INSTRUCTIONS FOR

CONSTRUCTION AND USE

CUSTERS® FAÇADE SCAFFOLDING

Type HANDY SUPER 4

maximum load 200 kg/m2

EN 12810-3N-SW06/305/250-H1-A-LS

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Contents

1. INTRODUCTION ............................................................................................................... 3 2. GUARANTEE AND LIABILITY ......................................................................................... 4 3. CHECK OF THE DELIVERY .............................................................................................. 4 4. SAFETY INSTRUCTIONS .................................................................................................. 5

4.1. Check before construction ......................................................................................... 5 4.2. Construction ................................................................................................................ 5 4.3. Raising of parts ........................................................................................................... 5

5. CONSTRUCTION OF THE FAÇADE SCAFFOLDING ...................................................... 6 5.1. General......................................................................................................................... 6 5.2. Brackets ..................................................................................................................... 11 5.3. Bridging ..................................................................................................................... 12 5.4. Steps ........................................................................................................................... 14 5.5. Installing on ground with differences in height ..................................................... 17

6. USE.................................................................................................................................... 18 7. DISMANTLING OF THE FAÇADE SCAFFOLDING ....................................................... 19 8. MAINTENANCE ............................................................................................................... 19 9. LIST OF PARTS ............................................................................................................... 20

Custers Hydraulica B.V., Venray, Netherlands - February 2011 Nothing from this publication may be copied and/or duplicated and/or published by means of photocopying / printing / microfilm / CD / DVD / internet or any other means without the prior specific written permission of the publisher Custers Hydraulica B.V.

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1. INTRODUCTION

Custers façade scaffolding is part of a broad range of types of aluminium scaffolding. When constructed in accordance with these instructions, Custers façade scaffolding complies with EN 12810. Custers façade scaffolding has been type tested by SP Technical Research Institute of Sweden (certificate number SC0120-11).

Custers façade scaffolding is available in the following versions:

bay length : 2.5 or 3.052 m bay width : 0.69 m stroke (or layer) height : 2.0 m.

These instructions are intended to direct you step-by-step in the safe and easy construction of your façade scaffolding. If the construction is not correct, danger may arise for the user. Before the construction, read the safety instructions carefully. The construction and dismantling should be done by experienced persons qualified for the task. The user is responsible for the presence of the instructions in the place where the façade scaffolding is being installed and used, as well as with the person who is supervising operations. If there is anything unclear with regard to these instructions, please contact your supplier and/or the producer. Producer: Custers Hydraulica B.V. P.O. Box 22, 5800 AA Venray, Netherlands Telephone +31 (0) 47 85 53 000 Telefax +31 (0) 47 85 53 010 E-mail custers@custers.nl Website www.custers.nl Supplier:

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2. GUARANTEE AND LIABILITY Custers gives a guarantee for up to 12 months after supply on faults in materials and manufacture. The guarantee means that we will repair faults at our expense or - exclusively at our discretion - will take back all or part of that supplied and replace it with a new delivery. If we replace products in fulfilment of our guarantee obligation, the products replaced become our property. All costs that exceed the obligation described above are for the account of the customer. If products are submitted for adjustments, repair etc., a guarantee is only given for the soundness of the adjustments commissioned. Our liability does not apply:

If the faults are a consequence of improper use or of causes other than faulty materials or manufacture.

If the cause of the faults cannot be clearly demonstrated. If not all the instructions given for the use of the product, including the directions

indicated in these instructions, have been adhered to precisely and completely. The liability of the manufacturer is not a p p l i c a b l e if the buyer carries out or has carried out changes and/or repairs to the products supplied on his/her own initiative. 3. CHECK OF THE DELIVERY After receipt, check whether the façade scaffolding has been delivered complete and undamaged. Immediately contact your supplier if you notice that parts of the façade scaffolding are damaged or that the scaffolding delivered is not complete.

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4. SAFETY INSTRUCTIONS

4.1. Check before construction Verify whether the mechanics are adequately qualified and check whether the place where the façade scaffolding is to be placed is safe and suitable. N o t a b e n e :

The base must be sufficiently strong: use sole boards with minimum dimensions of 200 x 32 x 500 mm under the base plate spindles. The maximum design load of a standard on the base amounts to 23 kN (2300 kg).

The space must be free of obstacles, both on the ground and above the ground. The structure behind must be sufficiently strong. Check whether the weather conditions (wind, snow, ice) are such that it is

possible to work with the façade scaffolding. Check whether all the parts and any ropes for hoisting are present at the place of

work. Damaged, wrong or not original parts must never be used.

