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1、TR7 Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=Boeing Co/5910770001 Not for Resale, 07/27/2008 18:59:22 MDTNo reproduction or networking permitted without license from IHS -,-,- SECOND EDITION, January 2006 NOTICE Disclaimer The use of any information cont
2、ained herein by any member or non-member of The Aluminum Association is entirely voluntary. The Aluminum Association has used its best efforts in compiling the information contained in this book. While the Association believes that its compilation procedures are reliable, it does not warrant, either
3、 expressly or implied, the accuracy or completeness of this information. The Aluminum Association assumes no responsibility or liability for the use of the information herein. All Aluminum Association published standards, data, specifications and other technical materials are reviewed and revised, r
4、eaffirmed or withdrawn. Users are advised to contact The Aluminum Association to ascertain whether the information in this publication has been superseded in the interim between publication and proposed use. About The Aluminum Association The Aluminum Association, based in Arlington, VA, with office
5、s in Detroit, MI, represents U.S.- and foreign- based primary producers of aluminum, aluminum recyclers and producers of semi-fabricated products as well as suppliers to the industry. Member companies operate almost 200 plants in North America and many conduct business worldwide. ALUMINUM ASSOCIATIO
6、N SHEET AND PLATE DIVISION COMPANIES Alcan Inc. Alcoa Inc. Aleris Rolled Products AMAG Rolling GmbH ARCO Aluminum, Inc. Coastal Aluminum Rolling Mills, Inc. Corus Aluminium Rolled Products, USA Golden Aluminum Gulf Aluminium Rolling Mill Co. Jupiter Aluminum Corporation Kaiser Aluminum and Chemical
7、Corporation Koenig Allow wrapping materials to remain intact (repair if torn) until the aluminum is used; Store away from outside doors where the metal could be subjected to rapid temperature fluctuations; Store away from high humidity areas (such as paint or anodizing lines) where the dew point is
8、usually high. The Aluminum Association publication, Guidelines for Minimizing Water Staining of Aluminum provides precautionary measures to prevent stained material. B. Flat Sheet and Plate Storage Various types of storage racks are being used today, and circumstances may warrant these racks being s
9、ecured permanently into the building structure. But an ever-changing product-mix demanded by industry has stimulated development of simple, rugged, self- supporting racking systems that can be erected, modified, or moved quickly and easily. Several manufacturers offer systems of this type. The next
10、two figures present typical examples. The cantilever rack shown in Figure 2 is self- supporting and easily erected from standard components. Arms of various lengths and capacities are interchangeable. They can be moved up or down by one employee to accommodate changing storage requirements. The type
11、 of rack shown in Figure 3 is also easily disassembled and moved. Figure 1B - Water Stain on Sheet Figure 1A - Water Stain on Coil Figure 2 - Typical type of cantilever rack Figure 3 - Typical type of storage rack Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee
12、=Boeing Co/5910770001 Not for Resale, 07/27/2008 18:59:22 MDTNo reproduction or networking permitted without license from IHS -,-,- 7 C. Coil Storage Since coils concentrate many pounds of metal in a compact, stable package, storage may or may not be a critical problem. Original skidded coil package
13、s can usually be stacked three or four high. But this is not always the most satisfactory answer for locations where coils are frequently removed and returned to the storage area. Storage of partially used coils can create their own problems. Coils should be tightly rebanded, or if tape is used, new
14、 tape should be used to secure the outer wrap to the coil as old tape can release itself. Figure 4 gives an example of loose wraps, which can cause scratches when processing the coil (as discussed in section 9B). An example of the “tension” scratches that occurs when the loose wraps are tightened du
15、ring subsequent processing is shown in Figure 5. An example of the “oscillation” scratching that can occur when coils with loose wraps are transported is shown in Figure 6. Storage of skidded coils under the cantilever arms of flat product storage units solves the problem of full floor-space utiliza
16、tion, providing direct accessibility to individual coils. If coils are stored “eye-horizontal” and on the floor, they should at the very least be placed on some debris- free padding between the coil and the floor as is shown in Figure 7A. Additionally, all coils need to be secured (braces, chucks, o
