The Fortress Box Frame Roller Gate, produced by TYMETAL, represents a significant advancement in the design, construction, and performance of large roller gates thanks to its innovative wheel system. This design has successfully safeguarded openings up to 500 feet. Under normal load conditions, the wheels glide smoothly along the flat surfaces of the top and sides of a steel beam. However, when lateral pressure from wind increases, the wheel system's width and low center of gravity help stabilize the gate. If the wind load becomes strong enough to lift the wheels off the beam, the safety guides come into play, making contact with the underside of the top flange of the track to ensure the gate remains securely anchored to the ground.
These Box Frame Roller Gates are crafted from 6063-T6 aluminum alloy extrusions. The main members (top and bottom) have a "P" shape in cross-section, measuring at least 2 inches on each side and weighing no less than 1.6 pounds per linear foot. The vertical members at the ends of each panel section are 2 inches by 2 inches in cross-section and weigh no less than 1.1 pounds per foot. Intermediate vertical members alternate between 1 inch by 2 inches and 1 inch by 1 inch, weighing at least 0.82 pounds and 0.52 pounds per linear foot, respectively. These members are spaced apart at intervals not exceeding the overall height of the box frame. The gate is constructed in a "box" shape, with the width between the frames measuring 24 inches from outside to outside. Inside the frames, a continuous series of 1-inch by 1-inch diagonal and horizontal bracing is welded at approximately 45 degrees to the frames.
Roller wheel trolley assemblies are bolted onto the box frame at specified intervals. Each assembly comprises several steel components welded together to provide support for the axle. The gate rolls on two parallel tracks embedded in concrete, ensuring the top of the track is flush with the ground surface.
For those interested in learning more, you can download our brochure or access the Specification Section 32 31 00.
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TYM-HYD Box Frame Roller Gate System with Hydraulic Operator (Chain Link)
Part 1 – General:
1.01 Section Includes:
A. The work in this section involves supplying all labor, materials, equipment, and tools necessary to complete all Fortress Box Frame Roller Gates and Hydraulic Operator Systems required for this project. All work must strictly adhere to this specification section and the accompanying drawings.
1.02 References:
A. Underwriters Laboratory Gate Operator Requirements (UL 325).
1. Current safety standards necessitate the use of multiple external sensors capable of reversing the gate in either direction if an obstruction is detected. Refer to 2.02 D.
2. Pedestrians should never use vehicle gates; separate pedestrian gates must always be provided when foot traffic is present.
3. Hydraulic Operator Model TYM-HYD-VF2 complies with usage Classes III and IV as per current safety standards.
B. ASTM F 2200 – Standard Specification for Automated Vehicular Gate Construction. Refer to 2.04 C.
C. American Welding Society AWS D1.2 Structural Welding Code. Refer to 2.04 D.
D. ASTM A 123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel.
1.03 Submittals:
A. Product Data:
1. Provide manufacturer’s catalog cuts with printed specifications and installation instructions.
2. Deliver two copies of operation and maintenance data for the installed products, including the contact information of the nearest fully equipped service center.
3. Each operator must bear a label indicating it has undergone full power and pressure testing of all hydraulic components, stress tests of all mechanical components, and electrical tests of all overload devices.
B. Shop Drawings:
1. Supply shop drawings showing the relationship between operating systems and gate components, including detailed views of all major components.
2. Include complete details of gate construction, height, and post spacing dimensions.
C. Each operator must bear a label indicating it has undergone full power and pressure testing of all hydraulic components, stress tests of all mechanical components, and electrical tests of all overload devices.
D. Certifications:
1. Aluminum welders and welding processes for gate manufacture must be certified per section 2.04 D.
2. Operator Manufacturer: A company specializing in hydraulic gate operators with at least ten years of experience.
3. Installer: A minimum of three years of experience installing similar equipment.
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Part 2 – Products:
2.01 Hydraulic Gate Operators:
A. Hydraulic Gate Operator TYM-HYD-VF2 with controller supplied by TYMETAL, located at 2549 State Route 40, Greenwich, NY 12834 – (800)-328-4283.
2.02 Operation:
A. Operation is achieved via a metal rail passing between a pair of solid metal wheels with polyurethane treads. Operator motors are hydraulic, roller-type, and do not include belts, gears, pulleys, roller chains, or sprockets to transfer power from the operator to the gate panel. The operator generates a minimum horizontal pull of 300 pounds without the drive wheels slipping or distorting the supporting arms. It can handle gates weighing up to 5,000 pounds. The operator is speed-controlled by an electronic Variable Frequency Drive (VFD), which accelerates and decelerates the gate gradually to prevent shock loads. The maximum gate velocity of the Model TYM-HYD-VF2 operator is not less than 26 inches per second. The VFD gradually accelerates the gate to its maximum speed and reduces the gate velocity to less than 1 foot per second before a limit switch stops the electric motor. Two adjustable hydraulic brake valves (one for each direction) assist in slowing the gate to a precise stop.
