Clemco FLAT-TRAK User manual
Do not use this
equipment until you
have READ this
MANUAL and YOU
UNDERSTAND its
contents. *
These WARNINGS are
included for the health
and safety of the
operator and those in
the immediate vicinity.
*If you are using a Clemco Distributor
Maintenance and Parts Guide, refer to
the orange warnings insert preceding
the Index before continuing with the
enclosed instructions.
Electronic files include a Preface
containing the same important
information as the orange cover.
WARNING
FLAT-TRAK®RECOVERY FLOOR
O. M. 07763
DATE OF ISSUE: 10/30/93
REVISION: M, 07/17
© 2017 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone (636) 239-4300
Fax (800) 726-7559
Email: info@clemcoindustries.com
www.clemcoindustries.com
PREFACE
[I]
• Employers are responsible for identifying all job site hazards, educating and training all persons who will operate and
maintain these products, and ensuring that all blast operators and their assistants understand the warnings and
information contained in these instructions relating to safe and proper operation and maintenance of this equipment.
• Serious injury or death can result from failure to comply with all Occupational Safety and Health Administration
(OSHA)regulations and all manufacturer’s instructions.
• This equipment is not intended for use in any area considered hazardous per National Electric Code NFPA 70 2011,
Article 500.
• Read this document and follow all instructions before using this equipment.
OSHA regulations relating to abrasive blasting are contained in the Code of Federal Regulations, Title 29 (29 CFR 1910 General Industry;
1915 Maritime; 1926 Construction). The most pertinent include: 1910.94 Ventilation, 1910.95 Occupational Noise Exposure, 1910.132
Personal Protective Equipment, 1910.133 Eye and Face Protection, 1910.134 Respiratory Protection, 1910.135 Head Protection,
1910.244 (b) Remote Controls. Consult www.osha.gov for complete information.
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Clemco proudly provides products for the abrasive blast
industry and is confident that industry professionals will use
their knowledge and expertise for the safe and efficient use of
these products.
The products described in this material, and the information
relating to these products, are intended for knowledgeable,
experienced users.
No representation is intended or made as to: the suitability of
the products described here for any purpose or application, or
to the efficiency, production rate, or useful life of these
products. All estimates regarding production rates or finishes
are the responsibility of the user and must be derived solely
from the user’s experience and expertise, not from information
contained in this material.
It is possible that the products described in this material may
be combined with other products by the user for purposes
determined solely by the user. No representations are
intended or made as to the suitability of or engineering
balance of or compliance with regulations or standard practice
of any such combination of products or components the user
may employ.
Abrasive blast equipment is only one component of an
abrasive blasting job. Other products, such as air
compressors, air filters and receivers, abrasives, scaffolding,
hydraulic work platforms or booms, equipment for lighting,
painting, ventilating, dehumidifying, parts handling, or
specialized respirators or other equipment, even if offered by
Clemco, may have been manufactured or supplied by others.
The information Clemco provides is intended to support the
products Clemco manufactures. Users must contact each
manufacturer and supplier of products used in the blast job for
warnings, information, training, and instruction relating to the
proper and safe use of their equipment.
GENERAL INSTRUCTIONS
This material describes some, but not all, of the major
requirements for safe and productive use of blast machines,
remote controls, respirator systems, and related accessories.
All equipment and accessories must be installed, tested,
operated and maintained only by trained, knowledgeable,
experienced users.
The blast operator and all workers in the vicinity must be
properly protected from all job site hazards including those
hazards generated by blasting.
Work environments involving abrasive blasting present
numerous hazards. Hazards relate to the blast process from
many sources that include, but are not limited to, dust
generated by blasting or from material present on the surface
being blasted. The hazards from toxic materials may include,
but are not limited to, silica, cyanide, arsenic, or other toxins
in the abrasives or in the coatings, such as lead or heavy
metals. Other hazards from toxins include, but are not limited
to, fumes from coating application, carbon monoxide from
engine exhaust, contaminated water, chemicals or asbestos.
In addition, physical hazards that may be present include, but
are not limited to, uneven work surfaces, poor visibility,
excessive noise, and electricity. Employers must identify all
job site hazards and protect workers in accordance with
OSHA regulations.
Never modify Clemco equipment or components or
substitute parts from other manufacturers for any Clemco
components or parts. Any unauthorized modification or
substitution of supplied-air respirator parts violates OSHA
regulations and voids the NIOSH approval.
IMPORTANT
Contact Clemco for free booklets:
Blast Off 2 – Guide to Safe, Productive, and Efficient Abrasive
Blasting, and Abrasive Blasting Safety Practices – Guide to Safe
Abrasive Blasting.
