The Monkeytoe XBEAM is a key to a revolutionary configurable aluminium Beam system that is part of our Modular XBEAM platform system.
XBeam is made from the combination of 2 technologies, carbon fibre-reinforced polymers and High Tensile T6 Aluminium. Carbon fibre’s strength as a material comes down to the nature of the composite. The ability to tailor the direction of the carbon fibres means it can yield stiffness 20 times greater than a metal baseline. That means carbon fibre structures can span further distances and support greater weights while also weighing less –opening doors for greater designs. This is also suitable for other external long span high load applications where Steel “I beams” are used.
Our Benefits
Lightweight – Up to 65% lighter than steel equivalent; less loading on supporting structure
No surface coating requirements for corrosion protection
Low deflection for superior acoustic performance
Substantial reduction in height work by enabling the platform to be assembled offsite, or at ground level then lifted to the roof fully assembled or in completed sections.
Reduce risk of damage to the roof by assembling the platform at ground level.
Less load on the building structure. 65% lighter than a steel equivalent.
A complete platform system. Compatible with all Monkeytoe handrails, louvre and Hushmonkey acoustic screening systems.
Pre-engineered and highly configurable, which enables Last minute configuration tweaks without extensive workshop drawing updates.
Manufactured under a ISO quality management system
NOTE: Configurations could take up to three minutes to load fully depending on the size & complexity as it is configured in real-time based on requirements.
This system is designed in accordance with Aluminium Structures, Part 1: Limit State Design AS/NZS 1664.1 Standards Australia / New Zealand NZS/AS 1657.
Fully documented third party testing to ensure compliance to the building code. These included deflection, horizontal, load and temperature and durability.
Frequently Asked Questions
Do you also take care of the waterproofing detail of the roof penetration?
Monkeytoe supplies the appropriately sized Dektite boot with our Stub leg kits, which should be installed by the main roofing contractor at the time of roof install. This typically means that the leg stubs are installed before the roof itself. On a retrofit project, if there is an existing roofing contractor then we recommend they be engaged to install the boots.
If there are no roofers currently on the job then Monkeytoe can engage one for you.
Do the penetrations through the roof require a flashing detail?
This will depend on the roofing type being used on the building. The standard manufacturer’s flashing detail should be used for a Ø250 round penetration using a Dektite boot. Backtray flashings may be required for some profiles and not for others.
Is the Xbeam a watertight unit?
The beam is manufactured as a sealed unit, however some penetrations are made for connection to the beam. Where required, these can be sealed using neoprene washers or an appropriate silicone sealant.
Are there any concerns about dissimilar metals at hub portal connections, such as between zinc bolts, aluminium structures and steel beams? Are there any risks of galvanic corrosion?
In short, no. Where these connections are made inside a building, there are no concerns. For galvanic corrosion to occur, an electrolyte must be present to complete the electrical circuit. This should not be happening inside a building often enough for corrosion to happen. As an added precaution, however, Monkeytoe recommend using a lanolin moisture/corrosion inhibitor spray at the time of install to prevent any moisture from being trapped during construction.
We have chosen zinc bolts for this application as they are more compatible with aluminium than galvanised fasteners are, and they maintain compatibility with the steel structure. Where this connection occurs in a weather-exposed area, isolation will be provided between all dissimilar metals to mitigate and prevent corrosion. This will typically be a thin rubber or hard plastic layer, but in some situations a specialised coating may be used.
Does Monkeytoe engineer and certify from portal up?
Monkeytoe will engineer from our connection point upwards, including the fasteners used. If we are providing the leg stubs, then this will be from the portal up (but not the portal itself). If we are mounting to support legs that are supplied by others, our engineering will cover from our connection upwards. Monkeytoe can assist with the design requirements for the legs in this case.
Monkeytoe’s aluminium is designed to AS/NZS1164 (Aluminium structures). How is carbon fibre covered?
This is covered by a combination of physical testing as per AS/NZ 1170.0 Appendix B, as well as reference to the European composites code where applicable.
Where and how is carbon fibre incorporated into the Xbeam?
Carbon fibre is fixed into the top and bottom flange cavity of the beams in the form of ‘Spar Caps’ by use of a structural acrylic adhesive.
What glues or adhesive are used to fix extrusions together, and what testing have these undergone?
We started with over 50 different potential options and narrowed these down over a period of more than six months, with various tests and discussions with adhesive chemists. We conducted hundreds of lap shear tests at temperatures ranging from below ambient to up to +200°C in order to select our adhesives.
The aluminium-aluminium bonding is achieved with a high temperature capable adhesive that has been specially formulated for us by Bondchem in the UK. The carbon fibre-aluminium bonding is done with a Bondchem structural acrylic. We also have other equivalent options that have been tested and that can be substituted if needed.
What testing has been completed for structural integrity in fire situations?
