Users Manual. Modular Framework for Construction Industry. Wheels the scaffolding people Scaffolding (India) Ltd. An ISO 9001:2000 Co.

Transcription

1 An ISO 9001:2000 Co. Wheels the scaffolding people Scaffolding (India) Ltd. formerly Wheels Fabricators Pvt. Ltd. Modular Framework for Construction Industry Users Manual

2 Introduction WSL CUPLOCK is the world s most widely used system scaffold. It is a fully painted/galvanised multipurpose steel scaffold system suitable for providing general access and supporting vertical loads. CUPLOCK s key feature is its unique circular node point which allows up to 4 horizontals to be connected to a vertical in a single fastening action -making it probably the fastest and safest system available. The comprehensive range of CUPLOCK components allows it to be used with traditional scaffold boards or battens. It can be used to create a huge range of access and support structures, staircase towers, circular scaffolds, loading towers and mobile towers. 7 Tank phosphating is the finest practical coating that can be applied to a scaffold system, providing a long working life and better handling. WSL CUPLOCK is manufactured to strict quality standards. This manual has been designed to enable CUPLOCK users to become proficient in planning and erecting conventional CUPLOCK scaffolds. It provides comprehensive details of components and guidance on the design and erection of access and support structures.

3 CUPLOCK Scaffolding System WSL CUPLOCK Formwork Support System The erection and application instructions Advantages contained in this booklet are the recommended Maximum leg load of 75* kn with a max grid methods to be used for WSL CUPLOCK spacing of 2.5m x 2.5m. products. * Maximum leg load is dependant on a set of The technical instructions contained in this conditions with regard to bracing, Ledger/ brochure must be accurately followed to achieve Transom spacing, load eccentricity, extension the correct function of the product. Any deviation of Adjustable Bases and U-Heads and out of from the recommended principles shown plumb of the system. Simple and efficient in this brochure may require a separate design interconnection of Ledgers and braces. and/or verification by the WSL Engineering Standards produced from 48.3 mm dia high Department. strength tube available in lengths up to 3.0m. Painted/Galvanised components for durability. The illustrations in these assembly instructions (all threaded components are zinc plated not are guidelines only. galvanised) Only WSL CUPLOCK Standards and WSL Choice of bay (grid) sizes to allow maximum CUPLOCK Adjustable Bases/Adjustable U-Head capacity of leg load to be developed. Assemblies must be used in the support Area below formwork can be decked out to structure. provide access or working platforms during The use of CUPLOCK Standards or any other erection and dismantling of soffit form. Adjustable Bases anywhere in the arrangement Fully systemised for ease of erection. reduces the leg load capacity of the structure to Minimum components and fittings. All parts that of the Standard CUPLOCK system and/or to are interchangeable. the capacity of the Adjustable Base used. Diagonal braces snap on to Ledgers at node Maximum capacities are only applicable for points and are easily dismantled by means of a equipment in good order and free from defects. quick release trigger. Designed and manufactured in accordance with required Standards. Important

4 the CUPLOCK locking procedure At the heart of the CUPLOCK system is its unique nodepoint locking device. This enables up to four horizontals to be loosely but safely connected to the standard then locked into position with a single hammer blow. The system uses no loose clips, bolts or wedges. The locking device is formed by fixed lower cups, welded to the standards at 0.5m intervals, and sliding upper cups which drop over the blade ends of the horizontals and rotate to lock them firmly into place giving a positive, rigid connection. It is this revolutionary node point which makes WSL CUPLOCK faster and simpler to erect than any other system scaffold. Once a CUPLOCK structure is based out and levelled, subsequent lifts are automatically erected square and horizontal. The lack of loose components makes the system easy to use and exceptionally robust - its painted/galvanised finish making it virtually immune to corrosion and damage.

5 General Technical & Application Manual One of the key strengths of the CUPLOCK system is the simplicity of the component range. Basic horizontals and verticals form the core of all structures. However, with the addition of a small number of special components, complex scaffolds can be constructed which safely address awkward access requirements WSL CUPLOCK Spigoted Standards (Verticals) There are five basic sizes of spigotted WSL CUPLOCK Standards. Made from 48.3mm diameter x 3.2mm thick high grade steel tube, all standards incorporate lower fixed cups at 0.5m intervals with captive rotating top-cups securing up to 4 components. The lowest bottom cup is 80mm from the base of the standard to give the scaffold improved structural strength and reduce the need for base bracing in support structures. Access Standards incorporate a 150mm spigot at the top to allow the vertical connection of further standards. Provision for a locking pin is also provided. (CUPLOCK Support Standards do not have this spigot -allowing the insertion of jacks with various support components). Name Code wt.(kg) WSLCUPLOCK 3.0 Standard CLS WSLCUPLOCK 2.5 Standard CLS WSLCUPLOCK 2.0 Standard CLS WSLCUPLOCK 1.5 Standard CLS WSLCUPLOCK 1.0 Standard CLS

6 General Technical & Application Manual WSL Standards (Verticals) Open Ended There are six basic sizes of open WSL CUPLOCK Standards. Made from 48.3mm diameter x 3.2mm thick high grade steel tube, all standards incorporate lower fixed cups at 0.5m intervals with captive rotating top-cups securing up to 4 components. The lowest bottom cup is 80mm from the base of the standard to give the scaffold improved structural strength and reduce the need for base bracing in support structures Name Code wt.(kg) WSLCUPLOCK 3.0 Open Ended Standard CLS WSLCUPLOCK 2.5 Open Ended Standard CLS WSLCUPLOCK 2.0 Open Ended Standard CLS WSLCUPLOCK 1.5 Open Ended Standard CLS WSLCUPLOCK 1.0 Open Ended Standard CLS WSLCUPLOCK 0.5 Open Ended Standard CLS Components in WSL CUPLOCKS 1: Spigot. 2: Heavy malleable casted top cup. 3: Bottom cup t B o t o m C u p 3 2

