a Certification Body at the manufacturing site of strategic products to appropriate Australian or internationally recognised standards. The Certification Body should have relevant accreditation by the Joint Accreditation System of Australia and New Zealand (JAS-ANZ) or by an equivalent international accreditation system recognised by JAS-ANZ.

NOTE:Refer to the quality assurance requirements appended to the “Products and Materials” sections of WSA 02-2002 or WSA 03-2002 and WSA 06-2004 for further information.



5.2 PERFORMANCE REQUIREMENTS

The appraisal criteria are based on the requirements of WSA 108-2001 Industry standard for fibre reinforced plastic ladders. (Copy is available at the WSAA website www.wsaa.asn.au )

Due to design and materials not covered by WSA-108 for the ADD-A-STEP ladder and its modular construction, additional criteria includes the dimensional suitability of the components for on-site assembly, the suitability of materials, the assembly process and the mounting system (brackets). The requirements specified in the WSAA Sewerage Code, WSA 02-2002 for ladders have also been addressed. WSA 02-2002 was published after WSA-108 and includes more precise dimensional requirements for ladders than given in WSA-108.

6 COMPLIANCE WITH APPRAISAL CRITERIA

6.1 COMPLIANCE WITH QUALITY REQUIREMENTS

To date Industrial Steps & Ladders clients have not required quality certification. As a requirement of WSAA Product Appraisal Network, Industrial Steps & Ladders is reactivating and revising an earlier certified quality management system that was sold with another business as a part of the assets of that business.

Industrial Steps & Ladders has engaged a Quality Management consultant to develop the QA Plan to suit current manufacturing requirements and initiate action to have it certified by BVQi for compliance with AS/NZS ISO 9001:2000. It is expected the QA Plan will be certified by the end of September 2006.

See Section 15 Future Work.

6.2 COMPLIANCE WITH APPRAISAL REQUIREMENTS

6.2.1 Performance requirements

Industrial Steps & Ladders conducted independent tests at Curtin University as the ladder was developed and test reports have been submitted for both PBT and FRN ladder versions.

6.2.1.1 Prototype testing

Industrial Steps & Ladders conducted initial prototype testing on 35% glass reinforced Nylon 66 (FRN) ladder components to establish the strength of a single stile /rung joint assembly. The submitted report is dated 21 August 2003, referenced 03-03544 and prepared by Dr Paul Kong, Lecturer, Department of Civil Engineering.

Two tests were conducted;

#1. A tensile test of a single stile / rung joint assembly to check its integrity. The tensile load was applied to the stile on either side of the stile / rung joint in 1 kN increments. A cracking sound was heard at 9 kN and total brittle failure of the stile joint occurred at 14.6 kN. The above test result would be doubled for an assembled ladder and the stile joint strength would comfortably exceed any expected tensile load applied to a fixed ladder. There is no test of this nature in WSA 108.

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#2. A flexural test to determine the response of the joint when subjected to transverse loading (bending). The stile assembly was supported at the end of each stile module and the load was applied on each side of a single stile / rung joint. Deflection was measured at 0.5 kg increments and a deflection of 4.3 mm was measured at a load of 9.5 kN. A cracking sound was heard at 9.5 kN and brittle failure of the stile joint occurred at 11.7 kN. The above test result would be doubled for an assembled ladder and the stile joint strength would comfortably exceed any expected transverse load applied to a fixed ladder. There is no test of this nature in WSA 108.

Further prototype comparative tensile testing was conducted on the final single stile / rung joint assembly after die modification and for different ladder materials when subjected to the effects of exposure to a 5% concentration by volume of H2SO4 acid solution for two (2) and six (6) weeks.

NOTE: This is similar to the chemical exposure requirement in the chemical resistance test in WSA 108.

The report is dated 23 November 2004, referenced DIV-ENG-DCE-GJ-40755-1 and prepared by J. R. Murray, Laboratory Manager, Faculty of Engineering and Computing. Six comparative tests were carried out under tensile loading to compare the performance of acid affected and unaffected joint assemblies.

• Test #1. - 35% glass fibre reinforced Nylon 66 (FRN), no acid exposure – joint failure load = 16.35 kN.

• Test #2. - 35% glass fibre reinforced Nylon 66 (FRN), two weeks acid exposure – joint failure load = 14.7 kN.

• Test #3. - 35% glass fibre reinforced Nylon 66 (FRN), six weeks acid exposure – joint failure load = 13.15 kN.

• Test #4. – 35% glass fibre reinforced polybutelene terephthalate (PBT), two weeks acid exposure – joint failure load = 12.10 kN.

• Test #5. - 35% glass fibre reinforced polybutelene terephthalate (PBT), six weeks acid exposure – joint failure load = 12.075 kN.

• Test #6. – ABS plastic, six weeks acid exposure – joint failure load = 8.525 kN.

These tests demonstrated that FRN has about 25% greater strength than PBT. That difference is reduced to marginal when FRN is affected by acid exposure for over 1000 Hrs. PBT is therefore recommended for sewer MH’s and Nylon is recommended for potable water immersion. ABS was not seen as a suitable material.

6.2.1.2 WSA 108 test results for FRP

The fibre reinforced polybutelene terephthalate (PBT) ladder, is recommended for use in chemically aggressive locations (e.g. sewer MH’s). The (PBT) ladder assemblies were tested to establish compliance with the performance requirements of WSA 108-2001 Industry Standard for fibre reinforced plastic ladders.

