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Gereg

Fulton Sluice Gates

and

Fluid Control Equipment

Gereg Sewage and Water Equipment (Pty) Ltd.

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Gereg Sewage and Water Equipment (Pty) Ltd. Reg. No. 1999/002945/07

Cnr. Joule and Newton Streets P.O. Box 18122 Laboré SUNWARD PARK BRAKPAN 1470 R.S.A. R.S.A.

Tel. +27 (0) 11 738-1423/4 Fax. +27 (0) 11 738-3204

Web Site : http://gereg.8k.com Email : gereg@global.co.za

Factory and Offices in Laborè, BRAKPAN

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INTRODUCTION

Gereg Sewage and Water Equipment (Pty) Ltd. w as established in 1988 to market sluice gates and other f luid control equipment, and in 1990 w e acquired from Valvemakers the manufacturing and marketing rights for the w ell-know n FULTON range of sluice gates, w hich w ere f irst manufactured in 1965, and of w hich w e are now the sole suppliers.

Soundness of design and high manufacturing standards are not compromised for the sake of cost reduction, resulting in a range of products of exceptional quality.

Manufacture is undertaken by our associate company, Hinteregger Erection (trading as Gereg Engineering) w ho is ISO 9001 listed, (Certif icate Registration No. 01 100 000685/2) and strict Quality Assurance and Control as required by ISO 9001 is practised.

Standard products

Sluice gates Up to 2000 w ide x 2000 high * Channel gates Up to 800 w ide x 3000 high * 1200 w ide x 2000 high * or 2000 w ide x 1500 high * Weir gates (dow nw ard-opening Up to 2000 w ide x 1200 high * Weir gates (tilting) Up to 5000 w ide x 500 high * Tw istlock gates 100 to 300 dia. Handstops and Stoplogs Custom made to requirements Flap gates 75 to 250 dia. (Cast iron) As required (Fabricated) Telescopic bellmouths Up to 500 dia. * Sludge drain valves 100 to 300 dia. * Hand-flushing valves 75 to 300 dia. Ground w ater relief valves 110 dia. Operating gear for gates and valves * Larger sizes can be made if required.

Non-standard products

Gates for special applications (roller, slide, radial, etc.) Revolving screens Bar screens Weir plates (plain or notched) Scum boards and brackets Clarif ier bridges Pipe w ork and specials Tanks Cat ladders General fabrication w ork in mild and stainless steel

Notes

1. The above lists give an indication of our normal range of products, and are not necessarily complete. We w elcome enquiries for items not mentioned here.

2. The range may be reduced or added to from time to time 3. We reserve the right to alter specif ications, data and dimensions given in this

catalogue at any time, as our policy is one of continual product improvement. 4. No liability is accepted for any errors or omissions.

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Final assembly of a batch of Channel Gates.

300 ton Hydraulic press.

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GENERAL INFORMATION

Most sluice gates are fabricated from various grades of stainless or corrosion-resistant

steel, but certain sizes can also be manufactured from cast iron. Aluminium is usually used for handstops and stoplogs. Gates may be supplied w ith or w ithout seals, depending on customer's requirements.

Operation of gates can be manual, electric, hydraulic or pneumatic.

Sluice gates may be broadly divided into the follow ing types :

Wall mounted gates, w hich are used to close off an opening in a w all, or the end of a pipe, and seal around the complete periphery of the opening. They can be either of the slide or roller type, and can be arranged to seal against on- or off-seating pressure, the former being w here the pressure or f low tends to force the gate on to its frame and the latter w here the gate tends to be forced off its frame. By f itting double music-note seals, a gate can be arranged to seal in both directions if necessary.

When a large gate has to be operated against a high unbalanced pressure, the force required to open it may be excessive, in w hich case rollers are f itted in order to reduce friction, and hence the operating effort.

Channel gates, used to control f low in open channels or canals, are of the 3-sided sealing type, having no seal along the top edge of the gate. They are normally screw operated, w ith handw heel or gearbox mounted on a bridge, w hich forms part of the headframe. Wide gates may require tw in-lif ting spindles.

Channel gates are usually mounted in slots cast into the sides and f loor of the channel, but can also be w all-mounted if required.