Clemco Industries Corp. One Cable Car Drive Washington MO 63090
Tel: 636 239-4300 — Fax: 800 726-7559
Website: www.clemcoindustries.com
PREFACE
[II]
OPERATIONAL INSTRUCTIONS
OPERATOR SAFETY EQUIPMENT
OSHA regulation 1910.134 requires appropriate respiratory protection for blast operators and workers in
the vicinity of blasting. These workers must wear properly-fitted, properly-maintained, NIOSH-approved,
respiratory protection that is suitable for the job site hazards. Blast respirators are to be worn only in
atmospheres not immediately dangerous to life or health from which wearers can escape without use of
the respirator.
The employer must develop and implement a written respiratory protection program with required
worksite- specific procedures and elements for required respirator use. The employer must provide
effective training to employees who are required to use respirators. The training must be comprehensive,
understandable, and recur annually, and more often if necessary.
NEVER use abrasives containing more than one percent crystalline silica. Fatal diseases, such as silicosis,
asbestosis, lead or other poisoning, can result from inhalation of toxic dusts, which include, but are not
limited to, crystalline silica, asbestos, and lead paint. Refer to NIOSH Alert 92-102; and OSHA CPL 03-00-007:
“National Emphasis Program – Crystalline Silica”, in which OSHA describes policies and procedures for
implementing a national emphasis program to identify and reduce or eliminate health hazards from exposure
to crystalline silica. Numerous topics associated with the hazards of crystalline silica in silica blasting sand
can be found on http:// osha.gov/. Clemco urges users of silica blasting sand to visit this website, and read
and heed the information it contains.
Always make sure the breathing air supply (respirator hose) is not connected to plant lines that supply
gases that include, but are not limited to, oxygen, nitrogen, acetylene, or other non-breathable gas. Never
modify or change respirator air line connections without first testing the content of the line for safe
breathing air. Failure to test the line may result in death to the respirator user.
• Breathing air quality must be at least GradeD,
as defined by the Compressed Gas Association
specification G-7.1, per OSHA Regulation 29 CFR
1910.134. When compressed air is the breathingair
source, a Clemco CPF (suitable sorbent bed filter)
should be used. Respirator hose connecting the
respirator to the filter must be NIOSH approved.
Non- approvedhose can cause illness from
chemicals employed to manufacture the hose.
• All workers must always wear NIOSH-approved
respirators when any dust is present. Exposure to
dust can occur when handling or loading abrasive,
blasting, cleaning up abrasive, or working in the
vicinity of blasting. Before removing the respirator,
test the air with a monitoring device to ensure it is
safe to breathe.
• Clemco respirators DO NOT removeor protect against
carbon monoxide or any other toxic gas. Monitoring
devices must be used in conjunction with the respirator to
ensure safe breathingair. Always locate compressors and
ambient air pumps where contaminatedair will not enter
the air intake.
• Always use Clemco lenses with Clemco respirators;
installing non-approvedlenses voids the NIOSH approval.
Respirator lenses aredesigned to protect the wearerfrom
rebounding abrasive; they do not protect against flying
objects, heavyhigh-speed materials, glare,liquids, or
radiation.
INDUSTRY ORGANIZATIONS
For additional information, consult:
Occupational Safety and Health Administration (OSHA) - www.osha.gov
Compressed Gas Association (CGA) - www.cganet.com
TheSociety for Protective Coatings (SSPC) - www.sspc.org
National Association of Corrosion Engineers (NACE) - www.nace.org
American Society for Testing and Materials (ASTM) - www.astm.org
National Institute of Occupational Safety and Health (NIOSH) - www.niosh.gov
American National Standards Institute (ANSI) - www.ansi.org
PREFACE
[III]
BLAST MACHINES AND REMOTE CONTROLS
OSHA regulation 1910.169 describes the necessity of pressure relief valves on compressed air equipment. Do not
operate blast machines with air compressors that are not equipped with properly functioning pressure relief valves.
OSHA regulation 1910.244(b) requires the use of remote controls on blast machines.
Serious injury or death can result from many sources, among them:
Involuntary activation of the remote controls. Never modify or substitute remote control parts; parts are not
compatible among different manufacturers. Welding hose is not suitable for remote control hose. Its ID and material
composition make it unsafe for remote control use.
Exceeding the maximum working pressure. Clemco blast machines are built to ASME-code and carry a ‘U’ or ‘UM’
stamp, and National Board/serial number. Every machine is marked with its maximum working pressure. Never
exceed the maximum working pressure limits of the blast machine.
Uncontrolled blast stream. High-velocity abrasive particles will inflict serious injury. Always point the blast nozzle
in the direction of the blast surface only. Keep unprotected workers out of the blast area.
Welding on the blast machine. Never weld on the blast machine; welding voids the National Board approval and
may affect the dimensional integrity of the vessel.
Moving the blast machine. Never manually move a blast machine containing abrasive, any machine containing
abrasive must be moved with appropriate mechanical lifting equipment.
HOSES, COUPLINGS, AND NOZZLE HOLDERS
The inside diameter (ID) of air hoses, fittings, and connections
should be at least four times larger than the nozzle orifice size. Blast
hose ID should be three to four times the size of the nozzle orifice.