17、r chains) in a manner that prevents rolling. The wedge shape of the padding device shown in Figure 7B can serve this purpose. Figure 4 - Loose Wraps on a Coil Figure 5 - Example of a Tension Scratch Figure 6 - Example of Oscillation Scratches Figure 7 - (A) Storage of Coil on Protective Padding (B)
18、Example of Wedge-shaped Protective Padding Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=Boeing Co/5910770001 Not for Resale, 07/27/2008 18:59:22 MDTNo reproduction or networking permitted without license from IHS -,-,- 6.Handling A. Coil Products Fork trucks
19、: Most coil stock is shipped with the ID or arbor in the vertical position. (“eye to the sky”). The fork truck is the most common method of unloading and transporting skidded material. When handling coils with a fork truck, care must be taken to avoid striking the material or the skid with sufficien
20、t force to cause either direct fork damage or side wall damage through the movement of coil against coil or coil against skid. In addition, as shown in Figure 8, the vertical portion of the fork should be padded to prevent damage to the coil. The skid weight must be uniformly distributed on the fork
21、s when lifting the skid. Normally, this is not a problem if the skid is properly designed and the forks are of sufficient length. Care must be taken to ensure that the forks are not so long as to strike the coil behind the one being lifted. A common type of side wall damage occurs when the weight of
22、 the skid is supported by the point of the fork causing it to break the skid decking and/or penetrate the package. This usually occurs when the skid is much larger than the length of the forks, causing an imbalance. Care should also be taken to ensure that, when properly loaded, the coil does not ex
23、ceed the rated capacity of the fork truck due to extending the load center beyond that for the stated truck capacity. For example, a 15,000 pound (6820 kg) coil measuring 48“ wide x 68“ OD (120 x 170 cm) can be picked up safely “eye to the side” with a truck which is rated for 15,000 pounds (6820 kg
24、) at a 24“ (60 cm) load center. However if the same coil is down ended onto a skid “eye to the sky” the load center has moved out to at least 34“ (85 cm) which has the effect of reducing the safe lifting capacity of the truck to only 10,588 pounds (4810 kg). A 8 Figure 9 - Fork Truck with Curved Lif
25、ting Arm Figure 8 - Padding on Forklift to Protect Coils While stacking coils directly upon each other in a pyramid type configuration is not recommended, if this is done then care should be taken to avoid damaging the outer wraps and / or collapsing the inside diameter (ID) of the coils. Additional
26、 bracing may be necessary to prevent movement of the coils in the stack. When skidded, eye-vertical coils are stacked upon other coils, it is important that there is proper edge protection and a smooth coil side wall with no oscillation. The height of the stacking will depend upon a number of issues
27、 such as floor loading, handling equipment limitations and safety considerations. Many of these same issues will apply to eye-horizontal coil stacking. Several manufacturers provide storage rack systems rugged enough for individual storage of coils in the vertical or horizontal position. The type of
28、 rack selected will depend upon individual requirements and types of handling equipment available. Storage systems planning should allow for expansion. It should take into account the trend toward larger coils as well as variation in coil sizes. Copyright The Aluminum Association Inc. Provided by IH
29、S under license with AA Licensee=Boeing Co/5910770001 Not for Resale, 07/27/2008 18:59:22 MDTNo reproduction or networking permitted without license from IHS -,-,- 9 movement out of the load center of only 6“ (15 cm) to 30“ (75 cm) has the effect of reducing the capacity of a 15,000 pound (6820 kg)
30、rated truck to only 12,000 pounds (5455 kg). Intermediate handling of coil products consists of moving stock from storage, unpacking and preparing the material for loading on equipment. Removing stock from storage usually involves the same procedures used during unloading. Once the coil has been tur
31、ned to a horizontal ID position (see “Upenders”) and unskidded, it can be handled by fork truck. Several precautions should be taken: (1) There should be a fixture that provides a rounded upper surface matching the curvature of the inside diameter of the coil which can be picked up by the fork truck
32、 prior to lifting the coil (a typical example is given in Figure 9); (2) The vertical portion of the fork should also be padded to prevent damage to the inside circumference of the coil; (3) Care must also be taken when lowering coils so that the inside diameter does not collapse. (A severe blow can
33、 cause this type damage.) Coils should be lowered slowly onto a protected area by the fork truck. In preparing the material for further processing, however, additional equipment is sometimes required. Upenders: Nearly all coil stock is shipped in a vertical ID position. It is necessary, therefore, t