Radial gates, w hich are often 3-sided sealing, are used in canals, or on dam w alls, for f low control.

Weir gates, are either dow nw ard-opening, or bottom-hinged tilting type, and the f low over the top of the gate is controlled by adjusting its height. Depending on w ater level, and w hether the gate must seal off the opening, w eir gates may be either 3- or 4-sided sealing.

Twistlock gates. Quick-action hand-operated gates w hich can be locked in any partially open position simply by turning the T-handle.

Handstops and stoplogs. Simple hand-lif t gates w hich do not normally have seals, as a certain amount of leakage is often permissible. How ever seals can be f itted if required.

Flow dividers. These are vertically pivoted sw ing gates used for diverting f low into either of tw o channels. Seals are optional.

Flap gates. Non-return gates, allow ing f low in one direction only.

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Other products for f luid control include:

Telescopic bellmouths are used to draw off scum and surface f luids in tanks. Adjustment of the upper (sliding) tube is by means of an extended spindle.

Sludge drain valves. These are used in reservoirs and tanks to allow complete emptying. They are screw operated by means of an extended spindle, but can also be opened and closed hydraulically or pneumatically.

Hand-flushing valves. Lever operated valves for rapid draining of tanks, etc.

Ground water relief valves, for casting into f loors of reservoirs, tanks, canals, etc., to prevent the build-up of excessive ground w ater pressure, w hich can cause lif ting of the f loor.

DESIGN FEATURES

Structural members

The design of all sluice gate structural members complies w ith the requirements of DIN Spec. 19704, and under full head conditions there are ample margins of safety over the yield and ultimate strengths of the materials used. In addition, deflections are calculated to be less than those allow able for the type of seals employed.

Seals

Sluice gates are f itted w ith Neoprene music-note ("J" type) seals, w hilst channel gates have Neoprene angle ("L") type. These bear against the frame surfaces, and give excellent sealing, as the higher the pressure, the greater the force pressing the seal against the frame, and the more effective the sealing action.

If , for any reason Neoprene cannot be used, metal to metal or thermoplastic seals can be provided.

For high off-seating pressures, and for metal or thermoplastic seals, gates are f itted w ith adjustable w edges to ensure positive contact betw een seal faces.

Leakage rates

Gates are designed for minimal leakage, and in practice are often found to be drop-tight. How ever the permissible leakage rates as laid dow n in AWWA Spec. C 501, w hich are ± 1,24 litres per minute per metre of seal for seating pressures, and ± 2,48 l.p.m. per metre for off-seating pressures up to 6m, are guaranteed maxima.

NOTE : Correct installation is essential if these rates are not to be exceeded.

Bearing strips

Hydraulic thrust is taken on low -friction H.D.P.E. strips f itted to the gate, and w hich slide on the frame as the gate moves. These strips are sized to give low bearing loading, resulting in long life and easy operation. They are also f itted to the larger sizes of channel gates for the same reason.

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Operating gear

For manual operation, handw heel diameters and gearbox ratios are matched to spindle sizes and thread pitches, so that the time required to stroke the gate is kept to a minimum, at the same time limiting handw heel rim effort to normal acceptable levels of betw een 100 and 150 N.

If gearing is necessary, bevel or combined bevel / spur gearboxes are used.

Spindles

Spindles are sized in accordance w ith calculated tensile and compressive loads w hich w ill be imposed w hile opening and closing the gate, and spindle guides are spaced so that buckling of the spindle under compression does not occur.

Cover tubes

Spindle cover tubes can be f itted if desired. If visual indication of gate position is required, the cover tube w ould be supplied in clear PVC, but steel or stainless steel, being more robust, is recommended w herever possible. The design of the handw heel boss allow s a cover tube to be f itted at a later stage, if it is subsequently found to be necessary

Channel gate headframes

We supply tw o types of headframes for channel gates. The f irst comprises integral head and embedded sections, w hilst the second, the upper piece is bolted to the embedded section, w hich facilitates transport, and allow s the low er portion to be installed in the slots prior to the balance of the equipment.

4m wide x 2,6m high mild steel stop gate for 13m unseating head.

(Supplied to Umgeni Water for Inanda Dam intake structure.)

