36 / 50. PROTRUSS MANUAL version 1

Transcription

1 36 / 50 PROTRUSS MANUAL version 1

2 INFORMATION technical specifications protruss Type R = Rectangle S = Square Tube *36 Ø 50 x 4 mm *50 Ø 50 x 4 mm Alloy 51 st. AlMgSi 1 F 31 ISO Standard AlMgSi EN-AW 6082 T6 Connection Alu. connection piece with steel spigot and R-spring Brace *36 Ø 25 x 3 mm *50 Ø 30 x 3 mm P 36 R P 36 S P 50 S P 50 SL P 36 R P 36 S P 50 SV P 50 SL PROTRUSS 36 SERIES TUBE - Ø 50 X 4 Standard Lenghts (m) 0,50 0,60 0,80 1,00 1,20 1,50 1,60 2,00 2,40 2,50 3,00 3,20 3,50 4,00 36R (kg) 6,5 9,5 13,5 18,5 23,5 27,5 36S (kg) 7,5 10,5 15,5 20,5 25,5 30 PROTRUSS 50 SERIES TUBE - Ø 50 X 4 Standard Lenghts (m) 0,50 0,60 0,80 1,00 1,20 1,50 1,60 2,00 2,40 2,50 3,00 3,20 3,50 4,00 PAGE P50SV (kg) P50SL (kg) 9,5 15,5 29, ,5 *All lenghts are possible between 0,50 m and 3 m Text: Rhino Riggs, final editing: Jan Verheijen ( Interal T.C. )

3 General Protruss Read the manual carefully and completely and make sure you fully understand its contents before attempting to install the truss modules. Cautionary notes: 1. Never attempt to couple Interal Protruss modules to similar modules or systems made by other manufacturers, even if they appear to fit well. Other manufacturers may use different tolerances or different materials or welding techniques, which may lead to reduced load-bearing performance and an unreliable connection. 2. Always subject the modules to a visual inspection before use. The reasons for rejection are listed at the back of this manual. If you have any doubt about the dependability or strength of a module, or part of a module, do not use it and mark it clearly in order to prevent accidental use. 3. Number or mark each truss module with a unique identifier a numerical code, for example - as a system documenting aid for inspections and/or tests. 4. Always use the load tables that are associated with the truss in question. 5. When using the trusses in hoisting or lifting structures, make sure the loading does not exceed 50% of the values indicated in the tables. 6. Always draw up a hoisting or lifting plan beforehand when truss components or truss structures are to be supported at more than two points. 7. Always support the trusses at the lattice joints. 8. Never subject the truss components or truss structures to excessive loads. 9. Avoid high intermittent loads and dynamic loads by ensuring that the trusses cannot flex up and down. 10. The specific static and dynamic loads must be calculated when building structures that do not use straight trusses as specified by Interal. Both the constructor and the user must be aware of all relevant national, regional or local legislation or regulations and ensure that these stress calculations are performed accordingly. 11. Never hoist people up on trusses, unless adequate safety precautions have been taken and the risk analysis and stress calculations indicate that it is safe to do so. WARNINGS IN RED: Risk of serious injury or death WARNINGS IN BLUE: Risk of personal injury WARNINGS IN GREEN: Risk of material damage Failing to follow instructions or disregarding warnings may lead to material damage, serious personal injury or death. The Protruss can easily be identified by the two grooves on the coupling sleeves and the Interal inspection/final check sticker which is applied to every protruss truss module made by Interal after June Application: The Interal Protruss has been developed to allow the construction of temporary structures of varying types, sizes and shapes by assembling sets of truss modules. The resulting truss structures can support a variety of types and combinations of loads and are generally installed above persons on theatre stages, TV studio floors, exhibition stands, dance floors, event stages etc. These loads are mainly static and consist of light armatures, loudspeakers, projection screens, decoration, displays, etc., etc. If other forms of use are envisaged, it will be necessary to perform a new risk assessment and evaluation analysis and recalculate stresses and safety factors. Protruss BAUART GEPRÜFT TYPE APPROVED Interal Quality Control Type/Size: Date: Welder: Checked by: P50 SV P. Basten S. Bottenberg Made by Interal T.C. bv The Netherlands Maasheseweg 73 NL-5804 AB VENRAY This product may only be used within the limits of the static and structural report. Reports available on request. PAGE 3