The submitted test report is dated 6 March 2006, signed and authorized by Dr. Prabir Sarker, Lecturer, Department of Civil Engineering, Faculty of Engineering and Computing at Curtin University of Technology, Bentley, Western Australia. The report includes photos of the apparatus and ladder during and after testing. The ladders were cut into test specimens of the required size in accordance with the Standards requirements.

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A summary of the tests and the conclusions is as follows:

1 Rung Torque Test – Appendix ‘C’ WSA 108

A torque of 100 N.m was applied to the top rung of a ladder assembly in a series of 10 cycles of clockwise and anti-clockwise application within a 4 minute period. The ladder section under test had four rungs and both stiles firmly secured to a steel rig and a concrete floor.

Visual inspection of the assembly on completion of the test revealed:

• No structural damage to the rung.

• No looseness or twisting of the rung in the stiles.

Passed.

2 Rung Strength Test – Appendix ‘D’ WSA 108

The ladder section under test had four rungs and both stiles firmly secured to a steel rig and a concrete floor. A static load of 375 kg was applied to a 100 mm long bearing block placed midway on the top rung of the ladder assembly. The load was applied gradually and held at 375 kg for 90 seconds and then released.


• No sign of structural damage to the ladder.

• No looseness or twisting of the rung in the stile.

• No significant residual deflection of the rung after removal of the load.

Results: Datum from ground = 839mm

Deflection at full load = 820mm (375kg – 19mm from datum)

Deflection after removal of load = 837mm

Residual deflection = 2mm

Passed.

3 Rung shear strength test – Appendix ‘E’ WSA 108

The ends of the stiles were supported by the concrete floor. A static load of 480 kg was applied to a 100 mm long bearing block placed on the top rung of the ladder assembly immediately adjacent to the stile. The load was applied gradually and held at 480 kg for 90 seconds and then released.


• No signs of structural damage such as splitting or delamination in the entry of the rung to the stile.

• No looseness or twisting of the rung in the stile

Results: Datum from ground = 838 mm Deflection at full load = 832 mm (480 kg – 6 mm from datum) Deflection after removal of load = 838 mm Residual deflection = 0.0 mm Passed.

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4 Rung Impact Resistance Test – Appendix ‘F’ WSA 108

This test was not carried out with PBT as the result was predicted to be similar to FRN where rung fracture occurred – See Clause 6.2.1.3 below.

It is recommended that this test be disregarded.

5 Side Sway Test – Appendix ‘G’ WSA 108

Tests were carried out for a span of 2400 mm. The nominated loads of 147 N, 260 N and 325 N were applied to the bearing block at mid-span for the nominated durations of 90 seconds, 120 seconds and 90 seconds respectively. The sideway deflection data is shown in the following Table:

Table 1 – Sideway deflection data

Span

2400mm

(a)

Load

147N

Load

260N

(b)

Load

325N

Deflection in percentage of span (%)

(b/a*100)

Remarks

Deflection

(mm)

7mm 14mm 17.5mm 0.58 <1%

Passed

Residual

(mm)

0.0mm 0.5mm 1mm


• No signs of structural damage to the stiles.

• No looseness of the rungs in the stiles.

Passed.

6 Ladder Fastening Test – Appendix ‘H’ WSA 108

A ladder section was mounted on 4 brackets and the ends of the stiles were not supported. A static load of 375 kg was applied gradually to a 100 mm long bearing block placed midway on the top rung of the ladder assembly and held for 90 seconds and then released.



• No significant looseness was felt in the ladder mountings.

• No structural damage was observed after undoing the bracket mountings.

Results: Datum from ground = 838 mm

Deflection at full load = 800 mm (375 kg – 38 mm from datum)

Deflection after removal of load = 823 mm

Residual deflection = 15 mm

Passed.

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7 Summary

The fibre reinforced polybutelene terephthalate (PBT) ladder assemblies have conformed to the WSA 108 performance requirements except for the Rung Impact Resistance test. The PBT ladder was not tested for impact resistance as the result was predictable and not considered relevant when considered against the result of the FRN test. See Clause 6.2.1.3 below. It is considered the Add-A-Step ladder in MHs, particularly is ‘fit for purpose’ as rung fracture would likely be rare following any entry and even rarer given the majority of MHs (being sewerage) would likely require person entry only a few times over the lifetime of a ladder.

6.2.1.3 WSA 108 test results for FRN

The 35% glass fibre reinforced Nylon 66 (FRN) ladder is recommended for use in potable water immersion situations such as in water reservoirs, tanks and towers.The FRN ladder assemblies were tested to establish compliance with the performance requirements of WSA 108-2001 Industry Standard for fibre reinforced plastic ladders.

The report is dated 19 January 2005, referenced DIV-ESC-DCE-GJ-40828-1 and prepared by Dr. Prabir Sarker, Lecturer, Department of Civil Engineering, Faculty of Engineering and Computing at Curtin University of Technology, Bentley, Western Australia. The report included photos of the apparatus and ladder during and after testing. The ladders were cut into test specimens of the required size in accordance with the Standards requirements.

A summary of the tests and the conclusions is as follows:

1 Rung Torque Test – Appendix ‘C’ WSA 108

A torque of 100 N.m was applied to the top rung of a ladder assembly in a series of 10 cycles of clockwise and anti-clockwise application within a 4 minute period. The ladder section under test had three rungs and both stiles firmly secured to a steel rig and a concrete floor.


• No structural damage to the rung.

• No looseness or twisting of the rung in the stiles.

Passed.

