USER S MANU HAKI UNIVERS UMINIUM HAKI AB 2005
Important information HAKI s product liability and erection instructions apply only to scaffolds that are entirely composed of components that have been made and supplied by HAKI. HAKI s type examination certificate applies only to scaffolds whose material, dimensions and design accord with those specified in the documentation upon which this certificate is based. HAKI s scaffold systems must not be erected using components of makes other than HAKI or be connected to scaffolds of makes other than HAKI. In such cases, a special study of loadbearing capacity must be carried out. However, HAKI has no objection to the customary addition of scaffold tubes and approved couplers to the scaffold. Adding components from different suppliers may invalidate the insurance cover. For scaffold structures that are not covered by these erection instructions, please contact HAKI s technical department. HAKI reserves the right to make technical modifications on a continual basis. Copyright HAKI AB, 2005 The reproduction of text and pictures/illustrations without HAKI s permission is prohibited. 2
BASIC INFORMATION HAKI Universal Aluminium The modular scaffold has been type examined by SP Swedish National Testing and Research Institute in accordance with Ordinance AFS 1990:12 of the Swedish National Board of Occupational Safety and Health Code of Statutes and SS-HD 1000 Certificate no. 14 55 07 for load class 3 (2.0 kn/m2). Calculations were carried out in accordance with SP Method 1172. General data HAKI Universal Aluminium is erected with bay widths of 700, 770, 1050, 1250 or 1655 mm and normally with a bay length of 3050 mm and 2.0 m between lifts. LB or ERB beams can be used both as ledger and transom beams. HAKI decking units or planks are suitable for decking. Marking components except for locks, locking pins, etc. are permanently marked with HAKI s logo and a combination of characters where the last two digits specify the year of manufacture ( S05). Guardrail frames Toeboard Decking Wall tie Standard Ledger beam 2.0 m Single tube beam Base jack 3050 mm 3
LIST OF COMPONENTS For steel components, the weights and article numbers apply to hot-dip galvanized products. For other accessories, please see type examination certificates numbers 145501 and 145509 for HAKI modular scaffolds and also HAKI s erection instructions. Name Art.Nr Code Weight (kg) Base jack 2071000 BS 5.0 Steel Adjustable 55-570 mm Standard 4017055 FSSH 500 1.3 Standard joint with spigot 4017105 FSSH 1000 2.4 Pockets at same level 4017155 FSSH 1500 3.5 Ø 48 mm 4017205 FSSH 2000 4.5 4017305 FSSH 3000 6.7 4017405 FSSH 4000 9.1 Locking pin for standard joint 2116000 0.2 Steel Ø 16 mm For reinforcing standard joint in 5141256 0.3 connection with tensile load, e.g. when scaffolding is suspended, when lifting or when scaffolding is used for temporary roof. Ledger beam 4021066 LB 650 2.9 With spring locking catch 4021073 LB 720 2.9 Ø 34 mm 4021101 LB 1000 3.5 4021121 LB 1200 4.2 4021161 LB 1605 4.8 4021191 LB 1914 5.8 4021246 LB 2450 7.2 4021301 LB 3000 8.5 Single tube beam 4022051 ERB 514 2.5 With spring locking catch 4022066 ERB 650 2.7 Ø 48 mm 4022073 ERB 720 2.9 4022101 ERB 1000 3.2 4022121 ERB 1200 3.5 4022161 ERB 1605 4.1 4022191 ERB 1914 4.5 4022246 ERB 2450 5.4 4022301 ERB 3000 6.0 4
