TECHNICAL BULLETIN
March 22, 2005
Material Handling and Slab Storage Z-2005-002
Zodiaq® is a heavy material weighing 10 lbs/ft2 and 15 lbs/ft2, for 2 and 3 cm product, respectively. Consequently, every business handling Zodiaq® must be outfitted with the appropriate material handling equipment to ensure the safe movement of slabs and work-inprocess product. The following is a description of the material handling issues that one needs to address in handling Zodiaq®. It is the responsibility of each business to determine the right material handling equipment for their facility. Safety: • To ensure the safe operation of equipment, all equipment should be inspected prior to use. • DuPont recommends two operators to ensure safe optimal handling of slabs: one operating the forklift and one on the floor to manage the slab. • Proper personal protective equipment should be worn at all times, leather gloves, sturdy shoes, safety glasses, and a hard hat if lifting material overhead. • Slabs are very heavy and awkward to handle. When moving a slab, avoid lifting the slab any higher than necessary. • Operators should never position themselves directly under, in front of, or between slabs. Always stand in a position that would prevent the slab from accidentally falling towards you. Material Handling: Every business that handles slabs of Zodiaq® will need a forklift to off-load A-frames from delivery trucks, move A-frames of slabs in and out of inventory, and to load A-frames for delivery to fabricators (AMI’s), or installers (AZI’s). Most businesses will equip forklifts with a slab boom (or forklift arm) and a slab lifter (clamp) to move slabs, and work-in-process, through their building. Since a fully loaded A-frame can weigh as much as 5500 lbs, DuPont recommends a forklift with a minimum capacity of 8000 lbs. Moving slabs on A-frames: A-frames are intended to be moved only when slabs are secured to the A-frame. Secure the slabs to the A-frame with banding or ratcheting tie down straps placed around the entire Aframe. The intent is to replace the original banding as it comes from the factory. Moving A-frames using clamps to secure the cross members is an unsafe practice as the Aframes are not designed for this use. Dragging A-frames across a floor can cause damage and is an unsafe practice. Slab Storage: At present, the most cost effective way to store Zodiaq® slabs is on an A-frame, or in vertical storage racks. A-frames used for storage are generally constructed of wood, while vertical storage racks are generally constructed of steel. Steel posts are often covered at the point of contact with carpet, rubber pads, wood, plastic, etc. to prevent scratching, gouging, or scoring of a slab. Verticle storage racks should be capacity rated and designed for stone slab storage.
The information contained in this Technical Bulletin is given by the E. I. du Pont de Nemours and Company free of charge. It is based on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of Zodiaq®. Zodiaq® is a DuPont registered trademark for its quartz surfaces. Copyright 2001 E. I. du Pont de Nemours and Company. Printed in the U.S.A Z-2005-002 March 22, 2005
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TECHNICAL BULLETIN
March 22, 2005
Material Handling and Slab Storage Z-2005-002 Slabs can be stored on A-frames without banding, but they should be protected from the weather and any impact that may tip a slab or the entire A-frame. The number of slabs on either side of the A-frame should be balanced to make the A-frame the most stable. A-frames are designed for delivering slabs and providing temporary storage. If slabs are to be stored on A-frames for an extended period of time, the A-frame should be periodically inspected to insure integrity. A-frames should not be stored outside or in a wet environment for an extended period of time because they are not made of treated wood. If Zodiaq® is stored outside in storage racks, it needs to be kept covered. Slabs should be stored with the polished faces unexposed. In addition, the use of waterproof canvas to cover the product or storage under a roof has been utilized to protect Zodiaq® from the sun. Over prolonged periods of time fully or partially exposed slabs can experience color fading due to exposure to direct sunlight. In northern climates where rain, ice, and snow fall during the winter months, ice can build up under the wood braces of the A-frame. The combination of ice build up and metal forks on a fork-lift require special handling. Care should be taken to defrost the ice. The fork-lift should be outfitted with rubber sheaths to prevent the A-frames from slipping during transport. In addition, individual slabs which are icy or frozen should be thawed prior to hoisting. This prevents slippage when gripping individual A-frames with rubber grips. Moving Slabs and/or Work-in-Process through a Fabrication Shop: There are a number of products that are effective for moving product through a shop. The following is not an exhaustive list. Please consult the appropriate vendor for the right equipment for your shop. Verify that the equipment is capacity rated for the intended use. • Forklift with a boom and slab clamp • Overhead crane with vacuum lift or slab lifter (clamp) • Carts/Tables/Dollies: Slab Cart/Buggy (Hydraulic and battery operated versions are available) Tilting hydraulic Transport Tables Workshop Cart with Wheels Fabrication Carts (A-frame mode that pivots to horizontal mode is available) Hand Trucks (multi-position versions available) Slab Dolly • Jib Crane • Conveyors Note: This technical bulletin is intended to replace technical bulletin Z-2001-015, dated November 2001. If you have any questions regarding the information contained in this technical bulletin, contact DuPont Technical Service at (877) 229-3935 or www.zodiaq.dupont.com The information contained in this Technical Bulletin is given by the E. I. du Pont de Nemours and Company free of charge. It is based on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of Zodiaq®. Zodiaq® is a DuPont registered trademark for its quartz surfaces. Copyright 2001 E. I. du Pont de Nemours and Company. Printed in the U.S.A Z-2005-002 March 22, 2005
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TECHNICAL BULLETIN
August 26, 2005
Unloading Zodiaq® Containers Z-2005-003 Overview: This document provides recommended procedures for safely unloading Zodiaq® slabs from 20-ft. open and closed top containers. Three types of container configurations are discussed: open canvas top, open hard “pop-top”, and closed top containers. Containers will arrive by truck on a trailer designed to properly handle containers. Containers can be off-loaded from a shipping dock, or the container/trailer can be off-loaded at a convenient location that is forklift accessible. The typical container will contain 54 slabs of 3-cm Zodiaq® and 81 slabs of 2-cm Zodiaq®. Equipment needed:
Forklift – Base the forklift capacity on the manufacturer recommendations for the load intended to be lifted.