B. Standard mechanical components include:
1. Supporting arms: Cast aluminum channel with fully bushed, 1-1/2" bronze bearing surfaces acting on arm pivot pins.
2. Arm pivot pins: 3/4" diameter, stainless steel, with integral tabs for easy removal.
3. Tension spring: 2-1/2" heavy-duty, 800-pound capacity.
4. Tension adjustment: Finger-tightened nut, not requiring tools.
5. Drive release: Instantly releases tension on both drive wheels and disengages them from the drive rail for manual operation.
6. Limit switches: Fully adjustable, toggle types, with plug connection to the control panel.
7. Electrical enclosure: Oversized, metal, with a hinged lid gasketed for protection from foreign objects and ample space for accessories.
8. Chassis: 1/4" steel base plate, and 10 Ga. sides and back welded and ground smooth.
9. Cover: 10GA. sheet steel, hot-dip galvanized, and gasketed. The box is powder-coated gray. All joints are welded, filled, and ground smooth. Finished corners are square and true with no visible joints. The cover is locked with a detention-quality mogul lock.
10. Finish: Fully zinc-plated, followed by a high-gloss powder coat finish withstanding 1000-hour salt spray test.
11. Drive wheels: 8" Diameter, metal hub with polyurethane tread.
12. Drive rail: Extruded 6061-T6, not less than 1/8" thick. The drive rail incorporates alignment pins for easy replacement or splicing.
13. Hydraulic hose: 1/4" synthetic, rated to 2750 p.s.i.
14. Hydraulic valves: Individually replaceable cartridge type, in an integrated hydraulic manifold.
15. Hose fittings: Quick-disconnect type at the manifold, swivel type elsewhere.
16. Hydraulic fluid: High viscosity index type with a temperature range of -30°F to 180°F.
17. Zero to 2000-PSI pressure gauge, mounted on the manifold for diagnostics, is a standard component.
18. The hydraulic fluid reservoir is formed from a single piece of metal, non-welded, and powder painted on the inside and outside to prevent fluid contamination.
C. Minimum standard electrical components:
1. Pump motor: 2 HP, 56C, TEFC, three-phase, continuous duty motor, with a service factor of 1.15 or greater.
2. All components have overload protection.
3. Controls: Smart Touch Controller Board with 256K memory containing:
- Inherent entrapment sensor;
- Built-in "warn before operate" system;
- Built-in timer to close;
- Liquid crystal display for system configuration and reporting of control status;
- 23 programmable output relay options;
- Anti-tailgate mode;
- Built-in power surge/lightning strike protection;
- Menu configuration, event logging, and system diagnostics are easily accessible with a PC and free START software;
- RS232 port for connection to laptops or other computer peripherals and RS485 connection of Master/Slave systems.
4. Transformer: 75 VA, non-jumpered taps, for all common voltages.
5. Control circuit: 24VDC.
D. Required external sensors: See 1.02 A2. Specify photo eyes or gate edges or a combination thereof to be installed such that the gate is capable of reversing in either direction upon sensing an obstruction.
E. Optional control devices: Consider card readers, key-switches, radio controls, pushbuttons, vehicle detectors, keypads, or seven-day timers.
F. 208/230 VAC single phase and 208/230/460 VAC three phase available. 115 is not available. (50 Hertz is available specify voltage.)
2.03 Factory Testing:
A. Fully assemble and test each gate operator at the factory to ensure smooth operation, sequencing, and electrical connection integrity. Apply physical loads to simulate field conditions. Tests simulate physical and electrical loads equal to the fully rated capacity of the operator components.
B. Check all operator mechanical connections for tightness and alignment. Verify all welds for completeness and continuity. Ensure welded corners and edges are square and straight.
C. Inspect operator-painted finish for completeness and gloss. Touch up imperfections prior to shipment.
D. Verify all hydraulic hoses and electrical wires to ensure chafing does not occur during shipping or operation.
2.04 Box Frame Roller Gates:
A. TYMETAL, 2549 State Route 40, Greenwich, NY 12834 – (800) 328-4283, shall manufacture the Box Frame Roller Gate(s).
B. Approved Substitution: All other systems must be submitted to the design team in accordance with substitution requirements as set forth in the general provisions of the specification manual for approval prior to the bid date. Products submitted after the bid date will not be approved.
C. Gate manufacturer shall certify gate is manufactured in compliance with ASTM F 2200, Standard Specification for Automated Vehicular Gate Construction, and the operators are UL 325 listed. See 1.02 B and 1.02 A respectively.
D. Gate manufacturer shall provide independent certification as to the use of a documented Welding Procedure Specification and Procedure Qualification Record to ensure conformance to the AWS D1.2 welding code. Upon request, Individual Certificates of Welder Qualification documenting the successful completion of the requirements of the AWS D1.2 code shall also be provided. See 1.02 C.
2.05 Gate Construction Details:
A. Gate Frame:
1. All welds on the gate frame shall conform to Welding Procedure Specification and Procedure Qualification Record to ensure conformance to the AWS D1.2 Structural Welding Code. All individual welders shall be certified to AWS D1.2 welding code. See 1.02 C.