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MATERIALS OF CONSTRUCTION

Component Material Options Gates and frames Stainless steel Handstops and stoplogs Corrosion-resistant steel (3CR12) Mild steel Aluminium Tw istlock gates Stainless steel Flap gates Corrosion-resistant steel Telescopic bellmouths Mild steel Sludge drain valves Cast iron (certain sizes only) Pedestals Stainless steel Support brackets Corrosion-resistant steel Wall brackets Mild steel Cast iron Ground w ater relief valves Cast iron Stainless steel Seals Neoprene Thermoplastic / metal Metal / metal Spindles Stainless steel Couplings Stop collars Bronze Spindle guides Lifting nuts Handw heels Aluminium (cast) Mild steel (fabricated) Cover tubes Stainless steel Mild steel Clear PVC Foundation bolts and fasteners Stainless steel

CORROSION PROTECTION

Material Protection Options Stainless steel Pickled and passivated Corrosion-resistant steel Mild steel Fusion bonded epoxy coated Cast iron Primed and painted Galvanised Aluminium Anodised

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OPTIONS AND THEIR APPLICATIONS

SLUICE GATES (4- sided sealing)

Feature Option Application Mounting Flat back Seating and low to medium

off-seating pressures Spigot back High off-seating pressures Wedging Gate retaining strips Neoprene seals Adjustable w edges Non-resilient seals Side seals Neoprene "J" type General use Metal or thermoplastic Where neoprene is not suitable Bottom seal Neoprene "J" type General use (Standard invert) Neoprene rectangular General use compression type Restricted f loor space (Flush invert) Grit in f luid

CHANNEL GATES (3- sided sealing)

Feature Option Application Mounting Slot f ixing Mid-channel location Flat back Wall mounting End of channel location Side seals Neoprene "L" type General use Bottom seals Neoprene rectangular General use compression type

HANDSTOPS and STOPLOGS

Feature Option Application Mounting Slot f ixing Mid-channel location Flat back Wall mounting End of channel location Seals None General use Neoprene "L" type Where sealing is required

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Channel Gates w ith manual gearboxes. (Olifantsfontein W.C.W.)

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OPERATING GEAR

Feature Option Application Spindle Rising General use Non-rising Tee-key operation Restricted headroom Mounting Pedestal on platform General use Pedestal on w all Where there is no support bracket overhead platform Headframe bridge Sluice gates w here w all is too low Channel gates Manual Handw heel Light to medium duty Bevel gearbox Medium to heavy duty Bevel/spur gearbox Heavy duty Tee-key Non-rising spindle Preventing unauthorised use Lifting handles Handstops and stoplogs and / or rods Tw istlock gates Pow er Electric actuator Heavy duty Hydraulic actuator* and/or Pneumatic actuator* Push-button / Remote control *Rising spindle only Various types of operating gear are shown on Page 8 (previous) :

a. Pedestal on w all support bracket

b. Bevel gearbox on pedestal

c. Hydraulic or pneumatic actuator

d. Electric actuator on pedestal

e. Platform mounted pedestal w ith handw heel

f . Tee-key on support bracket

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Wall-mounted Sluice Gate

Standard Inv ert Flush Inv ert

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WALL-MOUNTED SLUICE GATES

Wall-mounted sluice gates (occasionally referred to as penstocks) are used to close off an opening in a w all, often betw een adjacent tanks or chambers, as w ell as outlets in dam w alls.

The most common type of seals are Neoprene "music note" or "J" seals, and as it is not possible to utilise these seals on circular gates, all our sluice gates have square or rectangular openings.

Water pressure forces the bulb of the seal against the sealing surface on the frame, and the higher the pressure, the greater the force. To cater for off-seating pressures, the seals are reversed, so that the bulb is still forced against the frame, and in cases w here both seating and off-seating pressure conditions occur, double seals, one in the normal, and one in reverse configuration, are used.

The invert seal is either of the "J" type, for standard invert, or is rectangular, for f lush invert. The latter is recommended for use in sew age and other applications w here the f luid contains grit, sludge, etc., as no "pocket" occurs across the invert.

We can also f it non-resilient (metal or thermoplastic) seals to w all-mounted sluice gates, if specially required, and to ensure effective sealing, adjustable w edges w ould be used.

