K-Lock System Scaffold · • Scaffold structures are required to be inspected and recorded at...

K-Lock System ScaffoldUser Guide

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ACTAVO K’LOCK USER GUIDE V5 AUGUST 2018 1

Contents Introduction 2

Strength 2

Safety Compliance 2

Scaffolding Safety 3

Site Inspection 4

Safety Harness 4

Who can erect the scaffold? 4

Power Lines 4

Traffic 4

Cranes 5

User’s responsibilities 5

Components 6

Tube Components 6

Omega Components 12

Battens 14

Component Safe Working Loads 15

Bracing, Tying and Safe Working Heights 17

Bracing Requirements 17

Maximum Heights and Tie Patterns 17

Tie Details 19

Tie Patterns 20

Loading Classification and Safe Working Heights 23

Erection and Dismantling 25

Erection Sequence 25

Assembly Using Standard Scaffold Boards 25

Increasing the height of the scaffold 28

Dismantling the Scaffold 30

Instructions for Storage, Maintenance and Repair 31

Corner Details 33

Circular Access 37

Loading Platforms 38

Stair Access 40

2

Introduction This user guide has been prepared in accordance with the guidance as set out within BS EN12810-1:2003 clause 8, the NASC Code of Practice and where applicable additional information within associated European Standards.

Actavo K-Lok has been independently tested and assessed against the standards noted below. It is a fully galvanised multi purpose steel scaffold, suitable for general access. Robust and versatile the system can be erected in various configurations and is available for use with either steel or timber battens or traditional scaffold boards.

The system can provide savings in erection and dismantling times over traditional scaffolding and is easy to store and transport.

Horizontal and vertical members are manufactured from 48.3mm OD x 3.2mm wall thickness high tensile steel with a minimum grade of Grade 50c or S355.

Components are protected against corrosion by hot dipped galvanising.

Strength K’Lock independent tied access scaffolds built with bay widths up to 2.5m have a load capacity

of 3kN/m2. For other applications, such as birdcage, mobile towers and staircase the loadings may vary, and advice should be sought from your design office.

Safety ComplianceAll access scaffolds must comply with the general requirements of the following:

Work at Height Regulations 2005

Code of Practice BSEN12811-1

Statutory Regulations:

Health & Safety at Work Act 1974

Work at Height Regulations 2005

British Standards and Codes of practice for Steel Scaffolding:

BSEN12810-1:2003

BSEN12810-2:2003

BSEN12811-1:2003

BSEN12811-2:2003

BSEN12811-3:2003

ACTAVO K’LOCK USER GUIDE V5 AUGUST 2018

3

Scaffolding Safety • This guidance is not intended to replace any relevant British standards, European codes, work at

height regulations, company procedures, or other legislation but is a practical guide to goodscaffolding practice.

• Ensure that you follow your company’s safe systems of work at all times.

• Ensure that all persons erecting, dismantling or modifying any structure are competent to carryout the task.

• Ensure that all persons erecting, dismantling or modifying any structure are working to the latestversion of the National Access & Scaffolding Confederation SG4 guidance as a minimum.

• Access scaffolding should at all times comply with the latest version of the NASC TG20 best practicefor access and working scaffold structures in steel.

• Ensure all personal protective equipment is suitable and worn as appropriate.

• Consideration should be given as to where additional hazards may be present whilst scaffoldingoperations are taking place, such as overhead power cables, roadways, schools and if protectionis required, if the scaffold is to be sheeted, who is responsible for the design.

• Always display warning notices when the scaffold is under construction or being adapted and erectfixed barriers to prevent any unauthorized access.

• Scaffold structures are required to be inspected and recorded at regular intervals by a competentperson not exceeding 7 days, in addition to the structure being taken into use for the first time,after any alteration, after adverse weather or any event that is likely to affect its stability.

• No tradesman should work on the scaffold structure whilst it is being erected.

• Only genuine K’Lock components are to be used

• Never use any defective or modified equipment

• Access and egress should be considered as early as practicable, with both the scaffold operativesand end user in mind. Ladders should be used by the scaffolder’s when erecting, modifying ordismantling any structure. Ledgers, Braces etc. must not be used as a means of support.

• Employers must ensure that work at height is:o Properly plannedo Appropriately supervisedo Carried out in a safe manner “so far as is reasonably practicable” Include planning for

emergencies and rescueo Weather conditions do not jeopardise health and safety

• Never Bomb scaffold equipment or any other materials up or down

• Never undertake work at height when there is a potential to fall without wearing your safetyharness correctly and clipping the lanyard to a secure anchor point ideally above head height.

• Never remove or interfere with guards, they are there to protect you

• Never over load the scaffold you are erecting / dismantling with spare materials or rest scaffoldequipment against an object if there is a potential for it to fall.

• All working platforms from which a person could fall must be fitted with a double guardrail andtoe board.

• Never leave an exposed edge where people or materials could fall.

• Never accept and instruction from a client or anyone else that does not conform to the advicegiven in this guide.

• If you are in any doubt with regard to any of the information contained within this Handbook orneed further advice please contact your local Actavo office.