4 Description: The P 36 truss is available in two versions; as a rectangular (360 x 270 mm) and as a square truss (360 x 360 mm). The P 50 truss is available in two versions; as a square truss P 50 SV (520 x 520 mm) and as a square truss P 50 SL (520 x 520 mm). The P50SV has braces on all four sides; the P50 SL truss has braces on two sides and ladder bars on the other two sides. The Protruss 36 uses different tube sizes: - In the case of the Protruss 36, the longitudinal elements are made from round tube measuring 50 x 4 mm, and the lattice wall construction (verticals, diagonals) is made from 25 x 3 mm round tube. The Protruss 50 uses different tubes sizes: - In case of the P50 SV, the longitudinal elements are made from round tube measuring 50 x 4 mm, and the lattice wall construction (verticals, diagonals) is made from 30 x 3 mm round tube. - In case of the P50 SL the longitudinal elements are made from round tube measuring 50 x 4 and the vertical diagonals are made from 30 x 3 (2 sides). The ladder bars are also made from 50 x 4 mm ( 2 sides). See the summary on page 2 for more detailed information about dimensions, weights and material grades. The Protruss 36/50 is supplied in straight lengths of 0,5 m - 0,80 m - 1,0 m - 1,2 m - 1,5 m - 1,6 m - 2,0 m - 2,4 m - 2,5 m, up to and including 3m. In addition, various corner elements are available for this type of truss; these include L, T, and X elements in one plane, and also the same L, T and X variants with description one or two attachment points in the vertical plane. connection pieces The modules connect together using a system of removable biconical couplings (photo), which generally are left in place on one side. The two halves of the aluminium couplings are secured together by a steel truss pin. The coupling sleeve is welded into the longitudinal elements of the lattice frame, allowing the biconical couplings to connect to the coupling sleeves of each module. This biconical coupling is fastened to the sleeves by steel truss pins that are secured in place using a locking clip (R clip) or an M8 nyloc locknut. The same coupling sleeves are used on all the corner elements (L, T and X shaped, with or without extra vertical attachment points), and on arch elements of varying lengths and curvatures that can be assembled to form circles of different sizes and designs. Before use: Before using the Protruss 36/50, you must first determine the weight of the loads that will mounted to the truss and whether these loads still fall within specification when the envisaged span sizes are considered. You must also plan the installation sequence (the order in which various length pieces and/or corner elements will be assembled) and the identify the position of each of the assemblies in the total structure. You must also determine the combined loads exerted by the various types of equipment you plan to mount to the structure and the locations of the support points. The reactive force at each support point must be determined and compared with the permissible load of the supporting structures (hoists, stands or vertical truss legs) and with the permissible shearing force that the Protruss 36/50 can withstand. PAGE WARNING: Risk of failure of the L, T and X elements. Corner elements made of standard truss material may fail due to a localised accumulation of shearing and bending forces. When constructing corner elements in this way, you must halve the permissible load for the straight trusses that connect to the corner element (minus 50%). NB: Exceeding the maximum load capacity of any of the hoisting or lifting devices, or of the Protruss construction components, is forbidden. The hoisting or lifting plan can be drawn up in accordance with NERS or an equivalent directive or norm. You must have the information to hand for inspection and enforcement bodies.

