Acrow SuperCuplok Scaffolding System

Transcription

1 SCAFFOLDING PRODUCT TECHNICAL GUIDE Acrow SuperCuplok Scaffolding System General Technical and Application Manual Genuine Safety. Outstanding Service.

2 Support System Formwork Support System Advantages Maximum leg load of 75 * kn with a max grid spacing of 2.4m x 2.4m. * Maximum leg load is dependant on a set of conditions with regard to bracing, Ledger/Transom spacing, load eccentricity, extension of s and U-Heads and out of plumb of the system. Simple and effi cient interconnection of Ledgers and braces. Standards produced from 48 mm dia high strength tube available in lengths up to 3.0m. Galvanised components for durability. (all threaded components are zinc plated not galvanised) Choice of bay (grid) sizes to allow maximum capacity of leg load to be developed. Area below formwork can be decked out to provide access or working platforms during erection and dismantling of soffi t form. Fully systemised for ease of erection. Minimum components and fi ttings. All parts are interchangeable. Diagonal braces snap on to Ledgers at node points and are easily dismantled by means of a quick release trigger. Designed and manufactured in accordance with relevant Australian Standards. Full design support and technical assistance available. Important The erection and application instructions contained in this booklet are the recommended methods to be used for products. The technical instructions contained in this brochure must be accurately followed to achieve the correct function of the product. Any deviation from the recommended principles shown in this brochure may require a separate design and/or verifi cation by the Acrow Formwork & Scaffolding Engineering Department. The use and application of the system must be in accordance with AS 3610, AS 4576, Occupational Health and Safety Regulations, approved industry codes of practice and relevant regulatory authority requirements in conjunction with information in this brochure. The illustrations in these assembly instructions are guidelines only. Only Standards and s/adjustable U-Head Assemblies must be used in the support structure. The use of CUPLOK Standards or any other s/u-heads anywhere in the arrangement reduces the leg load capacity of the structure to that of the Standard CUPLOK system and/or to the capacity of the /U-Head used. Maximum capacities are only applicable for equipment in good order and free from defects. Safety Warning It is recommended that users of the system employ and implement appropriate procedures and control measures to eliminate or control any risk of musculoskeletal disorder/injury while manually handling components. Refer to Code of Practice on manual handling published by local Workcover Authority or other approved and recognised guidelines for correct and appropriate manual handling procedures. 2 Disclaimer 1 Photographs/illustrations shown within this brochure are intended as expressing the diversity and possible applications of the product and as such must not be used as assembly instructions. 2 In line with Acrow Formwork & Scaffolding s commitment to continuous product development and improvement, the information contained in this brochure may be changed without notice. 3 Every effort has been made to give appropriate guidelines for the use of this product, however, Acrow Formwork & Scaffolding Pty Ltd accepts no responsibility for any loss or damage suffered by any person acting or refraining from action as a result of this information. Should the users require any further information or guidance, they are encouraged to contact their local Acrow Formwork & Scaffolding outlet.

3 General Technical and Application Manual Product Description Code No. Mass kg (nom.) 150 Spigotted Standards There are fi ve basic sizes of spigotted Standards. These Standards are used in conjunction with Open Ended Standards to achieve the height of the formwork support. Integral spigots 150mm long, are provided at the top of each Standard to make vertical connections with other Standards. The spigots and base of each Standard incorporate 16mm dia. holes to enable the use of locking pins to interconnect Standards as and when required Standard 2.5 Standard SCS30 SCS Standard SCS Standard SCS Standard SCS Open Ended Standards There are fi ve basic sizes of Open Ended Standards. They are used at the top of the structure so that an Adjustable Base or Adjustable U-Head Assembly can be inserted to provide the fi nal support to the soffi t formwork. They are used in conjunction with the Spigotted Standards to build the structure to the correct height. The base of each Standard has a 16mm dia through hole to enable the use of locking pins to lock the structure together as and when required. 2.8 Open Ended Standard SCSOE Open Ended Standard 1.8 Open Ended Standard SCSOE23 SCSOE Open Ended Standard SCSOE Open Ended Standard * SCSOE * The 0.8m Standard should not be used as a 3 base lift unit. When used at the top of of the structure the internal space clear of the inserted spigot of the lower Standard will only allow an /U-Head to be inserted 645mm into the Standard meaning it would be 92mm short of its closed down height. Features for identification of Standards: 1 Notch in top of Spigots 2 Three ribs around each bottom cup and 3 Stamping of on each bottom cup