• Should the need arise to use scaffold components outside the K’Lock range the following standardsmust be specified:

o Tube – EN39:2001o Fittings – to appropriate standard EN 74-1:2005 or BS 1139-2:2009

• Ensure when the structure is handed over a signature is obtained from the competent personaccepting the structure i.e. the client/hirer.


4

Site InspectionBefore commencing the erection of any K’Lock System Scaffold, care should be taken to see that the ground is suitable, on soft or made up ground the scaffold should be erected on timber sole plates of appropriate size, bricks or blocks must never be used. The scaffold should be started on the highest part of the ground, this makes levelling easier as the scaffolding progresses horizontally. Always allow for any inside batten platform when determining the distance from the building the scaffold is to be positioned.

Safety HarnessUnder guidance from the NASC, endorsed by the HSE, all scaffold erectors must wear a harness and lanyard whilst erecting, dismantling and working on scaffolding. All methods of erection/dismantling scaffolding and the use of safety harnesses should be used in conjunction with the latest version of the NASC SG4 guidance notes.

Who can erect the scaffold?A competent person suitably trained and appointed by the company can erect, modify or dismantle a scaffold, the balance of the scaffold gang is to be determined by the company based on the complexity of the structure.

Power LinesFor information please review NASC latest guidance note SG5 and ensure detailed and robust safe systems of work are devised to identify and eliminate/control the hazards present.

TrafficIf the scaffold is to be built in an area that is used by cars or other mobile machinery, the vehicles should either be re-routed or operatives provided to direct the traffic.


5

CranesScaffolding and people within the operational radius or line of travel of a crane are at risk from suspended loads and/or the crane itself. In such circumstances the following precautions are recommended:

• Ensure the scaffold does not have any unnecessary projections such as oversized

components

• Clear the scaffold of personnel during crane operations

• Develop an operations plan for the crane for work carried out in the vicinity of the

scaffold.

User’s responsibilitiesOnce the scaffold is complete and handed over, it may be used by various personnel for general working. During this period of working, the scaffold may be subjected to many load variations and possible misuse or abuse. It is important that all people using the scaffold are aware of their responsibilities for the correct use and maintenance of the scaffold.

• The client must ensure that the scaffold erectors are made fully aware of all loading

requirements and use for which the scaffold is required.

• The client must ensure that the designated site for the erection of scaffolding is clear

and suitable for the erection of the structure and that the building foundations are

suitable for the loadings applied from the scaffold.

• Where applicable the client must obtain all necessary permits.

• When the scaffold is completed, the client must satisfy themselves that the scaffold

meets the requirements and that all materials have been erected in a safe and secure

manner. It is recommended the client obtains a standard hand over certificate for the

scaffold erector.

• Clear passageways must be maintained on working platforms.

• Under no circumstances should any alterations of the scaffold be undertaken by any

persons other than the scaffold contractor responsible for the original erection of the

scaffold.

• The scaffold must only be used and loaded to the original specification.

• The addition of extra components such as sheeting, extra boards must only be

undertaken by the original erectors of the scaffold.

Any event that may affect the strength or stability of the scaffold such as damage from vehicles, trench excavation etc., must be reported to the original scaffold contractor immediately.


6

Components

Tube Components

Verticals (Standards) Standards are made from 48.3mm OD x 3.2mm high grade steel tube, all standards incorporate lower fixed cups at 0.5m intervals. Captive rotating cups allow for the connection of up to 4 components. The lowest base cup joint is 80mm from the base of the standard to give the scaffold improved structural strength.

Available in 3 sizes:

Stock Code Length Overall Length Weight

023003 1.0m 1.15m 5.92Kg

023002 2.0m 2.15m 11.19Kg

023001 3.0m 3.15m 16.46Kg

Swan Necked Standards Used as a fixing location for the guardrails when an access opening is formed onto a boarded lift, and is toe be used in conjunction with a ladder safety gate.

The Swan Neck Standard hooks onto the tubular ledger at platform level. It is secured with a wedge coupler to an additional tube ledger which is fixed to the cups below the platform level.

Stock Code Length Weight

023070 1.72m 10.0Kg


7

Universal Base JacksMust always be used sitting on scaffold boards or other suitable sole plates as in normal scaffolding Practice.

The universal jacks fit into the bottom of the lowest standard and are used to level the scaffold. A minimum of a third of the threaded tube must be within the standard to remain stable.


023014 0.50m 3.8Kg

023024 0.65m 4.5Kg


8

Horizontals (Ledgers and Transoms) All ledgers and transoms incorporate symmetrical forged blade ends for simple erection and are completely interchangeable within the scaffold structure. They locate into the cups of the standards by simple insertion of the forged blade end. They are also used to form the guardrail.

The 2.5m ledger provides the basic bay length, and is suitable for most common access and loading conditions.

The 1.8m ledger provides flexibility in creating a run of scaffold

The 1.3m ledger can also be used to create flexibility in a run of scaffold in addition to being used as a transom when a 5 board platform is required. This unit is required to produce corner returns without the need to over lap boards.

Other small size ledgers are available if narrow width scaffolds are required.