Forklift boom – Minimum extension of 10 ft. is recommended.
Slab clamp – Several brands and models are available. Use manufacturer recommendations to determine proper model and capacity needed.
Storage racks or A-frames designed for safe slab storage.
Hand tools for removing packaging materials (hammer, crowbar, metal snips, etc…).
Safety:
All equipment should be inspected prior to the unloading process to ensure safe operation.
DuPont recommends three operators to ensure safe optimal unloading of slabs: one operating the forklift, one inside the container, and one on the ground to manage the slab off-loading to A-frames or storage racks.
Proper personal protective equipment (leather gloves, sturdy shoes, safety glasses, and hard hat when lifting material overhead) should be worn at all times.
Zodiaq® slabs are very heavy and awkward to handle. Operators should never position themselves directly under, in front of, or behind a slab. Always stand to the side to prevent the slab from accidentally falling towards you.
The information contained in this Technical Bulletin is given by the E. I. du Pont de Nemours and Company free of charge. It is based on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of Zodiaq®. Zodiaq® is a DuPont registered trademark for its quartz surfaces. Copyright 2001 E. I. du Pont de Nemours and Company. Printed in the U.S.A Z-2005-003 August 26, 2005
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TECHNICAL BULLETIN
August 26, 2005
Unloading Zodiaq® Containers Z-2005-003 Container configurations and options: 1.
Determine the type of container to be unloaded, open top with a soft canvas top, open top with a hard “pop-top”, or closed top container.
2.
Unlatch and open the rear doors of the container.
3.
If the container type is an open top with a soft canvas top design (see photo 1a), it is possible to remove the canvas top and supports to increase headspace for unloading (see photo 1b). The top support bar on the upper back portion of the container can also be unlatched and swung out of the way or completely removed to create additional headspace.
Photo 1a
4.
Photo 1b
If the container type is an open top with a hard “pop-top” design (see photo 2a), it is possible to remove the hard “pop-top” to increase headspace for unloading (see photo 2b). Unlock the hard “pop-top” locking bars located on all four sides of the container by turning the handles (see photo 2c). The hard “pop-top” is equipped with forklift accessible lifting attachments located in the center area of the top to aid with removal (see photo 2d). The hard “pop-top” weighs approximately 900 lb. An operator will need to use a ladder to guide the forklift operator into position on the lifting attachments. Set the hard “pop-top” aside (in a low traffic area) until slab removal is complete. The top support bar on the upper back portion of the container can also be unlatched and swung out of the way or completely removed to create additional headspace. When container is unloaded, replace the top support bar (if removed) and the hard “pop-top”. Lock down the top using the locking bars.
The information contained in this Technical Bulletin is given by the E. I. du Pont de Nemours and Company free of charge. It is based on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of Zodiaq®. Zodiaq® is a DuPont registered trademark for its quartz surfaces. Copyright 2001 E. I. du Pont de Nemours and Company. Printed in the U.S.A Z-2005-003 August 26, 2005
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TECHNICAL BULLETIN
August 26, 2005
Unloading Zodiaq® Containers Z-2005-003
Photo 2a
Photo 2c
5.
Photo 2b
Photo 2d
If the container type is a closed container (box) design it is not possible to remove the top or swing the top support bar because this is all one piece. The rear doors are opened and the slabs can only be removed from the end of the container. Typical headspace between the slabs and the top of the container is 32-36 inches.
The information contained in this Technical Bulletin is given by the E. I. du Pont de Nemours and Company free of charge. It is based on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of Zodiaq®. Zodiaq® is a DuPont registered trademark for its quartz surfaces. Copyright 2001 E. I. du Pont de Nemours and Company. Printed in the U.S.A Z-2005-003 August 26, 2005
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TECHNICAL BULLETIN
August 26, 2005
Unloading Zodiaq® Containers Z-2005-003 Unloading slabs: 1. Carefully cut the bundle straps and remove the wood bracing supports that secure the slabs to the container. Caution: never position your body, legs, or hands between slabs and/or the container wall. 2.