We’ve designed and tested to a range of parameters, and we’re currently working with fire engineers to look into additional fire capabilities using intumescent paints.
The aluminium bonds are designed to withstand at least 200°C for an extended duration. This covers scenarios where a fire-rated roof can emit a radiant temperature of up to 180°C for a specified duration.
In our adhesive lapshear testing to date, we’ve actually observed this particular bond increasing in strength with increases in temperature thanks to the nature of the specifically formulated product. We’ve tested this up to 220°C.
Beyond this temperature, it’s possible the aluminium bonding may fail, and that the system would be relying on the bond friction and the connecting bracketry only. We’ve tested this scenario with all bonds failed and the beam loaded to 1.5x its designed shear load held overnight, without observing a catastrophic integrity failure. So pretty successful, we think.
Above 300-350°C the aluminium itself will degrade in performance and reach expected failure.
Is the XBEAM unit watertight?
While the Xbeam is watertight along the main length, the end caps aren’t a sealed fit. We are now looking at making the entire beams watertight by using a waterproofing foam in the ends of the cavities before installing the end caps.
Do you have the Fire resistance properties of these beams, such as the FLR Ratings?
Currently we do not have any fire rating capability with these beams, though this is something we’re working on currently with fire engineering companies in Australia. This will take some time to complete.
As above, our design & testing to date has been around the beam maintaining structural integrity when exposed to 180°C+ radiant temperatures (based on the allowable radiant temperatures through a fire rated roof/wall).
How did we go about getting the capacities from the Xbeam? Was this through testing?
The properties and capacities of the Xbeam are both calculated and verified by FEA & physical testing to determine its performance under a range of stresses.
I worked with Monkeytoe at HMAS Cerberus to design and install 4 x mechanical plant decks. From design to the install onsite under strict defence guidelines nothing was a problem and the process was made easy by there willingness to achieve whatever was required to produce the best outcome. Even a design change mid assembly didn’t faze the onsite team that achieved a fantastic finished product that was better then expected given the install locations. I look forward to working with Monkeytoe in the future.
Joel Cowie
Icon Construction
Monkeytoe was very professional and helpful from the onset. They have an impressive range of designs for roof access and it’s obvious why they are leaders in the industry.
Divan Pretorius
McMillan & Lockwood
Monkeytoe were engaged to supply us with an alternative to our traditional structural steel rooftop mechanical plant platform.
The design utilising strong and lightweight materials is a great advantage. The seamless interface of their supports with our traditional structural steel roof beams works perfectly.
An all-in-one package complete with deck structure, mesh and sound wall, had a positive affect to the program that was a great bonus for the construction team. Monkeytoe did it all with great efficiency and speed, saving construction costs and time to our overall program. All components arrived from New Zealand on time and in good condition (even with the added complications of Covid-19!). Initial assembly was done in the carpark of the site and then easily craned into position on the roof.
The Monkeytoe team in New Zealand and here in Australia were efficient, easy to work with and a pleasure to deal with. We are more than proud to have the first of your systems, on our site, in Australia.
Platform Deck was supplied, and installed as per our expectations and designed in a manner as to accommodate extra support underneath larger plant units. Some extra supports were required as the units had to be adjusted in position onsite therefore causing some minor point load issues, however Monkeytoe were more than helpful to supply the additional supports despite it being the fault of another contractor.
In our opinion and also in the opinion of our acoustic engineer, the finish quality of the plant deck and especially the acoustic screening was standout. The acoustic engineer was impressed with the design and also quality of finishing and said it was some of the best he has seen. In early days we did have some concerns as to how the platform would be fixed through the kingspan roofing however the mounting clips worked perfectly.
Exceptional quality and exceptional administration service!
Originally the HVAC for Target road was designed across 4 platforms with numerous walkways for serviceability. However after a rethink and redesign a single platform was proposed and after discussions with Monkeytoe Xbeam was suggested as a solution. The advantages for our client have been the reduction of walkways, the ability to add an additional Air Con unit for future proofing and the reduction in structural upgrade with Xbeam supported from portal frames.
Brian Johns
RCG
The absorptive nature of the HushMonkey Acoustic Panel delivers superior performance over a standard barrier system, with more sound being absorbed within the enclosure, significantly reducing noise emissions to the surrounding environment.
Tim Beresford | Kanvin Chen
Norman Disney & Young
We have provided a safer, more accessible access method for our staff by using the Monkeytoe access solution.
Vitaco’s requirement for a 70m long elevated walkway was quickly understood by MonkeyToe and we were given 3D designs to review. MonkeyToe’s engineers worked closely with our architects and engineers to produce a final design. We’ve been kept well informed throughout the project and the result is an impressive looking walkway, which is rock solid, a critical factor as it’s 7m above the warehouse floor and used by 50 staff everyday.
NOTE: Configurations could take up to three minutes to load fully depending on the size & complexity as it is configured in real-time based on requirements.