Cup Lock Manual

An IS I SO 90 9001 01:2000 C o.

Wheels the scaffolding people Scaf affo folldi ding ng (I (I nd ndiia) Ltd. formerly Wheels Wheel s Fabr Fabricators icators Pvt. Ltd. Ltd.

M odu dullar Frame Framew work for C ons onsttruct ctiion Indust Industry

Users Manual

Introduction WSL CUPLOCK is the world’s most widely used system scaffold. It is a fully painted/galvanised multipurpose steel scaffold system suitable for providing general access and supporting vertical loads. CUPLOCK’s CUPLOCK’s key feature is its unique circular node point which allows up to 4 horizontals to be connected to a vertical in a single fastening action -making it probably the fastest and safest system available. The comprehensive range of CUPLOCK components allows it to be used with traditional scaffold boards or battens. It can be used to create a huge range of access and support structures, staircase towers, circular scaffolds, loading towers and mobile towers. 7 Tank Tank phosph phosphating is the finest finest practical practical coating coating that can be applied to a scaffold system, providing a long working lilife an and be bette terr ha handling. WSL CUPLOCK is is manufactured to strict quality standards. This manual has been designed to enable CUPLOCK users to become proficient in planning and erecting conventional CUPLOCK scaffolds. It provides comprehensive details of components and guidance on the design and erection of access and support structures.

Introduction WSL CUPLOCK is the world’s most widely used system scaffold. It is a fully painted/galvanised multipurpose steel scaffold system suitable for providing general access and supporting vertical loads. CUPLOCK’s CUPLOCK’s key feature is its unique circular node point which allows up to 4 horizontals to be connected to a vertical in a single fastening action -making it probably the fastest and safest system available. The comprehensive range of CUPLOCK components allows it to be used with traditional scaffold boards or battens. It can be used to create a huge range of access and support structures, staircase towers, circular scaffolds, loading towers and mobile towers. 7 Tank Tank phosph phosphating is the finest finest practical practical coating coating that can be applied to a scaffold system, providing a long working lilife an and be bette terr ha handling. WSL CUPLOCK is is manufactured to strict quality standards. This manual has been designed to enable CUPLOCK users to become proficient in planning and erecting conventional CUPLOCK scaffolds. It provides comprehensive details of components and guidance on the design and erection of access and support structures.

C UPLO PLOC C K Sca Scaff ffol old ding Sys ysttem WSL CUPLOCK Formwork Support System

The erection and application instructions

Advantages

contained in this booklet are the recommended recommended

• Maximum leg load of 75* kN with a max grid

methods to be used for WSL CUPLOCK

spacing of 2.5m x 2.5m.

products.

* Maximum leg load is dependant on a set of

The technical instructions contained in this

conditions with regard to bracing, Ledger/

brochure must be accurately followed to achieve

Transom spacing, load eccentricity, eccentricity, extension

the correct function of the product. Any deviation

of Adjustable Bases and U-Heads and out of

from the recommended principles shown

plumb of the system.• Simple and efficient

in this brochure may require a separate design

inter nterco con nnect nectiion of Ledg Ledger ers s and and brace races. s.

and/o nd/orr veri verifi fica cati tion on by the the WSL WSL Engi ngineer neerin ing g

• Standards produced from 48.3 mm dia high

Department.

strength tube available in lengths up to 3.0m. • Painted/Galvanised components for durability. durability.

The illustrations in these assembly instructions

(all threaded components are zinc plated not

are guidelines only. only.

galvanised)

Only WSL CUPLOCK Standards and WSL

• Choice of bay (grid) sizes to allow maximum

CUPLOCK Adjustable Bases/Adjustable U-Head

capacity of leg load to be developed.

Assemblies must be used in the support

• Area below formwork can be decked out to

structure.

provide access or working platforms during

The use of CUPLOCK Standards or any other

erec rection an and di dismantli tling of of so soffit fo form.

Adjustable Ba Bases an anywhere in th the ar arrangement

• Ful Fully syst system emis ised ed for for eas ease e of erec erecti tio on.

redu reduce ces s the the leg load oad capac apacit ity y of the the stru struct ctur ure e to

• Minimum components and fittings. All parts

that of the Standard CUPLOCK system and/or to

are interchangeable.

the capacity of the Adjustable Base used.

• Diagonal braces snap on to Ledgers at node

Maximum capacities are only applicable for

points and are easily dismantled by means of a

equipment in good order and free from defects.

quick release tr igger. • Designed and manufactured in accordance with required Standards. Important

the CU C UPLOC PLOCK K loc locki kin ng pro proce cedu dure re

At the heart of the CUPLOCK system is its unique unique node-

It is this revolutionary node point which makes makes WSL

point locking device. This enables up to four horizontals to be loosely but safely connected to the standard then

CUPLOCK faster and simpler to erect than any other system scaffold. Once a CUPLOCK structure is ‘based

locked into position with a single hammer blow. blow. The system uses no loose clips, bolts or wedges.

out’ and levelled, subsequent lifts are automatically erected square and horizontal.

The locking device is formed by fixed lower cups, welded to the standards at 0.5m intervals, and sliding upper

The lack of loose components makes the system easy to use and exceptionally robust - its painted/galvanised

cups which drop over the blade ends of the horizontals

finish making it virtually immune to corrosion and

and rotate to lock them firmly into place giving a positive, rigid connection.

damage.

General Technical & Application Manual One of the key strengths of the CUPLOCK system is the simplicity of the component range. Basic horizontals and verticals form the core of all structures. However, with the addition of a small number of special components, complex scaffolds can be constructed which safely address awkward access requirements. WSL CUPLOCK Spigoted Standards (Verticals) There are five basic sizes of spigotted WSL CUPLOCK Standards. Made from 48.3mm diameter x 3.2mm thick high grade st eel tube, all standards incorporate lower fixed cups at 0.5m intervals with captive rotating top-cups securing up to 4 components. The lowest bottom cup is 80mm from the base of the standard to give the scaffold improved structural strength and reduce the need for base bracing in support structures. Access Standards incorporate a 150mm spigot at the top to allow the vertical connection of further standards. Provision for a locking pin is also provided. (CUPLOCK Support Standards do not have this spigot -allowing the insertion of jacks with various support components). Name

Code

wt.(Kg)

WSLCUPLOCK 3.0 Standard

CLS01

15.2


CLS02

12.7


CLS03

10.3


CLS04

7.9


CLS05

5.5

0 5 1 0 2 4 0 0 5

0 0 5

0 0 5

0 0 5

0 0 5 0 8

General Technical & Application Manual WSL Standards (Verticals) Open Ended There are six basic sizes of open WSL CUPLOCK Standards. Made from 48.3mm diameter x 3.2mm thick high grade st eel tube, all standards incorporate lower fixed cups at 0.5m intervals with captive rotating top-cups securing up to 4 components. The lowest bottom cup is 80mm from the base of the standard to give the scaffold improved structural strength and reduce the need for base bracing in support structures. Name

Code

wt.(Kg)

WSLCUPLOCK 3.0 Open Ended Standard

CLS06

14.5


CLS07

12.0


CLS08

9.6


CLS09

7.2


CLS10

4.8


CLS11

2.4

Components in WSL CUPLOCKS 1: Spigot. 2: Heavy malleable casted top cup. 3: Bottom cup.