LIST OF COMPONENTS Name Art.Nr Code Weight (kg) Guardrail frame 4052066 SKRD 650 3.3 With spring locking catch 4052073 SKRD 720 3.5 4052101 SKRD 1000 4.5 4052121 SKRD 1200 4.8 4052161 SKRD 1605 5.9 4052191 SKRD 1914 6,6 4052246 SKRD 2450 7.8 4052301 SKRD 3000 8.9 Diagonal brace 4122245 DS 2450 6.1 4122300 DS 3000 6.7 Plan brace telescopic 4141010 HDS 6.3 Wall tie 7072060 SVF 600 0.6 Tie rod 7072080 SVF 800 0.8 Steel Rod Ø 12 mm Tie rod clamp 7071000 BVF 0.6 Steel Decking unit B=600 mm High hook location 4096121 Decking Unit 1200x600 12.2 Load class 4 (3,0 kn/m²) 4096161 Decking Unit 1605x600 15.0 4096250 Decking Unit 2450x600 21.4 4096302 Decking Unit 3000x600 25.5 B=400 mm 4097121 Decking Unit 1200x400 9.7 4097161 Decking Unit 1605x400 12.3 4097250 Decking Unit 2450x400 17.5 4097302 Decking Unit 3000x400 21.0 5
LIST OF COMPONENTS Name Art.Nr Code Weight (kg) Decking unit with trapdoor 4096254 Decking Unit 2450x600 25.9 See Decking unit Trapdoor 4096304 Decking Unit 3000x600 28.5 Trapdoor Ladder 2091210 ST 2100 3.4 For decking unit with trapdoor plank 2153120 P 1250x230x90 6.9 2153160 P 1655x230x90 8.0 2153245 P 2500x230x90 10.5 2153300 P 3050x230x90 12.3 Toeboard 2026050 Toeboard 564x180 1.3 2026070 Toeboard 700x180 1.6 2026100 Toeboard 1050x180 2.4 2026120 Toeboard 1250x180 2.8 2026160 Toeboard 1655x180 3.7 2026190 Toeboard 1964x180 4.4 2026250 Toeboard 2500x180 5.6 2026300 Toeboard 3050x180 6.8 Toeboard 2025331 FL 3300x150x32 6.7 Wood Toeboard clip 7161006 LF 70 1.0 Steel Bracket 4211024 SK 230 1.7 Without spigot for joint to standard 4211047 SK 460 1.9 With spring locking catch Ø 48 mm Bracket with spigot 4211051 SK 514 5.1 With spigot for joint to standard With spring locking catch 6
LIST OF COMPONENTS Name Art.Nr Code Weight (kg) Bracket 4211121 SK 1200 11.0 With spring locking catch Stairway 4102300 UTV 3000 27.2 Stair handrail 4058300 UTV 3000 10.3 Guardrail post 7015001 SRS 1000 7.3 Steel Guardrail post 7015002 SSK 1000 6.1 Steel Jaw width 23 mm Lattice beam 7031601 FBB 6050 59.1 Steel Standard adapter FBB 7011000 6.3 Steel Lattice beam 4032410 FB 4100 16.7 4032610 FB 6100 24.3 4032810 FB 8100 32.2 7
ERECTION Before erecting the scaffold, check and flatten out the support surface. The support surface must not be subject to uneven settlement. Its bearing capacity may be improved with the help of sole plates. 1. Set out the material for the base and the first lift along the facade. Place the base jacks about 200 mm out from the facade and at the modular distances that are to be used. If inside brackets are to be used, increase the distance accordingly. The greatest permissible distance between wall and work platform is 300 mm. Always start erection at the point 1. that is situated highest. 2. Erect the first four standards, linking them with the transom and ledger beams. The beams are fitted to the lowest group of pockets on the standards. Check that the beam locks are in the locked position after fitting. 2. 3. 8 3. Fit the SKRD guardrail frames along the scaffold at a level of 1.0 m. Guardrail frames must be fitted in each bay and at each lift level on the outside of the scaffold. Alternatively, fit the vertical diagonal braces. Continue erecting the base of the scaffold bay by bay using base jacks, standards, transoms and ledger beams and guardrail frames. If HAKI UTV stairways are to be used, plan a 3050 mm bay for the ascent. From time to time, check the levels in both the transverse and longitudinal directions using a spirit level and adjust using the swivel base jacks. If there are major differences in levels, adjust each individual standard in relation to the support surface so as to make the beams level.