7 WSL CUPLOCK Scaffolding System Ledgers/Horizontals CUPLOCK Ledgers are used as the main horizontal connecting members for the WSL CUPLOCK system. The Ledgers are manufactured from 48.3 mm O.D. tube with forged steel blade ends which locate into bottom cups of the Standards and are locked in place by the corresponding top cups. Ledgers are available in various lengths to provide the desired grid dimension when used with WSL CUPLOCK Standards for formwork support or Access Work System. Cuplock ledgers are available in B Class pipe as per customer requirement. Name Code Wt.(Kg.) Code Wt.(Kg.) B Class A Class CUPLOCK Ledger 2.50 CLL CLL CUPLOCK Ledger 2.00 CLL CLL CUPLOCK Ledger 1.8 CLL CLL CUPLOCK Ledger 1.5 CLL CLL CUPLOCK Ledger 1.25 CLL CLL CUPLOCK Ledger 1.2 CLL CLL CUPLOCK Ledger 1.0 CLL CLL Transoms CUPLOCK Transoms made out of 50x50x5mm angle are used as a horizontal connecting member for the WSL CUPLOCK support system when a working platform is required, providing that it is not located in a position where system diagonal bracing is also required, as the braces cannot attach to a Transom, alternatively non system bracing may be used. Transoms are fabricated from twin structural steel angles fixed back to back with a drop forged blade attached to each end. The Transom secures to the Standard in the same manner as the Ledger. The outward standing bottom leg of the angles supports the steel planks in a captive manner to provide working platforms. Available in various lengths to suit a range of support grids and applications. Name Code Wt.(Kg.) CUPLOCK Transom 2.5 CLT CUPLOCK Transom 2.0 CLT CUPLOCK Transom 1.8 CLT CUPLOCK Transom 1.5 CLT CUPLOCK Transom 1.3 CLT CUPLOCK Transom 1.2 CLT CUPLOCK Transom 1.0 CLT

8 WSL CUPLOCK Scaffolding System Intermediate Transoms Intermediate Transoms provide mid-bay support for 38mm scaffold boards by spanning between the inner and outer ledgers. The jaw section at each end is turned downwards to prevent dislocation. One end is provided with an integral locking device to prevent any movement along the ledgers during use. In addition to the standard 1.3m wide unit, shorter Intermediate Transoms are available for use where scaffold boards require support between hop-up brackets. They span between the inside ledger of the main scaffold and the ledger linking the hop-up brackets. For use with 2 board and 3 board hopup brackets respectively. Name Code Wt.(Kg.) CUPLOCK Intermediate Transom 2.5 CLI CUPLOCK Intermediate Transom 2.5 CLI CUPLOCK Intermediate Transom 2.0 CLI CUPLOCK Intermediate Transom 1.8 CLI CUPLOCK Intermediate Transom 1.5 CLI CUPLOCK Intermediate Transom 1.3 CLI CUPLOCK Intermediate Transom 1.2 CLI CUPLOCK Intermediate Transom 1.0 CLI Inside Board Transom: 1 and 2 Board Drop into place over the ledgers and are secured with a locking device to prevent movement. Act as conventional transoms but extend beyond the inside ledger to provide intermediate support to one or two inside boards. Description Code Overall Weight length (m) (kg) 1-Board CLIBT Board CLIBT Locking device Inside Board Supports Single Board Support Locates in the cup joint and provides support for a single inside board at a vertical. It replaces the inside board transom at that point. Code Overall length (m) Weight (kg) CLIBS

9 WSL CUPLOCK Scaffolding System Hop-up Brackets Designed to increase the overall width of the working platform to seven or eight boards by supporting two or three additional boards beyond the inner face of the scaffold. They incorporate a cup joint at the outside end to allow the fitting of an inside ledger which links the hop-up brackets and supports intermediate transoms. Also incorporates a facility to support a handrail post. Description Code Overall Weight length (m) (kg) 3-Board CLHB Board CLHB Return Device A conventional blade end connected to a hook section which locates over the ledger on the adjacent return elevation to provide a corner connection. Used in pairs. Code Weight (kg) CLRD Swivel Face Brace Provides face bracing on a CUPLOK access scaffold. Each brace has swivelling blade ends to allow for easy location within the node joint. As only one blade end can be located in each joint, parallel bracing is employed rather than the dogleg or zig-zag method. Description Code Weight Overall (Kg) length (m) 1.8 x 1.5m CLSFB x 2.0m CLSFB x 1.5m CLSFB x 2.0m CLSFB L Y Swivel blade X

10 WSL CUPLOCK Scaffolding System Handrail Post For use with Hop-up Brackets, staircase towersand on support scaffolds if required. Incorporates cup joints to allow the location of ledgers to form guard rails. Code Overall length (m) Weight (kg) CLHP The Omega Batten system incorporates all the main CUPLOCK components but replaces the tubular transom with a special Omega unit into which special boards or battens slot to provide a secure, flush work platform.no intermediate transoms are required as stronger battens are used in place of scaffold boards.battens are either 63mm thick (timber) or 57mm (steel). Omega Transom Provides a firm location for the Omega Battens. The specially designed Omega section provides a very strong supporting platform and prevents the battens from moving. Forged blade ends locate into the cup joint of the vertical in the normal way. Both the 2.5 and 1.8m Omega Transoms can be used when CUPLOCK is erected to form a birdcage access scaffold using timber or steel battens, or on mobile access towers in modular sizes. Size Code Overall Weight (M) length (m) (kg) 0.8 CLOT CLOT CLOT