023004 2.5m 2.452m 9.83Kg

023005 1.8m 1.752m 7.15Kg

023006 1.3m 1.252m 5.24Kg

023088 0.795m 0.747m 3.30Kg

023008 0.6m 0.556m 2.56Kg


9

Intermediate TransomsThis unit is designed to provide a mid-bay support for scaffold boards. The jaw section on each end is fitted onto the ledger, turned downwards to prevent dislocation. One end of the unit is fitted with an integral locking device to prevent movement along the horizontal during use.

This unit is also used to provide support between standard hop up brackets when scaffold boards are used.


023009 1.3m 1.366m 7.52Kg

023010 0.795m 0.861m 5.99Kg 023011 0.565m 0.631m 4.84Kg

Inside Board Transoms

Work in the same was as the intermediate transom, but extends beyond the inside ledger to provide intermediate support for 1,2 or 3 inside boards.

Stock Code No of Inside Boards Overall Length Weight

023012 1 1.645m 8.21Kg

023026 2 1.753m 9.80Kg 023027 3 1.983m 10.60Kg


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Single Board Support Locates in the cup joint to provide support at a vertical, replacing the 1 board inside board transom at that point

Stock Code Weight

023015 1.675Kg

Hop Up Brackets Are designed to increase overall width of working platforms to either 7 or 8 boards.

The unit locates in the cup on the standard and is fitted with a cup at one end for a ledger to fit which joins the units together and provide support for the intermediate transom.

There is also a facility to located a handrail post if required.


023016 2 0.585m 5.76Kg

023065 3 0.815m 9.55Kg


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Swivel Face Brace Are used to eliminate the tendency of the scaffold to distort or sway. Each unit has a swivelling blade end for location into the standard.

Stock Code Bay Size Weight

023018 2.5m x 2.0m 9.78Kg

023019 1.8m x 2.0m 8.34Kg

023031 2.5m x 1.5m 8.97Kg

023032 1.8m x 1.5m 6.84Kg

Return Device

This unit has one blade end to locate in the cup joint and a hooked section which locates over the ledger to form a return section on the scaffold.

Stock Code Weight

02030 2.8Kg


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Omega ComponentsThe Omega batten system incorporates all the main K’Lock components as listed in the previous pages, but replaces the tubular transom with an omega transom, no intermediate transom is then required as thick timber or steel battens are used in place of scaffold boards. Special hop up brackets are also designed to locate the same type of batten.

Omega Transom Gives a firm location for the K’Lock battens to site on. Forged blade ends locate into the lower cup joint of the vertical. The standard 1.3m will give a 5 board wide scaffold, with a shorter version available if access is restricted.


023050 1.3m 1.252m 7.66Kg

024014 0.795m 0.747m 4.80Kg

Omega Return Transom Comprises of a sheet steel section which locates over the ledger to form the return section of the scaffold. Incorporates a firm location on one side for the location of K’Lock battens.


023051 1.3m 9.00Kg


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Omega Ladder Access Transom Used to form an opening in the battened working platform for a ladder access. Utilises a half coupler to one end and a U-plate at the other to fix and hook respectively to the tubular ledgers. Cut battens are then supported on the two board wide upstand plate to maintain the working lift away from the ladder opening.


024038 1.3m 9.3Kg

Omega Single Board Support

Locates in the cup joint to provide support for a single inside batten.

Stock Code Weight

024107 2.07Kg

Omega Hop Up Brackets

Are designed to increase overall width of working platforms to either 7 or 8 boards.

The unit locates in the cup on the standard and is fitted with a cup at one end for a ledger to prevent movement.

There is also a facility to located a handrail post if required.


024108 2 0.585m 6.67Kg

024107 3 0.815m 8.64Kg


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Battens

Timber BattensAll K’Lock timber battens are 63mm thick and 225mm nominal width, weights specified allow for a 20% moisture content.


023040 1.3m 1.25m 9.25Kg

023041 1.8m 1.75m 13.25Kg

023042 2.5m 2.45m 17.50Kg

Steel BattensK’Lock Galvanised Steel Battens are 57mm thick and 238mm wide. They incorporate a non-skid surface for slip resistance in poor weather conditions.


023040 1.3m 1.25m 8.40Kg

023041 1.8m 1.75m 13.00Kg

023042 2.5m 2.45m 17.50Kg


15

Component Safe Working LoadsAll Section Capacities are based on unfactored safe working loads derived in accordance with BS EN 12811-1-2003 and BS EN 1993-1-1:2005