Example: a #6 nozzle (3/8” diameter orifice) calls for 1-1/2” ID blast
hose and 1-1/2” ID or larger compressor hose. All hose runs should be
kept as short as possible and run in as straight a line as possible to
reduce pressure loss.
To install, squarely cut the end of the hose so that it fits snugly
against the coupling or hose end shoulder. Always use the screws
recommended by the manufacturer ensuring that they do not
penetrate the inner wall. Make sure the couplings tightly fit the hose.
Install cotter pins at every connection or use couplings with built-in
lock-springs to prevent disengagement. Install safety cables at all
connections to prevent whipping if hoses disengage or blow out.
MAINTENANCE AND REPAIR
Completelyreadand follow all service instructions and recommended maintenance intervals. Always shut off compressor and
depressurize blast machine beforeperforming any maintenance. At everyservice interval, clean all filters, screens, and alarm systems. If
spring-loaded abrasive valves areused, always cage spring beforedisassembly.
WARRANTY
The following is in lieu of all warranties, express, implied or statutory, and in no event shall seller or its agents, successors, nominees or
assignees, or either, be liable for special or consequential damage arising out of a breach of warranty. This warranty does not apply to any damage or
defect resulting from negligent or improper assembly or use of any item by the buyer or its agent or from alteration or attempted repair by any person
other than an authorized agent of seller. All used, repaired, modified, or altered items are purchased “as is” and with all faults. In no event shall seller
be liable for consequential or incidental damages. The sole and exclusive remedy of buyer for breach of warranty by seller shall be repair or
replacement of defective parts or, at seller’s option, refund of purchase price, as set forth below
:
1. Seller makes no warranty with respect to products used other than
in accordance hereunder.
2. On products seller manufactures, seller warrants that all products areto
be freefrom defects in workmanship and materials for a
period of one yearfrom dateof shipment to buyer, but no warranty is
madethat the products arefit for a particular purpose.
3. On products which seller buys and resells pursuant to this order, seller
warrants that the products shall carry the then standard warranties of the
manufacturers thereof,a copy of which shall be madeavailable to the
customer upon request.
4. Theuse of any sample or model in connection with this order is for
illustrative purposes only and is not to be construed as a warranty that the
product will conform to the sample or model.
5. Seller makes no warranty that the products aredelivered freeof the
rightful claim of any third party by way of patentinfringement or the like.
6. This warranty is conditioned upon seller’s receipt within ten (10)
days afterbuyer’s discovery of a defect,of a written notice stating in
what specific material respects the product failed to meetthis
warranty. If such notice is timely given, seller will, at its option, either
modify the product or part to correct the defect,replacethe product or
part with complying products or parts, or refund the amount paid for
the defectiveproduct, any one of which will constitute the sole liability
of the seller and a full settlement of all claims. No allowance will be
madefor alterations or repairs made by other than those authorized
by seller without prior written consent of seller. Buyershall afford
seller prompt and reasonable opportunity to inspect the products for
which any claim is madeas abovestated.
Except as expressly set forth above,all warranties, express, implied
or statutory, including implied warranty of merchantability, are
herebydisclaimed.
PREFACE
[IV]
DAILYSET‐UPCHECKLIST
Make sure all blast operators are properly trained and suitably attired with a blast suit, safety boots, leather gloves, respiratory and hearing protection. Every day before start up,
check all equipment components, including piping, fittings, and hoses, and valves, for leaks, tightness, and wear. Repair or replace as needed. Use the following checklist.
1. PROPERLY-MAINTAINED AIR COMPRESSOR
sized to provide
sufficient volume (cfm) at given pressure for nozzle and other tools. ADD 50%
volume (cfm) reserve to allow for nozzle wear. Use large compressor outlet and
air hose (at least 4 times the nozzle orifice diameter). For oil-lubricated
compressors, the employer shall use a high- temperature or carbon monoxide
alarm, or both, to monitor carbon monoxide levels. If only high-temperature
alarms are used, the air supply shall be monitored at intervals sufficient to
prevent carbon monoxide in the breathing air from exceeding 10 ppm. Follow
the manufacturer’s checklist and maintenance instructions.
2. BREATHING-AIR COMPRESSOR
(or oil-less ambient air pump)
capable of providing Grade D quality air, located in a dust free area. Read # 1
above.
3. CLEAN, PROPERLY-MAINTAINED NIOSH-APPROVED SUPPLIED-AIR
RESPIRATOR
worn by blast operators, and other workers exposed to blast dust.
Make sure all respirator components are in place — all lenses, inner collar, and
cape. Thoroughly inspect all components for wear. The NIOSH approval (approval
number is listed in the owner’s manual) is for a complete assembly from point of
attachment on the CPF (sorbent bed) filter to the complete respirator. Substitution of
any part voids the NIOSH approval.