11 WSL CUPLOCK Scaffolding System Ladder Access Transom A square-section transom with an Omega profile across part of its width to support short battens behind a ladder opening. It has a claw at one end and a half coupler at the other to ensure secure positioning along the ledgers. Must only be used in conjunction with Omega transoms. Code Overall length (m) Weight (kg) CLLT Return Transom A transom with a steel hook profile which locates over the ledger of the adjacent return scaffold, linking the two sections together. The other side of the transom incorporates a conventional Omega section to receive timber or steel battens. Code Length (m) Weight (kg) CLRT Omega Single Board Support Locates at the cup joint and provides support for a single inside batten. Code Overall length (m) Weight (kg) CLOB Omega Hop-up Bracket Designed to increase the overall width of the working platform to seven or eight Battens by supporting two or three additional battens beyond the inner face of the scaffold. It incorporates a cup joint at the far end to allow the fitting of an inside ledger which links the hop-up brackets to prevent movement. It also incorporates an opening to support a handrail post. Description Code Overall Weight length (m) (kg) 3-Board CLOHB Board CLOHB

12 WSL CUPLOCK Scaffolding System Omega Two and Three Board Corner Units Provides an external corner support 2 or 3 battens wide. For use between hop-up brackets. Infill with timber, cut to fit. Description Code Length (m) Weight (kg) 2-Board CLOBC Board CLOBC Timber Battens 63mm thick and of 225mm nominal width. Weights shown are approximate at 20% moisture content. Description Code Weight Overall (kg) length (m) 1.3m TB m TB m TB Steel Battens CUPLOCK Galvanised Steel Battens are 57mm thick and 238mm wide. They incorporate a non-skid perforated surface for slip resistance in poor weather. Description Code Weight Overall (kg) length (m) 1.3m SB m SB m SB Toeboard Clips Timber For use with timber battens only. Locates around the standards and sits on the 'top-hat' section of the Omega transom Code Weight (kg) Size (mm) TCT x 120 x 171 Toeboard Clips Steel For use with steel battens only. Locates around the standards and locks the toeboard rigidly into position Code Weight (kg) TCS01 1.0

13 WSL CUPLOCK Scaffolding System End Toeboard Clip Locates on the Omega Transom. For use with timber or steel battens. Code ETC Weight (kg) CUPLOCK Tie Bars Tie bars are used to interlock the ends of Platform Brackets and to provide a means of preventing the Planks from sliding off the end of the bracket. The studs at the end of the tie locate into slots in the Platform Brackets. CUPLOCK Tie Bar 0.61m CUPLOCK Tie Bar 1.00m CUPLOCK Tie Bar 1.25m CUPLOCK Tie Bar 1.80m CUPLOCK Tie Bar 2.50m CUPLOCK Transom Beam Transom Beams are designed for special duty load applications. Allows high deck capacity and large grid patterns. CUPLOCK Transom Beam 1.80m CUPLOCK Transom Beam 2.50m CUPLOCK Transom Truss The Transom Truss is designed for high capacity loading platforms and overhead protective structures. Connects at 4 points, enhancing the rigidity of the scaffold. Consult WSL Engineering Department for load capacity details. CUPLOCK Transom Truss 1.80m CUPLOCK Transom Truss 2.50m CUPLOCK Transom Truss 3.00m

14 Typical Tubular Cuplock Access Layouts This section illustrates the methods in which CUPLOCK can be used to create returns and inside board platforms. In most cases, these will overcome the problems of corners and projections which could prevent the scaffold being erected close to the building Corner Return using the Return Device Corners can be made using the Return Device to link the two scaffold runs. It hooks over the ledger of the adjacent return elevation allowing a fly past which eliminates the need for non-standard bays. Corner Return using a 1.3m square bay The scaffold can incorporate a 1.3m square bay to form the corner. Note the positioning of the 1.3m Intermediate Transom to allow two runs of scaffold boards to butt together at right angles without overlapping.

15 7 Tank Phosphating at WSL

16 Adjustable Base & U Jacks Adjustable Base The Adjustable Base is used with all scaffold systems and some formwork systems. It has a solid stem of 32mm, 36mm nominal diameter which has a nut restraint to ensure the stem always has a minimum engagement into the Standard of 150mm. Adjustable Base (Solid) Form/Scaf The adjustable base is also made of 4mm thick pipe, 38mm outer diameter with threading with rolling machine. 32mm solid rod with base plate 150X150X6 Code Size Length-A Length-B Weight (mm) (mm) (mm) (kg) 32ABJ mm ABJ mm mm solid rod with base plate 150X150X6 Code Size Length-A Length-B Weight (mm) (mm) (mm) (kg) 36ABJ mm ABJ mm ABJ mm ABJ mm Le n gt h B L en gt h A 38mm solid rod with base plate 150X150X6 Code Size Length-A Length-B Weight (mm) (mm) (mm) (kg) 38ABJ mm ABJ mm ABJ mm ABJ mm ABJ mm mm plate 150

17 75 Adjustable Base & U Jacks Adjustable U-Head/Stirup Head The Adjustable U-Head is used with scaffold systems & formwork systems. It has a solid stem of 36mm nominal diameter which has a nut restraint to ensure the stem always has a minimum engagement into the Standard of 150mm. The U-Head is capable of accepting twin 100mm wide bearers. Adjustable U-Head (Solid) Form/Scaf 32mm solid rod with base plate 150X150X6 Code Size Length-A Length-B Weight (mm) (mm) (mm) (kg) 32ABJ mm ABJ mm mm solid rod with base plate 150X150X6 Holes for nailng 100 Code Size Length-A Length-B Weight (mm) (mm) (mm) (kg) 36ABJ mm ABJ mm ABJ mm ABJ mm mm solid rod with base plate 150X150X6 Code Size Length-A Length-B Weight (mm) (mm) (mm) (kg) 38ABJ mm ABJ mm ABJ mm ABJ mm ABJ mm Length B L en gt h A 120 travel adjustment