2 Rung Strength Test – Appendix ‘D’ WSA 108

The ladder section under test had three rungs and both stiles firmly secured to a steel rig and a concrete floor. A static load of 375 kg was applied to a 100 mm long bearing block placed midway on the top rung of the ladder assembly. The load was applied gradually and held at 375 kg for 90 seconds and then released.




• No significant set of the rung after removal of the load.

Passed.

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3 Rung shear strength test – Appendix ‘E’ WSA 108

The ends of the stiles were supported by the concrete floor. A static load of 480 kg was applied to a 100 mm long bearing block placed on the top rung of the ladder assembly adjacent to the stile. The load was applied gradually and held at 480 kg for 90 seconds and then released.


• No signs of structural damage such as splitting or delamination in the entry of the rung to the stile.

• No looseness or twisting of the rung in the stile

Passed.

3 Rung Impact Resistance Test – Appendix ‘F’ WSA 108

WSA 108 calls for a nominal 100 mm diameter, 20 kg steel striker with a 30 mm hemispherical nose dropped in a tube from a height of 1 M to impact on the centre of the rung. The Curtin University test used a smaller weight (9.01 kg) dropped from a greater height (2.22 M) to impact the rung with the same energy as required by WSA 108. The test results are as follows:

• Sudden snapping of the rung into two pieces at the point of impact by the striker.

• Complete structural damage of the rung.

• Delamination of the stile joint at entry of the rung into the stile.


The ladder rung failed this test as did the Miyama FRP ladder (PA 99/12). This test would likely be too severe for any PBT or FRN ladder. The impact forces specified are unlikely to be commonly encountered with vertical ladder installation and within the confined spaces where this ladder is designed to be located.

It is recommended that this test now be disregarded since it is not included in BS EN 14396 Fixed ladders for manholes which supercedes BS 1247, from which the test was adopted.

4 Side Sway Test – Appendix ‘G’ WSA 108

Tests were carried out for three different spans; 2400 mm, 1500 mm and 1000 mm. The nominated loads of 147 N, 260 N and 325 N were applied to the bearing block at mid-span for the nominated durations of 90 seconds, 120 seconds and 90 seconds respectively. The sideway deflection data is shown in the following Table:

Span mm

(a)

Deflection mm at 260 N

(b)

Deflection % of span

Remarks

2400 11.5 0.48 <1%

1500 5.0 0.33 <1%

1000 3.5 0.35 <1%

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• No signs of structural damage to the stiles.

• No looseness of the rungs in the stiles.

Passed.

5 Ladder Fastening Test – Appendix ‘H’ WSA 108

A ladder section was mounted on 4 brackets and the ends of the stiles were not supported. A static load of 375 kg was applied to a 100 mm long bearing block placed midway on the top rung of the ladder assembly. The load was applied gradually and held at 375 kg for 90 seconds and then released.



• No significant looseness was felt in the ladder mountings.

• No structural damage was observed after undoing the bracket mountings.

Passed.

6 Summary

The 35% glass fibre reinforced Nylon 66 (FRN) ladder assemblies have conformed to the WSA 108 performance requirements except for the Rung Impact Resistance test. The Rung Impact Resistance test, originally taken from BS 1247 for plastic encapsulated step irons, is severe but is considered of general applicability to metal ladder/step irons. The test loading represents a horizontally applied load to a vertically mounted rung/step and as such would be most likely representing a swinging load on a rope, such as equipment or tools being lowered or lifted in a maintenance hole. In a water industry installation an impact of this severity is possible but unlikely. The rung was fractured at the centre but would remain functional because the connection to the stile remained intact and capable of bearing a foot load (with some added care). It is considered the FRN ADD-A-STEP ladder is ‘fit for purpose’ as the impact loads required to create such a rung fracture in a water tower or tank are unlikely to be experienced.

6.2.2 Dimensional requirements

The ADD-A-STEP ladder was designed to comply with the requirements of AS 1657-1992 Fixed platforms, walkways, stairways and ladders – Design, construction and installation, and AS 4198-1994 Precast concrete access chambers for sewerage applications.

The ladder complies with Drawing No. SEW-1307 in WSA 02 in terms of width between stiles and rung spacing. SEW-1307 nominates 1000 mm maximum spacing for the fixings and the ADD-A-STEP installation can accommodate that requirement.

Passed.

6.2.3 Contact with drinking water

Industrial Steps & Ladders has submitted a Water Quality Centre Test Report No 4007/92.1566 dated 23/09/2004 demonstrating the FRN ADD-A-STEP ladder assembly compliance with AS/NZS 4020:2002 Testing of products for use in contact with drinking water.

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Testing was for use in water towers and tanks. The surface area to volume ratio was approximately 15000 mm2 per L. A bolt, nut and washer with two ladder clips were also included in the in use exposure.

The results stated that the product passed at exposure level of 15000 mm2 per L which is well within the expected surface area to volume ratios in water towers and tanks.

Passed.

6.3 WSAA AGENCY NETWORK REQUESTS

The following questions were raised by Network agencies and the answers are the responses from the manufacturer:

Q 1. Does the mounting bracket rely on a boss or lug to lock into the groove on the outside of the stile?

Answer: The bracket is thickened at the end that is attached to the stile to provide a boss that fits the profile of the stile.

Q 2. In the photo’s, the brackets that fasten the ladder to the MH wall, face inwards behind the ladder, rather than outwards to either side of the ladder. This significantly reduces the width between the bracket fixings and there is a feeling that it may cause the ladders to wobble when in use. Is information available on ladder stability with other given bracket spacing?