We strongly recommend using rising spindles w herever possible, since the threaded section, as w ell as the thrust arrangement, are at the top, out of the f luid. Unless their use is essential, non-rising spindles should be avoided, so obviating possible clogging of the threads.

Various operating gear options for sluice gates are described on Pages 8 and 9, and leading dimensions of the standard range of gate sizes appear on Page 13.

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Standard Inv ert Flush Inv ert

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WALL-MOUNTED SLUICE GATES

Standard Dimensions and Pressure Ratings

Gate size Pressure head (m) A B S (wxh) Standard Flush Min. Max. Seating Unseating Inv ert Inv ert

250 x 250 10 7 490 395 510 87 102

300 x 300 10 7 540 445 560 87 102

400 x 400 9 6 640 545 660 87 102

500 x 500 9 6 740 645 760 87 102

600 x 600 9 6 855 760 860 90 107

700 x 700 9 6 955 860 960 90 107

800 x 800 8 6 1055 960 1060 90 107

900 x 900 8 5 1155 1060 1160 90 107

1000 x 1000 8 5 1255 1160 1260 100 115

1100 x 1100 7 4 1355 1260 1400 100 115

1200 x 1200 7 4 1455 1360 1500 100 115

1400 x 1400 7 3 1655 1560 1600 115 135

1500 x 1500 6 3 1755 1660 1800 115 135

1800 x 1800 5 3 2055 1960 2100 115 135

2000 x 2000 4 3 2255 2160 2300 115 135

Notes:

1. Non-standard sizes and gates for higher pressure ratings can be specially manufactured.

2. Dimension S varies according to gate design.

3. Dimensions should not be used for construction purposes.

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Downward-opening Weir

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WEIR GATES

(a) Downward-opening weirs

These are similar to w all-mounted gates, except that the gate is closed in its "up" position, and as it is low ered, the opening is uncovered, to allow the f low over the top to be controlled.

A different seal configuration is used, w ith either "J" or "Triangular" type Neoprene seals being f ixed to the frame instead of the gate.

Dow nw ard-opening w eirs can be either four-sided sealing, if the head is greater than the height of the opening, and it is necessary to shut off the f low completely, or three-sided sealing, w hen no top seal is required.

Occasionally a w eir is required to have a w idth much greater than its height. As this may cause the gate to jam in the guides, the effective height can be increased by means of side extensions to the gate. If this is not practical, tw in lif ting spindles w ith tw o inter-connected gearboxes are used, but depending on gate size and the travel required, a tilting w eir may be preferable to a dow nw ard-opening type.

(b) Tilting weirs

Tilting w eirs are used for w ide openings w here the vertical travel required is not more than about 500 mm. The gate is hinged at the bottom, and is raised and low ered by means of a centrally mounted spindle w hich can be operated either manually, or by an actuator. As friction is very low , operating effort for tilting w eirs is minimal.

Sealing plates can be f itted to the end w alls if required, w hilst a f lat Neoprene seal across the w idth of the w eir prevents leakage along the hinged section.

Scum baff les, located upstream of the w eir, are optional.

End sealing plate

Tilting Weir

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Channel Gate Type F

Channel Gate Type G

Block-outs (Type F) Block-outs (Type G)

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CHANNEL GATES

As their name implies channel gates are used to control f low in open channels, and therefore do not have a top horizontal seal, since the gate height is made about 100 mm greater than the maximum depth of f luid in the channel. They are usually mounted in slots in the side w alls and f loor, but they can be adapted to bolt against a w all face if necessary.

Channel gates seals are Neoprene angle type dow n the tw o vertical sides, sealing against the embedded frame members, w hilst a rectangular compression type is used on the invert.

The operating gear is usually carried on the headframe bridge, but can also be pedestal- mounted on an overhead platform. Rising spindles are strongly recommended.

In cases w here the channel depth is considerably more than the gate height, or w here the height of the headframe is greater than normal, the spindle may have to be supported in guides in order to prevent buckling under compression w hen the gate is closed.

We can supply tw o alterative types of frames as follow s:

Type F w here the headframe legs are extensions of the embedded sections, or Type G having a separate bolt-on headframe, w hich facilitates transport and erection, as the embedded sections can be installed prior to the upper portion, w hich is then bolted on later after completion of the civil w ork.