18 General Technical and Application Access Work System W Working Load Limits L P Cross Section of Transoms L m Transom Transoms ** Note: Loads W and P shown are not simultaneous loads. The Transom Working Load Limits shown in the table. Typically, this limitation applies to working platform widths equal to transom size 'L' shown. CUPLOCK Transom Beams and Transom Trusses Transom Beam Transom Section 1.8m & 2.5m Transom Truss m 2.5m P = Working Load Limit for Point Load W = Working Load Limit for Uniformly Distributed Load General Notes: 1 Working Load Limits (P & W) may be limited by other components or assemblies. Section for all Trusses

19 General Technical & Application Access Work System Planks 225 P 65 L All Planks meet point load requirement specifi ed for Heavy Duty Loading to AS The sum of individual loads applied to planks must not exceed the Duty Live Load for the platform per bay. L (m) P (kn) Diagonal Braces Shear Capacity of Cup P? 4.4kN For all standard sizes P? 17kN P? 17kN Platform Brackets P? 2.0kN P? 2.0kN P? 2.0kN Total Load? 34 kn Max 1 Plank 2 Plank 3 Plank P = Working Load Limit for Point Load W = Working Load Limit for Uniformly Distributed Load General Notes: 1 Working Load Limits (P & W) may be limited by other components or assemblies.

20 Paintshop at WSL Hot Oven for Drying

21 General Technical & Application Access Work System Formwork Applications General Footings and/or foundation shall be satisfactory to support the imposed loads and prevent differential settlement. All Standards shall be erected plumb. After squaring up the initial Standards on the first bay, plan bracing is helpful to hold them during erection. Each bay must have Ledgers/Transoms connected at the cup positions nearest the Adjustable Bases or Adjustable U-Head Assemblies, for example at top and bottom of each leg (and at intermediate positions at design lift heights). The most recommended type of falsework is built by having continuous lines of Ledgers in both directions. When very long runs of falsework are to be constructed consideration shall be given to dividing the structure into smaller sections to avoid the build up of adverse tolerances. No more than one spigot joint per Standard is allowed between vertical lifts of Ledgers/Transoms. Spigot Joints shall be avoided in Base Lifts. Joints in Standards should be staggered if possible. Bracing Bracing shall satisfy two conditions: (1) Provide nodal restraint. (2) Transfer transverse forces to supports. Scaffolding requires that each restraining element be designed to transfer a transverse load equal to the sum of times the axial force in the compression member at the location of the restraint and an additional load equal to half that value for each additional compression member being restrained, up to a maximum of seven members. This load shall be assumed to act in addition to other loads. All nodal points which are considered in defining lift heights shall be restrained. The correct amount of bracing shall be calculated, however a minimum amount must always be used. This requires one complete bracing system from top to bottom on each row of Standards, once in every four bays, in each direction. Bracing can be provided externally (for example, using the permanent structure to act as a brace, in this case it shall be stated in the project documentation with the magnitude of the force) or internally by the bracing system. Bracing shall be installed immediately after each lift has been erected, and as close as possible to the node points (not more than 100mm from the node point). Transverse loads must act at node points on the Standards where Ledgers/ Transoms are fitted (no secondary bending moments are permitted). If any brace is not continued to the support and is terminated within the structure, the vertical compression component of the bracing force must be added to all other vertical compression forces and the total shall not exceed the published WLL. The horizontal component of the force must also be transferred to a suitable support, ie via butting/tying to a suitable structure or other suitable bracing system as required. When the formwork deck is not restrained (for example, no permanent structure like walls or columns to provide lateral restraint) particular care shall be taken in the design to restrain the formwork deck and top Adjustable U-Heads. Individual towers or narrow falsework systems shall be fully and effectively braced and the stability of the system be investigated in the design. The slenderness ratio of the system as a whole shall not be greater than that of the individual compression members. Internal Standard CUPLOCK Standard CUPLOK Ledger/Transom Plan View Node CUPLOCK Standard Applied Load < WLL Adjustable U-Head CUPLOK Open Ended Standard Spigot Joint CUPLOK Spigotted Standard Adjustable Base Suitable footing and foundation External Standard Base lift Main lift Main lift Top lift

22 General Technical & Application Access Work System CUPLOCK Standards Formwork Applications Maximum Bay Size 1.8 m X 1.25 m Working Load Limits for internal Standards Working Load Limit (kn) m Lift Adjustable Base/Adjustable U-Head Extension (mm) Working Load Limit (kn) m Lift 1.5m Lift Adjustable Base/Adjustable U-Head Extension (mm) 40 Working Load Limit (kn) m Lift 1.0m Lift 1.0m Lift Ad justable Base/Ad justable U-Head Extension (mm ) Notes: These graphs give Working Load Limits for internal Standards which are erected plumb, loaded concentrically and effectively braced in the major directions. For external Standards reduce Working Load Limits by 15%. These graphs must be read in conjunction with the Guidance Notes on page 11.

23 General Technical & Application Access Work System CUPLOCK Assembly Recommendations The following scaffold Assembly Recommendations will give you the foundation principles to assemble a basic scaffold structure. Through experience with the system, different and more complex configurations can be assembled. Persons erecting or dismantling the components should be competent in this type of work. For safety reasons, we recommend that no less than two erectors work as a team to erect CUPLOCK. Notes: Where assistance is required in erecting more complex designs other than Standard façade type independent scaffolding and configurations not shown in these recommendations. In certain areas scaffolding may be exposed to high winds and as such special precautions regarding tying in and cladding removal can apply. In some cases, particular configurations of scaffolds and particular sites may require scaffolders to use safety harnesses and lanyard systems to provide protection against a fall when erecting the scaffold over a void or lean out from the scaffold or supporting structure without the protection of a guardrail. Risk Management When planning the erection of any scaffolding, a site specific Risk Assessment process must be carried out. Generic Hazard Identification/Risk Assessments/Control method profiles and Safe Work Methods Statements for the erection, dismantling and the usage of scaffolding equipment. Hazard Identification and Risk assessments and Safe Work Methods Statements would need to be generated for specific projects. Manual Handling As part of the risk management processes we draw your attention the requirement that scaffolders must, aspart of their competency, be competent in manual lifting techniques. Therefore, Scaffolders erecting, altering or dismantling scaffolding must follow the manual handling guidelines published by Regulatory Authorities or other guidelines and codes of practice recognised as being acceptable by such Regulatory authorities. Simple Method of Component Connection Blade ends of horizontal members (Ledgers or Transoms) are located in the bottom cup. The top cup is then slid down over the top of the blades and is rotated until it engages the locking bar. The top cup is tightened by striking its lugs with a hammer. The inclined spiral top edge of the top cup acts against a fixed locking bar on the Standard to wedge the top cup tightly around the blades providing a positive and rigid connection.