Answer: When the ladder is assembled and installed there is no noticeable movement laterally or away from the wall. At the maximum spacing of brackets at 2.4 metres, and with a 60 Kgm horizontal load applied, the deflection at the mid-point was 8.21 mm. The WSA 108 Side Sway Test was conducted with 147 N, 260 N & 325 N loads over spans of 1.0 m, 1.5 m and 2.4 m and the resultant deflections were 3.5 mm (0.35%), 5.0 mm (0.33%) and 11.5 mm (0.48%), all being less than the required maximum of 1% of span.

Q 3. The photo's on the website show a bracket at the base of a ladder which is anchored to the benching. What locks this bracket to the ladder other than the stainless steel bolt on each side?

Answer: On the longer ladders we usually use the wall bracket 350-500mm up from the base of the ladder. It is a good point raised and the boss on the square bracket will be widened to lock into the ladder stile in both the vertical and horizontal plane. This modification will be completed before the end of April 2006.

Q 4. As important as the strength of the “ladder” is that of the supports. Is the ladder designed to only be used with the stiles on a solid foundation?

Answer: No. The ladder joint will withstand a tensile load up to 12 kN, where it was exposed to a 5% acid solution for 1000 Hrs. The ladder that was tested by Curtin University to the WSA 108 specification was mounted on a steel frame so the bottom of the ladder was not in contact with the concrete base slab.

Q 5. Are the brackets separately tested for ability to take eccentric loading such as will happen if the ladder was “hanging”?

Answer: The ladder will take a hanging load, as outlined in item 1(d). However, the brackets were not designed for an eccentric load, so bottom, top and intermediate brackets (where the span is greater than 2.4 metres) are required to provide lateral stability.

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Q 6. The maximum spacing of mounting points seems too great at 2.4m. Given the modular design of the ADD-A-STEP ladder, why isn’t the spacing of the brackets closer and similar to the spacing used for other fabricated FRP ladders?

Answer: The ladder spacing can be any interval up to a maximum of 2.4 metres. Each Authority may have an individual preference. The ladder is very stable at the maximum span and we were able to satisfy the requirements of the Water Corporation of Western Australia at that span.

NOTE: SEW-1307 nominates 1000 mm maximum spacing for the fixings.

Q 7. If the brackets are at 2.4 m spacing, is the ‘to and away’ from the wall deflection between brackets acceptable?

Answer: At 2.4 metres spacing the deflection was 8.21 mm. This deflection can be measured, but is barely detectable to a person climbing the ladder.

Q 8. Do the brackets provide correct offset from the wall?

Answer: The brackets provide 150 mm clearance from the wall surface and the backside of the rung (nearest the wall). In the case of the circular manhole the clearance is 150 mm at the closest point near the stile.

Q 9. Has it been considered whether there might be conflict of bracket locations and the joints in precast MH’s? Should special requirements such as distance from joints need to be imposed?

Answer: The bracket can be mounted at any point along the stile where there is a recessed profile, and therefore this is not a problem. Brackets should always be kept clear of MH segment joints.

Q 10. If there is a hole drilled through the stile to attach the support bracket using the stainless steel 12mm dia. bolt, does it have an impact on stile strength?

Answer: No.

Q 11. How is the ladder held in place and/or attached to items other than a MH wall?

Answer: We currently manufacture two types of bracket (See Section 3 above). If another profile was required, it is possible to provide a bracket to suit providing the quantities are required to offset the cost of another bracket die or die insert.

Q 12. How slippery are the rung treads? Have the rungs been comparatively assessed for slip resistance? Do they have projections to assist grip?

Answer: The profile of the rung between the base of the tread and the top surface is the same as our step iron, which has been in use in sewer and stormwater manholes for over ten years. The profile and tread pattern was approved by the Water Corporation of Western Australia prior to the manufacture of the die. The relief between the high and low points on the tread is equal to the profile of a steel reo bar, which is the equivalent used in a steel ladder. The slots on the upper surface are 2 mm wide and 2 mm deep, see the cross section photo below.

25 July 2006 18 Issue 1


Rung cross section

Q 13. Has there been any consideration of the wear of the joining lugs? It is suggested that after a number of cycles, wear of the joints is likely to start and then it will become worse with each cycle. Has there been any repeated use or cyclic variations of the sway test (WSA 108 Appendix H) completed?

Answer: All of the tests as laid down in WSA 108 were conducted, with only the Rung Shear Strength Test causing a failure. The joint is a very heavy profile, and the Rung Torque Test as detailed in WSA 108, did not cause any looseness in the joint. The joint is made up of several shapes, and none are cylindrical. There is sufficient straight faces of reasonable length to provide the long term stability required.

Q.14. Has there been any consideration of the need for the stiles to cantilever above brackets into DN 600 neck of MH? Is special treatment of the top of stiles required for safety reasons e.g. rounding or capping?

Answer: Yes. We often have the ladder finish up to two rungs above the last bracket. If considered a problem a cap could be moulded to form a rounder profile. Alternatively the material can be sanded to take of the sharper edges by the installer if required.

Q.15. Is there a limiting angle for use of the ladder or is it for vertical applications only?

Answer: The ladder has been developed and tested for the upright position. It would be possible to test for an incline if the party could advise of the incline required. Another bracket would need to be developed along with the fixing bolts (more than one bolt).

Q.16. What effect does sunlight and heat have on the ladder performance?

Answer: Both FRN and PBT moulded materials are UV tolerant. The colour additive used can be UV tolerant at a slightly higher cost. As all of our ladders to date have been installed underground, this point has not been raised. The additional cost would be minimal, and it might be an option to include as part of the product before we launch into sales in the eastern states. The standard material will pass a spark test, however it can be manufactured in a flame retardant FRN if required, at a cost.