Standards 48.3mm diameter 3.2mm wall thickness, minimum S355 High Yield Steel

Effective Height Axial Capacity

1.000 m 62.8kN

1.500 m 40.4kN

2.000 m 26.2kN

2.500 m 18.0kN

Tubular Transom System Effective Height in Tie Patterns to TG20:08

Axial Capacity

2.5 x 1.3 x 2.0m(A) 3.600m

2.5 x 1.3 x 2.0m(B) 3.360m

2.5 x 1.3 x 2.0m(D) 3.600m

2.5 x 1.3 x 2.0m(E) 3.420m

9.8kN

11.1kN

9.8kN

10.7kN

Omega Transom System Effective Height in Tie Patterns to TG20:08

Axial Capacity

2.5 x 1.3 x 2.0m(A) 3.220m

2.5 x 1.3 x 2.0m(B) 3.010m

2.5 x 1.3 x 2.0m(D) 3.220m

2.5 x 1.3 x 2.0m(E) 3.040m

11.4kN

12.8kN

10.0kN

12.8kN


16

Spigots Tensile Capacity at Spigot

Moment Capacity at Spigot

10.0kN

1.33kN.m

Base Jack Axial Capacity 60.0kN

Brace 48.3mm Diameter 3.2mm Wall thickness S235 Steel

Axial Capacity 6.8kN

Ledger & Tube Transom

Moment Capacity Shear Capacity

Shear Capacity

Ledger/Transom Moving Down

Ledger/Transom Moving Up

1.40kN.m

35.8kN

0.92kN

1.31kN


17

Bracing, Tying and Safe Working Heights

Bracing RequirementsDiagonal Face Bracing:

All scaffolds require a certain amount of diagonal face bracing to eliminate the tendency of the scaffold to distort or sway. Face bracing is required on all K’Lock access structures in two bays every six bays, i.e. every sixth bay, for the full height of the scaffold. For a scaffold more than 10 metres (4 bays) long, a minimum of 2 bays should be face braced. Bracing the end bays should be avoided if possible.

Ledger and Plan Bracing:

K’Lock access structures do not generally require ledger or plan bracing. Exceptions occur where ties cannot be placed in the correct position, where ties have to be removed for some reason, or in scaffolds that extend above the building. Where these situations apply please consult your design office.

Maximum Heights and Tie Patterns

Maximum Working Heights and Tying-in Pattern Requirements

The maximum height to which a K’Lock scaffold may be erected is dependent upon a number of factors, the most important of which are:

1. The vertical and horizontal distances between tied points on a standard.2. The lift height.3. Wind loading.4. The vertical loadings in the legs due to self-weight and the working platform loading.5. Whether or not the cantilever platforms are used.6. Whether or not the foot ties are used.7. The inclusion of Debris Netting or Sheeting to the Scaffold.

The parameters detailed in this manual are based on calculations and the results of testing.

IMPORTANT

The maximum height given for scaffolds in the following tables has been limited to 30 metres, incorporating a maximum of 2 working lifts. Scaffolds above 30 metres and / or incorporating more than 2 working lifts can be constructed, but special consideration should be given to their design and the necessary design advice sought.


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General Notes

The safe working height tables should be read in conjunction with the safe working loads - axial capacities on Page 15 of this user guide which illustrates the permissible leg loads for the respective tie patterns. The tie patterns themselves are shown on Page 20. The tie patterns considered are those illustrated in TG20:08 under arrangements A, B, D and E.

The proposal within TG20:08 for providing guidance scaffold arrangements with internal lightly loaded boards with an intensity of 0.75kN/m2 has been incorporated into the safe working height tables. This allows the safe working height table to be compared to TG20:08 as an alternative to tube and fitting access scaffolds using this loading criteria.

The tabulated values are for scaffolds having no working lifts above the last tied level. For scaffolds having working platforms above the last tied level, ledger bracing must be used in the lifts.

Given the complexity of the wind loading code, these tables have had wind loading applied in accordance with requirements of BS EN 12811-1:2003. A temporary works engineer should be consulted for suitable wind loading design on any structures in excess of 10 metres high or in extreme positions, such as the top of a hill, exposed landscapes, sea views or in-between closely spaced buildings for further guidance.

The safe height tables and section capacities contained within this User Guide are based upon live loading from the intended use only. Additional loading may accrue on the working platforms or components as a consequence of atmospheric precipitations such as ice, snow, sand or dust. The working processes may also cause debris such as sand, grit or demolition debris to accumulate on the working platform of components which will increase the live loading above that allowed for within the design. Where this is known or observed to occur, further design advice should be sought.

All access scaffolds will impose forces upon the structure they are fixed to through their ties. An assessment should be initially made regarding the ability of the structure to sustain the loads either globally, due to its own instability, or locally as a result of defective finishes. Loadings from the ties into the supporting structure are dependent upon the live loading to the working platforms, the height of the scaffold and in the majority of cases the wind loading imposed upon the scaffold and its cladding status. For guidance with regards to the design of ties into building facades refer to Section 5 of TG20:08 or seek appropriate design advice.


19

Tie Details Commonly, masonry anchors are used to tie a scaffold back to a supporting structure using the required tie pattern. When it is not possible to fix masonry anchors, other alternatives can be adopted as shown in the following diagrams.

Through Ties

Through ties secure the scaffold through an opening in the supporting façade, which should be approved by a suitably qualified structural engineer.

Girder Clamp Tie

Ties can be fixed to a suitable steel column using girder ties. The column must be checked as being suitable to resist the applied forces.

Box Ties

A tie is formed by ‘boxing’ around a column using tube and fitting. Similar to the Girder Clamp Tie, the column should be checked as being suitable to resist the applied forces.