1 3 2

0 2 4 0 0 5

0 0 5

0 0 5

0 0 5

0 0 5 0 8

o m C u t t p

o

B

WSL CUPLOCK Scaffolding System Ledgers/Horizontals CUPLOCK Ledgers are used as the main horizontal connecting members for the WSL CUPLOCK 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 WSL CUPLOCK Standards for formwork support or Access Work System. Cuplock ledgers are available in B Class pipe as per customer requirement. Name

Code

Wt.(Kg.) B Class

Code

Wt.(Kg.) A Class

CUPLOCK Ledger 2.50

CLL01

9.0

CLL08

7.8

CUPLOCK Ledger 2.00

CLL02

7.1

CLL09

6.3

CUPLOCK Ledger 1.8

CLL03

6.5

CLL10

5.7

CUPLOCK Ledger 1.5

CLL04

5.5

CLL11

4.8

CUPLOCK Ledger 1.25

CLL05

4.5

CLL12

4.0

CUPLOCK Ledger 1.2

CLL06

4.4

CLL13

3.9

CUPLOCK Ledger 1.0

CLL07

3.8

CLL14

3.3

Transoms CUPLOCK Transoms made out of 50x50x5mm angle are used as a horizontal connecting member for the WSL CUPLOCK 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 fixed back to back with a drop forged blade attached to each end. The Transom secures to the Standard in the same manner as t he Ledger. The outward standing bottom leg of t he 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. Name

Code

Wt.(Kg.)

CUPLOCK Transom 2.5

CLT01

18.94

CUPLOCK Transom 2.0

CLT02

15.14

CUPLOCK Transom 1.8

CLT03

13.62

CUPLOCK Transom 1.5

CLT04

11.34

CUPLOCK Transom 1.3

CLT05

9.82

CUPLOCK Transom 1.2

CLT06

9.06

CUPLOCK Transom 1.0

CLT07

7.54

WSL CUPLOCK Scaffolding System Intermediate Transoms Intermediate Transoms provide mid-bay support for 38mm scaffold boards by spanning between t he inner and outer ledgers. The jaw section at each end is turned downwards to prevent dislocation. One end is provided with an integral locking device to prevent any movement along the ledgers during use. In addition to the standard 1.3m wide unit, shorter Intermediate Transoms are available for use where scaffold boards require support between hop-up brackets. They span between the inside ledger of the main scaffold and the ledger linking the hop-up brackets. For use with 2 board and 3 board hopup brackets respect ively. Name

Code

Wt.(Kg.)

CUPLOCK Intermediate Transom 2.5

CLI 01

12.59


CLI 02

10.99


CLI 03

9.39


CLI 04

8.75


CLI 05

7.79


CLI 06

7.15


CLI 07

6.83


CLI 08

6.19

Inside Board Transom: 1 and 2 Board Drop into place over the ledgers and are secured with a locking device to prevent movement. Act as conventional transoms but extend beyond the inside ledger to provide intermediate support to one or two inside boards. Description

Code

Overall

Weight

length (m)

(kg)

1-Board

CLIBT01

1.570

9.0

2-Board

CLIBT02

1.850

11.5

Locking device Inside Board Supports Single Board Support Locates in the cup joint and provides support for a single inside board at a vertical. It replaces the inside board transom at that point. Code CLIBS01

Overall length (m) 0.26

Weight (kg) 1.5

WSL CUPLOCK Scaffolding System Hop-up Brackets Designed to increase the overall width of the working platform to seven or eight boards by supporting two or three additional boards beyond the inner face of the scaffold. They incorporate a cup joint at the outside end to allow the fitting of an inside ledger which links the hop-up brackets and supports intermediate transoms. Also incorporates a facility to support a handrail post. Description

Code

Overall

Weight

length (m)

(kg)

3-Board

CLHB01

0.815

7.7

2-Board

CLHB02

0.585

6.3

Return Device A conventional blade end connected to a hook section which locates over the ledger on the adjacent return elevation to provide a corner connection. Used in pairs. Code

Weight (kg)

CLRD01

1.15

Swivel Face Brace Provides face bracing on a CUPLOK access scaffold. Each brace has swivelling blade ends to allow for easy location within the node joint. As only one blade end can be located in each joint, parallel bracing is employed rather than the ‘dogleg’ or ‘zig-zag’ method. Description

Code

Weight

Overall

(Kg)

length (m)

1.8 x 1.5m

CLSFB1

8.7

2.396

1.8 x 2.0m

CLSFB2

9.8

2.744

2.5 x 1.5m

CLSFB3

10.7

2.969

2.5 x 2.0m

CLSFB4

11.5

3.255

L

Y

Swivel blade

X

WSL CUPLOCK Scaffolding System Handrail Post For use with Hop-up Brackets, staircase towersand on support scaffolds if required. Incorporates cup joints to allow the location of ledgers to form guard rails. Code

Overall length (m)

CLHP01

Weight (kg)

1.150

4.8

The Omega Batten system incorporates all the main CUPLOCK components but replaces the tubular transom with a special Omega unit into which special boards or battens slot to provide a secure, flush work platform.No intermediate transoms are required as stronger battens are used in place of scaffold boards.Battens are either 63mm thick (timber) or 57mm (steel).

Omega Transom Provides a firm location for the Omega Battens. The specially designed Omega section provides a very strong supporting platform and prevents the battens from moving. Forged blade ends locate into the cup joint of the vertical in the normal way. Both the 2.5 and 1.8m Omega Transoms can be used when CUPLOCK is erected to form a birdcage access scaffold using timber or steel battens, or on mobile access towers in modular sizes. Size

Code

(M)

Overall

Weight

length (m)

(kg)

0.8

CLOT01

0.752

3.9

1.3

CLOT02

1.252

6.6

1.8

CLOT03

1.752

10.0

WSL CUPLOCK Scaffolding System Ladder Access Transom A square-section transom with an Omega profile across part of its width to support short battens behind a ladder opening. It has a claw at one end and a half coupler at the other to ensure secure positioning along the ledgers. Must only be used in conjunction with Omega transoms. Code

Overall length (m)

Weight (kg)

CLLT01

1.3

9.3

Return Transom A transom with a steel hook profile which locates over the ledger of the adjacent return scaffold, linking the two sections t ogether. The other side of the transom incorporates a conventional Omega section to receive timber or steel battens. Code

Length (m)

Weight (kg)