4. CARBON MONOXIDE MONITOR/ALARM
installed at the CPF filter or
inside the supplied-air respirator for monitoring for the presence of deadly CO gas
and warning the operator(s) when the CO level reaches an unacceptable level.
When an ambient air pump is used for breathing air, a CO monitor provides a
measure of safety. Read # 1 above.
5. BREATHING-AIR FILTER (OSHA-REQUIRED
sorbent bed filter) for
removal of moisture and particulate matter in the compressed air breathing-air
supply. Monitor the condition of the cartridge and replace when odor is detected or
at 3 month intervals, whichever comes sooner. The breathing air filter does NOT
detect or remove carbon monoxide (CO). Always install a CO monitor/alarm.
6. BLAST MACHINE
(bearing U or UM stamp, National Board Number, and
Maximum Working Pressure) sized to hold a 30-minute abrasive supply. Examine
pop-up valve for alignment. Check piping, fittings, screens, valves for tightness,
leaks, and wear. Always ground the machine to eliminate hazard of static shock.
Install a blast machine screen to keep out foreign objects. Use a blast machine
cover if left outdoors overnight. Never exceed the maximum working pressure of the
vessel.
7. AIR LINE FILTER
(moisture separator) installed as close as possible to the
blast machine inlet and sized to match the size of the inlet piping or larger air supply
line. Clean filter and drain often. Damp abrasive causes operational problems.
8. REMOTE CONTROLS
are required by OSHA and must be in perfect
operating condition. Test and check all components to ensure all parts are present
and fully functional. Use genuine replacement parts. NEVER mix parts from different
manufacturers. Never use welding hose for remote control hose.
9. BLAST HOSE
should have an inside diameter sized to suit the blast nozzle.
The ID should be three to four times the size of the nozzle orifice diameter. Blast hose
should be arranged in as straight a line as possible from the blast machine to the
work area, avoiding sharp bends.
10. COUPLINGS AND NOZZLE HOLDERS
should fit snugly on the hose and
be installed with manufacturer recommended screws. Coupling lugs must snap firmly
into locking position. Gasket must always be used to form a positive seal, and cotter
pins must be installed. Replace gasket when wear, softness or distortion is detected.
Check nozzle holder for thread wear; replace at any sign of wear. Install safety cables
at all connections.
11. NOZZLE
orifice size should be checked and nozzle replaced when worn
1/16” from original size. (No. 5 nozzle has 5/16” orifice diameter; replace when it
measures 3/8”). Threads should be inspected daily for wear and nozzle should be
replaced when wear is detected. Always use a nozzle washer.
12. ABRASIVE
must be a material specifically manufactured for blasting. It
should be properly sized for the job. Check material safety data sheet for free-
silica, cyanide, arsenic, lead and other toxins and avoid use when these toxic,
harmful substances are present.
SURFACE TO BE BLASTED
should be examined for hazardous substances.
Take appropriate protective measures as required by OSHA to ensure the blast
operator, other workers in the vicinity, and any bystanders are properly protected.
©Clemco Industries Corp., Stock No. 20954P, 0692 Rev. F, 06/12
1. Air Com
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7. Air Line
Moisture
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5. CPF Air Filte
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6. ASME Code
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8. Remote
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9. Blast Hose 10. Hose Couplings and Safety Cables
11. Appropriately Sized Nozzle
12. Abrasive
4. External or
Helmet Mounted
Carbon Monoxide
Monitor /Alarm
2. Breathing Air Compressor for
High Pressure Respirators3. NIOSH Approved
Supplied-Air Respirator
or Ambient Air Pump for
Low Pressure Respirators
FLAT-TRAK®RECOVERY FLOOR Page 1
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
1.0 INTRODUCTION
1.1 Scope
1.1.1 This manual covers the installation, operation,
maintenance, and replacement parts for Clemco’s Flat-
Trak®Recovery Floor. Assembly drawings supplied with
this manual apply to the specific floor and accessories
provided. Use the manual and the drawings for sizing,
arrangement, and other specific information about the
recovery floor supplied.
1.1.2 This manual contains important safety
information. All operators and personnel involved with
the abrasive blast process must read and understand
the contents of these instructions, including the orange
cover. It is equally important that the operator is trained
and qualified to safely operate the blast machine and
remote controls and all other equipment used with the
blast machine. To ensure safe blasting, before operating,
read the manuals for all devices used in conjunction with
this recovery floor.
1.1.3 All personnel involved with the abrasive blasting
process must be made aware of the hazards associated
with abrasive blasting. The Clemco booklet Abrasive
Blasting Safety Practicesis included with every blast
machine; it contains important safety information about
abrasive blasting that may not be included in equipment
operation manuals. The booklet is available in both
English and Spanish; to request copies, email
1.2 Safety Alerts
1.2.1 Clemco uses safety alert signal words, based on
ANSI Z535.4-2011, to alert the user of a potentially
hazardous situation that may be encountered while
operating this equipment. ANSI's definitions of the signal
words are as follows:
This is the safety alert symbol. It is
used to alert you to potential physical
injury hazards. Obey all safety
messages that follow this symbol to
avoid possible injury or death.