20

Tie PatternsThe scaffold is an unboarded scaffold with 2.5m wide bays and 2m lifts, using the tie patterns indicated below, the tie density is 1 tie per 20m sq.

The base jacks are extended by 0.5m and alternate standards are tied at the top lift. A foot lift is incorporated at the lowest level and the scaffold has full façade bracing and ties that connect to both standards.

Pattern Types A = Square B = Diamond

C = Chevron D = Diagonal


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The scaffold module analysed is shown in figure 3 with ties at alternative levels. In the case of this scaffold, the mode of buckling is the same for all four of the tie patterns A-D, and is normal to the façade. This is the case for both Tubular and Omega transoms.

Figure 3. Scaffold model

Buckling Loads – Tube Transoms The elastic buckling loads per standard are given in Table 1 for the four tie patterns A-D previously shown.

Note: the load shown is without allowance for the use of intermediate transoms in each bay as board bearers and stiffening members, use of which significantly increases the safe load.

In Table 1 it can be seen that tie patterns (B) and (D) are a little stronger that patterns (A) and (C). The weakness of patterns (A) and (C) is that alternative standards have no ties connected directly to them to restrain the standard normal to the façade.

The characteristic loads Nkd are based on Eurocode 3 (buckling curve d) for cold rolled circular hollow sections. The safe load per standard has been calculated using the partial safety factors in BS EN12811-1.


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Tie Pattern Bay Size (m) Safe Load (kN)

A 2.5 9.8

B 2.5 11.1

C 2.5 9.8

D 2.5 10.7

Table 1. Summary of the buckling behaviour of the scaffold model using Tube Transoms.

Buckling Loads – Omega Transoms The elastic buckling loads per standard are given in Table 2 for the four tie patterns A-D previously shown.

In Table 2 it can be seen that tie patterns (B) and (D) are a little stronger that patterns (A) and (C). The weakness of patterns (A) and (C) is that alternative standards have no ties connected directly to them to restrain the standard normal to the façade.

The characteristic loads Nkd are based on Eurocode 3 (buckling curve d) for cold rolled circular hollow sections. The safe load per standard has been calculated using the partial safety factors in BS EN12811-1.

Tie Pattern Bay Size (m) Safe Load (kN)

A 2.5 11.4

B 2.5 12.8

C 2.5 10.0

D 2.5 12.8

Table 2. Summary of the buckling behaviour of the scaffold model using Omega Transoms.


23

Loading Classification and Safe Working HeightsSafe height tables are based on the following load classifications:

Designation (See note below) Loading and Bay Width

3-5-0 Load Class 3 2.0kN/m2 Lightly Loaded 2.5m Bay


3-5-0s Load Class 3 2.0kN/m2 Lightly Loaded 1.8m Bay






Note: Designation 3-5-1 denotes Load Class 3, 5 Board Working Platform, 1 Inside Board.

Partial Load Factors, to BSEN 12811-1:2003 Section 10.3.2 Partial safety factors for actions:

Ultimate Limite State: Yf = 1.5

Permanent and Variable: Yf = 1.0

Accidental Serviceable Limit State: Yf = 1.0

Partial safety factors for resistance: Ym = 1.1, or as specified in the relevant standard.

Imposed Loading Criteria on working lifts (Example of 3kN/m2):

One working lift at 100%: One working lift @ 3.0kN/m2

One working lift at 50%: One working lift @ 1.5kN/m2


24

Tube Transoms, 2m Lifts, Top Two Lifts Boarded, Lightly Loaded Inside Boards,

Ledgers Unbraced, Unclad. 30m max

Designation Wind Speed

m/s

Max Lift Height (m) for Tie Pattern (Country)

Max Lift Height (m) for Tie Pattern

(Town)

A B C D A B C D

3-5-0 24 8 30 12 28 10 30 12 28

3-5-1 24 8 26 10 20 10 28 12 20

3-5-0s 24 16 30 18 30 16 30 18 30

3-5-1s 24 16 30 18 30 16 30 18 30

4-5-0 24 0 14 0 14 0 16 0 14

4-5-1 24 0 16 0 12 0 16 0 12

4-5-0s 24 12 30 12 30 12 30 14 30

4-5-1s 24 8 22 12 30 12 26 14 30

Omega Transoms, 2m Lifts, Top Two Lifts Boarded, Lightly Loaded Inside Boards,

Ledgers Unbraced, Unclad. 30m max

Designation Wind Speed

m/s

Max Lift Height (m) for Tie Pattern (Country)

Max Lift Height (m) for Tie Pattern

(Town)

A B C D A B C D

3-5-0 24 12 28 12 30 12 30 12 30

3-5-1 24 12 24 12 30 12 28 12 30

3-5-0s 24 20 30 20 30 20 30 20 30

3-5-1s 24 20 30 10 30 20 30 20 30

4-5-0 24 8 24 4 22 8 24 4 22

4-5-1 24 6 24 0 22 6 24 0 22

4-5-0s 24 16 30 16 30 15 30 16 30

4-5-1s 24 16 30 16 30 16 30 16 30


25

Erection and Dismantling

Erection Sequence Each erector will require a scaffold hammer, a scaffold key, a tape measure and a small magnetic spirit level. Appropriate safety clothing and equipment must also be used.