ERECTION 4. Fit the transom and ledger beams for the second lift 2.0 m above the beams that were fitted first. Fit HAKI decking units to the transom beams. Don t forget to lock the decking. Fit the second set of 3000 or 2000 mm standards. Install SKRD guardrail frames for the second lift and fit the toeboards with the aid of the toeboard clips. Don t forget the end guardrails. 4. 5. Fit the transom and ledger beams for the third lift and then decking, guardrails and toeboards. Don t forget to lock the beams and decking. Anchor the scaffold at a height of approximately 4.8 m using tie rods and clamps. Check that the fixings in the facade can carry the forces involved. 5. 6. 6. Continue erecting the subsequent lifts as described above. Use approved lifting aids for transport of the material. If steel/aluminium planks are used, these should be locked in the outer bays. The planks otherwise lock each other. When decking using scaffold boards, these must be provided with yokes if the span exceeds 2.5 m. Dismantling is done in the reverse order. Scaffolding material must not be thrown down from the scaffold. 9
External stairways ERECTION There are two options for external stairways: the HAKI UTV of steel and the HAKI UTV of aluminium. Both options are fitted in a similar manner. 7. 8. 7. The UTV stairway is fitted in an external bay using ERB 720 and LB/ERB 3000 beams. The stairway is usually built into the scaffold proper. Alternatively, the stair tower is erected using separate standards. Set out the base jacks and erect the standards. Fit the ERB 720 and LB/ERB beams into the lowest group of pockets. Fit the transom beams for the second lift too. At other levels, the handrails replace the ledger beams. 8. Fit the hooks of the UTV stairway over the tubes of the transom beams and lock the stairs using the locking device. Fit the handrail at the 1.0 m level and provide the top end with SKRD 720 guardrail frames. Fit the next set of standards, transom beams, stairs, handrail and guardrail frames. 9. 10 9. Continue erection up to the desired height. At the top level, an ERB 3000 beam is fitted externally in the scaffold. An SSK 1000 guardrail post is fitted on the beam so that an SKRD 2450 guardrail frame can be fitted between post and standard. Alternatively, an LB 3000 beam can be combined with an SRS 1000 guardrail post. The guardrail frame provides fall protection at the top level of the scaffold. At other levels, the next stairway provides sufficient protection.
LOADING CONDITIONS Base jacks The scaffold is erected on base jacks of type BS, which are adjustable between 55 and 570 mm. This means that it is always possible to adjust the standards so as to make the beams level. Standards Standards of length 3000 or 2000 mm are normally used in the scaffold. When FSSH 2000 standards are used throughout the scaffold, the permissible construction height is reduced by 6.0 m. Standards shorter than 2000 mm may only be used as landing standards. Beams The scaffold is erected using LB or ERB beams as ledger and/or transom beams with 2.0 m between the lifts. Each lift must be provided with beams on both the inside and outside. The bottom lift must always be placed at the lowest possible level. Guardrails Decked lifts must be provided with guardrail frames or double guardrails and toeboards if the drop is 2.0 m or more. Access ways must be provided with double handrails. Decking HAKI decking units are used for decking. These units are available in lengths of 1200, 1605, 2450 and 3000 mm with widths of 600 and 400 mm. Alternatively, HAKI aluminium or steel planks may be used. These are available in all modular dimensions and in widths of 230 or 170 mm. Other options are wooden gratings in lengths of 1950 or 1400 mm and of width 485 mm. The wooden gratings are placed across the ledger beams of the scaffold. Decking may also be done using 195 x 50 mm scaffold planks, class K24. Headroom When using ERB beams and HAKI decking units, the headroom is 1910 mm. Using aluminium/steel planks, the headroom is more than 1910 mm. Brackets Brackets can be placed at the five highest lift levels of the erected scaffold. Each level at which a bracket is fitted must be provided with a wall tie. Load classes for brackets apply provided that the brackets are fitted in a bay of length max. 3050 mm and in connection with decking of weight 16 kg/m2. In the specified weight classes, no consideration has been paid to the bearing capacity of the decking. Using HAKI decking units, max. load class 4 applies. Bracket SK 230 SK 460 SK 1200 Load class 6 4 3 11