4.2. Construction

The construction of the façade scaffolding is described in the construction instructions and must be carried out by at least 2 persons. Beware of the danger of falling during the construction; install guardrails as soon as possible. Use a body harness with a safety lanyard if there is a danger of falling because of the lack of guardrails. The façade scaffolding must be set up horizontally. Check this with a spirit level. Correction is possible by turning the adjusting nuts on the base plate spindles. Start the construction at the highest point on the site with the spindles in the lowest position. The platforms must be secured by shifting the catch of the blow-away protection under the rung. The frames must be secured together by means of joint pins. The horizontal ledgers and rails must be attached to the standards in such a way that the openings of the claws are pointing outwards. Make sure that the claws of the horizontal and diagonal braces are secured by means of the sprung securing pegs. Install guardrails (upper ledger, middle ledger and toeboard) at each level as prescribed in these instructions. The upper and middle ledgers must be fixed above the end stops welded onto the standards. Apply the anchorage and the diagonal braces as prescribed in these instructions. If the distance between the side of the platform and the façade is greater than 30cm, adequate guardrails must also be installed on the inside (that is on the side of the façade). The toeboard on the inside can be omitted if persons on the spot cannot be hit by falling materials or objects.

4.3. Raising of parts

The raising of parts for higher sections must take place by passing the parts from platform to platform. Parts can also be hoisted up with a strong rope. Use a proper knot, loop or hook to fix the parts securely in place. Lifting tackle must not be fixed onto the scaffolding.

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5. CONSTRUCTION OF THE FAÇADE SCAFFOLDING

5.1. General

The façade scaffolding is constructed layer by layer:

Place the base plate spindles at a distance of 3.052 or 2.5 m apart from one another.

The base plate spindles are set at roughly the correct height in advance, so that the later levelling off is made easier.

Place the first layer of frames (the base frames) on the base plate spindles. Place the horizontal ledgers on the standards of the frames. Place the diagonal braces in the prescribed diagonal pattern. Determine the place for one or more ladders, in order to take this in account

when installing the platforms. Place an additional platform at the bottom (instead of the two horizontal ledgers); place the ladders in the section alternately on the left and the right.

As an alternative to ladders, steps can be installed; see 5.4. Place the platforms on the frames. The blow-away protection on the underneath

of the platforms must be carefully bolted in place (2 pieces on each platform).

base plate

spindle

base frame

horizontal

brace

diagonal

brace

platform platform with

ladder and

trapdoor

extra

platform

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The diagonal braces must be installed as follows: in columns; do not omit any sections always in the two outer (end) sections with maximum 4 sections of scaffolding next to one another without diagonal

braces the diagonal braces may be placed in a zigzag or in one direction according to

preference (in one section, the diagonal braces must run in one direction, however, in the 5th subsequent section, the diagonal braces must then be placed in the opposite direction).

The anchorage must always be applied as follows:

anchor the joints at 4, 8, 12, 16 m and so on anchor the first and last standard with V-anchors (2 single anchors at an angle of

90°) anchor each fifth standard with V-anchors anchor the intermediate standards with a single anchor.

diagonal and anchoring pattern

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The anchorage must be applied as soon as the construction of the layer in question has been completed. Anchor at sound and suitable places on the façade; note the following points:

assess the suitability of the construction behind remain at an adequate distance from the edges, etc. adjust the various parts well to one another (e.g. length of plug) and follow the

instructions of the supplier.

The anchorage can be placed either in front of the frame (as illustrated) or behind the frame. If required, the anchorage can be pushed in a vertical direction; place the anchorage as close as possible to the joint (maximum 20 cm from the joint). Tighten up the ties with a moment of 50Nm (50Nm corresponds to a force of 20 kg on a lever arm of 25cm). The maximum design load for the anchorage amounts to:

V-anchor: 3.3 kN (330 kg) parallel to the façade and 6.5 kN (650 kg) perpendicular to the façade

single anchor: 2.8 kN (280 kg) perpendicular to the façade. It is forbidden to use EN74 ties (intended for a tube dimension of 48.3 mm).

wall anchor

swivel joint

hook into eyebolt

in façade

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Install the second layer of frames (the construction frames); secure each construction frame with 2 joint pins.

Install the upper and middle ledgers (horizontal braces). Place the end rails at the ends of each layer. Install the diagonal braces in the prescribed diagonal pattern. Place the platforms on the frames. The blow-away protection on the underneath

of the platforms must be carefully bolted in place (2 pieces on each platform). Install the anchorage (wall anchors with swivel joint and eyebolt with plug) in

the prescribed anchoring pattern. Click the toeboard holders onto the standards. Install the toeboards and the end toeboards.

construction

frame upper ledger

middle ledger

end rail

diagonal

brace

platform

anchorage

toeboard holder toeboard end toeboard

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Install the subsequent layers in an identical way until the desired height is reached. Then complete the construction of the top layer of the scaffolding as follows:

Install the rail stands; secure each rail stand with a joint pin. Place the guardrail frames at the ends of the upper layer; secure each guardrail

frame with 2 joint pins. Install the upper and middle ledgers (horizontal braces). Click the toeboard holders onto the standards. Install the toeboards and the end toeboards.

rail stand guardrail

frame upper ledger

middle ledger

toeboard holder toeboard end toeboard

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5.2. Brackets

The brackets make it possible to widen the façade scaffolding, so that it is possible to get closer to the façade. The brackets can be installed at several levels at the same time, on the inside of the façade scaffolding. The brackets must be placed at a joint; with each bracket, anchorage must be installed. The bracket is intended to take the weight of persons (150 kg/m2); it is not permitted to store materials on the brackets.