5 Storage: The Protruss 36/50 should be stored in an area that is as free as possible of dust (preferably completely dust-free). The truss components should be stored horizontally wherever possible. Measures must be taken to minimise the accumulation of dirt or dust in the area of the couplings. Dust and dirt in the couplings make assembly difficult and may cause damage to the coupling components. Transportation: The Interal Protruss should be transported in the horizontal position. The truss parts should not be laid directly on top of each other and should not come into contact with the wall or floor of the vehicle or sea container. They may not come into direct contact with any other equipment that is transported at the same time. Any movement or vibration in the loading area might cause parts to rub together, thereby damaging the aluminium. The use of transport dollies is more efficient and reduces the risk of damage. In addition, a truss trolley increases efficiency when erecting and dismantling the structure, and reduces the time taken to load the vehicle, etc. Obviously the total weight of the load must be considered when pushing the load up or down vehicle loading ramps and other inclines. Make sure enough helpers are present to control the weight safely. Interal T.C. offers a so-called truss carrier for transporting trusses. These beams make it easier to stack trusses for transportation. The truss carrier is suitable for both triangular and square 36/50 trusses. Loose biconical couplings and the steel truss pins should preferably be transported along with the tools required (copper-headed hammer) in a pin storage box. NB: Never transport trusses in the vertical position. This will cause the trusses to rub against each other each time irregularities in the road surface cause movement of the vehicle body, leading to wear and loss of strength. Also, if a securing strap were to break, there would be a significant risk of injury by falling trusses when unloading the vehicle or container. description truss carrier WARNING: Risk of injury by falling trusses when loading and unloading. Trusses stood vertically on the vehicle bed may easily topple over if the floor is not perfectly level. PAGE 5

6 Erection: It is recommended that the biconical couplings are left in place on one end of the truss modules. This significantly increases the speed of erection, and reduces wear and tear caused by unnecessarily frequent disassembly and reassembly. This also minimises the quantity of loose parts that need to accompany the trusses. Loose parts can easily be forgotten or inadvertently exchanged with other similar-looking, but not identical parts. It is preferable to work in teams of two. 1. Roll the dolly as close as possible to the area where erection is planned without creating an obstruction. 2. Loosen and remove the securing straps from the dolly and lift off the top truss part. 3. Visually inspect each truss module for signs of wear or damage. See page 5. Damaged modules or modules with other defects should be laid out of the way and clearly marked as defective. 4. Lay the first truss module in the position shown on the drawing (truss plan). 5. Select the next truss module and connect it to the first. 6. Slide the second truss part with the protruding (male) couplings into the sleeves (female connection) of the first part. The conical shape of the couplings make it easy to guide the protrusions into the sleeves. 7. To secure the truss parts to each other, one man should joggle the free end of the second module up and down and from left to right while the other man inserts the truss pins into the locating holes and pushes them home. A hammer is not generally necessary if the trusses have been properly maintained. 8. A copper-headed hammer can be used if the pins are difficult to seat. This is generally only required when making connections in a different direction, e.g. L and T shaped corner pieces. WARNING: Risk of damaging the truss. Do not use a steel hammer as this might damage the truss pin and truss, and avoid the use of unnecessary force when tapping in the truss pin; this may also lead to damage. Joggling the end up and down and from side to side is more effective. 9. Insert the securing clips (R clips) in the truss pin holes. 10. Repeat steps 4 to 7 until the required length has been assembled. 11. Rotate the assembled truss about its longitudinal axis by a half turn. WARNING: Risk of crushed feet or ankles Alert the people close by that their feet could be crushed if the full truss length were to roll out of position by approx. 80cm. 12. Insert the truss pins into the remaining locating holes and secure them in place with the R clips. 13. Turn the full truss length back to its original position. PAGE 6 WARNING: Risk of crushed feet or ankles Alert the people close by that their feet could be crushed if the full truss length were to roll out of position by approx. 100cm. 14. Mount any corner elements that are required to the assembled truss length. 15. If any lengths are to be connected to the corner elements: repeat steps 4 to Mount the assembled length to the corner element.