24 General Technical & Application Access Work System CUPLOCK Assembly Recommendations (cont) 1 Before commencing the erection of any CUPLOCK scaffold, care should be taken to see that the ground is suitable and clear of loose rubble to provide a stable base and clear access for erection. On soft or made up ground, the scaffold should be erected on adequate timber soleplates. As a general rule, each soleplate should be long enough so that it supports at least two Standards. Bricks or masonry blocks are not suitable and should not be used. 2 Check whether or not platform brackets are required adjacent to the workface. If so, you will need to make allowance for the width of the platform brackets and increase the distance between the workface and the closest Standard. 3 Commence erection - where possible - on the highest point of the ground and work down the incline - this will make levelling easier as the scaffolding progresses horizontally. 4 Lay out the Ledgers and Transoms for the fi rst bay in their approximate positions. Then insert an Adjustable Base into each of the first pair of Standards. 5 Where foundations are not level use Adjustable Bases and always start erecting the scaffold from the highest point of the work site. Set the nut of the Adjustable Base near (not at) the bottom of the threaded stem to allow maximum adjustment as the scaffold progresses to lower ground levels. 6 Connect the Standards with a Transom in the lowest cup joint, by inserting the blades into the bottom cups. Approximately level the transom by raising or lowering the Adjustable Base. Always start the scaffold with a 3 metre Standard on the outside face and a 2 metre Standard on the inside. 7 With one erector still holding the first pair of Standards, the second erector inserts an Adjustable Base into the third Standard and connects it to the fi rst pair with a Ledger. The upper cups can then be dropped temporarily into the locking position. The structure is now self supporting and the fourth Standard can now be connected by a further Ledger and Transom and the bay levelled. 8 The bay can now be levelled. Starting from the highest point use a spirit level to adjust the bases so that Ledgers and Transoms are level. Accuracy in levelling at this stage makes for a good start. Do Not Tighten the Top Cups - Yet 9 The bay should now be squared in plan and correctly located in relation to the structure being scaffolded. Check Start here at top

25 General Technical & Application Access Work System squareness across the diagonally opposite Standards. Checking squareness is assisted by placing the recommended number of Planks between Transoms and ensuring that Planks sit correctly with an even gap between the ends of the Planks and the supporting Transom. If the Standards are moved an appreciable distance in the squaring up process, then recheck the levels. Fix a Diagonal Brace to the outer face and end face of the first bay. Always start by fixing the brace to the upper cup first: this makes for safer handling. 10 The first bay of CUPLOCK is completed by locating the upper Ledgers and Transoms. Top cups can now be tightened in this first bay. No need for heavy hammering. It is now a simple matter to extend the scaffold structure by connecting Ledgers, Transoms and Standards to the existing bay. The top fixing cups can now be secured with a hammer. 11 The Working Platform can now be constructed using Scaffold Planks as decking and toeboards. 12 Now complete the base layout by adding bays horizontally, levelling and and positioning each bay as you go before tightening cups. Continue the 2m and 3m Standard combination for the fullrun. Note: Erection & dismantling of scaffold bays should be carried out from a fully decked platform or a platform of at least two Planks wide. Refer to local statutory regulations. 13 Planks are now moved up to fully deck out the the first lift. When these Planks remain in place as a Working Platform, Ledgers are positioned at 0.5m and 1m above the planked level to form a guardrail and midrail. For working platforms, toeboards on the outer face are also required. A Mesh Panel which incorporates a toeboard 1m high can be used in lieu of a midrail and toeboard

26 General Technical & Application Access Work System 14 Additional lifts can now be constructed by adding further Standards into spigots of the Standards of the lower lift and staggering joints wherever possible. Transoms and Ledgers are placed at platform levels connecting them with Ledgers and Transoms. Working levels should be fully decked out and fitted with guardrails, midrails and toeboards (or Mesh Panels) at the required positions. Fully complete the longitudinal erection of a lift before progressing to the next lift. Stagger joints in Standards wherever possible. If 2.0m Standards were used on the inside face of the first lift and 3.0m Standards on the outside face of the first lift and each successive lift uses Standards of the same height ie: inside and outside both 3.0m or both 2.5m or 2.0m then the initial stagger of the joints will remain through the height of the scaffold. 15 Face Bracing All scaffolds require a certain amount of diagonal face bracing to eliminate any tendency for the scaffold to distort or sway. Before the scaffold goes beyond the second lift, Bracing should be added to the outside face and on the ends. Braces attach to the outward facing of the cup on the Standard. Further bracing must be placed on the scaffold as it progresses in length and height. Braces should span from lift level to lift level and cross over joints in Standards and be positioned all the way to the top of the scaffold. 2.0m max Lift height (typical) Typical '? ig? ag' Longitudinal Bracing along external face Alternative 'Node to Node' type Longitudinal Bracing pattern along external face 3 Bays max Unbraced Transverse Bracing at ends Diagonal Braces provide stability to the scaffold and are used to brace adjacent Standards longitudinally or transversely. Face Diagonal Braces are positioned in the end bays of a scaffold run on the external face of the scaffold. They extend from the first cup near ground level to the top working level. They are typically arranged in an alternating (zig-zag) manner to provide more stability to the scaffold. For scaffold runs exceeding 5 bays in length, intermediate bracing is required where a maximum of 3 bays can be left unbraced. Variations to this spacing must be checked by the appropriate designer and specified in the design layout. End Diagonal Braces are used between end pair of Standards in the transverse direction. They extend from the first cup near ground level to the top working level in an alternating manner.