Install brackets with 2 ties (the end brackets at the end, the intermediate brackets in the intermediate sections); place brackets in such a way that the rung of the bracket is in line with the rung of the frame; tighten the ties up firmly.

Place the narrow platforms on the brackets. The blow-away protection on the underneath of the platforms must be carefully bolted in place (2 pieces on each platform).

Place the rail stands on the two end brackets, and secure each rail stand with a joint pin.

Install the narrow end rails. Install the anchorage (wall anchors with swivel joint and eyebolt with plug) next

to each bracket.

intermediate

bracket

end bracket

rail stand

narrow end rail

narrow

platform

anchorage

swivel joint

swivel joint

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5.3. Bridging In order to enable free passage along the façade scaffolding, two bridging joists are used, together with the appertaining foot frame. The joints at the beginning and at the end of the bridging joist must be anchored. There must always be at least one section of the façade scaffolding placed next to the bridging joist.

Install the two bridging joists with 2 ties to one of the frames and 2 ties to the other frame; tighten the ties up firmly.

Install the foot frame with 2 ties to one of the bridging joists and 2 ties to the other bridging joist; ensure that the rung of the foot frame is at the same height as the rung of the construction frame; tighten the ties up firmly.

bridging joist

foot

frame

swivel joint

swivel joint

swivel joint

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Install the two platforms. The blow-away protection on the underneath of the platforms must be carefully bolted in place (2 pieces on each platform).

Install the anchorage (wall anchors with swivel joint and eyebolt with plug) at begin and end of the bridging joist.

Complete the rest of the construction of the layer as described in 5.1. Install the two additional diagonal braces.

platform

diagonal

brace

anchorage

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5.4. Steps The steps are intended to provide access to the façade scaffolding; as alternative access, the ladder can be used.

bottom layer:

Remove the horizontal ledger (if present). Install the two base frames, each with one base plate spindle; connect the

standards below and above together with swivel joints; ensure that the standards in the outside sections of the façade scaffolding are in one line.

Install the steps; ensure that the steps are well secured (under the rungs).

4 standards

in a line

remove

horizontal

ledger here

base frame

base plate

spindle

swivel joint

swivel

joint

steps

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next layer:

Install the construction frame (1) with a swivel joint at the top of the standards. Place the stair handrail on the outside. Install the end rail (1). Install the steps; ensure that the steps are well secured (under the rungs). Place the construction frame (2) with a swivel joint on the top of the standards. Install the end rail (2). Click the toeboard holders onto the standards. Install the end toeboard.

Subsequently install the following sections of the steps in an identical way until the desired height is reached, and then construct the top section of the steps.

construction

frame (1)

swivel joint

construction

frame (2)

swivel

joint

outer

stair

handrail

end rail (1)

steps

end rail (2)

end toeboard

toeboard holder

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top layer:

Install the two rail stands; secure each rail stand with a joint pin. Install the stair handrail on the outside. Install the end rail. Install the stair-landing rail with 2 swivel joints on the standards.

rail stand

rail stand end rail

stair

handrail

outside

stair-landing

rail

swivel joint

swivel

joint

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5.5. Installing on ground with differences in height It is possible to construct neighbouring frames on surfaces that each differ in height up to 2.0 m. The availability of 3 different heights of frames (0.5m, 0.75m, and 1.0m.), in combination with 2 different spindles (adjustability of 250 and 500 mm), means that differences in height of 0 to 2.0 m can be bridged. Depending on the desired height to be bridged, the spindles are adjusted and the frames combined. Always place 2 horizontal ledgers on the standards of the frames (as in the diagram).

