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Duplex coatings the components whilst assisting with the aesthetic look of the ROPS and FOPS fitted to the mining vehicles. Marven’s Ndlovu ROPS has been tested by SABS, Gerotek, and a team of Engineers conforming to ISO 3471 ROPS, ISO 3449 FOPS, Finite Element testing (FEA), and physical testing verifying the FEA results – including deliberately destroying a vehicle in a multiple roll. The major advantage of hot dip galvanizing and Bulldog’s duplex coating system is that clients who rotate their fleet of vehicles every two and half years or so, are able to transfer their same Ndlovu ROPS structures from one vehicle to the next new vehicle, enabling them to enjoy the full 7 year warranty of Marven’s Ndlovu ROPS. This in turn offers the companies huge cost savings in that there is no need for major capital outlays for new ROPS structures, for their replacement fleet of vehicles during this period ( unless the ROPS has been involved in an accident, or there is obvious visible damage, in which case the ROPS is immediately scrapped and destroyed). During the transfer from one vehicle to another, the ROPS structures undergo inspections prior to fitments, and new fitment kits are used. Traceability is very important, and Certificate of Conformance is updated with the new vehicle details. A new ID tag is fitted, ‘marrying’ the current ROPS to the new vehicle. New fitments and transfers may only be done through Marven Equipment and authorised agents. TESTS TO DATE ON MARVEN’S NDLOVU ROPS SABS - SANS 1563 - R 66 Hill Roll test on a 60 degree hill SAE J857 and SAE J996 Anglo American specification ISO 3471 ROPS (Roll Over Protection Structure) Anglo American specification ISO 3449 FOPS (Falling Object Protection Structure) Finite Element Testing ROPS – non linear FEA structural analysis of prototype # 9 according to the exact requirements of the (ROPS) international standard ISO 3471 first edition 1994-02-01 Earth moving machinery roll over protective structures and laboratory tests - performance requirements and the international standard ISO 3164:1995 (E) Earth-moving machinery laboratory evaluations of protective structures - specifications for deflecting limiting volume. FOPS – A level II FOPS dynamic transient impact non linear FEA structural analysis of prototype # 9 according to the exact requirements of the (FOPS) international standard ISO 3449 fourth edition 1992-05-15 Earth moving machinery – falling object protective structures – laboratory tests and performance requirements. The FEA test results show that our Ndlovu ROPS/FOPS is capable of handling in excess of 10 tons vertically, laterally, and horizontally. BHP Billiton Standard light commercial vehicle test of dropping a vehicle from behind a moving truck with truck speeds of 60km/h to 80 km/h which equate to rollover speeds of 100km/h to 120 km/h. The test vehicle drop height is to be at least 200mm with 5° to 10° pitch, 20° to 25° roll and 25° to 35° yaw. Marven Equipment’s Ndlovu Test Vehicle was dropped at 80km/h, equating to a roll over speed of 120km/h. The real protection is hidden! While hot dip galvanizing is frequently used for protection of steelwork on its own and is easily seen to be doing this, there are many instances where the coating is hidden and performs the essential back-up of corrosion control to various forms of over coatings and covers. An example of this is when duplex coating systems are applied and while the performance of the two systems are working synergistically to provide the corrosion control solution, the hot dip galvanizing is out of sight. Similarly, when reinforcement for concrete is hot dip galvanized it too is providing the essential back up but hidden! This private home in Hermanus has utilised a duplex coating system to synergistically protect the steelwork. This process has now become the standard for all the heavy duty Ndlovu ROP structures manufactured by Marven Equipment thanks to the Hot Dip Galvanizers Association Southern Africa and Bulldog Projects. Marven’s Ndlovu ROPS is approved by Anglo American, BHP Billiton (for contractors), and De Beers. 18 Hot Dip Galvanizing Today Volume 9 Issue 2 2012
Duplex coatings Communicate to achieve specification requirements When specifying general hot dip galvanizing, SANS 121 (ISO 1461) should always be used but for an above ordinary finish required for either Architectural Galvanizing or subsequent over coating with powder or solution paints, written communication with the respective participating parties is always recommended. BS EN 15773:2009, “Industrial application of powder organic coatings to hot dip galvanized or sherardised (for the purposes of this summary all reference to sherardising shall be omitted) steel articles (duplex systems) - Specifications, recommendations and guidelines,” places huge emphasis on this and other important issues: In this summary of the standard, only the issues with regard to the galvanizer (particularly that of communication) or the hot dip galvanized coating are highlighted. (Italics in blue are deemed relative to SA via the HDGASA) Introduction Quote: ”In order to achieve a duplex system which satisfies the many varied aesthetic and performance requirements currently in existence in the marketplace, the following aspects of the supply and application of the systems should be controllable.” Ordering “The client shall make sure that all of the parties involved are notified that a duplex system will be applied. This requires good communication between the client, the steel purchaser, the fabricator, the galvanizer and the companies applying the pre-treatment and the powder coating.” Information provision “The information provided by the client to the galvanizer shall be in accordance with EN ISO 1461 and (particularly) Annex A. The client shall inform the purchaser of the steel that the steel will have a duplex coating applied and that the duplex system will include hot dip galvanizing. The client shall inform all parties about the intended use of the product.” continued on page 20... Volume 9 Issue 2 2012 Hot Dip Galvanizing Today 19
Page 1: 2012 Volume 9 Issue 2 HOT DIP GALVA
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Page 23 and 24: Duplex coatings Supply phase Essent
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Page 29 and 30: Education 3 CPD POINTS 3-day Galvan
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Page 33 and 34: Coating report Photo 8. Photo 9. Ph
Page 35: HOT DIP GALVANIZING MEMBERS GALVANI

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