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28 General Technical & Application Access Work System 16 TIES It is essential that scaffolds be tied to the building or suitable structure to prevent inwards or outwards movement of the scaffold. As such they provide stability and enable effective performance of the scaffold structure as it grows in height and length. As general rule, ties need to commence where the scaffold height exceeds 3 times its least width. Typically ties comprise scaffold tube and right angle scaffold couplers and are connected to the Standards with right angled scaffold couplers. Care must be taken that ties do not obstruct clear access along the full length of the working and access platforms. The scaffold must not be built to allow it to cantilever more than 4m beyond the last level of ties (see diagram). The following examples show tie configurations for assembling around columns and through openings. Note: Where it is not possible to use the typical tie configurations, other tie methods incorporating drilled in friction and 'cast-in' type anchors are available. Warning: Tie tubes must not be attached to Ledgers. Tie Double Lip or U Tie Box Tie Plan View Column Tie with Butt transom tubes must be attached directly to Standards, if this is not possible then scaffold tube must be fixed between Standards with right angled couplers and the tie tube is attached to this scaffold tube. Tie Tubes Tie Configuration The diagram at right shows an example of staggered tie configuration for scaffolding assembled with 2m lifts and without any cladding, such as shade cloth or other semi or non porous material. Ties are installed at no more than 3 bays apart for a maximum bay length of 2.5m in the longitudinal direction and 2 bays apart for bay lengths of 3.00m. Ties should have a 4m overlap in the vertical direction. Cladding the scaffold will cause wind loads to increase and tie spacings may need to reduce accordingly. 2.om max Lift height (typical) 4.0m max between staggered Ties 4.0m max Tie Level height of first 4.0m max beyond tied level Through Ties should be placed as close as possible to the window reveal and secured with right angle couplers. 3 Bays max (7.32m) between ties or from a tied return One Bay max between Ties at ends with no returns Staggered Tie Points Staggered Tie Points Note: When using 3.05m ledgers the max distance between ties is 2 Bays.

29 General Technical & Application Access Work System 16 TIES (cont) Tying to Standards Ties tubes must be connected to Standards and be parallel to transoms at a position adjacent to the junction of the Transom and Ledgers, with the following restrictions: (a) Within 300mm from the underside of the cup at the junction - connected to the front Standard with addition of a Check Coupler. (b) Further than 300mm from underside of the cup at the junction - Tie connected to both front and rear Standards. (c) If unable to connect to two Standards then reinforce front Standard for the full height of the lift with scaffold tube and swivel couplers with couplers attached at 900mm centres. Note: The 300mm distance given in (a), (b) and (c) may need to be reduced, subject to the amount of tie force. Increased distance between tie points In cases where ties cannot be placed in the correct position, where ties have to be removed, where tie spacings exceed those given in these assembly recommendations or in scaffolds which extend above the building, with the result that typical tie spacings given in these Assembly Recommendations cannot be achieved, then consult WSL for technical design assistance with tie spacing and configurations to suit your specific needs. More than 300mm Tie More than 300mm Tie Within 300mm Add Check Coupler Ti e Connect to both Standards Add Check Coupler Reinforce Tied Standard (a) (b) (c) Maximum Height of Scaffold When determining the maximum height of a scaffold, a number of factors must be considered. Live load of working platforms, for example Heavy Duty, Medium Duty or Light Duty. Number of Working Platforms. Live load of Platform Brackets. Dead load of scaffold, for example Standards, Transoms, Ledgers, Guardrails, Mesh Guards, Platform Brackets, Planks, Bracing, shadecloth and chainwire mesh. The position of the top tie in relation to the top of the scaffold. Wind Loading (in relation to tie forces). Strength of the supporting structure for the scaffold. Scaffolding configurations can vary greatly, so for a CUPLOCK scaffold of typically 1.25m wide, constructed using 2m lifts, braced and tied in accordance with patterns given in these recommendations, without cladding, with a maximum of two Heavy Duty Working Platform levels (6.6kN), two levels of Planks and Platform Brackets, guardrails at the outside face at 1m vertical spacing for full height of scaffold, diagonal bracing for full height, the maximum height of the scaffold scaffold constructed with bay lengths of 3.00m or less is 45m. Note: Any additional equipment such as additional planked levels, Working Platforms, Platform Brackets, spurs or the like will increase leg load and hence reduce the maximum height of the scaffold. Therefore, where assessment shows that scaffold configuration exceeds the above conditions, consult Engineering Representative for technical design assistance with the maximum heights of CUPLOK and tying configurations to suit your specific needs.

30 General Technical & Application Access Work System 17 Access and Egress Methods Every working platform level must be provided with a safe and suitable access. This can be achieved by means of a built-in ladder or stair access tower or by direct access from within the building or structure. Stair access can be constructed with either Aluminium Stair units or steel Stair Stringers as outlined on the following pages: (i) Ladder Access Ladder access is typically used where only a few persons need access to the working platform and where tools and equipment can be delivered separately to the working platform (such as by rope and gin wheel, materials hoist or crane). Ladder access bays can be constructed within the main run of the scaffold, however, where space permits it is preferable that a separate ladder access bay be placed adjacent to the main run. Single ladders need to extend at least 0.9m above the landing level, secured at top and base and successive landing levels should be vertically spaced at no more that 6m. Ladder s inclined at slope of between 4 to 1 and 6 to 1 Standard Ladder Access Ladder secured to alternate each side of Bay Install guarding & edge protection around opening 1.3m Transom s Ladder Access Transom secured between Ledger s 2.44m 2.4m Ledger s Ladder Access Bay Plan View 1.3m Planks x 2 3.2m Braces CUPLOCK Ladder Access Transoms are used to enable the formation of an opening within the deck through which the ladder can pass. These Transoms span between Ledgers and are typically positioned at midspan of the Ledgers or at the appropriate position to support two shorter length Planks. The remaining bay width is decked out with Planks that span between Transoms in the usual manner. 1.27m 1.27m 2.4m Planks x 3 Tie Ladder Access Bay at Standards every 4.0m ma x 0.9 m ma x Important: Ensure that guarding and edge protection is installed around openings in Ladder Access Bays that are in or beside working platforms. 4.0m ma x 6.0m ma x 1.27m End View 2.44m Elevation