(x) = horizontal ledger (front and back)

adjustable

spindle 500

adjustable

spindle 250

adjustable

spindle 500

frame

500 frame

750 frame

1000

frame

1000

frame

500

frame

2000

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6. USE Prior to use, each time it must be checked whether:

the entire construction is correct and complete there have been any changes in circumstances which might influence the safe use

of the façade scaffolding. Façade scaffolding is intended to carry out work (such as, e.g., restoration, renovation, maintenance, painting, plastering, pointing, inspection, cleaning) on a façade. The façade scaffolding must never be overloaded; the maximum scaffold class load amounts to 200 kg/m2 (scaffold class 3); only 1 layer may be loaded to the maximum (or 2 layers to half the load, or 3 layers to a third, etc.) The maximum platform height amounts to 24 m. It is forbidden to attach surfaces that catch the wind, such as sails, nets or billboards, to the façade scaffolding. The façade scaffolding may only be mounted by means of the steps (of the constructed staircase) or by means of ladders (mounted on the platforms). Horizontal ledgers, upper and middle ledgers and diagonal braces must not be used as steps. It is forbidden to jump on the floors. The trapdoor of the platform must always be closed, except when climbing or descending the ladder. Do not place crates, steps, ladders or other equipment on the operating floor in order to gain height. The façade scaffolding must not be exposed to aggressive liquids or gasses. The façade scaffolding must be left as quickly as possible when there is:

wind force greater than 7 Beaufort (from 13.9 m/s) thunder and lightening heavy snowfall, hail or ice.

The maximum admissible load on the scaffold frames amounts to:

9 kN (900 kg)/standard (scaffold out of service) 12.7 kN (1270 kg)/standard (scaffold in service).

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7. DISMANTLING OF THE FAÇADE SCAFFOLDING Beware of the danger of falling while dismantling; keep the guardrails in place for as long as possible; use a body harness with a safety lanyard if there is a danger of falling because of the lack of guardrails. Dismantling the façade scaffolding takes place in reverse order from installation. Start at the top by removing the toeboards and toeboard holders. Pass the parts down via the platforms. Dismantle the façade scaffolding from the top to the bottom. Never let the parts fall and never throw them down! 8. MAINTENANCE All parts, particularly the moving parts and the welds, must be regularly checked for wear or damage, but at least once a year. Missing and broken parts must be replaced. Aluminium parts must no longer be used in one or more of the following cases:

if round tubes have one or more smooth dents with a depth of more than 3.0 mm if round tubes have one or more dents next to a welded joint, regardless of the

depth and form of the dent if square/oblong pipes have one or more smooth dents with a depth of more than

2.0 mm if tubes or pipes have one or more creased dents or cracks, regardless of the

length/depth and location of the dent/crack. Moving parts must be clean and running properly. Repair of scaffolding material should always take place in consultation with the manufacturer.

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9. LIST OF PARTS

Designation Article number Weight

(kg)

base plate spindle with plate length 600 adjustable range 410

0501 520 020 4

base frame 0501 210 017 10.3

construction frame 0501 210 019 8.5

ledger frame 0501 200 140 4.5

rail stand 0501 903 025 1.7

joint pin 0501 410 162 0.05

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Designation Article number

Weight (kg)

platform with trapdoor and ladder length 2500

0501 320 027 23

platform with trapdoor and ladder length 3052

0501 320 037 27.5

platform length 2500

0501 310 020 19.5

platform length 3052

0501 310 030 24

narrow platform length 2500

0501 340 020 11.6

narrow platform length 3052

0501 340 030 14.3

Designation Article number Weight

(kg)

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wall anchor 0501 800 350 2.3

swivel joint 0501 800 934 1.2

eyebolt 0501 800 340 0.1

plug 0501 800 341 -

plug cap 0501 800 342 -

toeboard holder 0501 800 087 0.2

end toeboard 0501 200 092 1.2

toeboard length 2500

0501 200 080 4.4

toeboard length 3052

0501 902 080 5.8

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Designation Article number Weight (kg)

horizontal ledger length 2500

0501 200 030 3

horizontal ledger length 3052

0501 200 040 3.5

diagonal brace length 3202 (2500 x 2000)

0501 200 055 3.6

diagonal brace length 3649 (3052 x 2000)

0501 200 061 4

end rail 0501 903 035 2.3

narrow end rail 0501 903 029 1.7

end bracket 0501 800 550 2.0

intermediate bracket

0501 800 555 1.3

foot frame for bridging joist

0501 800 606 4.6

Designation Article Weight

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number (kg) bridging joist length 2 x 2500

0501 800 605 20.0

bridging joist length 2 x 3052

0501 800 615 24.4

steps length 2500

0501 600 170 24

steps length 3052

0501 600 150 29

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Designation Article number Weight (kg)

outer stair handrail length 2500

0501 600 175 7.6

outer stair handrail length 3052

0501 600 155 8.5

stair-landing rail length 2500

0501 600 185 7.3

stair-landing rail length 3052

0501 600 165 8.2

Designation Article number Weight

26

(kg) base plate spindle with plate length 435 adjustable range 250

0501 520 022 3.4

base plate spindle of plate length 720 adjustable range 500

0501 520 024 4.4

frame 1000 0501 210 022 6.0

frame 750 0501 210 024 5.2

frame 500 0501 210 026 4.3