NOTICE
Notice indicates information that is considered
important, but not hazard-related, if not
avoided, could result in property damage.
CAUTION
Caution indicates a hazardous situation that, if
not avoided, could result in minor or moderate
injury.
WARNING
Warning indicates a hazardous situation that, if
not avoided, could result in death or serious
injury.
DANGER
Danger indicates a hazardous situation that, if
not avoided, will result in death or serious
injury.
1.3 General Description
1.3.1 The Flat-Trak®recovery floor comprise of three to
ten modular floor conveyor sections, and one modular
cross conveyor. See Figure 1 for a typical sample
arrangement. In operation, the floor conveyor sections
feed abrasive to the cross conveyor. The cross conveyor
moves abrasive to the bucket elevator, or customer’s
equipment modified to interface with the Flat-Trak®.
1.3.2 Floor conveyor sections: Floor sections are 36
inches or 24 inches wide from center to center (other
widths are available by special order). These section
widths enable floors to be widened in 24-inch and 36-inch
increments, from a standard minimum width of 9 feet
(three, 36-inch sections) to a maximum width of 30 feet
(ten sections). Floor sections consist of an 8-foot drive
segment (where the cylinder mounts), and when the floor
is longer than 10 feet, one or more extension segments.
Floor extension segments are 30-inches, 60-inches, or
120-inches long. They bolt together in any combination to
form a maximum length of 30 feet. Two floor conveyor
floors can be mounted on each side of a cross conveyor
section (forming a center cross conveyor), for a total
maximum length of 60 feet.
1.3.3 Cross conveyor section: The cross conveyor
section is 18-inches wide. It consists of a 109-1/2 inch
base segment and 40-13/16 inch drive segment. If the
recovery floor is wider than 9 feet, use one or more cross
conveyor extensions. Cross conveyor extensions are 36
inches, and 72 inches long (24-inch extensions are
available by special order). They bolt together in any
combination to form a maximum length of 30 feet.
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Figure 1
FLAT-TRAK®RECOVERY FLOOR Page 3
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1.4 Tools Requirement
Open/box end wrenches, 7/16" - 3/4"
Socket wrench w/ 7/16" - 3/4" sockets
Screw drivers
Hex keys
Hand drill with bit assortment
Hammer
Drift pin
Welder
Measuring tape, long enough to measure the
floor area diagonally
Chalk line
2.0 INSTALLATION
2.1 Installation Notes
2.1.1 These instructions are general guidelines for all
sizes of Flat-Trak®floors. The assembly illustrations shown
throughout the manual are for a typical arrangement.
Layout drawings for specific jobs are provided with the job
manual. All floor drive sections are 98-1/2-inches long. If
floor extensions are used, they will be 30-inches, 60-
inches, or 120-inches long. All cross conveyor base
segments are 9-feet long, with a 40-13/16-inch long drive
section. If cross conveyor extensions are used, they will be
24-inches, 36-inches, and/or 72-inches long.
2.1.2 When both short and long conveyor extensions
are used, the shorter extensions should be located
between two longer extensions. See the example shown in
Figure 1. The 30-inch and 60-inch extensions are placed
between the longer drive section and 120-inch extension.
2.1.3 Extensions can be placed in any order; however,
the same sequence must be used on all floor sections.
See Note 1 in Figure 1.
2.1.4 Conveyor section widths are measured from
center to center. Since the beams are 3-inches wide, an
additional 1-1/2 inches is needed on each side of the floor
layout. For example: If a floor is four sections wide, the
total outside dimension of the floor width will be 147 inches
(four 36-inch sections plus 3 inches [1-1/2 inches on each
side]). Be sure to allow for the extra 1-1/2 Inches when
laying out the floor perimeter.
2.1.5 If the Flat-Trak®Floor is recessed in a pit or in an
existing room, it is necessary to have 3 inches between
the outside perimeters of the floor and pit or room wall.
The 3-inch space is needed to replace rollers.
2.1.6 Track beams are labeled "This side up" and "This
end toward drive cylinder". When laying out the tracks,
make sure the side labeled "up" is facing up, and the end
marked toward drive cylinder, is facing the drive cylinder.
Splice holes in the beams are positioned so they are on
the lower side when the tracks are right side up. If the
splice holes of two adjoining tracks do not lineup one of
the tracks may be upside down.
2.1.7 The Flat-Trak®floor is installed on a single level. If
the Flat-Trak®replaces an existing multi-level floor, a
single level floor capable of sustaining the gross weight of
the recovery floor, abrasive, grate, parts to be blasted, and
operator, will have to be constructed.