The following procedure is much easier and therefore safer using a three-person team.

Establish the setting out of the scaffold, the foundation levels, and the levels at which working platforms are required. Plan to erect the scaffold in a continuous sequence, starting from a convenient point such as the highest ground level corner of the building. Please note he maximum allowable gap between the building or structure and the edge of the working platform is 200mm, we however recommend a gap of 100mm.

Assembly Using Standard Scaffold Boards• Layout the ledger and transoms for the first bay in their approximate positions. Then

insert an adjustable universal jack into each of the first pair of standards.


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• Connect the standards with a transom in the lowest cup joint by inserting the bladeinto the cups. Level the transom. Always start the scaffold with a three metre standardon the outside and a two metre standard on the inside, so the joints are staggered.

• With one person still holding the first pair of standards, the second person inserts ajack into the third standard and connects it to the first pair with a ledger. The uppercup can then be dropped temporarily into the locking position. The structure is nowself supporting and the fourth standard can now be connected by a further ledger andtransom and the bay then levelled using the adjustment on the universal jacks. Oncethe base lift has been completed, your spirit level will no longer be required

Note: Using the Omega Batten System


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The same procedure is adopted for the Omega Batten System as for the Scaffold Board System, except that the Omega transom is used in place of the tubular transom. No intermediate board supports will be required.

• The first bay of K’Lock is completed by locating the upper ledgers and transoms. It isnow a simple matter to extend the scaffold structure by connecting ledgers, transom’sand standards to the existing bay. The top fixing cups can now be secured with ahammer.

• Intermediate transoms are secured at strategic points (1.2m and 1.5m supportfrequency) across the ledgers to support 38mm scaffold boards. The scaffold boardscan now be placed across the width of the scaffold, toe boards can now be positionedimmediately underneath all handrails. Use toe board clips or some other suitablemeans to secure the board in place. Two standard ledgers are located 0.5m and 1.0mabove the working platform to form double guardrails. This double guardrail is toinclude the end of the scaffold

• Attach a face brace between the standards on the outside of the scaffold, at the lowest

cup to the ground. Repeat this process to place a face brace on every 3rd bay.


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• Where possible create a corner by placing ledgers into standards which form part ofthe original run of scaffolding. Alternatively, adjacent runs of scaffolding can be linkedto the first run at any point using the return device.

Increasing the height of the scaffold

• When erecting additional lifts, erectors must work off fully boarded bays of scaffold.

• Always fix single guardrails 1 metre above the temporary working platform as soon as

is practicable during the erection process. Where no guard rail is in place, safety

harnesses will be worn.

• All equipment must be raised or lowered using a suitable rope and wheel.

The recommended and maximum lift height for each and every lift above the first lift is 2 meters, and for the first lift is 1.5 meters. This “splice” in a standard is the joint where 2 standards are connected, using this method the height of the splice will never be more than 1.3m above the temporary working platforms, provided that all lifts are of the recommended height of 2m. This configuration will eliminate the occurrence of a “height splice” in the standards, making the erection process easier and contributing to the safety of the erectors.

Once the first base lift has been completed continue to erect the scaffold using the sequence below:

• Add a 2m standard on top of all existing standards on the scaffold, if it is intended to

extend the scaffold by more than one lift, it is recommended that 3m standards are

used. Then fix the ledgers and transoms 2m above the existing working platform to

create the next 2m lift.

• A diagonal cross brace should then be fitted to each end of the scaffold between the

outside and inside standards. End braces should run continuously from the bottom

cup on the lowest standard to the top working lift of the scaffold.

• Diagonal face braces should be fixed to the end bay of the scaffold and at least every

third bay along the scaffold. Face braces should also run continuously from the bottom

cup on the lowest standard to the top working lift of the scaffold.

• The scaffold should now be tied to the building or structure using tube and double

couplers to create a series of positive ties.


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Please note: The correct placement of bracing and positive ties is critical to ensuring the stability and strength of any scaffold and consequently the safety of persons using it. Work must not proceed on the scaffold until the bracing and ties are securely in position.

• Working form the existing working platform below, place a full set of boards in the

newly created lift – working from the end furthest from the access point, if the lower

working platform is not required in the final structure , working from the end bay,

then backwards towards the access point the platform can be raised to the lift

immediately above.

• The placement of the extra set of boards in the bay ensures that the scaffolder always

has a full set of boards on which to work. The boards are removed from their existing

position by rolling the outside plank onto the adjacent plank and sliding it back into

the bay in which the scaffolder is standing. Two people should move the last plank in

each bay, as one of the two will only have the steel frame of the scaffold on which to

stand. Therefore they should be equipped with a suitable safety harness and lanyard

with which to connect themselves to the scaffold.

• Working out from the access point on the temporary working platform, place a

standard (if necessary) in the first standard point. A ledger is then fixed to the second

bottom cup up from the working platform. This process is then repeated in each

individual bay until there is a single handrail to the outside standards. In certain

circumstances it may also be necessary to place a handrail on the inside of the scaffold.