Dimensions of the block-outs required in the channel sides and f loor for both types are given on Page 16.

For very w ide gates, tw in-lif ting spindles may be required, in w hich case tw o inter-connected gearboxes are used, as show n below .

Twin-lift Channel Gate

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TWISTLOCK GATES

Tw istlock gates are used in the same applications as small w all-mounted sluice gates, w here hand operation is acceptable. They can be locked in any partially open position by tw isting the handle, w hich brings a cam into play, forcing the gate against its frame. This same action seals the gate in its closed position.

Tw istlocks are suitable for balanced heads up to 3m seating or 2m unseating, but it must be borne in mind that operating effort increases w ith size and pressure.

Usually of cast iron construction w ith bronze seating faces, they can also be cast in stainless steel, or fabricated from stainless, corrosion-resistant or mild steel.

Dimensions of the cast range are given below :

Bore A B C

100 305 390 82

150 305 390 82

200 381 480 102

225 432 540 102

300 570 655 145

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HANDSTOPS AND STOPLOGS

These are used in open channels, and are normally supplied w ithout seals, but for special applications, Neoprene angle-type seals can be f itted to minimise leakage. Handstops are usually fabricated from aluminium, but can also be made in steel if required.

For deep channels, the gate can be made in sections, know n as stoplogs, w hich are raised and low ered by means of loose lif ting rods.

Maximum w idth for handstops is about 1000mm, and all but very small sizes should be raised under balanced conditions.

Dimensions of the recesses w hich should be left in the channel sides and f loor for installation of handstops and stoplogs, both sealing and non-sealing, are given below , but note that w ith our aluminium frame extrusion, w all mounting, as an alternative to slot f ixing, is also possible, as is the case w ith fabricated steel frames if required.

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FLAP GATES

These are used in w alls or on the ends of pipes to prevent reversal of f low , and consist of a frame w ith a gate or f lap w hich is hinged at the top. In order to ensure proper closure against the frame, the gate is double hung, by means of stainless steel pins in bronze bushes.

The smaller sizes, leading dimensions of w hich are tabulated below , are generally of cast iron, but can also be cast in stainless steel, and have bronze or stainless steel sealing faces.

Larger sizes, having square or rectangular openings, are fabricated from stainless, corrosion-resistant, or mild steel, and are usually supplied w ith neoprene seals.

Bore A B C D

75 184 92 92 77

100 216 147 108 60

150 280 149 140 118

200 336 168 168 75

300 406 205 203 100

Cast Iron Flap Gate

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TELESCOPIC BELLMOUTHS

Telescopic bellmouths are used extensively in sew age purif ication w orks to draw off surface f luids and scum. They consist of a low er (outer) tube w hich is connected to a drain pipe, and an upper (inner) tube w hich slides up and dow n, so varying the level at w hich skimming is required to take place. Seals are f itted betw een the inner and outer tubes to prevent leakage.

Operation is usually manual by means of a handw heel and spindle connected to a bridge-piece f itted across the top of the sliding tube, and care must be taken to allow enough room betw een the bridge and the underside of the operating platform w hen the inner tube is fully extended.

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SLUDGE VALVES

Sludge valves are used for complete draining of reservoirs and tanks, being cast into the f loor as illustrated.

They can be supplied in cast iron or cast steel, or, as is usual for the larger sizes, they can be fabricated from stainless steel, corrosion-resistant steel, or mild steel. Bronze/Neoprene is standard for the seats, w ith stainless steel being used w here specially required.

Normal operation is by means of a handw heel, but hydraulic or pneumatic operation can be utilised if necessary.

Bore A B C D

75 190 184 180 20

100 220 215 180 20

150 280 265 205 20

200 346 316 270 20

300 480 450 305 25

450 720 600 430 25

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HAND FLUSHING VALVES

These valves are quick opening lever-operated types, used for draining f luid from tanks, etc., and are suitable for heads up to 3m.

They are supplied in cast iron as standard, but can also be cast in stainless steel for special purposes. Bronze seats are standard.

Leading dimensions are given below .