Q.17. What is its co-efficient of expansion and is there likely to be a buckling effect? The coefficient of expansion for PBT is 0.2-0.3 10-4/K.

Answer: The expansion due to heat is insignificant. The FRN material is used in several other applications including electrical appliances and car parts.

Q.18. In the “WSAA Additional Info for Application” document distributed with the Preliminary Review, at the section on ‘Use of Product’ it discusses: “As the plastic material used in the ladder is UV tolerant and non-corrosive then there is no maintenance required other than occasional cleaning if desired.” Can the life of the material be

25 July 2006 19 Issue 1


projected for “full sun” installations and can the ladder material be coated for UV protection with a suitable anti-slip paint?

Answer: FRN and PBT are used in several car part components such as wiper blades, and is therefore structurally stable over many years. As indicated above we can substitute our current colour additive with a UV stable colour additive. This will assist with the colour performance over time, however some colours are better than others when it comes to UV performance and ‘black’ is the best performer. The application of any paint to FRN or PBT is unnecessary.

Q.19. Can a ‘Chemical Capability’ chart be provided for the materials used to assist designers in selecting the correct installation outcomes?

Answer: Yes – A chart has been developed and is included in Appendix ‘A’.

Q.20. In a sewer and potable water environment are microbes etc likely to live in the crevices?

Answer: We have subjected the ladder components to testing through the Australian Water Quality Centre. All of the components tested passed the AS/NZS 4020:2002 testing procedures. The Mean Dissolved Oxygen Control for nylon was 7.3 mg/L. The Water Quality Center spokesman advised that it is highly unlikely that the nylon or the crevices in the ladder would contribute to any growth of micro-organisms, as the ladder is a very minor part of a holding tank. FRN is an approved material for tanks, and a greater contributor to this problem would be the lining of the tank, or the possibility of vermin or wildlife entering the tank.

Q.21. Agencies asked for information on the behavior of the ladder material in a highly corrosive septic sewer situation. The following comments have been received; ‘Sudden brittle failure of ladder systems could be catastrophic and metal products have some advantage in that deterioration due to corrosion is generally obvious’; ‘Experience with most other “plastic” type products has not been encouraging, e.g. PVC goes brittle and fiberglass striates’; ‘Approval will not be provided without long term or accelerated field testing regarding corrosion and material behavior, particularly in regard to brittle failure’; ‘Have the ladders been installed in the most aggressive locations currently in WA sewers and has their condition been monitored?’

Answer: It is true that our ladder has only been in use since October 2003 in gravity sewers, and more recently in the conditions quoted. Along with the Water Corporation in WA, we will be constantly monitoring the ladder performance. All personnel entering manholes in WA use harness and recovery equipment for safety purposes. The life expectancy of the product would be the same as any other FRP product under the same conditions. I understand that other FRP ladders have been in use in WA for at least eight years with little adverse effects due to high concentrations of acid.

Testing for corrosion and deterioration resistance in a highly aggressive sewer environment such as the sewage test chamber at SA Water should be arranged. This test will take some time and has been included in the Appraisal Report as “Future Work” for addition of a test report in a later issue of the Appraisal Report.

Q.22. One agency has requested a test of the locking strength and surety of the components as it is not covered in the current WSAA specification.

Answer: Correct. However our original tensile test carried out by Curtin University provides that test of strength. See Clause 6.2.1.1 above.

25 July 2006 20 Issue 1


Q 23. Do the packs come with spare retaining clips? They look pretty flimsy & may break!

Answer: We always supply a few extra clips with orders being supplied in kit form, not because the clips break, but because they are usually lost.

Q 24. Comment on photo included in the report: “A metal mallet should not be promoted as a tool to assemble the ladder. It would have a high likelihood of doing damage I would have thought. A rubber mallet should be promoted!”

Answer: Not so we always use a metal mallet and it has never caused us a problem. The product is a high strength engineering grade plastic that resists impact chips.

Q 25. Comment on the test result statement; “No significant looseness was felt in the ladder mountings”. - Was there some looseness in the mountings – if so was this from loosening of the bolts – would want to have seen reported no looseness not ‘no significant looseness’!

Answer: The writer of the report probably used this term as a matter of laboratory terms. In fact the rung did not move any more after the testing than it does when it is first assembled. We have not had any problems or complaints from the Water Corporation or the Contractors that we have supplied in the three years of marketing the product. I don’t believe that I should influence the writer’s report. The report was submitted without any editing on our part.

Q 26. Comment on water tank use; “As this product is recommended for water industry applications, there is no getting away from an exposure to heavily chlorinated waters whether 'immersed' in the water or projecting into an even more aggressively (gaseous) chlorinated environment above the water e.g. in tanks/towers. Arising from our experience, the use of 316 SS fasteners for ladder fixing is limited to immersed zones below TWL with galvanised steel fasteners elsewhere. Some ladder components may be fixed to one another with FRP fasteners. Idealists may suggest that, for longevity, all fixing to water storage structures should be by means of duplex or super duplex stainless steels for a reasonable fastener life expectancy and for user safety well into the future.”

Answer: We are investigating other materials for use in very high corrosive conditions, and the fasteners will be included in that investigation. However in the testing for “normal potable water” conditions FRN, 316 stainless steel and acetyl plastic (Clip) all passed the Australian Water Quality Centre tests.