CLRT01

1.3

8.6

Omega Single Board Support Locates at the cup joint and provides support for a single inside batten. Code CLOB01

Overall length (m)

Weight (kg)

0.267

2.3

Omega Hop-up Bracket Designed to increase the overall width of the working platform to seven or eight Battens by supporting two or three additional battens beyond the inner face of the scaffold. It incorporates a cup joint at the far end to allow the fitting of an inside ledger which links the hop-up brackets to prevent movement. It also incorporates an opening to support a handrail post. Description

Code

Overall

Weight

length (m)

(kg)

3-Board

CLOHB01

0.815

7.6

2-Board

CLOHB02

0.585

6.6

WSL CUPLOCK Scaffolding System Omega Two and Three Board Corner Units Provides an external corner support 2 or 3 battens wide. For use between hop-up brackets. Infill with timber, cut to fit. Description

Code

Length (m)

2-Board

CLOBC01

6.6

3-Board

CLOBC02

9.3

Weight (kg)

Timber Battens 63mm thick and of 225mm nominal width. Weights shown are approximate at 20% moisture content. Description

Code

Weight

Overall

(kg)

length (m)

1.3m

TB01

9.5

1.250

1.8m

TB02

13.0

1.750

2.5m

TB03

18.0

2.450

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

Description

Code

Weight

Overall

(kg)

length (m)

1.3m

SB01

6.7

1.250

1.8m

SB02

9.11

1.750

2.5m

SB03

12.4

2.450

Toeboard Clips Timber For use with timber battens only. Locates around the standards and sits on the 'top-hat' section of the Omega transom Code

Weight (kg)

Size (mm)

TCT01

1.0

150 x 120 x 171

Toeboard Clips Steel For use with steel battens only. Locates around the standards and locks the toeboard rigidly into position

Code

Weight (kg)

TCS01

1.0

WSL CUPLOCK Scaffolding System End Toeboard Clip Locates on the Omega Transom. For use with timber or steel battens.

Code

Weight (kg)

ETC01

1.5

CUPLOCK Tie Bars Tie bars are used to interlock the ends of Platform Brackets and to provide a means of preventing the Planks from sliding off the end of the bracket. The studs at the end of the tie locate into slots in the Platform Brackets. CUPLOCK Tie Bar 0.61m CUPLOCK Tie Bar 1.00m CUPLOCK Tie Bar 1.25m CUPLOCK Tie Bar 1.80m CUPLOCK Tie Bar 2.50m

CUPLOCK Transom Beam Transom Beams are designed for special duty load applications. Allows high deck capacity and large grid patterns. CUPLOCK Transom Beam 1.80m CUPLOCK Transom Beam 2.50m

CUPLOCK Transom Truss The Transom Truss is designed for high capacity loading platforms and overhead protective structures. Connects at 4 points, enhancing the rigidity of the scaffold. Consult WSL Engineering Department for load capacity details. CUPLOCK Transom Truss 1.80m CUPLOCK Transom Truss 2.50m CUPLOCK Transom Truss 3.00m

Typical Tubular Cuplock Access Layouts This section illustrates the methods in which CUPLOCK can be used to create returns and inside board platforms. In most cases, these will overcome the problems of corners and projections which could prevent the scaffold being erected close to the building Corner Return using the Return Device Corners 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’ which eliminates the need for non-standard bays. Corner Return using a 1.3m square bay The 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.

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Adjustable Base & U Jacks Adjustable Base The Adjustable Base is used with all scaffold systems and some formwork systems. It has a solid stem of 32mm, 36mm nominal diameter which has a nut restraint to ensure the stem always has a minimum engagement into the Standard of 150mm. Adjustable Base (Solid) –Form/Scaf The adjustable base is also made of 4mm thick pipe, 38mm outer diameter with threading with rolling machine.

32mm solid rod with base plate 150X150X6 Code 32ABJ 01 32ABJ 02

Size (mm) 350mm 450mm

Length-A (mm) 225 325

Length-B (mm) 125 125

Weight (kg) 3.5 4.1

36mm solid rod with base plate 150X150X6 Code 36ABJ 36ABJ 36ABJ 36ABJ

01 02 03 04

Size (mm) 350mm 450mm 550mm 650mm

Length-A (mm) 225 325 400 500

Length-B (mm) 125 125 150 150

Weight (kg) 3.8 4.6 5.4 6.2

B h t g n e L A h t g n e L

38mm solid rod with base plate 150X150X6 Code 38ABJ 01 38ABJ 02 38ABJ 03 38ABJ 04 38ABJ 05

Size (mm) 350mm 450mm 550mm 650mm 750mm

Length-A (mm) 225 325 400 500 600

Length-B (mm) 125 125 150 150 150

Weight (kg) 2.7 3.0 3.3 3.8 4.1

0 1 5

1 5 0

6mm plate

Adjustable Base & U Jacks Adjustable U-Head/Stirup Head The Adjustable U-Head is used with scaffold systems & formwork systems. It has a solid stem of 36mm nominal diameter which has a nut restraint to ensure the stem always has a minimum engagement into the Standard of 150mm. The U-Head is capable of accepting twin 100mm wide bearers. Adjustable U-Head (Solid) –Form/Scaf

32mm solid rod with base plate 150X150X6 Code 32ABJ 01 32ABJ 02

Size (mm) 350mm 450mm

Length-A (mm) 225 325

Length-B (mm) 125 125

Weight (kg) 3.7 4.3

Holes for nailng

1 0 0

36mm solid rod with base plate 150X150X6 Code 36ABJ 36ABJ 36ABJ 36ABJ

01 02 03 04

Size (mm) 350mm 450mm 550mm 650mm

Length-A (mm) 225 325 400 500

Length-B (mm) 125 125 150 150

Weight (kg) 4.6 5.4 6.2 7.0

38mm solid rod with base plate 150X150X6 Code 38ABJ 38ABJ 38ABJ 38ABJ 38ABJ

01 02 03 04 05

Size (mm) 350mm 450mm 550mm 650mm 750mm

Length-A (mm) 225 325 400 500 600

Length-B (mm) 125 125 150 150 150

Weight (kg) 2.9 3.2 3.5 3.8 4.1

5 7

A h t g n e L B h t g n e L

0 1 2

travel adjustment

General Technical and Application Access Work System Working Load Limits

W

L

P

Transoms ** Note: • Loads W and P shown are not simultaneous loads. • The Transom Working Load Limits shown in t he table. Typically, this limitation applies to working platform widths equal to transom size 'L' shown.

L

Cross Section of Transoms 1.0 - 2.50m Transom

CUPLOCK Transom Beams and Transom Trusses Transom Beam

Transom Section

1.8m & 2.5m

Transom Truss

1.8

3.00m

2.5m

Section for all Trusses

P = Working Load Limit for Point Load W = Working Load Limit for Uniformly Distributed Load General Notes: 1 Working Load Limits (P & W) may be limited by other components or assemblies.