7 USE 1. Check all the joints for correct location of the truss pins and R clips. 2. Place the truss onto the support points (of stands or lifts) - or: 3. Use a flexible means of attachment to hoist the truss. The following are suitable: tubular polyester slings, steel cable slings with a protective coating or so-called Softsteels, tubular webbing slings with a wirereinforced core. If there is a risk of contact with spotlights or other hot objects in the direct vicinity, plastic tubular slings should be equipped with a steel cable safety back-up. WARNING: Risk of falling truss parts Never use steel cables unless they are equipped with a protective mantle or coating that prevents direct contact with the aluminium tubes. The steel cable is much harder and will saw into the aluminium tubes. 4. Attach the truss to the hoisting or lifting equipment and lift it to the desired working height. WARNING: Risk of overloading and falling trusses. Always use hoisting or lifting equipment of a suitable lifting capacity and ensure that the truss is lifted at a constant speed. Speed variations during lifting may generate high bending moments in the trusses and could ultimately cause breakage. 5. Recheck all the joints for correct location of the truss pins and R clips. 6. Install the load(s) as shown on the drawing (lighting plan, decoration plan etc.) 7. Check that any loads supported on a hoisting/lifting structure made of 36/50 truss material do not exceed half the value in the table. The load table for the 36/50 truss can be found on page 10. In the case of fixed portal structures it is not necessary to halve the load values as stipulated by NPR WARNING: Risk of breakage and falling trusses. ALWAYS avoid overloading trusses. 8. Check the amount of deflection of the truss after the loads have been attached. The permissible deflection is listed in the load table on page 10. Excessive deflection may indicate deformation in one or more truss modules. 9. Raise the truss or truss structure to the desired trim height. 10. Note that the positions where the heavier loads are supported on the support points will move more slowly. Where there are more than two support points, the truss may start to bend locally. Stop hoisting in good time and allow the slower hoisting points to align with the rest of the truss or truss structure. 11. Once the truss has reached the desired height, attach safety slings as required. Always check the necessity for this against the requirements of national, regional or local regulations. WARNING: Danger of falling from a height. Climbing in the Interal Protruss is strictly forbidden. 12. This is not even permitted for adjusting or maintaining the spotlights mounted in the truss. The truss has been designed to withstand static loads and NOT the kind of additional loads that are generated by the movements of a person climbing in the truss, or the forces that are exerted on a safety line attachment point if the person in the truss were to fall. Use a cherry-picker or telescope lift for work on the spotlights, or lower the entire structure back down. PAGE

8 dismantling 1. Dismantling takes place in the reverse order to assembly. 2. The use of a copper-headed hammer is recommended when loosening the truss pins. WARNING: Risk of injury by truss pins travelling at high speed. It may sometimes be necessary to use a steel hammer to loosen jammed truss pins. Only use a steel hammer if the exit route of the pin has been shielded effectively. The pins can sometimes loosen abruptly and fly out at high speed. 3. Pick up the truss pins straightaway and check them for damage. Put undamaged pins back in the pin storage box and lay the damaged ones aside for repairs. WARNING: Risk of slipping or stumbling. Leaving pins lying around on the ground increases the risk of somebody slipping or stumbling in high traffic areas where truss parts are carried from place to place. 4. Load the truss modules onto a trolley or dolly and secure them with a ratchet strap. Roll the loaded dollies away from the working area. Maintenance: The Interal truss requires little maintenance, but is not totally maintenance-free. The parts that require the most attention are the steel truss pins and the conical coupling components. 1. The truss pins should be viewed as consumables. Conscientious maintenance and/or timely replacement of these pins will extend the service life of the truss sections. The truss pins should not exhibit mushroom-shaped burrs as a result of heavy blows with a hammer. Burrs at the thin end in particular will significantly reduce the service life of the trusses and have a detrimental effect on ease of assembly. Deburr the pins regularly using a grinding stone or abrasive paper and lubricate them with silicon spray or some other form of lubrication. The pins should be thrown away when bent or worn, or if the R clip hole is no longer useable. 2. Conical couplings that exhibit burrs or dents due to contact with other objects should also be smoothed down using abrasive paper, blown clean and then lubricated with a silicon-based oil. 3. The inside surface of the conical sleeves (attached to the truss tubes) should be checked for burrs on a regular basis. If burrs are found, the inside of the sleeves must be lightly rubbed down with abrasive paper to remove the burrs, blown clean and then lubricated with a silicon-based oil. 4. Bent diagonals and end tubes can generally be straightened with a hammer. Use a wooden wedge to protect the aluminium. 5. It is also recommended that all the coupling components are cleaned and lubricated again during the annual service. PAGE 8