4 Support System Product Description Code No. Mass kg (nom.) 1 Nut Restraint 2 48mm dia Sleeve Identifi cation features for s 1 38mm dia solid stem 2 Acrow stamping on nut handle 3 48mm dia sleeve welded at plate end of stem. 3 Solid (38mm Dia) The provides adjustment for the base Standard. It fi ts directly into the Standard and features a 48mm dia sleeve at the base of the stem to enable bracing where necessary to be attached. The stem has a nut restraint feature to ensure the Adjustable Base stem has a minimum of 250mm insertion into the Standard. Fully opened the extends 600mm from the end of Standard. Fully closed the extends 124mm from the end of Standard. The is also used at the top of the structure to support the soffi t formwork, with or without the Detachable U-Head, depending on the application. SCDUH Detachable U-Head Internal The Detachable U-Head attaches to an to form an Adjustable U-Head Assembly. The Detachable U-Head has two 14mm dia pins which locate through the base plate of the and the unit is held in place by the insertion of 3mm diameter R-Clips through the pins. The assembly is generally used at the top of the Support system to support formwork main bearers. SCDUH 4.5 Adjustable Jack Brace The Adjustable Jack Brace 4 Range = 1.14m to 1.93m is a telescopic push/pull brace featuring a double nutted adjustment facility. The brace is used to diagonally brace the or Adjustable U-Head Assembly. The top end locating pin attaches to the Bracing Coupler. The lower end features a locking claw which can be quickly snapped over the top Ledger in the support structure. It is recommended that the bearers be positioned in the U-Head and the U-Head rotated to lock against the bearer prior to attachment of the Bracing Coupler. SCAJB 10.4 Working Load Limit for axial load W.L.L = 6.25 kn View on arrow Bracing Coupler The Bracing Coupler attaches to the sleeve of the and is used as the attaching point for the Adjustable Jack Brace. SCBC 1.1

5 General Technical and Application Manual Product Description Code No. Mass kg (nom.) Adjustable Braces L Adjustable Braces are used to provide node to node diagonal bracing for the support assembly. The brace comes in three sizes each covering a range of diagonal brace lengths for the varying grid and height dimensions. The brace is telescopic to facilitate a range of adjustment to achieve the required lengths. The two telescopic members of the brace are locked together by a 12mm dia pin with R-Clip. The end locking claw locks quickly over the Ledger with no need for further tightening. The use of a brace, which operates independently to the cups on the Standard, leaves the cup free to accept up to four horizontal components as required. (Refer also to Guideline Notes on page 13) The three charts below show the extension the braces should be set at to suit the various bay configurations. The inner member of the braces has hole positions Quick fi x/release wedge or spring action claw for ease of use. which correspond to the required set dimension. Extra Short Adjustable Brace SCDBXS 8.7 Short Adjustable Brace SCDBAS 11.2 Long Adjustable Brace SCDBAL 14.4 Working Load Limit for axial load W.L.L = 10 kn 5 Long Adjustable Brace Bay Length Height Extension 'L' (mm) (mm) (mm) Extra Short Adjustable Brace Bay Length Height Extension 'L' (mm) (mm) (mm) Short Adjustable Brace Bay Length Height Extension 'L' (mm) (mm) (mm) 'L' = centre to centre of locking claws

6 Support System Product Description Code No. Mass kg (nom.) Ledgers CUPLOK Ledgers are used as the main horizontal connecting members for the support 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 Standards for formwork support. Production of the Ledger since 1997 has been from thinner high grade steel tube with the equivalent capacity as the original mild steel tube. This reduction in tube thickness contributes to a lighter product and thereby easier handling. Earlier Ledgers made from the thicker wall tube weigh approximately 20% heavier than the weights stated below. CUPLOK Ledger 2.44 CUPLOK Ledger 1.83 CUPLOK Ledger 1.52 CUPLOK Ledger 1.27 CUPLOK Ledger 1.05 CUPLOK Ledger 0.83 CUPLOK Ledger 0.61 CUPLOK Ledger 0.34 Transoms CL24 CL18 CL15 CL13 CL105 CL083 CL061 CL CUPLOK Transoms are used as a horizontal connecting member for the 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 fi xed 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. CUPLOK Transom 2.44 CUPLOK Transom 1.83 CUPLOK Transom 1.52 CUPLOK Transom 1.27 CUPLOK Transom 1.05 CUPLOK Transom 0.83 CUPLOK Transom 0.61 CT24 CT18 CT15 CT13 CT10 CT08 CT

7 General Technical and Application Manual Product Description Code No. Mass kg (nom.) Bracing Bay Transoms Bracing Bay Transom 0.61m Bracing Bay Transom 0.83m Bracing Bay Transom 1.05m Bracing Bay Transom 1.27m Bracing Bay Transom 1.52m Bracing Bay Transom 1.83m Bracing Bay Transom 2.44m SCBBT061 SCBBT083 SCBBT105 SCBBT13 SCBBT15 SCBBT18 SCBBT SuperCuplok Cantilever Frame SCCF

