Despite their robust appearance, the manhole covers and grates that we drive or walk over every day still need to go through rigorous testing. That is according to NATA Member, the EJ Group, a global manufacturer of iron products which is responsible for the construction castings found in major metropolitan areas, as well as worldwide.
In Australia, manhole covers and grates must be tested to ensure they meet all local and current safety and performance standards under the Australian Standard AS3996:2019. Testing confirms they can withstand long-term stress, environmental conditions, and heavy loads without failure.
Simulating Everyday Traffic
The testing as prescribed by AS3996:2019 is very rigorous and possibly the toughest Standard in the world.
To replicate daily wear from cars and trucks, EJ uses two types of prescribed load testing from the Standard. These tests apply pressure to simulate real-world traffic, helping to assess fatigue resistance and long-term durability.
For Serviceability Testing, the load is applied and repeated for five cycles. The deflection under load can then be measured and the permanent set against a strict set criteria.
Not only is this test preformed in the geometric centre of the cover, but also at the weakest point – generally an unsupported edge – to ensure that covers are meeting traffic conditions across their entire surface.
The Ultimate Limit State Test is then applied, which is the ultimate load rating for the cover or grate, and it is carefully examined for any prescribed issues.
Testing for Heavy Loads
For extreme applications, such as mining, ports, and airports, the Australian Standard has this covered with higher load class ratings of Class F(600kN) and Class G(900kN). The Standard prescribes the required testing, so testing for both Serviceability and Ultimate Limit State Loadings is used.
EJ has a NATA-accredited load testing machine that is fully calibrated to simulate heavy loads using hydraulic press systems, with digital monitors and cameras to accurately read and record the deflections. These tests ensure that its products can safely support oversized vehicles and equipment.
It is due to these tests that EJ products can be found on many of the words leading airports and seaports. More recently, they were implemented at the new Western Sydney Airport.
Accredited for Toughness
EJ in Australia is accredited by NATA. Accreditation by a local authority not only means its methods and equipment meet the nation’s strict standards, but also guarantees reliable, repeatable results, which it enables it to build trust for its construction castings with clients and regulators.
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