2.1.8 The electro/pneumatic cylinder control panel(s)
must be accessible to an air supply line and electrical
source, and located to enable installation of poly tubing air
lines to run from the panel to each air cylinder. One
cylinder is used on each floor conveyor section, and cross
conveyor section. The panel must be located within a
distance to require no more than 15 feet of tubing to the
cross conveyor cylinder. See note # 2 and the typical
arrangement in Figure 1.
2.1.9 Cylinder timing control panels come with four, five,
or six stations. One station operates one conveyor section
(one cylinder for each section). If the system has more
than six conveyor sections, more than one panel is
required. For example, if the floor has nine conveyor
sections, a four-station and five-station panel is used. If the
floor has seven-sections, two four-station panels are used.
The unused station(s) must be looped with a short piece of
5/16 inch poly tubing, and the flow control valve (used to
time the cylinder cycles) must be closed.
2.1.10 Control panels do not need to be mounted
together. It is best to separate the panels on large
systems, and mount each one as close as possible to the
cylinders they control. See Paragraph 2.1.8.
2.1.11 The Flat-Trak®is designed to connect to a Clemco
elevator, and recovery components. If other brand
recovery components are used, transitions must be made
to adapt to them.
2.2 Uncrating
2.2.1 Uncrate and identify all parts. Use the checklist
shipped with the equipment, and the illustrations in Figures
2, 3, 4, and 5 to identify the parts. To help keep the
assembly area organized, and to avoid loss, leave small
parts in marked boxes until they are required.
2.2.2 Sort all parts into groups. The first parts to be
used will be the track beams. Identify and sort them as
shown in Figure 2.
2.2.3 Identify and sort hardware shown in Figure 3,
carriages shown in Figure 4, and cylinder equipment
shown in Figure 5. Make sure the carriages are flat.
Straighten any that may have bent during shipment. It is
important that the carriage frames lay flat on the floor.
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Figure 2
FLAT-TRAK®RECOVERY FLOOR Page 5
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
Figure 3
FLAT-TRAK®RECOVERY FLOOR Page 6
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
Figure 4
Figure 5
FLAT-TRAK®RECOVERY FLOOR Page 7
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
2.3 Layout
2.3.1 Layout notes
2.3.1.1 The typical layout used in Figure 1 is used in all
floor illustrations in this manual. It is only a sample floor
layout. Since the Flat-Trak®is modular in design; the floor
supplied may vary in size.
2.3.1.2 Center feed cross conveyor floors do not have a
cross conveyor track. Carriages ride on rollers mounted
on front roller angle brackets that attach to the ends of the
floor tracks. The two halves of the recovery floor must be
squared with the cross-conveyor drive-segment and the
18-inch cross end beam as shown in Figure 6. Use the
same procedures as described in this text for both sides
of a center feed floor.
2.3.1.3 Use the typical layout in Figure 1 to determine
the final position for the elevator, blast machine, cylinder
control panels, starter control panel, blast room doors,
etc. Make sure space is available for all accessories, and
that the floor cross conveyor drive section ends at the
elevator inlet.
Figure 6
FLAT-TRAK®RECOVERY FLOOR Page 8
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
Figure 7
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© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
2.4 Perimeter Tracks, Ref. Figure 7
2.4.1 Run chalk lines around the perimeter of the floor.
Make sure the perimeter is square. Recheck the final
location for the elevator, cross conveyor and floor
conveyor sections. Be sure to allow 1-1/2-inches around
the perimeter. If the floor is mounted in a pit or existing
room, allow 3-inches for service. See Sections 2.1.4 and
2.1.5.
2.4.2 Place the cross conveyor tracks (C channels) as
shown in Figure 7. Beginning at the elevator location,
place the left and right hand cross drive tracks, cross
extensions (if used), and the cross conveyor base
segment. The flat side of the cross conveyor tracks must
face the inside of the floor recovery area.
2.4.3 Bolt the cross conveyor tracks together, using
fasteners and track splice brackets shown in Figure 8.
Cross Track to Cross Track
Figure 8
2.4.4 Lay the 18-inch cross conveyor end beam at the
end of the cross-conveyor base-segment track. Use an
end-channel splice-bracket, and loosely bolt the end beam
to the track as shown in Figure 9.
2.4.5 Place the floor conveyor tracks along both sides
of the perimeter. Note: The tracks are labeled
"This side up" and "This end toward drive cylinder".
Make sure each track is placed accordingly.
Cross Base Segment to Cross End Beam
Figure 9
2.4.6 Splice the perimeter track adjacent to the 18-inch
cross conveyor end beam to the beam, using a track
splice bracket and fasteners shown in Figure 10.
Floor Track to Floor Track
Figure 10
2.4.7 Splice all the perimeter tracks together using the
track splice brackets and fasteners as shown in Figure 10.
NOTE: The splice can go on either side of the I-beam
track.