Bore A B C D E

75 185 270 145 125 80

100 218 325 175 150 92

150 280 448 220 228 155

200 336 555 295 260 165

225 370 575 300 275 165

300 460 722 405 317 224

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GROUND WATER RELIEF VALVES

These valves are used for relieving pressure caused by ground w ater under the f loors of reservoirs, canals, etc., and are cast in as show n below . The body is of either cast iron or cast stainless steel, w hilst the f lexible disc and sealing ring are Neoprene.

Maximum recommended pressure head on the valve is 4m.

Approximate f low rates for various differential heads are as follow s:

Differential head (m) 0,2 0,4 0,6 0,8 1,0

Flow rate (litres / minute) 90 160 210 250 280

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WEIR PLATES AND SCUM BOARDS

Most applications for these items are on clarif iers.

Material, as w ell as plate depth (Dw ), thickness, and total circumferential length should be specif ied. Whether plain or notched, and type of notching required should also be mentioned. Note that maximum length per section of plate is 3m.

Similar remarks apply to scum boards, except that these are not notched.

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INFORMATION REQUIRED WITH ENQUIRIES

Requests for quotations should specify as fully as possible :

1. Type of gate required (sluice, channel, w eir, etc.) 2. Method of operation (manual, electric, hydraulic or pneumatic) 3. Height of operating gear above platform or top of w all ( C ) 4. Rising or non-rising spindle 5. Whether cover tube is required for rising spindle 6. Materials of construction 7. Fluid to be controlled (w ater, eff luent, etc.) 8. Corrosion protection required 9. Dimensioned sketch of structure or gate arrangement 10. Whether installation is required 11. Any special requirements or conditions

NOTE: Wherev er possible, gates should be arranged for on-seating pressure and rising spindle.

Additional information required for the follow ing:

Sluice gates (wall-mounted)

1. Width x height or diameter of opening ( w x h or Ø ) 2. Maximum pressure head on gate w hen closed ( Hm ) 3. Maximum unbalanced head against w hich gate w ill be operated 4. Direction of f low ( seating, off-seating or both ) 5. Height of operating platform or top of w all above invert of opening ( X ) 6. Height of operating gear above platform or top of w all ( C ) 7. Height of invert above f loor ( F ) N.B. Min. F = 200 mm 8. Whether standard or f lush invert is required 9. How operating gear is mounted (pedestal on platform, support bracket, etc.)

Channel Gates

1. Width x depth of channel ( w x d ) 2. Height of gate ( h ) 3. Gate travel ( B ) 4. Height of operating gear above top of channel

Handstops and Stoplogs

1. Width x depth of channel ( w x d ) 2. Height of gate ( h ) 3. Whether seals are required

Telescopic Bellmouths

1. Diameter of inner tube ( D ) 2. Closed length ( A ) N.B. Minimum A = B + 300 mm 3. Travel ( B ) N.B. Allow freeboard top and bottom 4. Height of operating gear above platform ( C ) 5. Bottom connection to underside of operating platform ( E ) 6. Thickness of concrete platform ( T ) 7. Size and drilling details of bottom connecting f lange

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Weir Gates ( downward-opening )

1. Width of opening ( w ) 2. Height of opening ( h ) for 4-sided sealing 3. Gate height ( h ) for 3-sided sealing 4. Maximum head on gate ( Hm ) 5. Direction of f low ( seating or off-seating ) 6. Dimensions X and F N.B. Min. F = h + 260 mm 7. How operating gear is to be mounted

Weir Gates ( tilting )

1. Width x height of opening ( w x h ) N.B. Clear opening width of weir = w-120mm 2. Gate vertical travel ( B ) N.B. Allow freeboard top and bottom 3. Dimension X 4. Whether end sealing plates are required

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4,2m wide x 3,5m high Channel Gate with Rotork electric actuator.

(Johannesburg Northern Works)

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INSTALLATION INSTRUCTIONS

The follow ing instructions are given as a guide for erecting fabricated gates f itted w ith Neoprene resilient seals. It is important to realize that w hilst every care is taken in assembling the gates in the factory, both gates and frames are f lexible to some extent, and therefore that deflections and distortions can and do occur during transport and installation. Although the seals themselves w ill cater for minor distortions, it is essential that these be eliminated as completely as possible w hen the gates are installed, by making the adjustments described herein.