General Technical & Application Access Work System Planks 225 P 5 6

L • All Planks meet point load requirement specifi ed for Heavy Duty Loading to AS1576.1 • The sum of individual loads applied to planks must not exceed the Duty Live Load for the platform per bay.

L (m) 1.25 1.80 2.5

P (kN) 4.1 2.8 2.1

Diagonal Braces P?

Shear Capacity of Cup

4.4kN

For all standard sizes

P ? 17kN

P ? 17kN

Platform Brackets P ? 2.0kN

P ? 2.0kN

P ? 2.0kN

Total Load ? 34 kN Max

1 Plank

2 Plank

3 Plank

P = Working Load Limit for Point Load W = Working Load Limit for Uniformly Distributed Load General Notes: 1 Working Load Limits (P & W) may be limited by other components or assemblies.

Paintshop atWSL

Hot Oven for Drying

General Technical & Application Access Work System Applied Load < WLL

Formwork Applications General • Footings and/or foundation shall be satisfactory to support the imposed loads and prevent differential settlement. • All Standards shall be erected plumb. • After squaring up the initial Standards on the first bay, plan bracing is helpful to hold them during erection. • Each bay must have Ledgers/Transoms connected at the cup positions nearest the Adjustable Bases or Adjustable U-Head Assemblies, for example at top and bottom of each leg (and at intermediate positions at design lift heights). • The most recommended type of falsework is built by having continuous lines of Ledgers in both directions. • 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. • No more than one spigot joint per Standard is allowed between vertical lifts of Ledgers/Transoms. • Spigot Joints shall be avoided in Base Lifts. • Joints in Standards should be staggered if possible.

Adjustable U-Head

0 9 1

CUPLOK Open Ended Standard

t f i l p o T

Node t f Bracing i l n i • Bracing shall satisfy two conditions: a M Spigot (1) Provide nodal restraint. Joint (2) Transfer transverse forces to supports. Scaffolding requires that each restraining element be designed to transfer a t f i l transverse load equal to the sum of 0.025 times the axial force in the compression member at the location n i a of the restraint and an additional load equal to half that value for each additional compression member M being restrained, up to a maximum of seven members. This load shall be assumed to act in addition to other loads. t • All nodal points which are considered in defining lift heights shall be restrained. f i CUPLOK l e • The correct amount of bracing shall be calculated, however a minimum amount must always be used. Spigotted s a Standard B This requires one complete bracing system from top to bottom on each row of Standards, once in every four bays, in each direction. 0 Bracing can be provided externally (for example, using the permanent structure to act as a brace, in this 1 1 case it shall be stated in the project documentation with the magnitude of the force) or internally by the bracing system. • Bracing shall be installed immediately after each lift has been erected, and as close as possible to the node points (not more than 100mm from the node point). Adjustable Base • Transverse loads must act at node points on the Standards where Ledgers/ Transoms are fitted (no secondary bending moments are permitted). Suitable footing and foundation • If any brace is not continued to the support and is 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. • When the formwork deck is not restrained (for example, CUPLOCK CUPLOCK no permanent structure like walls or columns to provide Standard Standard lateral restraint) particular care shall be taken in the design to restrain the f ormwork deck and top Adjustable U-Heads. • Individual towers or narrow falsework systems shall be fully and effectively braced and the stability of the system CUPLOK Ledger/Transom be investigated in the design. The slenderness ratio of the system as a whole shall not be greater than that of the Internal Standard External Standard individual compression members.

Plan View

General Technical & Application Access Work System CUPLOCK Standards Formwork Applications Maximum Bay Size 1.8 m X 1.25 m Working Load Limits for internal Standards 30

) N k ( t 25 i m i L d 20 a o L g n 15 i k r o W 10

2.0m Lift

0

100

200

300

400

500

Adjustable Base/Adjustable U-Head Extension (mm)

30

) N k ( t i 25 m i L d 20 a o L g n 15 i k r o W 10

1.5m Lift

1.5m Lift

0

100

200

300

400

500

Adjustable Base/Adjustable U-Head Extension (mm)

40

) N k ( t 35 i m i L d 30 a o L g n 25 i k r o W 20

1.0m Lift

1.0m Lift

1.0m Lift

0

100

200

300

400

Ad justable Base/Ad justable U-Head Extension

500

(mm )

Notes: • These graphs give Working Load Limits for internal Standards which are erected plumb, loaded concentrically and effectively braced in the major directions. • For external Standards reduce Working Load Limits by 15%. • These graphs must be read in conjunction with the Guidance Notes on page 11.

General Technical & Application Access Work System CUPLOCK Assembly Recommendations The following scaffold Assembly Recommendations will give you the foundation principles to assemble a basic scaffold structure. Through experience with the system, different and more complex configurations can be assembled. Persons erecting or dismantling the components should be competent in this type of work. For safety reasons, we recommend that no less than two erectors work as a team to erect CUPLOCK. Notes: • Where assistance is required in erecting more complex designs other than Standard façade type independent scaffolding and configurations not shown in these recommendations. • In certain areas scaffolding may be exposed to high winds and as such special precautions regarding tying in and cladding removal can apply. • In some cases, particular configurations of scaffolds and particular sites may require scaffolders to use safety harnesses and lanyard systems to provide protection against a fall when erecting the scaffold over a void or lean out from the scaffold or supporting structure without the protection of a guardrail. Risk Management When planning the erection of any scaffolding, a site specific Risk Assessment process must be carried out. Generic Hazard Identification/Risk Assessments/Control method profiles and Safe Work Methods Statements for the erection, dismantling and the usage of scaffolding equipment. Hazard Identification and Risk assessments and Safe Work Methods Statements would need to be generated for specific projects. Manual Handling As part of the risk management processes we draw your att ention the requirement that scaffolders must, aspart of their competency, be competent in manual lifting techniques. Therefore, Scaffolders erecting, altering or dismantling scaffolding must follow the manual handling guidelines published by Regulatory Authorities or other guidelines and codes of practice recognised as being acceptable by such Regulatory authorities.

Simple Method of Component Connection

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 fixed locking bar on the Standard to wedge the top cup tightly around the blades providing a positive and rigid connection.