34、o upend coils to the horizontal ID position before loading on equipment mandrels. Various types of upenders, such as that shown in Figure 10, are available. They allow for fast, safe unskidding and turning of coils. Vertical Coil Grabs: When coils must be handled with the ID vertical, vertical coil
35、grabs (Figure 11) are the preferred method. Vertical coil grabs are used in conjunction with a crane. The portion of the grab that comes into contact with the coil edges should be padded to prevent damage. “C” Hooks and Horizontal Coil Grabs: Using a “C” hook with a crane, shown in Figure 12, is sim
36、ilar to handling Figure 10A - Loading Coil on Upender Figure 10B - Upender Changing Coil from “Eye Vertical” to “Eye Horizontal” Figure 11 - Overhead Crane w/Vertical Coil Grab Figure 12 - Overhead Crane w/ Coil on a “C” Hook Copyright The Aluminum Association Inc. Provided by IHS under license with
37、 AA Licensee=Boeing Co/5910770001 Not for Resale, 07/27/2008 18:59:22 MDTNo reproduction or networking permitted without license from IHS -,-,- 10 Figure 15 - Moving Coils with a Vacuum Lift horizontal ID material with a fork. The coil, however, must be properly centered on the hook to maintain a ho
38、rizontal ID If the load is not properly centered, it will tilt and when returning it to the floor one edge will support the entire weight of the coil causing edge damage to the outside diameter. Padding should be placed wherever the metal can come in contact with the hook (see Figure 13). Horizontal
39、 Coil: Horizontal coil grabs used with a crane, Figure 14, are usually best for handling material in the horizontal ID position; however, the grabs should be padded to prevent edge damage. Vacuum Lifts Vacuum lifts are another method of moving coils (see Figure 15), but they require a very smooth co
40、il sidewall. If automated coil movers are used, such as is shown in Figure 16, attention must be given to the protective padding that is used on the coil cradle to ensure that no damage or debris is present. Automated coil movers (also called automatic guided vehicles or AGVs), Figure 16, have no hu
41、man operator and are programmed to transport coils between work stations. Attention must be given to to the protective padding that is used on the coil cradle to ensure that no damage or debris is present. Collision avoidance systems are typically employed in AGV design, but since they may begin mov
42、ing without warning, pedestrians should keep a safe distance away and take care not to place themselves between the AGV and immovable objects. B. Flat Sheet and Plate Products Fork Trucks: The same comments regarding coil stock handling apply to flat sheet and plate. Handling long skidded material w
43、ith short forks will present problems. While neither method is recommended, the practice of pushing or pulling long skids is common when overhead equipment is unavailable. Of these two methods, pushing the skid with the fork truck is less likely to cause metal damage. Damage to the skid and possibly
44、 the metal is the common result of pushing large skids with a fork truck. Slings: Slings, as shown in Figure 17, are a common method for handling flat sheet and plate. They can either be steel cable or nylon belts. Since slings wrap the load, edge damage can result if the material is not Figure 13 -
45、 C-Hook w/Padding to Protect Coils Figure 14 - Crane w/Horizontal Coil Grabs Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=Boeing Co/5910770001 Not for Resale, 07/27/2008 18:59:22 MDTNo reproduction or networking permitted without license from IHS -,-,- 11 su
46、fficiently protected from the cable. Nylon belts have an advantage over cable in that they distribute the load over a greater area, thereby reducing the chance for damage. They are also less prone to slip. Grabs: Grabs, Figure 18, are the preferred method for handling flat sheet and plate with a cra
47、ne although care must be taken to avoid gouging the sides of the sheet. In general, they offer excellent support and minimize the chance for damage. Figure 16 - Automated Coil MoverFigure 17 - Slings for Handling Skidded Sheet and Plate Figure 18 - Grabs for Handling Plate and Flat Sheet 7.Turning F
48、lat Sheet This operation sounds so simple that many people overlook its importance. In spite of new equipment in use or in development, size limitations, problems of location, and the need to inspect both sides of the material still make hand turning a widely used method of transferring sheet and li
49、ght plate from one skid or stack to another. (See Figure 19) Bright finished sheet as well as mill finished sheet will mark easily if dragged across another sheet. The scratches at the far edge of bottom sheet in Figure 20 were caused when the top edge was dragged over it. If operators are careless, the top sheet will