Only by experience w ill the erector learn all the " tricks of the trade", but should there be any points that require clarif ication, the reader is w elcome to discuss these w ith us.

A set of these instructions is provided w ith every gate w hich is not being installed by ourselves, and w e strongly recommend that they be follow ed closely in order to ensure optimum performance and service from the equipment.

WALL-MOUNTED GATES

1. Foundation Bolts

The follow ing types are commonly used:

(a) Anchor and epoxy grouted Accurately mark off the positions of the bolts, and drill holes of correct diameter for the anchors being used, ensuring that they are perpendicular to the face of the w all. Clean out the holes thoroughly before inserting the anchors, this being particularly important for epoxy-grouted (chemical) types. (b) Cast-in These may be cast directly into the primary concrete, or into preformed pockets. They must be accurately positioned by means of a drilled template or shutter to hold them in place during pouring of the concrete. (c) Weld-on These are used for very large gates, and are w elded to previously cast-in w all plates w hen the frame is installed. Some latitude is permissible in positioning the w all plates. N.B. The foundation bolts must be perpendicular to the wall, and must project the correct amount.

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2. Gate and frame

Before commencing to install, roughen all concrete surfaces w hich w ill come into contact w ith grout, and w ash dow n w ith clean w ater. See that the back of the frame and underside of the pedestal base, etc. are all clean and free of oil and grease.

Remove the gate from its frame by loosening the gate retainers. Screw a half- nut on to each foundation bolt, hang the frame on the bolts, and secure w ith further nuts as show n, allow ing 25 to 30 mm space for grout betw een the back of the frame and the w all. If the frame is very heavy, place packers beneath it for support.

N.B. NEVER bolt the frame directly on to the wall, even if some form of packing is used, as this w ill inevitably cause the frame to distort, resulting in the gate leaking.

Adjust the nuts until the frame is true and vertical, and the sealing faces are not distorted. Ensure that the inside faces of the side angles are parallel to each other by moving a straight-edge of correct length dow n the tw o sides, and observing its contact w ith the sealing faces. Jack out any distortions by slackening and tightening the appropriate nuts and half-nuts. Note that the lintel and sill (horizontal) frame members project about 20 mm proud of the back of the frame angles, and they must remain clear of the w all face. If necessary they can be w edged outw ards from the w all, and the larger gates are provided w ith jacking screw s for this purpose. In the event that one of the horizontal members is bow ed outw ards, remove the frame from the w all and eliminate the deflection, preferably in a press.

Once the sealing faces are completely f lat and true, proceed as follow s:

For gates up to about 600 sq., apply grease sparingly along the length of the bulb of the J-seals, and then carefully place the gate in position, pressing it against the frame. After w ithdraw ing the gate, examine the frame sealing faces to see that the bulb has made proper contact over the entire surface, and adjust again if necessary.

The seal configuration for off-seating pressures has the seals reversed, w ith the bulb on the inside of the frame, and provided access to the back of the gate is possible, seal contact can be checked visually, or by means of a feeler gauge.

For large gates w hich are too heavy to handle as above, f irst make sure that the bulb of the seal protrudes 1 to 2 mm proud of the bearing strip, then f it the gate in its frame and tighten the retainers in their original positions. Check that the gap betw een the bearing strips and the frame is not more than 0,5 mm, paying particular attention to the lintel and sill, and adjust as necessary.

On f lush invert gates the rectangular bottom seal is easily checked for contact w ith the sill beam. If necessary slacken the seal retainer on the gate, and adjust the seal as required.

After making the above adjustments and checks, nip up and lock all nuts, being careful not to cause any movement or distortion to the frame.

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3. Operating gear

Using a plumb bob, determine the correct position of the pedestal, before marking off and drilling the foundation bolt holes. Ensure that the spindle w ill be accurately aligned w ith the connection on the gate, and w ill be true and vertical. If a w all support bracket is to be installed, similar care must be taken w ith its positioning and alignment.

Using the nuts on the foundation bolts, make sure that the pedestal is true and vertical, again leaving about 30 mm grout space betw een its base and the top of the platform.