General Technical & Application Access Work System CUPLOCK Assembly Recommendations (cont) 1 Before commencing the erection of any CUPLOCK scaffold, care should be taken to see that the ground is suitable and clear of loose rubble to provide a stable base and clear access for erection. On soft or made up ground, the scaffold should be erected on adequate timber soleplates. As a general rule, each soleplate should be long enough so that it supports at least two Standards. Bricks or masonry blocks are not suitable and should not be used. 2 Check whether or not platform brackets are required adjacent to the workface. If so, you will need to make allowance for the width of the platform brackets and increase the distance between the workface and the closest Standard. 3 Commence erection - where possible - on the highest point of the ground and work down the incline - this will make levelling easier as the scaffolding progresses horizontally. 4 Lay out the Ledgers and Transoms for the fi rst bay in their approximate positions. Then insert an Adjustable Base into each of the first pair of Standards. 5 Where foundations are not level use Adjustable Bases and always start erecting the scaffold from the highest point of the work site. Set the nut of the Adjustable Base near (not at) the bottom of the threaded stem to allow maximum adjustment as the scaffold progresses to lower ground levels. 6 Connect the Standards with a Transom in the lowest cup joint, by inserting the blades into the bottom cups. Approximately level the transom by raising or lowering the Adjustable Base. Always start the scaffold with a 3 metre Standard on the outside face and a 2 metre Standard on the inside. 7 With one erector still holding the first pair of Standards, the second erector inserts an Adjustable Base into the third Standard and connects it to the fi rst pair with a Ledger. The upper cups can then be dropped temporarily into the locking position. The structure is now self supporting and the fourth Standard can now be connected by a further Ledger and Transom and the bay levelled. 8 The bay can now be levelled. Starting from the highest point use a spirit level to adjust the bases so that Ledgers and Transoms are level. Accuracy in levelling at this stage makes for a good start. Do Not Tighten the Top Cups - Yet 9 The bay should now be squared in plan and correctly located in relation to the structure being scaffolded. Check

Start here at top

General Technical & Application Access Work System squareness across the diagonally opposite Standards. Checking squareness is assisted by placing the recommended number of Planks between Transoms and ensuring that Planks sit correctly with an even gap between the ends of the Planks and the supporting Transom. If the Standards are moved an appreciable distance in the squaring up process, then recheck the levels. Fix a Diagonal Brace to the outer face and end face of the first bay. Always start by fixing the brace to the upper cup first: this makes for safer handling. 10 The first bay of CUPLOCK is completed by locating the upper Ledgers and Transoms. Top cups can now be tightened in this first bay. No need for heavy hammering. It is now a simple matter to extend the scaffold structure by connecting Ledgers, Transoms and Standards to the existing bay. The top fixing cups can now be secured with a hammer. 11 The Working Platform can now be constructed using Scaffold Planks as decking and toeboards. 12 Now complete the base layout by adding bays horizontally, levelling and and positioning each bay as you go before tightening cups. Continue the 2m and 3m Standard combination for the fullrun. Note: Erection & dismantling of scaffold bays should be carried out from a fully decked platform or a platform of at least two Planks wide. Refer to local statutory regulations. 13 Planks are now moved up to fully deck out the the first lift. When these Planks remain in place as a Working Platform, Ledgers are positioned at 0.5m and 1m above the planked level to form a guardrail and midrail. For working platforms, toeboards on the outer face are also required. A Mesh Panel which incorporates a toeboard 1m high can be used in lieu of a midrail and toeboard

General Technical & Application Access Work System 14 Additional lifts can now be constructed by adding further Standards into spigots of the Standards of the lower lift and staggering joints wherever possible. Transoms and Ledgers are placed at platform levels connecting them with Ledgers and Transoms. Working levels should be fully decked out and fitted with guardrails, midrails and toeboards (or Mesh Panels) at the required positions. Fully complete the longitudinal erection of a lift before progressing to the next lift. Stagger joints in Standards wherever possible. If 2.0m Standards were used on the inside face of the first lift and 3.0m Standards on the outside face of the first lift and each successive lift uses Standards of the same height ie: inside and outside both 3.0m or both 2.5m or 2.0m then the initial stagger of the joints will remain through the height of the scaffold. 15 Face Bracing All scaffolds require a certain amount of diagonal face bracing to eliminate any tendency for the scaffold to distort or sway. Before the scaffold goes beyond the second lift, Bracing should be added to the outside face and on the ends. Braces attach to the outward facing of the cup on the Standard. Further bracing must be placed on the scaffold as it progresses in length and height. Braces should span from lift level to lift level and cross over joints in Standards and be positioned all the way to the top of the scaffold.

) l a c i p y t ( t h g i e h t f i L x a m m 0 . 2

Typical '? ig ?ag' Longitudinal Bracing along external face

Diagonal Braces provide stability to the scaffold and are used to brace adjacent Standards longitudinally or transversely. Face Diagonal Braces are positioned in the end bays of a scaffold run on the external face of the scaffold. They extend from the first cup near ground level to the top working level. They are typically arranged in an alternating (zig-zag) manner to provide more stability to the scaffold. For scaffold runs exceeding 5 bays in length, intermediate bracing is required where a maximum of 3 bays can be left unbraced. Variations to this spacing must be checked by the appropriate designer and specified in the design layout. End Diagonal Braces are used between end pair of Standards in the transverse direction. They extend from the first cup near ground level to the top working level in an alternating manner.

Alternative 'Node to Node' type Longitudinal Bracing pattern along external face

3 Bays max Unbraced

Transverse Bracing at ends

General Technical & Application Access Work System 16 TIES It is essential that scaffolds be tied to the building or suitable structure to prevent inwards or outwards movement of the scaffold. As such they provide stability and enable effective performance of the scaffold structure as it grows in height and length. As general rule, ties need to commence where the scaffold height exceeds 3 times its least width. Typically ties comprise scaffold tube and right angle scaffold couplers and are connected to the Standards with right angled scaffold couplers. Care must be taken that ties do not obstruct clear access along the full length of the working and access platforms. The scaffold must not be built to allow it to cantilever more than 4m beyond the last level of ties (see diagram). The following examples show tie configurations for assembling around columns and through openings. Note: Where it is not possible to use the typical tie configurations, other tie methods incorporating drilled in friction and 'cast-in' type anchors are available. Warning: Double Lip or U Tie Box Tie Column Tie with Tie tubes must not be Butt transom attached to Ledgers. Tie Plan View tubes must be attached directly to Standards, if this is not possible then scaffold tube must be fixed between Standards with right angled couplers and the tie tube is attached to this scaffold tube. Tie Tubes Tie Configuration The diagram at right shows an example of staggered tie configuration for scaffolding assembled with 2m lifts and without any cladding, such as shade cloth or other semi or non porous material. Ties are installed at no more than 3 bays apart for a maximum bay length of 2.5m in the longitudinal direction and 2 bays apart for bay lengths of 3.00m. Ties should have a 4m overlap in the vertical direction. Cladding the scaffold will cause wind loads to increase and tie spacings may need to reduce accordingly.

x d l a n e v e m o l y m e d e 0 . b i 4 t

) l a c i p y t ( t h g i e h t f i L x a m

x n d e a e r s m e e e g i w t g T m e t a 0 . b 4 s t s r i x l f a e v f m e o L t m e h i 0 g . i 4 T e h

m o . 2

3 Bays max (7.32m) between ties or from a tied return

Staggered Tie Points

Staggered Tie Points

One Bay max between Ties at ends with no returns

Note: When using 3.05m ledgers the max distance between ties is 2 Bays.