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32 WSL CUPLOK Erection Guide General Before commencing the erection of any WSL CUPLOCK support arrangement a risk assessment should be carried out.the grid line should be marked out to ensure the legs of the structure are positioned correctly. Sole plates must be positioned under each Adjustable Base to spread the load effectively to the foundation. Sole plates may also be required when assembled on a concrete slab. All Adjustable Bases and Standards must be checked as they are erected to ensure they are WSL CUPLOCK components; the use of CUPLOCK Standards or CUPLOCK Adjustable Bases will reduce the structure s load capacity to that of CUPLOCK losing the advantage of the higher WSL CUPLOCK loading capacity. Erection should commence from the highest ground level to allow the best use of the adjustability of the bases. This should have been considered in the form design so that each leg reaches its correct height. Constructing the first bay. The first four Adjustable Bases are placed in position, then two Standards are placed over two of the bases (making sure the Standards are the correct size as shown on the drawing). A Ledger is then connected to the lowest bottom cup on the Standards joining the two Standards together. With one erector holding the first pair of Standards, the third Standard of the first bay is then placed in position over its Adjustable Base and is connected to the other Standards with a Ledger. The unit is then self standing and the remaining Standard can be placed and connected. In this way the first bay is formed, it must then be levelled by placing a spirit level on the top of the Ledgers and adjusting the nut on the Adjustable Base taking care to maintain the lowest setting where indicated on the drawing. The first lift of Ledgers/Transoms is then added and Adjustable Braces are fixed to two adjacent sides of the bay to maintain the rigidity of the bay (refer also to Guideline Notes on page 12). From this first bay other bays are erected in a similar manner. If the structure is a birdcage layout (multi directional bay construction) then it is simply expanded outwards by adding new Standards and connecting them to the structure with Ledgers or Transoms as applicable. If the formwork structure is a series of towers, then each tower is built similar to the first bay. In either type of construction as each subsequent bay is added it must be levelled. The structure is built upwards by fixing the Ledgers for more lifts in height adding additional Standards as the drawing dictates. The last Standard must be a WSL CUPLOCK Open Ended Standard to accommodate the WSL CUPLOCK Adjustable Base or Adjustable U-Head Assembly. After the structure has been erected the formwork soffit bearers are placed in the U-Heads and are levelled by means of the screw adjustment of the Adjustable U-Head Assembly. The structure must be inspected by a suitably experienced competent person to ensure it has been erected exactly as shown on the formwork design drawing. Dismantling Care must be taken when dismantling as the stability of the structure must be maintained. Ledgers must not be removed from a level containing scaffold planks until the planks have been removed. Components must be passed down hand to hand and not dropped or thrown down onto the ground as this practice can cause injury to personnel and damage to the components.

33 WSL CUPLOCK Bracing Method Examples Example of Side Elevation with Soffit Formwork Restrained Externally by Walls and Columns Soffit formwork is restrained externally in both directions (eg by walls, columns*). Braces are terminated at every lift. Bottom jacks are not restrained. (Only where braces are not required to transfer external transverse forces to foundation/footing as determined by design). * Permanent structure(project Engineer must verify suitability of Structure.) Adjustable Braces Example of Side Elevation with Soffit Formwork Restrained by Internal Bracing Soffit formwork is not restrained externally Top deck is restrained with internal bracing. Bracing is continued from support to top Ledger to Adjustable U-Head. Continuous bracing is the preferred method. Bottom Adjustable Bases are restrained. Adjustable Base with U-Head Adjustable Jack Braces used longitudinally and transversely Ledger Open ended WSL CUPLOCK Standard Max 100mm (typical) Ledger (typical) Adjustable Brace (typical) Sectio n A-A A A Note: Base plates may be required to be anchored to resist the horizontal and/or uplift components of the bracing force.

34 WSL CUPLOCK Bracing Method Examples Example of Front Elevation (Row or Tower Confguration) Conventional formwork Note: WSL CUPLOCK Adjustable Base with U-Head WSL CUPLOCK Open Ended Standard This symbol indicates that the top deck is restrained externally in both directions, (eg by walls, columns). Adjustable Braces WSL CUPLOCK Adjustable Base Ledgers Ex ample of Side Elevation (Row Confguration) Conventional formwork WSL CUPLOCK Adjustable Base with U-Head WSL CUPLOCK Open Ended Standard Adjustable Braces Adjustable Braces WSL CUPLOCK Adjustable Base Ledgers Example of Side Elevation (Tower Confguration) Conventional formwork WSL CUPLOCK Open Ended Standard Adjustable Braces Ledgers WSL CUPLOCK Adjustable Base