2. The gate frames shall be fabricated from 6063-T6 aluminum alloy extrusions. The primary members (top and bottom) shall be "P" shaped in cross-section with no less than 2 inches on a side and weighing not less than 1.6 lb/lf. The vertical members at the ends of each panel section shall be 2 inches by 2 inches in cross-section weighing not less than 1.1 lb/ft. Intermediate vertical members shall alternate between 1 inch by 2 inches and 1 inch by 1 inch in cross-section weighing not less than 0.82 lb/lf and 0.52 lb/lf, respectively. They shall be spaced at a distance not to exceed the overall height of the box frame. The gate shall be constructed in "box" form with the width between the frames measuring 24 inches from outside to outside. Between these frames there shall be a continuous series of 1 inch by 1 inch diagonal and horizontal bracing with the diagonals welded at approximately 45 degrees to the frames.
3. Box Frame trolley assemblies shall be bolted to the box frame at intervals as specified on the bid drawings. Each assembly shall consist of a galvanized steel carriage to which two (2) wheel assemblies are secured. Each wheel shall be rated for a minimum load capacity of 2,000 lb.
4. Safety guides of 3/8 inch by 3 inch galvanized steel bar with attached guide wheels shall be provided at a maximum of 10 feet on center along the entire gate length.
5. Wheel assemblies shall be covered by a single 11 gauge galvanized steel cover at each location.
B. Gate Track:
1. The gate shall roll on two parallel tracks, which are embedded in concrete so that the top of the track is level with the ground surface. The track shall consist of two (2) parallel W4 x 13 A36 steel beams (may be provided by others). The tracks shall be hot dipped galvanized and set so as to vary no more than 1/4 inch in width between tracks with the maximum width as shown in the bid drawings (i.e.: +/- 1/8 inch for each track).
C. Diagonal Bracing:
1. Diagonal "X" bracing of 3/16 inch minimum diameter stainless steel aircraft cable shall be installed throughout the gate to brace the gate panels and to provide a ready means for vertical adjustment.
D. Gate Filler:
1. Chain Link: 2 inch by 2 inch by 9 gauge aluminized steel chain link fabric shall extend the entire length of the gate (if operated gate, counterbalance must also have fabric to prevent reach-through and comply with ASTM F 2200, see 1.03 C.1). Fabric shall be attached at each end of the gate frame by standard fence industry tension bars and tied at each 2 inch by 2 inch (51 mm by 51 mm) vertical member with standard fence industry ties. ASTM F 2200 requires an attachment method that leaves no leading or bottom edge protrusions (cannot exceed 0.5 inch).
2. The gate filler shall extend to a minimum height of 72 inches above grade and shall be sized to prevent a 2¼ inch diameter sphere from passing through openings anywhere along the length of the gate frame.
E. Finish:
1. Gate to be mill finished aluminum or color coated with polyester powder as specified. If powder coated, the gate (including track member) and all accessories shall be pretreated chemically by sand blasting or other acceptable method to ensure proper coating adherence. Gate posts (to be supplied by others) shall be galvanized or coated as specified by the design team.
F. Gate Lock:
1. (Optional) Gate system shall be furnished with an electro-mechanical lock. Lock shall be supplied with status indication and with a six-tumbler mechanical lock. All gates shall be keyed alike. Lock requires additional 115V power supplied by others.
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Part 3 – Execution:
3.01 Site Inspection:
A. Final grades and installation conditions shall be examined. Installation shall not begin until all unsatisfactory conditions are corrected.
B. Locate concrete mounting pad in accordance with approved shop drawings.
C. Ensure that the gate is level and operating smoothly under manual conditions before installing the gate operators. Do not proceed until the gate panel is aligned and operates without binding.
3.02 Installation:
A. Equipment in this section shall be installed in strict accordance with the company’s printed instructions unless otherwise shown on the contract drawings.
B. The gate and installation shall conform to:
1. ASTM F 2200 standard specification for automated vehicular gate construction.
2. UL 325 standards.
C. Installer shall ensure that the electric service to the operator is at least 20 AMPS. The operator wattage is 2400.
D. The installing contractor shall be responsible to ensure that appropriate external primary entrapment safety devices be installed for the specific site conditions to protect against all potential entrapment zones. Proper operation of these safety devices shall be verified and training as to the operation and maintenance of these devices for the users and owners shall be documented.
3.03 System Validation:
A. The complete system shall be adjusted to assure it is performing properly. Test gate operator through a minimum of ten full cycles and adjust to ensure operation without binding, scraping or uneven motion. Test limit switches for proper "at rest" gate position.
B. All anchor bolts shall be fully concealed in the finished installation.
C. For operated gate systems – test and explain safety features:
1. Each system feature and device is a separate component of the gate system.
2. Read and follow all instructions for each component.
3. Ensure that all instructions for mechanical components, safety devices and the gate operator are available for everyone who will be using the gate system.
4. The warning signs shipped with the gate operator must be installed in prominent position on both sides of the gate.
D. Ensure the owner is clear with regard to the safety points concerning the basic operational guidelines of the safety features of the gate operator system. These safety points are listed in the gate operator manual and must be read prior to system use.
Note: TYMETAL reserves the right to modify and/or make changes as deemed necessary without previous notice.
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