Q 27. Comment on materials; “Clauses 2.2/2.3 of WSA 108 require use of a thermosetting isophthalic polyester resin complying with BS 3532, reinforced with E-glass whereas the "Add-a-Step" ladder offers different resin bases e.g. polybutylene trephthalate for chemically aggressive applications and nylon 66 for "water immersion" applications. This may mean that the resin prescription in WSA 108 is too restrictive and that resin selection should merely satisfy selected short/long term structural performance criteria. I believe, rightly or wrongly, that nylon 66 could creep (or lose strength/strain capacity) with time which could lead to a weakened ladder structure but maybe this depends on the fibre reinforcing content.

Answer: The resin description in WSA 108 may be too restrictive, however both the FRN (water) and PBT were tested in the conditioned state. Both materials are pre-dried prior to manufacture, and are reintroduced to moisture in water tanks over the following days by immersing the parts in water until an equilibrium is reached. We describe this process as conditioning and the process usually takes one or two days to complete.

25 July 2006 21 Issue 1


Q 28. A general comment; “The intent of the report and its recommendations should be qualified to (explicitly) caution users wherever they consider this product and the 'standard' supplied fasteners for facilities that receive or store heavily (> 1mg/l and almost impossible to avoid in my experience) chlorinated waters; and applications that require other than upright (vertical non-inclined) ladder disposition where additional testing to ensure an adequate structural safety factor (against bending failure) should apply to the ladder stile design. The minimum/maximum inclines recommended in AS 1657 for rung ladders are 70/75 degrees to the horizontal.”

Answer: I agree. The ladder was designed for use as a vertical ladder, and to this time has not been tested as an inclined ladder. Refer to item 5 for 316 grade stainless steel. The ladder was primarily as an access ladder for sewer and storm water drainage conditions.

All other questions and issues raised are answered in the body of the report.

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION

Specific training is not seen as a requirement for assembling and installing the ADD-A-STEP modular ladder. The assembly instructions are included in Appendix ‘A’. Industrial Steps & Ladders provide additional photographic step by step information at the following extension to their web site:

www.industrialsteps.com.au/ladderpics/compilation.html

The photos in Section 3 – The Product, provide a limited demonstration of the mounting of the ADD-A-STEP ladder using brackets supplied and as ordered. Industrial Steps & Ladders recommend a maximum spacing of 2400mm. WSA 02 recommends a maximum spacing of 1000 mm which can be accomplished by ordering additional brackets.

The brackets are supplied with 12 mm x 50 mm Grade 316 stainless steel bolt assemblies. Industrial Steps & Ladders recommend the ladder be secured to the access chamber wall using HILTI 10 mm x 40 mm grade 316 stainless steel drop-in anchors. HILTI anchors are guaranteed to resist a pullout force of 750 kgm.

8 PRODUCT MARKING

Each stile module is moulded with the following:

ADD-A-STEP MODULAR LADDER SYSTEM

INDUSTRIAL STEPS AND LADDERS

42 HOGARTH ST CANNINGTON WA 6107

T +61 8 9258 9488

F +61 8 9258 9599

PATENT PENDING

AS4198-1994 AS1657-1992

No identification is shown on the rungs or brackets.

Printed assembly instructions as per Appendix ‘A’ are available for inclusion with the delivered ladder packs.

The date of manufacture is not included in the moulding.

25 July 2006 22 Issue 1

http://www.industrialsteps.com.au/ladderpics/compilation.html


9 PACKAGING AND DELIVERY

Industrial Steps & Ladders supply ADD-A-STEP ladder components on a pallet containing approximately 120 lineal metres. Each module of the ladder is packaged separately in a box 450 mm x 80 mm x 80 mm. In each package there are two stiles, one rung and two retaining clips (See Figure 1). Brackets and bolts are packaged separately. Stock will be available in the eastern states ex. Melbourne.

10 WATER AGENCIES EXPERIENCE / FIELD TESTING REPORT

In October 2003 Industrial Steps & Ladders installed two ladders in sewer lines for trial. The Water Corporation of Western Australia had been informed of the progress of the ladder from its inception. John Bond, Principal Engineer, Wastewater Civil & Standards for the Water Corporation, Western Australia, and his committee has been supportive of the idea of a non-steel ladder product. They have used a fibreglass product in areas of high corrosion, but the cost has precluded them from using that product unilaterally throughout the sewer systems. In April 2005, the PBT ladder system was approved for use in main sewers, DN 300 and greater by the Water Corporation of Western Australia (copy provided). This approval is in addition to an earlier interim approval (March 2004) for the FRN material.

11 PRODUCT WARRANTY

The products are covered by the normal commercial and legal requirements of The Trade Practices Act 1974, which covers manufacture to the relevant Standard.

12 DISCUSSION

The failure of the ADD-A-STEP rung in the Rung Impact Resistance Test (Appendix ‘F’ WSA 108) should not be considered cause for concern since the ladder structure and rung connections at the stiles remained intact. The ladder has been in use in sewers for well over twelve months in Perth and there have not been any failures of this type. In the process of installation a toolbox is lowered and raised in the MHs, and to date while the toolbox has edged against the ladder many times, we have not experienced any damage or failure. All other tests and use indicate that the Add-a-step ladder will perform its task as required.

The "Miyama” GRP ladder (Refer PA 99/12) also failed the rung impact resistance test by bending when impacted with a 20 kg point load from a height of 1 m onto the rung. The performance test was adopted from BS 1247 for plastic encapsulated step irons. It is a severe test and generally applicable to metal ladder/step irons. The test loading represents a horizontally applied load to a vertically mounted rung/step and as such would be most likely representing a swinging load on a rope, such as equipment or tools being lowered or lifted in a maintenance hole. In a water industry installation an impact of this severity is possible but unlikely. It is considered this should not limit the use of PBT / FRN ladders, particularly as the majority of these ladders will have infrequent use and a damaged rung would not make the ladder unscaleable.

