WHAT'S NEW
What are we up to?
For those who don't know Composite can refer to many things but on this occasion we are referring to fiberglass which offers many benefits that metals can not.*Light weight in comparison to cast iron and concrete at the same loadings
*Corrosion resistant so doesn't suffer underside from sewer gasses like metal or concrete can
*Doesn't bind in the frame like cast iron
*Is of no interest to scrap metal thieves
*Less traffic noise than cast iron
We had designed our construction based on the load ratings of AS3996-2006 which is 210kN ultimate limit state design for a Class D lid which was our main quarry.
EN124-5 Class D calls for 400kN ultimate limit state design.
Our Class D lid easily exceeded 210kN, so as far as load rating met AS3996-2006, it had also ticked all the other boxes for gastight, watertight, UV, slip resistance and permanent set.
Because EN124-5 has been chosen by WSSA we found ourselves needing the 210kN rated lid being able to pass a 400kN test, this was never going to happen so in frustration packed up our toys and went home.
So what is happening now?
10/12/2018
There is now a second draft standard DR2 AS3996:2018 which actually incorporates Composite as an accepted material and states a bunch on tests that apply only to the composite(polymeric materials).
The load requirements are now in line with all other materials that can be used to produce lids and surrounds which the Class D has actually changed from 210kN to 240kN.
We are so confident that our product will surpass the new standard AS3996 that we have produced new tooling to give us a 50mm insertion depth rather than 40mm as before and to be able to load to 240kN, rather than 210kN as before.
We expect new product for testing by late February 2019 and should complete testing by mid March 2019
Once successful testing has been completed production quantities of the new product could be available in 6-8 weeks.
Our intention is to complete all necessary tests as per the new AS3996 and apply for a WSSA appraisal.
We also expect the new Class D lid to pass the inverted pull out test which gives resistance to pressure or flood.
In the meantime we will continue to supply our current customer base with existing product which meets the requirements of AS3996-2006.
Happy Pit Lidding!
But wait, there is more. 30/4/19
The final standard AS3996-2019 was published 22/3/2019 and we have sent lids to a NATA testing facility to undergo fatigue testing.
This involves an 80kN load being applied 300,000 times at a rate of 40kN/s, +-15kN
We have undertaken preliminary inhouse testing for gastightness and watertightness, both successfully.
Both these tests will be confirmed by a testing facility.
Once this testing has completed we will then do the rest of the tests required.
And more again. 27/5/2019
We couldn't sit still and wait for the fatigue test as it will take many days to complete and is only scheduled to start on 29/5/19 so we went ahead with other testing and passed the following tests.
Type test
Water tightness test
Gas tightness test
Creep resistance test
Impact resistance
Elevated temperature test will be completed this week
WOW THAT'S IMPRESSIVE 27/6/19
We sent two lids to a NATA testing facility back in April for
A second type test which passed as expected
Fatigue Resistance test, this is the impressive bit. The lid was loaded from 1-80 kN at the rate of 55 kN/s for 300,000 cycles with no visible signs of cracking, collapse or other forms of structural failure.
The new M12 316 stainless steel threaded inserts or bolts had no signs of wear or galling.
5/8/2019
WSSA appraisal application posted today.
21/8/2019
Back to the testing facility with a new DN600 Class D240 lid and frame for an uplift resistance to pressure or flood.
This was achieved by an inverted pullout test, this were the lid and frame is turned upside down and a load is applied to simulate the uplift caused by .5 bar of internal pressure.
The calculated target was 14kN and was to be held for a minimum of one minute, it did this easily.
We then applied an increasing load until the threaded inserts actually pulled out of the frame, this happened at 23kN
Have a look at our videos page, it's fairly tame but anyone who knows what we are working with will understand our exitement.
Coming up 28/8/2019
Slip resistance test to AS4586