Spindle guides and brackets (w here supplied) should be equally spaced, but take care that there is enough space betw een the top of the gate and the low est guide to allow the gate to open fully. Also note that if there are any couplings on the spindle, these must be able to travel freely betw een guides w ithout fouling.

After determining the w all bracket positions, drill the holes for the bolts, and adjust the brackets by means of the nuts as previously described, so that they are correctly aligned and true prior to grouting.

Install the spindle complete w ith guides, and adjust these on the brackets, using the slots provided on the latter.

The gate should then be operated up and dow n through its full travel, to ensure that the spindle is free, and that there is no fouling anyw here. Next, carefully lock all nuts, w ithout causing any movement or distortion.

4. Grouting

Clean all metal and concrete surfaces, w et the latter, and grout up the spaces from the bottom upw ards, using a proprietary brand of non-shrink grout, and making the mix as dry as possible. Shuttering should be used as required.

The grout should be lightly rammed, taking great care not to distort any frame members during the process.

After the grout has set, remove all excess, clean the metal surfaces, and f inished off neatly. Replace the gate in its frame, tighten the retainers, and again operate up and dow n through the full travel to ensure that no misalignment has occurred during grouting.

5. Commissioning

Lubricate the spindle threads w ith all-purpose grease, and raise and low er the gate fully.

With the gate f irmly in its closed position, check that the stop collar is correctly located on the top of the spindle, so as to prevent over-closing of the gate, w hich could cause the spindle to buckle due to excessive compression. The collar must be securely locked on the spindle by means of the grub screw s provided. This is very important.

The gate is now ready to be w et tested under operating conditions.

N.B. Apart from incorrect installation or seal adjustment, leakage is often caused by grit, pieces of concrete, or other foreign objects lodging in the seals, or betw een gate and frame, and under the bottom seal in the case of f lush invert gates, so preventing proper closure.

NEVER attempt to stop leaks by over-tightening the handw heel.

36

37

CHANNEL GATES

1. Frame

Clean the slots in the concrete and insert gate and frame so that the seals are on the upstream side. Using the jacking screw s provided, level the invert member f lush w ith the bottom of the channel, checking that the invert seal makes contact along its full w idth.

Position and align the vertical frame members so that they are parallel to each other, and are free of all tw ist. Check that the vertical seals make contact w ith the frame sealing faces along their entire length, w edging the frame members inw ards if necessary, at the same time making sure that the gate does not jam in the frame. Wooden struts placed across the inside of the frame as show n, w ill prevent it from being bow ed inw ards during grouting.

Check that the headframe is true, vertical and free of tw ist, and that the embedded frame is held f irmly by the jacking screw s. Next, stroke the gate up and dow n through its full travel, again checking for correct seal contact, w ith the gate closed, but not over-tightened.

2. Grouting

Grouting can now be done, bearing in mind the previous remarks concerning w all-mounted gates.

In cases w here the headframe has been removed from the embedded section, and w ill only be f itted later, it w ill not be possible to screw the gate dow n on to the invert, and care must be taken not to force the invert member upw ards by ramming the grout too vigorously.

3. Commissioning

Commission as for w all-mounted gates, again taking care to adjust and lock the stop collar on the spindle in its correct position w ith the gate f irmly closed.

N.B. See the remarks made on Page 35 concerning likely causes of leakage.

MAINTENANCE

Periodically clean all dirt from the spindle threads, and apply all-purpose grease. Site conditions w ill determine how often this needs to be done, it being important not to allow excessive build-up of dirt and grit on the threads.

Pump grease into the nipples on the operating gear at about 6-monthly intervals, and in the case of gates having non-rising spindles, the bronze lif ting nut in the gate should be greased at the same time.

Every 6 to 9 months, inspect the seals for damage and deterioration, and replace as necessary

Regularly check gate closure, and re-adjust the stop collar if required.

38

Reg. No. 1999/002945/07

Gereg

Gereg Sewage and Water Equipment (Pty) Ltd. Cnr. Joule and New ton Streets P.O. Box 18122

Laboré SUNWARD PARK

BRAKPAN 1470

R.S.A. R.S.A.

Tel: +27 (0) 11 7381423/4

Fax: +27 (0) 11 7383204

E-mail: gereg@global.co.za