Through Ties should be placed as close as possible to the window reveal and secured with right angle couplers.

General Technical & Application Access Work System 16 TIES (cont) Tying to Standards Ties tubes must be connected to Standards and be parallel to transoms at a position adjacent to the junction of the Transom and Ledgers, with the following restrictions: (a) Within 300mm from the underside of the cup at the junction - connected to the front Standard with addition of a Check Coupler. (b) Further than 300mm from underside of the cup at the junction - Tie connected to both front and rear Standards. (c) If unable to connect to two Standards then reinforce front Standard for the full height of the lift with scaffold tube and swivel couplers with couplers attached at 900mm centres. Note: The 300mm distance given in (a), (b) and (c) may need to be reduced, subject to the amount of tie force. Increased distance between tie points In cases where ties cannot be placed in the correct position, where ties have to be removed, where tie spacings exceed those given in these assembly recommendations or in scaffolds which extend above the building, with the result that typical tie spacings given in these Assembly Recommendations cannot be achieved, then consult WSL for technical design assistance with tie s pacing and configurations to suit your specific needs.

More than 300mm

Within 300m m

Ti e

Connect to both Standards

Tie

More than 300mm

Tie

Add Check Coupler Reinforce Tied Standard

Add Check Coupler

(a) (b)

(c)

Maximum Height of Scaffold When determining the maximum height of a scaffold, a number of factors must be considered. • Live load of working platforms, for example Heavy Duty, Medium Duty or Light Duty. • Number of Working Platforms. • Live load of Platform Brackets. • Dead load of scaffold, for example Standards, Transoms, Ledgers, Guardrails, Mesh Guards, Platform Brackets, Planks, Bracing, shadecloth and chainwire mesh. • The position of the top tie in relation to the top of the scaffold. • Wind Loading (in relation to tie forces). • Strength of the supporting structure for the scaffold. Scaffolding configurations can vary greatly, so for a CUPLOCK scaffold of typically 1.25m wide, constructed using 2m lifts, braced and tied in accordance with patterns given in these recommendations, without cladding, with a maximum of two Heavy Duty Working Platform levels (6.6kN), two levels of Planks and Platform Brackets, guardrails at the outside face at 1m vertical spacing for full height of scaffold, diagonal bracing for full height, the maximum height of the scaffold scaffold constructed with bay lengths of 3.00m or less is 45m. Note: Any additional equipment such as additional planked levels, Working Platforms, Platform Brackets, spurs or the like will increase leg load and hence reduce the maximum height of the scaffold. Therefore, where assessment shows that scaffold configuration exceeds the above conditions, consult Engineering Representative for technical design assistance with the maximum heights of CUPLOK and tying configurations to suit your specific needs.

General Technical & Application Access Work System 17 Access and Egress Methods Every working platform level must be provided with a safe and suitable access. This can be achieved by means of a built-in ladder or stair access tower or by direct access from within the building or structure. Stair access can be constructed with either Aluminium Stair units or steel Stair Stringers as outlined on the following pages:

Ladder Access 2.44m

1.3m Planks x 2

Standard Ladder secured to alternate each side of Bay Install guarding & edge protection around opening

m 7 2 . 1

(i) Ladder Access 1.3m Transom s Ladder access is typically used where only a few persons 1.27m 2.4m Planks x 3 need access to the working platform and where tools and equipment can be delivered separately to the working Ladder Access Transom platform (such as by rope and gin wheel, materials hoist or secured between Ledger s 2.4m Ledger s 3.2m Braces crane). Ladder Access Bay Ladder access bays can be constructed within the main run Plan View of the scaffold, however, where space permits it is preferable that a separate ladder access bay be placed adjacent to the main run. Single ladders need to extend at least 0.9m above the landing level, secured at top and base and successive landing levels should be vertically spaced at no more that 6m. CUPLOCK Ladder Access Transoms are used to enable the Ladders inclined at slope of between formation of an opening within the deck through which the 4 to 1 and 6 to 1 ladder can pass. These Transoms span between Ledgers and are typically positioned at midspan of the Ledgers or at the appropriate position to support two shorter length Planks. The remaining bay width is decked out with Planks that span between Transoms in the usual manner. Important: Ensure that guarding and edge protection is installed around openings in Ladder Access Bays that are in or beside working platforms.

x a m m 9 . 0

Tie Ladder Access Bay at Standards every 4.0m ma x

x a m m 0 . 6

x a m m 0 . 4

1.27m

End View

2.44m

Elevation

WSL CUPLOK Erection Guide General Before commencing the erection of any WSL CUPLOCK 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 Adjustable Base to spread the load effectively t o the foundation. Sole plates may also be required when assembled on a concrete slab. All Adjustable Bases and Standards must be checked as they are erected to ensure they are WSL CUPLOCK components; the use of CUPLOCK Standards or CUPLOCK Adjustable Bases will reduce the structure’s load capacity to that of CUPLOCK losing the advantage of the higher WSL CUPLOCK 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. The first four Adjustable Bases 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 first pair of Standards, the third Standard of the first bay is then placed in position over its Adjustable Base 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 first 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 Adjustable Base taking care to maintain the lowest setting where indicated on the

drawing. The first lift of Ledgers/Transoms is then added and Adjustable Braces are fixed to two adjacent sides of the bay to maintain the rigidity of the bay (refer also to Guideline Notes on page 12). From this first 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 first bay. In either type of construction as each subsequent bay is added it must be levelled. The structure is built upwards by fixing the Ledgers for more lifts in height adding additional Standards as the drawing dictates. The last Standard must be a WSL CUPLOCK Open Ended Standard to accommodate the WSL CUPLOCK Adjustable Base or Adjustable U-Head Assembly. After the structure has been erected the formwork soffit bearers are placed in the U-Heads and are levelled by means of the screw adjustment of the Adjustable U-Head Assembly. 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.

WSL CUPLOCK Bracing Method Examples Example of Side Elevation with Soffit Formwork Restrained Externally by Walls and Columns • Soffit formwork is restrained externally in both directions (eg by walls, columns*). • Braces are terminated at every lift. • Bottom jacks are not restrained. (Only where braces are not required to transfer external transverse forces to foundation/footing as determined by design). * Permanent structure(Project Engineer must verify suitability of Structure.)

Example of Side Elevation with Soffit Formwork Restrained by Internal Bracing • Soffit formwork is not restrained externally • Top deck is restrained with internal bracing. • Bracing is continued from support to top Ledger t o Adjustable U-Head. • Continuous bracing is the preferred method. • Bottom Adjustable Bases are restrained.

Adjustable Braces

Adjustable Base with U-Head

Adjustable Jack Braces used longitudinally and transversely

Open ended WSL CUPLOCK Standard

Max 100mm (typical)

Ledger (typical)

Adjustable Brace (typical)

A

Section A-A

Note: Base plates may be required to be anchored to resist the horizontal and/or uplift components of the bracing force.