35 Staircase Towers CUPLOCK staircase towers provide a safe, user-friendly solution and are quick and simple to erect. Additionally, by speeding the circulation of staff, staircase towers generate significant time savings for everyone on site. There are four basic staircase options in the CUPLOCK range; from simple, compact units to high capacity, full public access models. All use the basic CUPLOCK system to provide the main structure - with a small number of additional staircase components, including a choice of steel and aluminium stair Units. The CUPLOCK staircase tower offers a stable, rigid structure designed with a key emphasis on user safety. Broad landing platforms with steel or timber battens Full hand railing to stairs and landings with double guardrails Stairways are rigid and provide firm, non-slip treads to ensure maximum security for users The removal of potentially hazardous deck openings normally created by ladder access Staircase sizes CUPLOCK staircase towers are based on three plan layouts, using 8 leg tower structures. Staircase flights are available in steel, aluminium and modular form - (separate stringer and tread units), for maximum flexibility. Each staircase type comes in 1.5m or 2m lifts. Different lift sizes may be combined in the same tower to suit platform Levels. 8 Leg Staircase Tower Plan area: 1.8m x 4.4m This larger configuration can be built to a height of 38m, subject to ties and loadings. Landing platforms are 1.3m wide and the staircase is 0.8m wide. It can be built in lift heights of 1.5 or 2m and using either aluminium or steel stair units. The plan module is 4.4m long overall, incorporating a centre bay of 1.8m and two 1.3m landing modules at either end. Omega transoms are used in conjunction with timber or steel battens to form the landing platforms. The width of the tower is 1.8m. Exit from the tower at upper levels is made from the top landing platform by removing the appropriate guardrail.

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38 Formwork Applications Working Load Limits (WLL) given hereafter may be used in multi-bay systems when the requirements as set out in the General Guidance Notes and the Bracing Guidance Notes on page 12 are met. Working Load Limits as shown on the following pages are for two cases: Case 1: Bottom Adjustable Bases and top Adjustable U-Head Assemblies are restrained in both directions. Case 2: Bottom Adjustable Base is not restrained but top Adjustable U-Head Assembly is restrained as Case 1. Both cases cover internal and external Standards, each case has separate tables for 1.0m, 1.5m and 2.0m lifts. Suitable bracing has to be designed for the system. The eccentricity 'e' as referred to on following tables and graphs is the eccentricity of the applied load or the reaction as appropriate. To determine the WLL per Standard/leg, the least value of the appropriate tables shall be used for each case. Self weight of the components must be considered and added to all other vertical loads as appropriate. Applied load < WLL WSL CUPLOCK Top Adjustable U-Head Assembly 190 Definitions Plan View Y X Internal Standard WSL CUPLOCK Standard Defnitions Side View CUPLOCK Ledger/Transom WSL CUPLOCK Standard External Standard Node WSL CUPLOCK Open Ended Standard Spigot Joint Main lift Main lift Top lift CUPLOCK Ledger/Transom WSL CUPLOCK Adjustable Brace Suitable lateral support WSL CUPLOCK Adjustable Brace WSL CUPLOCK Adjustable Brace WSL CUPLOCK Spigotted Standard Base lift direction X direction X direction A B C 110 'A' Bottom Adjustable Base is NOT restrained in the 'X' direction 'B' and 'C' Bottom Adjustable Bases are restrained in the 'X' direction Note: 0 Same applies to 'X' direction. 'Y' direction is 90 to the 'X' direction Suitable footing and foundation SUPERCUPLOK Bottom Adjustable Base

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40 Guideline Notes General 1 The Standards, Adjustable Bases and Adjustable U-Head Assemblies must be checked to ensure that only WSL CUPLOCK components are being used. 2 Footings and/or foundation shall be satisfactory to support the imposed loads and prevent differential settlement. 3 All Standards shall be erected plumb. 4 After squaring up the initial Standards on the first bay, plan bracing is helpful to hold them during erection. 5 Each bay must have Ledgers/Transoms connected at the cup positions nearest the Adjustable Bases or Adjustable U-Head Assemblies ie: at top and bottom of each leg (and at intermediate positions at design lift heights). 6 The most recommended type of falsework is built by having continuous lines of Ledgers in both directions. 7 When very long runs of falsework are to be constructed, consideration shall be given to dividing the structure into smaller sections to avoid the build up of adverse tolerances. 8 No more than one spigot joint per Standard is allowed between vertical lifts of Ledgers/Transoms. 9 Spigot Joints shall be avoided in Base Lifts unless Adjustable Bases are braced. 10 Joints in Standards should be staggered if possible. Bracing 1 Bracing shall satisfy two conditions: (a) Provide nodal restraint. (b) Transfer transverse forces to supports. WSLtandard requires that each restraining element be designed to transfer a transverse load equal to the sum of times the axial force in the compression member at the location of the restraint, and an additional load equal to half that value for each additional compression member being restrained, up to a maximum of seven members. This load shall be assumed to act in addition to other loads. 2 All nodal points which are considered in defining lift heights shall be restrained. When braces are required to only provide nodal restraint then bottom Adjustable Bases may be used unrestrained. In this case the tables for CASE 2 shall be used. Top Adjustable U-Head Assemblies shall always be restrained, externally or internally). See also notes 4 and 8. 3 The correct amount of bracing shall be calculated, however a minimum amount must always be used. This requires one complete bracing system from top to bottom on each row of Standards, once in every 6 bays, in each direction. 4 Bracing can be provided externally (ie using the permanent structure to act as a brace, in this case it shall be stated in the project documentation with the magnitude of the force), or internally by WSL CUPLOCK bracing system. 5. Bracing should be installed immediately after each lift has been erected and fixed to the Ledgers as close as possible to the node points (not more than 100mm from the node point). 6. Transverse loads must act at node points on the Standards where Ledgers/Transoms are fitted (no secondary bending moments are permitted). 7. If any brace is not continued to the support and terminated within the structure, the vertical compression component of the bracing force must be added to all other vertical compression forces and the total shall not exceed the published WLL. The horizontal component of the force must also be transferred to a suitable support (ie via butting/tying, to a suitable structure or other suitable bracing system as required). 8 When formwork deck is not restrained (eg no permanent structure like walls or columns to provide lateral restraint) particular care shall be taken in the design to restrain the formwork deck and top Adjustable U-Head Assemblies. 9. Individual towers or narrow falsework systems shall be fully braced and the stability of the system be investigated in the design. The slenderness ratio of the system as a whole shall not be greater than that of the individual compression members.