Please note: If the temporary scaffold is to be used as a working platform a double handrail and toe board should be fitted.


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Dismantling the Scaffold

This process is equally important as the erection and safety must be considered to ensure the well being of all operatives and the safety of the scaffolding

• Visually inspect that the scaffold has been correctly erected and that the bracing and

ties are still in place.

• All materials and debris are to be removed from the working deck prior to the

commencement of dismantling.

• The work area should be barricaded off to prevent access to other workers and

members of the public.

• Dismantle the scaffold one complete lift at a time and leave the handrails in place until

the other components are dismantled. Remove ties in a sequence so that there are

never more than 2 lifts of scaffold above the top row of ties.

• Ensure all scaffold components are removed from the structure as it is dismantled.

Never “ Bomb” scaffold equipment down as this would cause damage to the

component or injury to people below

• Continue the dismantling process on the next lift; in necessary relocate the boards to

the lift below to ensure you have a full working platform on which to continue the

process.

• When the scaffold is dismantled to the base lift remove the bottom transom, leaving

the standard supported by the ledger. Then hold the standard and unlock the top cup

to remove one end of the ledger only. Lift the standard off the jack and stack into a

pallet.

• All scaffold equipment should then be stacked into pallets for collection. Battens

should be stacked on suitable bearers so they can be lifted by forklift or crane.


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Instructions for Storage, Maintenance and Repair

Storage

• Prefabricated components shall be stored, if possible, under a suitable cover,

protected from weather in a dry location. They shall be exposed to good

ventilation. They shall be supported during storage so as to avoid permanent

set.

• At the work site, provide enough space to drive the forklift and other vehicles

otherwise there are chances of damages to the components.

• Tags should be used to differentiate good components from the damaged

components.

• All the components shall be stored in a marked storage place.

• Do not stack any items on the road to avoid injury to passersby.

Maintenance

• Before allowing people or material on the scaffold structure ensure that it has

been erected correctly and complies with the user’s requirements.

• Ensure that all people using the scaffold are aware of the purpose for which it

is intended to be used and the maximum loading to which it can be subjected.

• Ensure that users understand that any unauthorised modification to the

scaffold or removal of components other than those which have been

specifically designed for it will materially weaken the scaffold and create a

safety hazard.

• Carry out regular inspections to check that components have not been

removed or damaged, or that components have not been removed and

replaced incorrectly.

• Alterations or extensions-(e.g. removal or repositioning of ties, removal of

guardrails or handrails, the addition of boarded platform, sheeting, debris

netting, etc) should only be carried out within the restrictions set out in this


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handbook or under the direction of a competent designer who is prepared to

accept the onus of his modifications.

• Provide barriers and warning notices to prevent access to incomplete sections

of scaffolding.

• Ensure that safe access and egress routes are provided to all working

platforms, and that such route, including ladders or preferably stairways, are

kept clear.

• Do not overload platforms-use properly designed loading towers and ensure

that crane and forklift drivers understand loading restrictions on each part of

the scaffold structure.

• Where necessary ensure that all areas below scaffolds in use are marked so

that site personnel can avoid the area. If the area has to be accessed then the

site personnel should be made aware of the potential risks or hazards.

• Because of the increased use of mechanical lifting plant on site there is an

increased possibility for scaffolding components to become found / caught.

When using cranes or other mechanical lifting devices near any scaffold

structure care should be taken to ensure that nothing catches under any part

of the scaffold otherwise uplift could occur with potentially dangerous

consequences.

Repairs If any scaffold gets damaged, inform the scaffolding contractor or authorised person then repairs can be carried out. The repaired item is only to be used after the approval of said competent person.

Transport During transportation it should be ensured that the prefabricated components are loaded properly and securely tightened to the vehicle to avoid dropping of components during travelling. Loading and unloading should be carried out under the supervision of a competent person to avoid damage to the components


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Corner Details Corners and Inside Board Platforms (Tube transoms)K’Lock can be used for returns and inside board platforms to overcome the problems of corners and projections that prevent the scaffold being erected.

Corners Using a Return DeviceCorners 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’ - this eliminates the need for non-standard bays.

Corners Using a 1.3m Square BayThe 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.

Internal Platform Corners – 1 Board The addition of an extra single board support at the corner standard ensures maximum safety when the 2 inside scaffold boards butt together at 90°.

An Inside Board Transom must also be used adjacent to the corner standard


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External Platform Corners – 1 Board Single Inside Board Platforms are constructed using the Single Board Support in conjunction with the Inside Board Transom. Either the 1.3m square bay (Figure A) or the standard method using the Return Device (Figure B) can be used. Note the positioning of the inside board transom to allow boards to butt together without overlapping.

Platform Corners – 2 & 3 Board Two or three board Inside Platforms are constructed using Hop-up Brackets.

These are linked together with Ledgers to allow the location of the 2 or 3 Board Intermediate Transom which supports the scaffold boards at the required centres.

On internal corners, end guardrails above the Hop-up Brackets can be formed using small butts of tube and fittings.