8 Support System Erection Guide The arrangement of the grid will be determined by the formwork design and will be shown on the design drawing. This drawing must be adhered to in setting out the structure. The ground must be assessed and verifi ed to ensure it is capable of carrying the loads to be transferred to it. The ground must also be checked prior to erection to ensure construction processes have not changed the conditions since the formwork design was done. The precise grid arrangement is critical to the support of the loads, the design must not be deviated from except by written agreement with the formwork designer. Acrow Formwork & Scaffolding recommends for safety reasons that a minimum of two erectors work as a team to erect. Persons erecting or dismantling should be competent in this type of work. The /CUPLOK unique locking action 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 fi xed locking bar on the Standard to wedge the top cup tightly around the blades providing a positive and rigid connection. Adjustable Brace Adjustable Jack Brace 8 Diagonal braces clamp securely over Ledgers using spring loaded locking claws. These braces must be located within 100mm of the cup (refer also to Guideline Notes on page 13). Bracing Coupler s and Adjustable U-Head Assemblies are diagonally braced using a Adjustable Jack Brace and a Bracing Coupler. The bracing coupler secures to the sleeve at the end of the stem of the base/u-head unit. The Adjustable Jack Brace fi xes to the bracing coupler and its other end clamps over a Ledger in the same manner as the other diagonal braces.

9 General Technical and Application Manual Erection Guide General Before commencing the erection of any 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 to spread the load effectively to the foundation. Sole plates may also be required when assembled on a concrete slab. All s and Standards must be checked as they are erected to ensure they are components; the use of CUPLOK Standards or CUPLOK s/u-heads will reduce the structure s load capacity to that of CUPLOK losing the advantage of the higher 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 9 The fi rst four s 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 fi rst pair of Standards, the third Standard of the fi rst bay is then placed in position over its 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 fi rst 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 taking care to maintain the lowest setting where indicated on the drawing. The fi rst lift of Ledgers/Transoms is then added and Adjustable Braces are fi xed to two adjacent sides of the bay to maintain the rigidity of the bay (refer also to Guideline Notes on page 13). From this fi rst 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 fi rst bay. In either type of construction as each subsequent bay is added it must be levelled. The structure is built upwards by fi xing the Ledgers for more lifts in height adding additional Standards as the drawing dictates. The last Standard must be a Open Ended Standard to accommodate the or Adjustable U-Head Assembly. After the structure has been erected the formwork soffi t bearers are placed in the U-Heads and are levelled by means of the screw adjustment of the Adjustable U-Head Assembly. Note: A minimum extension of 200mm is recommended for the Adjustable U-Head to facilitate the stripping of formwork. 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.

10 Support System - Bracing Method Examples Example of Side Elevation with Soffit Formwork Restrained Externally by Walls and Columns Soffi t formwork is restrained externally in both directions (eg by walls, columns*). Lifts are braced and braces are terminated at every lift. Jacks are not braced. (Only where braces are not required to transfer external transverse forces to foundation/footing as determined by design). Adjustable Braces * Permanent structure (Project Engineer must verify suitability of structure.) Example of Side Elevation with Soffit Formwork Restrained by Internal Bracing with U-Head Soffi t 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 s are restrained. Adjustable Jack Braces used longitudinally and transversely Open ended Standard Ledger Ledger (typical) Max 100mm (typical) Adjustable Brace (typical) A A 10 Section A-A Note: Base plates may be required to be anchored to resist the horizontal and/or uplift components of the bracing force.

11 General Technical and Application Manual Example of Front Elevation (Row or Tower Configuration) Conventional formwork Note: with U-Head This symbol indicates that the top deck is restrained externally in both directions, (eg by walls, columns). Open Ended Standard Adjustable Braces Ledgers Example of Side Elevation (Row Configuration) Conventional formwork with U-Head Open Ended Standard Adjustable Braces Adjustable Braces Ledgers Example of Side Elevation (Tower Configuration) Conventional formwork 11 Open Ended Standard Adjustable Braces Ledgers

12 Support System 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 13 are met. Working Load Limits as shown on the following pages are for two cases: Case 1: Bottom s and top Adjustable U-Head Assemblies are restrained in both directions. Case 2: Bottom s are not restrained but top Adjustable U-Head Assemblies are 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, some guidelines can be found in the Guidance Notes on Page 13. Note: Extension is measured from top of Standard to underside of U-Head Applied load < WLL Assembly 190 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. Definitions Plan View Y X Internal Standard Standard Definitions Side View CUPLOK Ledger/Transom Standard External Standard Node Open Ended Standard Spigot Joint Main lift Main lift Top lift CUPLOK Ledger/Transom Adjustable Brace 'A' Bottom is NOT restrained in the 'X' direction Spigotted Standard Base lift x direction 12 Suitable lateral support A Adjustable Brace Adjustable Brace 110 Suitable footing and foundation Bottom X direction X direction B 'B' and 'C' Bottom s are restrained in the 'X' direction C Note: Extension is measured from bottom of Standard to underside of Note: Same applies to 'Y' direction and also adjustable U-Heads. 'Y' direction is 90 0 to the 'X' direction