LOADING CONDITIONS Bracing and tying-in Bracing with vertical diagonal braces and tying-in Bracing with SKRD guardrail frames and tying-in Vertical diagonal bracing between the outside standards must be installed in every 5th bay and always in the end bays. SKRD guardrail frames can replace vertical diagonal braces, but must then be fitted in each bay and at every lift level, including the bottom level. PLEASE NOTE when bracing with SKRD guardrail frames, the permissible loads on standards are reduced. See table on page 13. Plan braces must be fitted in every 5th bay and always in the end bays at every 12th metre in height. Each inside standard must be tied to the facade or equivalent at every 4th metre in height in conjunction with the node between standard and beam. The lowest tie must be fitted no more than about 4.8 m above ground level. There must be ties that can carry horizontal forces on at least every 6th pair of standards along the scaffold and at every level of ties. In addition, we recommend that the scaffold always be anchored as high up as possible. Where a scaffold is contained, the number of ties must be increased to take account of wind load. See instructions for the containment in question. 12
LOADING CONDITIONS Permissible loads on standards When calculating permissible construction heights for the scaffold, the following permissible loads on standards can be applied for different combinations of lift height and vertical distances between ties. Lift height Vertical distance between ties Permissible load on standard Permissible load on standard SKRD* [m] [m] [kn] [kn] 2.0 2.0 2.0 2.0 3.0 4.0 17.2 11.9 9.0 15.7 10.9 8.2 * Scaffold braced with SKRD guardrail frames 1 kn = 100 kp 13
Permissible construction heights The table applies to HAKI Universal Aluminium with bay lengths 3050 mm, lift heights 2.0 m, bracing using vertical diagonal braces and different vertical distances between ties. PLEASE NOTE when bracing with SKRD guardrail frames, the permissible loads on standards are reduced. Work must not be carried out on more than one lift at a time. Decking has been calculated at 16 kg/m². LOADING CONDITIONS SS-HD 1000 recommends a bay width of at least 1.0 m for load classes 4, 5 and 6. Other bay lengths, bay widths and decking alternatives will have an effect on the permissible construction height. Please contact HAKI s technical department in these cases. Vertical distance between ties [m] 2.0 3.0 4.0 Bay width [mm] 700 5 770 5 1050 5 1250 5 700 5 770 5 1050 5 1250 5 700 5 770 5 1050 5 1250 5 Number of decked lifts 1 0.75 200.8 80.8 196.8 76.8 182.8 64.8 174.8 56.8 128.8 54.8 126.8 52.8 114.8 42.8 106.8 38.8 90.8 40.8 88.8 38.8 78.8 30.8 70.8 26.8 Load class/ Permissible load [kn/m 2 ] 2 3 4 5 1.5 2.0 3.0 4.5 188.8 76.8 184.8 72.8 168.8 58.8 156.8 52.8 118.8 50.8 114.8 46.8 98.8 36.8 88.8 32.8 80.8 36.8 76.8 32.8 62.8 26.8 52.8 22.8 182.8 74.8 176.8 70.8 156.8 56.8 144.8 48.8 112.8 48.8 106.8 44.8 88.8 34.8 76.8 28.8 72.8 32.8 68.8 30.8 52.8 22.8 40.8 18.8 168.8 68.8 162.8 64.8 136.8 50.8 120.8 40.8 98.8 42.8 92.8 38.8 68.8 28.8 52.8 22.8 58.8 28.8 52.8 24.8 30.8 16.8 16.8 10.8 6 6.0 146.8 60.8 124.8 52.8 138.8 114.8 56.8 46.8 106.8 74.8 40.8 30.8 82.8 46.8 30.8 20.8 76.8 54.8 34.8 26.8 68.8 44.8 30.8 22.8 38.8-18.8 8.8 16.8-10.8-38.8 16.8 20.8 12.8 30.8-16.8 8.8 - - 6.8 - - - - - 1 kn = 100 kp 14