A

Ledger

WSL CUPLOCK Bracing Method Examples Conventional formwork

Example of Front Elevation (Row or Tower Confguration)

WSL CUPLOCK Adjustable Base with U-Head

Note:

WSL CUPLOCK Open Ended Standard This symbol indicates that the top deck is restrained externally in both directions, (eg by walls, columns).

s r e g d e L

Adjustable Braces WSL CUPLOCK Adjustable Base

Example of Side Elevation (Row Confguration) Conventional formwork

WSL CUPLOCK Adjustable Base with U-Head WSL CUPLOCK Open Ended Standard

Adjustable Braces

Adjustable Braces Ledgers

WSL CUPLOCK Adjustable Base

Example of Side Elevation (Tower Confguration) Conventional formwork

WSL CUPLOCK Open Ended Standard

Adjustable Braces Ledgers

WSL CUPLOCK Adjustable Base

Staircase Towers CUPLOCK staircase towers provide a safe, user-friendly solution and are quick and simple to erect. Additionally, by speeding the circulation of staff, staircase towers generate significant time savings for everyone on site. There are four basic staircase options in the CUPLOCK range; from simple, compact units to high capacity, full public access models. All use the basic CUPLOCK system to provide the main structure - with a small number of additional staircase components, including a choice of steel and aluminium stair Units. The CUPLOCK staircase tower offers a stable, rigid structure designed with a key emphasis on user safety. • Broad landing platforms with steel or timber battens • Full hand railing to stairs and landings with double guardrails • Stairways are rigid and provide firm, non-slip treads to ensure maximum security for users • The removal of potentially hazardous deck openings normally created by ladder access

Staircase sizes CUPLOCK staircase towers are based on three plan layouts, using 8 leg tower structures. Staircase flights are available in steel, aluminium and modular form - (separate stringer and tread units), for maximum flexibility. Each staircase type comes in 1.5m or 2m lifts. Different lift sizes may be combined in the same tower to suit platform Levels.

8 Leg Staircase Tower Plan area: 1.8m x 4.4m This larger configuration can be built to a height of 38m, subject to ties and loadings. Landing platforms are 1.3m wide and the staircase is 0.8m wide. It can be built in lift heights of 1.5 or 2m and using either aluminium or steel stair units. The plan module is 4.4m long overall, incorporating a centre bay of 1.8m and two 1.3m landing modules at either end. Omega transoms are used in conjunction with timber or steel battens to form the landing platforms. The width of the tower is 1.8m. Exit from the tower at upper levels is made from the top landing platform by removing the appropriate guardrail.

Formwork Applications Applied load < WLL 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 12 are met. Working Load Limits as shown on the following pages are for two cases: Case 1: Bottom Adjustable Bases and top Adjustable U-Head Assemblies are restrained in both directions. Case 2: Bottom Adjustable Base is not restrained but top Adjustable U-Head Assembly is 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. • 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.

WSL CUPLOCK Top Adjustable U-Head Assembly

0 9 1


t f i l p o T

Formwork Applications Applied load < WLL 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 12 are met. Working Load Limits as shown on the following pages are for two cases: Case 1: Bottom Adjustable Bases and top Adjustable U-Head Assemblies are restrained in both directions. Case 2: Bottom Adjustable Base is not restrained but top Adjustable U-Head Assembly is 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. • 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.

WSL CUPLOCK Top Adjustable U-Head Assembly

0 9 1


t f i l p o T

Spigot Joint

t f i l n i a M

Definitions – Plan View WSL CUPLOCK Standard

Y

WSL CUPLOCK Standard

Node

CUPLOCK Ledger/Transom

X

Internal Standard

External Standard t f i l n i a M

Defnitions – Side View WSL CUPLOCK Adjustable Brace

CUPLOCK Ledger/Transom

Suitable lateral support

direction

WSL CUPLOCK Spigotted Standard

X direction

A 'A' Bottom Adjustable Base is NOT restrained in the 'X' direction

Note:

WSL CUPLOCK Adjustable Brace

WSL CUPLOCK Adjustable Brace

0 1 1

X direction

B

t f i l e s a B

C

'B' and 'C' Bottom Adjustable Bases are restrained in the 'X' direction

0 Same applies to 'X' direction. 'Y' direction is 90 to the 'X' direction

Suitable footing and foundation

SUPERCUPLOK Bottom Adjustable Base

Guideline Notes General 1 The Standards, Adjustable Bases and Adjustable U-Head Assemblies must be checked to ensure that only WSL CUPLOCK 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 first bay, plan bracing is helpful to hold them during erection. 5 Each bay must have Ledgers/Transoms connected at the cup positions nearest the Adjustable Bases 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 Adjustable Bases 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. WSLtandard requires that each restraining element be designed to transfer a transverse load equal to the sum of 0.025 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 defining lift heights shall be restrained. When braces are required to only provide nodal restraint then bottom Adjustable Bases may be used unrestrained. In this case the tables for CASE 2 shall be used. Top Adjustable U-Head Assemblies shall always be restrained, externally or internally). 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 WSL CUPLOCK bracing system. 5. Bracing should be installed immediately after each lift has been erected and fixed to the Ledgers as close as possible to the node points (not more than 100mm from the node point). 6. Transverse loads must act at node points on the Standards where Ledgers/Transoms are fitted (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 f ormwork 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.

Formwork Applications For 2.44m x 2.44m maximum bay size CASE 1: Top Adjustable U-Head: Restrained, e = 0, 8, 15, 25 and 55mm Bottom Adjustable Base: Restrained, e = 0, 8 and 15mm Working Load Limit - WLL (kN) per Standard/Leg Note: WLL for Bottom and Top Adjustable Bases or U-Heads are shown beneath their shaded area.

Lift = 1.0m, Internal Standard

Lift = 1.0m, External Standard

Bottom Adjustable Base


Top Adjustable U-Head


Extension (mm)

e = 0mm

e = 8mm

e = 15mm

e = 25mm

e = 55mm

Extension (mm)

e = 0mm

e = 8mm

e = 15mm

e = 25mm

e = 55mm

100

75.9

70.4

66.2

50.6

27.3

100

72.7

66.4

58.9

47.8

27.3

200

75.4

70.0

64.9

47.9

26.2

200

72.3

66.2

58.1

47.3

26.2

300

75.0

69.6

60.2

44.4

25.3

300

71.8

65.7

57.5

44.4

25.3

400

74.7

69.5

54.6

41.2

24.0

400

71.5

65.3

54.6

41.2

24.0

500

74.3

62.5

48.9

37.7

22.8

500

71.0

62.5

48.9

37.7

22.8

600

73.9

54.9

43.8

34.5

21.4

600

70.7

54.9

43.8

34.5

21.4







Extension (mm)

e = 0mm

e = 8mm

e = 15mm

e = 25mm

e = 55mm

Extension (mm)