13 General Technical and Application Manual GUIDELINE NOTES General 1 The Standards, s and Adjustable U-Head Assemblies must be checked to ensure that only 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 fi rst bay, plan bracing is helpful to hold them during erection. 5 Each bay must have Ledgers/Transoms connected at the cup positions nearest the s 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 s 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. AS 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 defi ning lift heights shall always be restrained if not refer to H.O.Eng for guidance. Tables for CASE 1 are applicable where all top and bottom s are also braced/restrained. When top deck is restrained and braces are required to provide nodal restraints only, and top s are braced but bottom s are unbraced, tables for CASE 2 shall be used. When top deck is restrained and braces are required to provide nodal restraints only, but both top and bottom s are not braced, tables for CASE 2 may still be used by using fi gures for bottom s for top s as well with their applicable jack extension. 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 bracing system. 5. Bracing should be installed immediately after each lift has been erected and fi xed to the Ledgers 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 fi tted (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.

14 Support System FORMWORK APPLICATIONS For 2.44m x 2.44m maximum bay size CASE 1: : Restrained, e = 0, 8, 15, 25 and 55mm Bottom : Restrained, e = 0, 8 and 15mm Working Load Limit - WLL (kn) per Standard/Leg Note: WLL for Bottom and Top s or U-Heads are shown beneath their shaded area. Lift = 1.0m, Internal Standard Bottom Extension e = e = e = e = e = (mm) 0mm 8mm 15mm 25mm 55mm Lift = 1.0m, External Standard Bottom Extension e = e = e = e = e = (mm) 0mm 8mm 15mm 25mm 55mm Lift = 1.5m, Internal Standard Bottom Extension e = e = e = e = e = (mm) 0mm 8mm 15mm 25mm 55mm Lift = 1.5m, External Standard Bottom Extension e = e = e = e = e = (mm) 0mm 8mm 15mm 25mm 55mm Lift = 2.0m, Internal Standard Bottom Extension e = e = e = e = e = (mm) 0mm 8mm 15mm 25mm 55mm Lift = 2.0m, External Standard Bottom Extension e = e = e = e = e = (mm) 0mm 8mm 15mm 25mm 55mm Notes: 1 WLL for the lift is the minimum value of WLLs for Top and Bottom s/u-head Assemblies. 2 e = Load eccentricity (mm) 3 Limit State Conversion Factor = These charts must be read in conjunction with the Technical Information and the Bracing Guideline Notes on pages 12 and It is recommended to consider the load with at least 8mm eccentricity for possible unintentional eccentricity.

15 General Technical and Application Manual FORMWORK APPLICATIONS For 2.44m x 2.44m maximum bay size CASE 2: : Bottom : Restrained, e = 0, 8, 15, 25 and 55mm Not restrained, e = 0, 8 and 15mm Working Load Limit - WLL (kn) per Standard/Leg Lift = 1.0m, Internal Standard Extension (mm) e = e = e = e = e = 0mm 8mm 15mm 25mm 55mm Bottom e = e = e = 0mm 8mm 15mm Lift = 1.0m, External Standard Extension (mm) e = e = e = e = e = 0mm 8mm 15mm 25mm 55mm Bottom e = e = e = 0mm 8mm 15mm Lift = 1.5m, Internal Standard Extension (mm) e = e = e = e = e = 0mm 8mm 15mm 25mm 55mm Bottom e = e = e = 0mm 8mm 15mm Lift = 1.5m, External Standard Extension (mm) e = e = e = e = e = 0mm 8mm 15mm 25mm 55mm Bottom e = e = e = 0mm 8mm 15mm Lift = 2.0m, Internal Standard Extension (mm) e = e = e = e = e = 0mm 8mm 15mm 25mm 55mm Bottom e = e = e = 0mm 8mm 15mm Lift = 2.0m, External Standard Extension (mm) e = e = e = e = e = 0mm 8mm 15mm 25mm 55mm Bottom e = e = e = 0mm 8mm 15mm Notes: 1 WLL for the lift is the minimum value of WLLs for Top and Bottom s/u-head Assemblies. 2 e = Load eccentricity (mm) 3 Limit State Conversion Factor = These charts must be read in conjunction with the Technical Information and the Bracing Guideline Notes on pages 12 and It is recommended to consider the load with at least 8mm eccentricity for possible unintentional eccentricity.

16 Updated May 2012 Formwork Scaffolding Industrial & Mining Scaffolding Contact Phone: or contact your business development manager.