2.4.8 Place the drive-segment end-channels in position
as shown in Figure 7. The cylinder mounting tabs must
face the floor area and be on the lower side when the
channels are right side up.
2.4.9 Position a drive segment track at the end of each
drive end channel.
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© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
2.4.10 Connect the drive segment tracks to the drive end
channels, using end channel brackets as shown in Figure
11. Inside tracks will have two brackets as shown, while
perimeter tracks will have only one. NOTE: The bracket
bolts for the end channels must face away from the
floor area as shown.
Floor Conveying Drive Segment to
Floor End Channel
Figure 11
2.4.11 Make sure the cross conveyor tracks are straight
and aligned with the chalk line. Anchor them as noted on
the assembly drawings, just enough to keep them from
moving, while squaring the rest of the perimeter tracks.
2.4.12 Square the perimeter tracks. Make sure that the
sides are parallel. Check diagonally to make sure the
perimeter is square, by measuring from the points shown
in Figure 7.
2.4.13 Anchor the perimeter tracks as noted on the
assembly drawings, just enough to hold them in place.
2.5 Inside Tracks
2.5.1 Position all the inside tracks on the floor. The track
extensions for each section must be positioned in the
same order and parallel to the perimeter track extensions.
See note in Figure 7.
2.5.2 Splice the inside tracks together using the splice
brackets and fasteners as shown is Figure 10.
NOTE: The splice can go on either side of the I beam
track.
2.5.3 Make sure the measurement from the inside of
the cross-conveyor track-channel to the front of each floor
track beam is 18-inches as shown in Figure 12.
2.5.4 Make sure each section is square and parallel,
per the illustrations in Figures 7 and 12. The 36-inch
dimension between the floor track rails is measured from
center to center.
2.5.5 As each channel is checked, Anchor them as
noted on the assembly drawings, just enough to prevent
movement during the remainder of the assembly.
2.6 Rollers
Note: The roller assemblies shown in detail "A" of Figure
13 are factory assembled. If they are taken apart, they
must be reassembled as shown. When attaching the roller
assemblies to the tracks, the button head screw must be
inserted into the side with the recessed bearing. The flush
side faces the track, with a spacer between the bearing
and track.
2.6.1 Attach roller assemblies to the inside of the
perimeter tracks as shown in Figure 13 detail "B". Two
rollers are required on each drive section, including the
cross drive, and on 72-inch, and 120-inch extensions. One
roller is required on each 30-inch, 36-inch, and 60-inch
extension.
2.6.2 Attach roller assemblies hand tight to both sides
of the inside tracks as shown in Figure 13 detail C". Four
rollers are required on each drive section, and 120-inch
extension. Two rollers are required on each 30-inch, and
60-inch extension. When rollers are in place on the inside
beams, one will be slightly offset from the other. It is not
necessary to mount rollers in each segment directly
opposite one another, but roller mounting should be done
uniformly. Aligning the rollers may mean moving some of
the perimeter rollers.
2.6.3 Attach the front roller angle brackets to the inside
tracks as shown in Figure 13 detail "D".
2.6.4 Attach rollers to the angle brackets.
2.6.5 Recheck the location of the rollers to make sure
they are in-line, and on the same elevation.
2.6.6 Tighten all the roller assemblies and check each
one to ensure that it turns freely.
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© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
Figure 12
FLAT-TRAK®RECOVERY FLOOR Page 12
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
Figure 13
FLAT-TRAK®RECOVERY FLOOR Page 13
© 2015 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev L
2.7 Carriages
2.7.1 Carriage Assembly Notes
2.7.1.1 All carriages except the cross conveyor "drive"
carriage are installed inside the room. The cross drive
carriage is different from floor drive carriages, because the
cross drive cylinder is mounted on top of the carriage
rather than within the carriage, inside the cylinder
compartment as with the floor drive.
2.7.1.2 Complete one entire conveyor section of carriages
before starting the next. Doing so will train the assembler,
and identify any procedural problems.
2.7.1.3 Floor carriages must be laid in the tracks with the
vane guides sloping toward the cross conveyor as shown
in Figure 15. Vane guides on cross conveyor tracks slope
toward the elevator as shown in Figure 20.
2.7.2 Floor Carriage Assembly
Refer to Floor Drive and Floor Extension
Drawings
2.7.2.1 Lay the carriages inside the corresponding size
track. For example, a 30-inch carriage lays in a 30-inch
extension. The drive carriage, identified by the cylinder
compartment (frame weldment in the back), lays in the
drive track.
2.7.2.2 Make sure all the carriages lay flat on the floor. If
any are bent, they must be straightened.
2.7.2.3 Install only the front vane on each carriage section
as shown in Figure 14. If the front vane is not put in before
the carriages are spliced together, it will be necessary to
remove some of the splice bolts to install them. The vane
slides in from the back and rests on the guide.