25 July 2006 23 Issue 1


13 SUMMARY

The ADD-A-STEP ladder has the following benefits:

• It is modular and can be transported over long distances more economically than fully assembled ladders.

• It does not have to be measured prior to order and can be made up to any length as required.

• The ADD-A-STEP ladder packs can be transported in a lift or by crane and assembled on a top floor of a building where a ladder may be required for a fire water tower or service ladder.

• The ADD-A-STEP ladder has excellent insulation properties so it can be used in applications where electrical cables are present.

• The ADD-A-STEP ladder can also be manufactured to resist fire.

• The fibre reinforced plastic materials used are UV tolerant and non-corrosive.

• The FRN product is suitable for contact with drinking water.

• There is no maintenance required other than occasional cleaning with a pressure hose if desired.

The ADD-A-STEP modular ladder system has satisfied the requirements of the appraisal criteria (apart from the impact test requirement which is considered having a low possibility of occurrence) and adequately answered the questions of the WSAA Product Appraisal Network. The ADD-A-STEP modular ladder system offers the water industry a new and innovative product with many benefits and is seen as ‘fit for purpose’.

14 LIFE EXPECTANCY RATING

A life expectancy for this product is very subjective as the information available for this product to establish long term performance is limited. No data has been presented for long term performance in aggressive sewage environments, immersion in heavily chlorinated waters or exposure to a heavily (gaseous) chlorinated environment above water in an enclosed tank. The general knowledge of the Product Appraisal Network has accepted a ‘B’ rating with a suggested life expectancy in excess of 50 years. This rating is only a general guide to life expectancy and may increase or decrease as a result of the system operating conditions, preventative maintenance programs, operating environment and other geographical and site specific factors.

15 FUTURE WORK

Industrial Steps & Ladders is required to have their Quality Management System (AS/NZS ISO 9001:2000) certified to meet the WSAA Product Appraisal Network requirements by the end of September 2006.

Industrial Steps & Ladders is required to arrange for corrosion testing and deterioration resistance in the highly aggressive sewer environment at the sewage test chamber at SA Water. This test will take some time and a progress report including testing the exposed ladder section to the performance requirements specified in WSA 108, should be added to this Appraisal Report before July 2008.

25 July 2006 24 Issue 1


The Water Services Association of Australia is to review WSA 108 in light of the release of the European Standard EN 14396 for manhole ladders and consider whether WSA-108 should be replaced in part or full by EN 14396 by 1 January 2007.

Network reviewers’ comment: EN14396 does not have any equivalent tests to the following tests in WSA-108:

• Rung Torque test

• Rung Shear Strength Test

• Side Sway Test

• Ladder Chemical Resistance test

• Corrosion Barrier Delamination Resistance Test

The first three of the above tests came from AS 1892.3 for Portable Reinforced Plastic Ladders, last two from AS 3571 and 3572. The testing procedures in AS 1892.3 and testing reporting were tightened up for WSA-108 as they could not be directly referenced therefore. These tests were selected as they were applicable for both portable and fixed ladders. AS 1892.3 has 26 ladder tests, most only applicable to portable ladders.

16 RECOMMENDATION

It is recommended that, subject to the cautions noted in the report for extreme exposure situations and only vertical installation, WSAA members and associates accept/authorise the Industrial Steps & Ladders ADD-A-STEP modular ladder system in FRP and FRN as required.

25 July 2006 25 Issue 1


17 DISCLAIMER

17.1 ISSUE OF REPORT

This Product Appraisal Report (Report) has been published and/or prepared by the Water Services Association of Australia, Inc and nominated Project Manager and peer group of technical specialists (the Publishers).

The Report has been prepared for use within Australia only by technical specialists that have expertise in the function of products such as those appraised in the Report (the Recipients).

By accepting this Report, the Recipient acknowledges and represents to the Publisher[s] and each person involved in the preparation of the Report that the Recipient has understood and accepted the terms of this Disclaimer.

17.2 LIMITS ON RELIANCE ON INFORMATION AND RECOMMENDATIONS

17.2.1 Disclaimer of liability

Neither the Publisher[s] nor any person involved in the preparation of the Report accept[s] any liability for any loss or damage suffered by any person however caused (including negligence or the omission by any person to do any thing) relating in any way to the Report or the product appraisal criteria underlying it. This includes (without limitation) any liability for any recommendation or information in the Report or any errors or omissions.

17.2.2 Need for independent assessment

The information and any recommendation contained (expressly or by implication) in this Report are provided in good faith. However, you should treat the information as indicative only. You should not rely on that information or any such recommendation except to the extent that you reach an agreement to the contrary with the Publisher[s].

This Report does not contain all information that a person might require for the purposes of assessing any product discussed or appraised within it (Product). The product appraisal critieria used in preparing this Report may not address all relevant aspects of the Product. Recipients should seek independent evidence of any matter which is material to their decisions in connection with an assessment of the Product and consult their own advisers for any technical information required. Any decision to use the Product should take into account the reliability of that independent evidence obtained by the Recipient regarding the Product. Recipients should also independently verify and assess the appropriateness of any recommendation in the Report, especially given that any recommendation will not take into account a Recipient's particular needs or circumstances.