9 Repairing and modifying modules: Repairs to a damaged module may only be carried out by Interal or by a welder or welding firm that is in possession of a certificate of competence issued by Interal. All repairs, modifications, or changes in use must be inspected and approved by Interal. Interal will then issue a written declaration approving any change in use. Interal reserves the right to refuse to carry out repairs on the grounds of prohibitive expense and/or technical limitations. Inspections and certification In accordance with EU regulations, the truss parts must be inspected once a year by a qualified person, company or institution. A record must be kept of the findings of the inspecting party. Please contact Interal for more advice and more detailed information. The truss should be rejected and taken out of service if one or more of the faults listed below are detected: 1. Missing coupling components 2. Missing diagonal or vertical tubes (wall latticework) 3. Major or minor cracks in the coupling-to-tube weld area. 4. Major or minor cracks in the weld on the diagonals. 5. Longitudinal cracks in the main tube (extrusion fault) 6. Sharp scratches > 1mm x 20mm long in the circumference of the edge tubes. 7. Drilled holes > 10mm diameter 8. Cut marks made by chains or spotlight brackets > 1mm deep or > 20mm long 9. Loss of surface material of > 10% of the tube diameter 10. Bent truss parts 11. Twisted truss parts 12. Bent side tubes > 5 degrees 13. Bent wall tubes > 10 degrees 14. Bent truss pins 15. Truss modules with sharp burrs in the couplings 16. Couplings with truss pin hole wear > 10 % 17. Dents in the side tube or wall tube with a deformation of > 10% PAGE

10 LOADING FIGURES PROTRUSS P36R Length (M) Point Load (Kg) Point Load (Kg at ¼, ½ and ¾) Uniformly Distributed load (Kg/M) Uniformly Distributed Load (Kg) PROTRUSS P36S Length (M) Point Load (Kg) Point Load (Kg at ¼, ½ and ¾) Uniformly Distributed load (Kg/M) Uniformly Distributed Load (Kg) PROTRUSS P50SV Length (M) Point Load (Kg) Point Load (Kg at ¼, ½ and ¾) Uniformly Distributed load (Kg/M) Uniformly Distributed Load (Kg) PROTRUSS P50SL Length (M) Point Load (Kg) Point Load (Kg at ¼, ½ and ¾) Uniformly Distributed load (Kg/M) Uniformly Distributed Load (Kg) The loading figures are valid only for application of the truss under static loading. The figures have been determined in accordance with DIN standards 4113 Part 1 and Part 2. Whenever dynamic loads are expected, the loading figures should be reduced by 50% ( we recommend to perform a recalculation ). For other loading conditions a structural engineer or Interal T.C. should be consulted. The load tables assume that the means of attachment of the loads (clamps, slings, etc.) that are hung from the truss will be located as closely as possible to a point where several diagonals come together. PAGE 10

11 TUBE - Ø 50 X TUBE - Ø 50 X TUBE - Ø 50 X TUBE - Ø 50 X PAGE 11

12 NO PART OF THIS CATALOG, INCLUDING THE PRODUCTS DESCRIBED IN IT, MAY BE REPRODUCED, TRANSMITTED, TRANSCRIBED, STORED IN A RETRIEVAL SYSTEM, OR TRANSLATED INTO ANY LANGUAGE FORM OR BY ANY MEANS, WITHOUT THE EXPRESS WRITTEN PERMISSION OF INTERAL T.C. BV. SPECIFICATIONS AND INFORMATION CONTAINED IN THIS CATALOG ARE FURNISHED FOR INFORMATIONAL USE ONLY, AND ARE SUBJECT TO CHANGE AT ANY TIME WITHOUT NOTICE, AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY INTERAL T.C. BV. INTERAL T.C. BV ASSUMES NO RESPONSIBILITY OR LIABILITY FOR ANY ERRORS OR INACCURACIES THAT MAY APPEAR IN THIS CATALOG, INCLUDING THE PRODUCTS DESCRIBED IN IT. Maasheseweg 73 NL 5804 AB Venray Netherlands t. +31 (0) f. +31 (0) e. info@interal.nl w.