e = 0mm

e = 8mm

e = 15mm

e = 25mm

e = 55mm

100

51.4

47.7

44.8

39.5

27.3

100

47.1

43.0

39.4

34.0

23.9

200

51.1

47.6

44.6

39.2

26.2

200

46.8

42.8

39.3

33.8

23.8

300

50.9

47.3

44.4

39.1

25.3

300

46.5

42.5

38.8

33.5

23.8

400

50.5

47.1

44.1

38.7

24.0

400

46.2

42.3

38.5

33.3

23.7

500

50.4

46.9

43.7

37.7

22.8

500

45.9

42.1

38.3

33.0

22.8

600

50.1

46.7

43.4

34.5

21.4

600

45.7

41.9

38.0

32.9

21.4







Extension (mm)

e = 0mm

e = 8mm

e = 15mm

e = 25mm

e = 55mm

Extension (mm)

e = 0mm

e = 8mm

e = 15mm

e = 25mm

e = 55mm

100

32.8

32.1

31.5

30.7

26.9

100

29.3

28.5

27.8

26.9

21.4

200

32.8

32.0

31.5

30.7

26.2

200

29.3

28.4

27.8

26.9

21.3

300

32.8

32.0

31.4

30.6

25.3

300

29.2

28.4

27.7

26.8

21.3

400

32.7

32.0

31.4

30.6

24.0

400

29.2

28.3

27.7

26.8

21.2

500

32.6

31.9

31.3

30.5

22.8

500

29.1

28.3

27.6

26.7

21.1

600

32.6

31.9

31.3

30.5

21.4

600

29.1

28.3

27.6

26.7

21.1

Notes: 1 WLL for the lift is the minimum value of W LLs for Top and Bottom Adjustable Bases/U-Head Assemblies. 2 e = Load eccentricity (mm) 3 Limit State Conversion Factor = 1.5 4 These charts must be read in conjunction with the Technical Information and the Bracing Guideline Notes on pages 11 and 12. 5 It is recommended to consider the load with at least 8mm eccentricity for possible unintentional eccentricity.

Formwork Applications For 2.44m x 2.44m maximum bay size CASE 2: Top Adjustable U-Head: Restrained, e = 0, 8, 15, 25 and 55mm Bottom Adjustable Base: Not restrained, e = 0, 8 and 15mm Working Load Limit - WLL (kN) per Standard/Leg

Lift = 1.0m, Internal Standard Top Adjustable U-Head Extense= ion 0mm (mm)

e= 8mm

Lift = 1.0m, External Standard Bottom Adjustable Base

e= e= e= 15mm 25mm 55mm

Extense= ion 0mm (mm)

e= 8mm

e= 15mm

Top Adjustable U-Head Extense= ion 0mm (mm)

e= 8mm


e= e= e= 15mm 25mm 55mm


e= 8mm

e= 15mm

100

75.9

70.4

66.2

50.6

27.3

100

75.9

70.4

66.2

100

72.7

66.4

58.9

47.8

27.3

100

72.7

66.4

58.9

200

75.4

70.0

64.9

47.9

26.2

200

75.4

70.0

64.9

200

72.3

66.2

58.1

47.3

26.2

200

72.3

66.2

58.1

300

75.0

69.6

60.2

44.4

25.3

300

75.0

69.6

60.2

300

71.8

65.7

57.5

44.4

25.3

300

62.5

62.5

57.5

400

74.7

69.5

54.6

41.2

24.0

400

55.7

55.7

54.6

400

71.5

65.3

54.6

41.2

24.0

400

45.5

45.5

45.5

500

74.3

62.5

48.9

37.7

22.8

500

43.8

43.8

43.8

500

71.0

62.5

48.9

37.7

22.8

500

32.9

32.9

32.9

600

73.9

54.9

43.8

34.5

21.4

600

36.1

36.1

36.1

600

70.7

54.9

43.8

34.5

21.4

600

26.3

26.3

26.3


e= 8mm


e= e= e= 15mm 25mm 55mm


e= 8mm

e= 15mm


e= 8mm


e= e= e= 15mm 25mm 55mm


e= 8mm

e= 15mm

100

51.4

47.7

44.8

39.5

27.3

100

51.4

47.7

44.8

100

47.1

43.0

39.4

34.0

23.9

100

47.1

43.0

39.4

200

51.1

47.6

44.6

39.2

26.2

200

51.1

47.6

44.6

200

46.8

42.8

39.3

33.8

23.8

200

46.8

42.8

39.3

300

50.9

47.3

44.4

39.1

25.3

300

50.9

47.3

44.4

300

46.5

42.5

38.8

33.5

23.8

300

46.5

42.5

38.8

400

50.5

47.1

44.1

38.7

24.0

400

50.5

47.1

44.1

400

46.2

42.3

38.5

33.3

23.7

400

45.5

42.3

38.5

500

50.4

46.9

43.7

37.7

22.8

500

43.8

43.8

43.7

500

45.9

42.1

38.3

33.0

22.8

500

32.9

32.9

32.9

600

50.1

46.7

43.4

34.5

21.4

600

36.1

36.1

36.1

600

45.7

41.9

38.0

32.9

21.4

600

26.3

26.3

26.3


e= 8mm


e= e= e= 15mm 25mm 55mm


e= 8mm

e= 15mm


e= 8mm


e= e= e= 15mm 25mm 55mm


e= 8mm

e= 15mm

100

32.8

32.1

31.5

30.7

26.9

100

32.8

32.1

31.5

100

29.3

28.5

27.8

26.9

21.4

100

29.3

28.5

27.8

200

32.8

32.0

31.5

30.7

26.2

200

32.8

32.0

31.5

200

29.3

28.4

27.8

26.9

21.3

200

29.3

28.4

27.8

300

32.8

32.0

31.4

30.6

25.3

300

32.8

32.0

31.4

300

29.2

28.4

27.7

26.8

21.3

300

29.2

28.4

27.7

400

32.7

32.0

31.4

30.6

24.0

400

32.7

32.0

31.4

400

29.2

28.3

27.7

26.8

21.2

400

29.2

28.3

27.7

500

32.6

31.9

31.3

30.5

22.8

500

32.6

31.9

31.3

500

29.1

28.3

27.6

26.7

21.1

500

29.1

28.3

27.6

600

32.6

31.9

31.3

30.5

21.4

600

32.6

31.9

31.3

600

29.1

28.3

27.6

26.7

21.1

600

26.3

28.3

26.3

Notes: 1 WLL for the lift is the minimum value of W LLs for Top and Bottom Adjustable Bases/U-Head Assemblies. 2 e = Load eccentricity (mm) 3 Limit State Conversion Factor = 1.5 4 These charts must be read in conjunction with the Technical Information and the Bracing Guideline Notes on pages 11 and 12. 5 It is recommended to consider the load with at least 8mm eccentricity for possible unintentional eccentricity.

Cup Lock Manual

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