17.2.3 No updating

Neither the Publisher[s] nor any person involved in the preparation of this Report [has][have] any obligation to notify you of any change in the information contained in this Report or of any new information concerning the Publisher[s] or the Product or any other matter.

17.2.4 No warranty

The Publisher[s] do[es] not, in any way, warrant that steps have been taken to verify or audit the accuracy or completeness of the information in this Report, or the accuracy, completeness or reasonableness of any recommendation in this Report.

25 July 2006 26 Issue 1


APPENDIX A TECHNICAL MANUAL/BROCHURES

Includes:

• Ladder assembly and installation instruction (3 pages)

• Ladder chemical uses chart (not recommended marked ‘x’ RT – room temperature SS – super saturated 80c – 80 degrees Celsius (2 pages)

See also: www.industrialsteps.com.au

25 July 2006 27 Issue 1

www.industrialsteps.com.au

ADD.A.STEP MODULAR LADDER SYSTBM

ASSEMBLY PROCEDURE

The following instructions should be read in conjunction with the photographsdi splayed at www. industrial step s. com. aulladderpic s/compilation.

PHOTOGRAPHS1. Ladder module - two stiles, one rung and two retaining clips (green).2" Measuring cutting length for the ladder base set of stiles (2).3. Cutting the stiles on a bandsaw, or any other cutting tool.4. Continuing the cutting process.5. Preparing to assemble the rung to the two base stiles.6. Breaking out the spacer on the next set of stiles (2) in preparation for attaching

to base module.7 " Lining up the second set of stiles (2) with the first rung. Aligning the pin on

the female end of the stile with the slot in the rung.8. Commence hammering the joint together making sure that the joint is always

square as the joint comes together.9. Completing the hammering of the joint together.10. Fixing the retaining clips into the rung slots to lock each side joint.

1 1. The clip is shown in its locked position.12. The base module is assembled with the second module stiles (2).13. Assembling the second stile.14" Assembling the second stile.15. Assernbling the top cap (off-cut from the base stiles (2) cut offin photograph 3

and 4).16. Breaking out the spacer on the top caps (2).17. Lining up the top caps (2) with the top rung.18. The completed ladder assembled to any length required to the nearest 300mm

module.

COMPONENTSff iodularladdersystembasedona300mmspacingbetweentherungs.Each module is made up of two vertical stiles, one horizontal rung and two retainingclips" The ladder is assembled to the required length by adding the required number of*od.rl.r together. For example a 2.100 metre long ladder is made up of sevenmodules. Brackets (not shown) are attached to the stile by using l2mm diameter grade

316 stainless steel bolts x 5Omm long.

ASSEMBLY OF TIIE I,ADDERUsing the photographs as a guide, assemble the ladder as follows;

l. select two itiles and cut the to length (260mm down from the rung slot end ofthe stile as shown in photograph 2 to 4 inclusive).

2" Assemble the rung to each of the base stiles by inserting the rung into the rungslots at the top of each of the stiles. The rung and the stiles can only be

assembled one way. Each of the rung slots in the stiles should be facinginward, and the company and product name inscriptions are therefore facing

outwards on the ladder (Refer to photograph 5).

aJ . Select two more stiles and remove the spacer from both stiles at the female

end of the stile. Align the pin on the stile to the slot in the rung with the

company inscription facing outwards and then hammer the joint closed,making sure that the joint is kept in the same plane as it is hammered together.The joint is designed as a tight taper joint and will take some hammering to

secure the joint fully closed. A light steel hammer with a broad face (Mallet) is

best used for this procedure (Refer to photographs 6 to 9 inclusive).Fix the retaining clips into the slots at each end of the rung (Refer tophotographs 10 and I 1).Continue the process through items 2, 3 and 4 until the desired number ofmodules are assembled to give the correct ladder length required. When thecorrect ladder length has been assembled take the two oflcuts from the base

stiles (2) and remove the spacer from each oFcut, and assemble them in thesame way as each stile was assembled. Fit the two retaining clips to the top

rung and the ladder is assembled and ready to have the brackets attached(Refer to photographs 12 to 18 inclusive).There are two types of bracket available for use. One for round access liners(1050mm - 1200mm diameter) and one for square face access chambers. Eash

of the brackets have a thickened end (20mm thick) while the remainder of thebracket section is 10mm thick. The bracket has been designed to fit snuglyinto the recessed side if the stile" The bracket is fitted to the outside face of thestile with the end to be attached to the access chamber facing into the centre of

the ladder. The bracket has preformed 14mm diameter holes at each end of the

bracket" Through the thickened end of the bracket a l2mm diameter x 50mm

long 316 grade stainless steel bolt is used to attach the bracket to the ladder. At

the other end of the bracket a 10mm x 40mm long llilti drop-in anchor is

recommended for use in conjunction with a l0mm x 25mm long set screw to

attach the bracket to the mounting face of the access chamber. The Hilti

anchor is recommended as it has a pullout force guaranteed by Hilti. Hilti is a

Qualrty Assured supplier.The recommended maximum spacing of the brackets is 2.400 metres.

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APPENDIX B QUALITY ASSURANCE

CERTIFICATES

Pending – see Future Work.

25 July 2006 33 Issue 1


APPENDIX C SUPPLIER CONTACT DETAILS

INDUSTRIAL STEPS & LADDERS

42 Hogarth Street

Cannington,

Western Australia

6107

Phone: 08 9258 9488

Fax: 08 9258 9599

Mobile: 0418 936 853

Email: [email protected],au

25 July 2006 34 Issue 1

mailto:[email protected],au

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