Equip forklift with appropriate boom and slab clamp. Refer to manufacturer recommendations for forklift, boom, and clamp lifting capacities (an example of a typical lifting capacity chart is attached to this document as a reference).
3. Move forklift into position at the rear of the container. 4. When removing slabs from a container design that utilizes an “A-Frame”, the slabs will need to be removed one at a time starting from the “far sides” of the container (alternating from one side to the other) and working towards the “A-frame”. Alternating the slab removal aids in keeping the load balanced in the container.
Typical Container Configuration with A-frame 5. When removing slabs from a container design that utilizes a “U-Frame”, the slab removal begins in the “center” of the container (closest to the “U” frame) and continues towards the outsides of the container (alternating from one side to the other). Alternating the slab removal aids in keeping the load balanced in the container.
The information contained in this Technical Bulletin is given by the E. I. du Pont de Nemours and Company free of charge. It is based on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of Zodiaq®. Zodiaq® is a DuPont registered trademark for its quartz surfaces. Copyright 2001 E. I. du Pont de Nemours and Company. Printed in the U.S.A Z-2005-003 August 26, 2005
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TECHNICAL BULLETIN
August 26, 2005
Unloading Zodiaq® Containers Z-2005-003
Typical Container Configuration with U-Frame 6.
The operator inside the container will need to separate the slab being removed from the adjacent slabs. The slab will need to be wedged apart slightly to enable the slab clamp to properly grip the slab. The wedge should be made of wood or another soft material, so as not to damage the slab surface.
7.
The forklift operator should manipulate the boom and slab clamp into position to secure the slab. Operator in the container should guide the clamp into position at the center of the slab and ensure clamp safety devices are in place before any attempt to move the slab takes place.
8.
Use the forklift to raise the slab carefully and only high enough to allow free movement of the slab without impinging the boom and clamp. Slowly back the forklift and slab away from the container. Upon safely clearing the container, lower the slab to a safe distance from the ground for transport and maneuvering. The ground operator should stand to the side of the slab and control the slab movement, while the forklift operator carefully moves the slab to a proper storage device (see technical bulletin Z-2005-002, Material Handling).
9.
The forklift operator and ground operator should carefully position the slab in place on a properly rated “A”-frame or storage rack. When the slab is safely in a storage position, the ground operator can release the slab clamp safety mechanism.
10. Repeat the previous steps until the container is unloaded.
The information contained in this Technical Bulletin is given by the E. I. du Pont de Nemours and Company free of charge. It is based on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of Zodiaq®. Zodiaq® is a DuPont registered trademark for its quartz surfaces. Copyright 2001 E. I. du Pont de Nemours and Company. Printed in the U.S.A Z-2005-003 August 26, 2005
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TECHNICAL BULLETIN
August 26, 2005
Unloading Zodiaq® Containers Z-2005-003 Reference chart for Slab Clamps: SLAB CLAMPS
Grip Range (mm)
Clamp Wt. (lb.)
Lifting Capacity (lb.)
Information
Abaco Slab Lifter (Braxton-Bragg Corp., Granite City Tool, Regent Stone Products) Model 30 10 - 30 50 2640 www.braxton-bragg.com Model 40 10 - 40 51 2640 www.granitecitytool.com Model 50 10 - 50 51 2640 www.regentstoneproducts.com Model 60 15 - 60 55 2640 www.abaco.au Model 75 20 - 75 56 2640 Aardwolf Slab Lifter (Gran Quartz, Braxton-Bragg Corp., Regent Stone Products) Model 30 0 - 30 28 2640 www.granquartz.com Model 40 0 - 40 36 2640 www.braxton-bragg.com Model 50 10 - 50 36 2640 www.regentstoneproducts.com Model 60 15 - 60 47 2200 Model 75 30 - 75 47 2200 Alligator Slab Lifter (Granite City Tool) Model 30 0 - 30 Model 40 0 - 40 Model 50 10 - 50 Model 60 15 - 60 Model 75 30 - 75
28 36 36 47 48
2200 2200 2200 2200 2200
www.granitecitytool.com
Reference chart for forklift booms: TELESCOPING FORKLIFT BOOMS up to 144" extended
Capacity 1200-2300 lb. extended
Manufacturer Aardwolf Aardwolf Abaco Vestil Vestil Vestil Abaco Regent Hercules Weha VIC
Model 750118 750034
Purchasing Information Websites www.granquartz.com/ www.abaco.com.au/
LM-EBT LM-EBT-6 LM-1T-6
www.vestil.com/ www.regentstoneproducts.com/ www.braxton-bragg.com/ www.vicintl.com
If additional information is needed, please contact DuPont™ Zodiaq Technical Service at 302-999-5662.
The information contained in this Technical Bulletin is given by the E. I. du Pont de Nemours and Company free of charge. It is based on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of Zodiaq®. Zodiaq® is a DuPont registered trademark for its quartz surfaces. Copyright 2001 E. I. du Pont de Nemours and Company. Printed in the U.S.A Z-2005-003 August 26, 2005
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