LOADING CONDITIONS Permissible loads on beams Permissible loads on beams installed in HAKI standards. Beam type Permissible load q [kn/m] Permissible distributed load Q [kn] Permissible centrepoint loads P [kn] Permissible centrepoint loads P3 [kn] Permissible point loads P4 [kn] LB 1605 16.8 27.0 13.5 10.1 13.5 LB 1914 11.8 22.6 11.3 8.5 11.3 LB 2450 7.2 17.6 8.8 6.6 8.8 LB 3000 4.8 14.4 7.2 5.4 7.2 ERB 650 26.2 17.0 8.5 6.4 8.5 ERB 720 23.6 17.0 8.5 6.4 8.5 ERB 1000 17.0 17.0 8.5 6.4 8.5 ERB 1200 11.8 14.2 7.1 5.3 7.1 ERB 1605 5.6 9.0 4.5 3.4 4.5 ERB 1914 3.8 7.3 3.7 2.8 3.7 ERB 2450 2.4 6.0 3.0 2.3 3.0 ERB 3000 1.6 4.7 2.4 1.8 2.4 1 kn = 100 kp 15
LOADING CONDITIONS Permissible load classes for different beam combinations The tables apply to HAKI Universal Aluminium LB or ERB beams for varying bay sizes, decking of weight 16.5 kg/m² and unilateral or bilateral loading. In the specified load classes, no consideration has been paid to the bearing capacity of the decking. Permissible load classes for LB beam for unilateral loading a [mm] LB 1605 LB 1914 LB 2450 LB 3000 700 6 6 6 6 770 6 6 6 6 1050 6 6 6 6 1250 6 6 6 5 1655 6 6 5 5 1964 6 6 5 4 2500 5 5 4 4 3050 5 5 3 3 Permissible load classes for ERB beam for unilateral loading a [mm] ERB 650-720 ERB 1000 ERB 1200 ERB 1605 ERB 1914 ERB 2450 ERB 3000 700 6 6 6 6 6 5 4 770 6 6 6 6 6 5 4 1050 6 6 6 6 5 4 3 1250 6 6 6 6 5 4 3 1655 6 6 6 5 4 3 3 1964 6 6 6 5 4 3 2 2500 6 6 6 4 3 3 1 3050 6 6 5 4 3 2 1 Loaded beam Loaded beam a a Wide scaffold Facade scaffold 16
LOADING CONDITIONS Permissible load classes for LB beam for bilateral loading a [mm] LB 1605 LB 1914 LB 2450 LB 3000 700 6 6 5 5 770 6 6 5 5 1050 5 5 4 4 1250 5 5 4 3 1655 4 4 3 3 1964 4 4 3 3 2500 3 3 3 2 3050 3 3 3 - Permissible load classes for ERB beam for bilateral loading a [mm] ERB 650-720 ERB 1000 ERB 1200 ERB 1605 ERB 1914 ERB 2450 ERB 3000 700 6 6 6 5 4 4 3 770 6 6 6 5 4 3 3 1050 6 6 6 5 3 3 2 1250 6 6 6 4 3 3 1 1655 6 5 5 3 3 2 1 1964 6 5 5 3 2 1 1 2500 5 4 4 3 1 1-3050 5 4 3 2 1 1 - Loaded beam Loaded beam a a a a Wide scaffold Facade scaffold 17
Lattice beams LOADING CONDITIONS Access ways Access is usually provided by means of HAKI UTV stairways that are fitted to the outside of the scaffold using components designed for this purpose. Alternatively, a HAKI tower scaffold may be used, see type examination certificate 14 55 05. Ascent via ladders may be arranged by means of HAKI decking units with trapdoors and ladders, or HAKI STV ladders. Lattice beams of steel FBB 6050 steel lattice beams are designed to allow the scaffold to continue to be erected across a span equivalent to two 3050 mm bays. When installing the lattice beams, it is very important to brace these against lateral movement by fitting a beam to the fixings in the middle of the lattice beams. Steel lattice beams are fitted to the standards of the scaffold by hooking them over two groups of pockets. The FBB standard adapter is used to continue erecting. Lattice beam of steel Lattice beams of aluminium Aluminium lattice beams are fitted in pairs on the inside and outside of the scaffold. Both the top and bottom tubes must be fixed to the standards using KV 48x48 swivel couplers. The height of the lattice beams is 450 mm. Permissible loads on lattice beams Lattice beam of aluminium Lattice beam Permissible load q [kn/m] Permissible distributed load Q [kn] 18 Permissible centre-point load P [kn] Permissible point loads P3 [kn] Steel FBB 6050 2.93 17.7 12.3 - Aluminium FB 4100 2.95 11.7 11.6 - FB 6100 1.77 10.5 5.9 - FB 8100 1.09 8.7-3.8 1 kn = 100 kp
HAKI INT 2005 09 P000078 Published by Holmbergs in Malmö 20054 SAFETY SHECKLIST 1. Supporting surface checked with regard to bearing capacity 2. Distance to wall or similar as short as possible 3. Scaffold aligned correctly horizontally and vertically 4. Components correctly fitted and locked 5. Bracing correctly done 6. Anchoring with right number and placing of ties 7. Decking correctly done 8. Guardrail with toeboard if drop is two metres or more 9. Suitable means of access to scaffold 10. Scaffold erected for correct class of load HAKI AB is ISO 9001:2000 certified HAKI AB SE-280 63 Sibbhult, Sweden Tel +46 44 494 00 Fax +46 44 494 72 info@haki.se www.haki.com