2.7.2.4 Bolt both sides of the floor carriages together
using splice brackets and 3/8" fasteners as shown in
Figure 15. Splice brackets mount on the outside of the
carriages.
2.7.2.5 Use 1/4" fasteners to bolt the roller plate onto the
carriage over each roller as shown in Figure 16. The edge
of the roller plate should extend over the roller.
2.7.2.6 When all roller plates are installed and the
fasteners are tight, the carriage should be off the floor, and
should slide freely. If it does not, determine the reason,
and correct it.
2.7.2.7 Install the remainder of the vanes. The vanes
slide in from the back and rest on the sloping guides.
Figure 14
Figure 15
Figure 16
2.7.2.8 After all the vanes are installed, check movement
of the carriages by sliding them forward and backward.
Make sure they move freely, rest flat on the rollers, and
that none of the vanes bind or drag.
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CAUTION
The vanes may be left in, or removed to complete
the assembly of the floor. If the vanes are left in,
they may pose a tripping hazard until the grating
is in place. Use care not to step on them or catch
them on tools used during the remainder of the
installation.
2.7.2.9 Install the remainder of the floor conveyor
carriages as previously described.
2.7.3 Cross Drive Carriage Assembly
Refer to Cross Drive Base Drawings, Cross
Extension Drawings, and Cross Drive
Drawings
2.7.3.1 Individual carriage sections may be bench-
assembled, set in the frame and spliced together.
2.7.3.2 Place 2 x 4 blocks or similar material under the
carriage to raise if off the floor or bench.
2.7.3.3 Use 1/4" fasteners to attach vane-hanger mount
plates to the carriages, hanger cutouts must face inward
as shown in Figure 17. When correctly placed, hanger
cutouts should be above the sloping vane guides.
Figure 17
2.7.3.4 Refer to the cross drive drawings and illustration
in Figure 18 to make sure the vanes and hangers are
placed in front of the slopping vane guides. When correctly
installed the vane rest against the slopping guide and
freely pivots forward.
Figure 18
2.7.3.5 The vane closest to the elevator is installed
differently. Refer to Figure 19 and the frame assembly
drawings. The assembly consist of a short left and right-
hand end-vane with pivot rod, and a 14-9/16-inch middle
vane.
2.7.3.6 Insert the end-vane pins into the holes as shown
in Figure 19. The flat side (away from the pivot rod) is
toward the elevator. Bolt the middle vane to end-vanes
Figure 19
2.7.3.7 Lay the carriages inside the corresponding size
track. The 48" drive carriage mounts outside the room.
Mount plate, Vane hanger
Carriage
Mount plate
installed on
carriage
Align holes and
secure w/ 1/4NC
x 1" fasteners
Hanger Cutout
Hanger Cutout
Insert vane-pin into last
hole in carria
g
e
Right Hand End-Vane
Left Hand End-Vane
Middle Vane
1/4NC x 3/4" Fasteners
Vane Hanger
Vane Hanger
Vane
Vane
Vane Han
g
e
r
Vane Guide
1/4NC x 3/4" Fasteners
FRONT VIEW
SIDE VIEW
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© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 07763, Rev M
2.7.3.8 Bolt both sides of the cross conveyor carriages
together as shown in Figure 20. Splice brackets mount on
the outside of the carriages.
Figure 20
2.7.3.9 Assemble the lower cylinder mount and mount
plate to the cross drive carriage as shown in Figure 21.
NOTE: The vane guides must slope toward the bucket
elevator
Vane Guides must slope toward the bucket elevator
Figure 21
2.8 Cylinders
NOTE: Care must be taken to keep dirt or any other
dust or debris out of the cylinders ports and tubing
during assembly. Dirt will accelerate cylinder wear.
2.8.1 Floor Drive Cylinders
2.8.1.1 Remove the protective plugs from the front and
back cylinder ports. Using Teflon tape, install tube-fitting
elbows into the cylinder ports. Elbows should face the
back of the cylinder.
2.8.1.2 Using the rubber spacer and clamps provided,
attach the rod boots to the front of the cylinders as shown
in Figure 22.
2.8.1.3 Attach the rod-end jam-nuts and rod-ends to the
cylinder rods. Tighten the jam nuts after the rod end is
installed.
2.8.1.4 Lay the cylinder assemblies into the cylinder
compartments as shown in Figure 22.
Figure 22
2.8.1.5 Mount the cylinders to the end channels and
carriage as shown in Figure 23. The clevis pin on the
cylinder base must face down. Both rod and base clevis
pins are retained with pin clips.
Figure 23
Cross Track
Vane Guides (Vanes) must
slope toward elevator
Elevator
Carriage Splice Bracket
Attach brackets to the outside
of both sides of the carriage.
3/8 x 1-1/4
Capscrew and
Lock washer
3/8 Lock washer
3/8 Flat washer
3/8 Nut
3/8 Flat washer
3/8 Lock washer
3/8 Nu
t
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