Figure C – Internal corners

Figure D – External corners


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Corners and Inside Board Platforms (Omega transoms)

Corner Returns Corner returns using the Omega Batten System can be formed either by using the Omega Return Transom - which locates over the ledger of the adjacent return elevation, or by using a 1.3m square bay in the corner which is constructed using 1.3m Omega Transoms on three sides.

Platform Corners – 1 Board Inside board platforms are constructed using the Omega Single Board Support. When constructing the scaffold with the 1.3m square corner bay, note the extra Omega Transom used to accept the inside batten from the return elevation, and the use of the return transom to eliminate the gap when using battens. A loose batten is required to cover the remaining gap in the inside board run

Figure A – Internal corners

Figure B – External corners

Figure A Figure B


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Figure BInternal Platform Corners – 2 & 3 Board The 1.3m square corner is constructed using Omega Transoms on all 4 sides, use of Omega Hop-Up Brackets, Guardrail Posts and tube give protection at the corners as shown in Figure A. The corner piece is then filled in with cut down timber battens.

Figure A Figure B

External Platform Corners – 2 & 3 Board Both elevations of scaffolding incorporate a 1.3m square bay at the end which share two common standards. Note the use of the extra Omega Transom in one elevation to receive the inside battens from the return elevation. Two loose battens are required to cover the remaining gap in the inside board run.

Figure C


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Circular AccessBy virtue of the unique 360* cup, K’Lock is ideally suited to form circular or curved structures. By using varying sizes of ledger, both internal and external radii can be achieved.

Curved structures can be created by using a mix of rectangular (square) bays and trapezium bays. Intermediate trapezium bays should be made with short ledgers to ensure boards are not spanned beyond their support limit. Boards should oversail by at least 150mm. In rectangular bays Intermediate Transoms can be used to support boards every 1.2m. For Omega circular structures, rectangular bays can consist of standard size battens, 1.3m wide. In the curved position, it will not be possible to fit Ledgers unless they are at 90* to each other.

In this case, the outer Ledger can be positioned as double handrails. An internal Ledger can be lowered by 0.5m, as it will not be supporting an Intermediate Transom. Care should be taken to ensure that scaffold boards are cut appropriate to the curve and no traps are encountered. Ties should always be used and positioned within 300mm of a secure node point. For all applications involving circular access design advice should be sought.

Internal and External Curves using Rectangular and Trapezium Bays. For Trapezium bays and special structures use the full range of alternative Ledger lengths.


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Loading Platforms K’Lock can be used to create loading towers for the purpose of distribution of pallets of materials to the working level by site forklift or loader. The tower is built progressively with the working lift to match bricklayer’s progress.

Made from a square 2.5m bay the tower can be free standing up to 6m or tied or integrally built to the main structure. Eight Board Bearers are required to form the working platform, and plan bracing will be required at the foot tie and under the loaded platform using regular tube and fittings. Towers should be face braced on each lift on each side using Swivel Face Braces appropriate to the lift

Board Bearers 8 evenly spaced board bearers are used under the boarded or battened platform to be supported by the loading bay beam.

Component Stock Code Length Weight

Board Bearer 023017 2.5m 17.3Kg

Batten Bearer 023047 2.5m 17.3Kg

Loading Bay Beam Fixes into the standards and two cups at the platform level. This allows the lower level to be used as a working platform or another loading bay. This arrangement will require an assessment of the capacity of the tower standards with potentially a reduction in the loadings advised below.


023059 2.5m 30.0Kg


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Permissible Uniformly Distributed Loads Decking is made up of regular 38mm scaffold boards cut to size at 2.43m and supported at no more than 345mm centres using eight loading tower board bearers. A K’Lock Erection Guide is available via your local branch.

When erecting Loading Towers, consideration needs to be given to the use of harnesses and if required collective protection methods as noted in NASC guidance note SG4:10. Temporary platforms will be required at each lift level to safely erect these towers.

Four No. 10kN (1 Ton) Pallets Six No. 0.85kN (0.85 Ton) Pallets


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Stair Access K’Lock system scaffolding can be used to provide a safe, stable site staircase enabling personnel to gain access to the working level swiftly and efficiently. Independently to other scaffolds or integral to K’Lock façade scaffolds, towers can be erected with full access landings, double handrails and non-slip stair units in either steel or aluminium.

The use of K’Lock staircases on site improves safety, replacing ladders and allows multiple numbers of personnel to climb safely to their work place at one time. The most popular are a four-leg tower with a footprint of 1.8m by 3.0m and an eight-leg tower with a footprint of 1.8m by 4.4m providing a full width landing at each level. Stair units are available in 1.5m and 2.0m units.

1.5m can be used where access is required to a base lift of 1.5m. Further lifts will rise at 2m increments.

Erection of staircases does not follow the normal sequence of access scaffolding and care must be taken in their erection. It will be necessary to create temporary working platforms and additional hand railing to efficiently and safely erect staircase towers. Erectors should work within the guidance of SG4:10 and should consider where appropriate the use of collective protection systems.

TG20:13 states that “toe boards should be provided where there is a risk of falling meterials or objects as appropriate. Toe boards are not normally required adjacent to the steps.” The required for toe boards should therefore be subject to a health and safety assessment based on the specific usage of the stair.


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