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Marcegaglia Buildtech Realpont system 75 Instruction Manual

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Summary of Contents for Marcegaglia Buildtech Realpont system 75

  • Page 1 Instruction manual Prefabricated frames...
  • Page 2 SUPPLY Various modes of supply are available: • sale • sale with buyback agreement • rent • rent with redemption All these modes of supply can be combined with the following services: • assembly • disassembly • service at the building site MATERIAL hot dip galvanized steel Sendzimir galvanized steel...

  • Page 3: Table Of Contents

    Index REALPONT SYSTEM DESCRIPTION Prefabricated frames: Realpont system 75 Prefabricated frames: Realpont system 105 Realpont system components TEL DAL T5/UNIFORM SYSTEM DESCRIPTION Prefabricated frames: Tel Dal T5/Uniform system Tel Dal system T5 components Uniform system components TUBE-COUPLER SYSTEM DESCRIPTION Tube-coupler system components...
  • Page 4 Instruction manual Prefabricated frames •...
  • Page 5 Description Realpont system Prefabricated frames: Realpont system 75 Prefabricated frames: Realpont system 105 Realpont system components Instruction manual Prefabricated frames •...

  • Page 6: Prefabricated Frames: Realpont System 75

    Prefabricated frames: Realpont system 75 System with 75 cm frames with bushings 750 mm deep/wide frame • Painted or hot dipped galvanizing protection Erection of 2500 mm and 3000 mm mixed bay structures • Bushing fit- tings SUPPLY Sales, rent.

  • Page 7: Prefabricated Frames: Realpont System 105

    Prefabricated frames: Realpont system 105 System with 105 cm frames with bushings Installation of 1050 mm deep working bays • Protection or hot dipped galvanizing protection • Erection of 2500 mm and 3000 mm mixed bay structures • Bushing fittings. SUPPLY Sales, rent.

  • Page 8: Realpont System Components

    Realpont system - Components Base plate Realpont half-frame material IT/EN 3030100006 0,92 material 1050x1300 3040105980 15,04 1050x1300 3040105981 15,08 Adjustable base jack 1050x1300 3040105991 15,99 Realpont compensation-frame material IT/EN 3040800902 2,49 material IT/EN 3060300141 3,30 750x1300 3040106130 13,17 1000 IT/EN 3040501012 4,69 750x1300...
  • Page 9 Horizontal-diagonal Horizontal-diagonal brace brace for pedestrian walk-thru frame with forged connection device material material 1798x3000 3040201745 7,68 748x1800 3040206160 2,86 748x1800 3040206165 3,33 748x2500 3040206175 5,94 Vertical-diagonal brace 748x3000 3040201725 6,87 1048x1800 IT/EN 3040206010 3,12 1048x1800 IT/EN 3040206015 3,26 1048x2500 IT/EN 3040201195 6,23...
  • Page 10 Steel definitive Side fencing structure guardrail frame with toeboard material 3040201691 14,08 1050 3040201681 15,10 1800 3040201661 16,98 material 2500 3040201671 18,74 3040206040 8,25 3000 3040201751 21,96 3040206141 8,67 3040206041 9,37 1050 3040206100 10,75 Transom 1050 3040206131 10,82 1050 3040206101 11,23 Securdeck scaffold steel plank...
  • Page 11 Steel plank Toeboard with trapdoor material 1800 3070200001 5,02 2500 3070200051 7,35 material 3000 3070200071 7,321 1800x490x50 3070100011 28,68 1800x490x50 3070100031 28,68 Ladder 2500x490x50 3070800031 38,41 1800x660x60 3150200191 35,04 2500x660x60 3150200201 45,38 Aluminium-plywood plank with frontal opening trapdoor material material 2000 3070300130 6,05...
  • Page 12 Ladder handrail Walk-thru frame material 3070300141 2,78 Simple reinforced terminal material 1796x2516 3040104081 33,68 1796x2400 3040104051 34,14 Lower support material 3040404080 7,15 3040404081 7,84 3040303021 7,84 Top guardrail upright material 3040101030 18,21 3040101031 19,66 Upper support material 2000 3040404090 11,82 2000 3040404091 12,36...
  • Page 13 Bracket Bridging ledger for Realpont system 75 material 3040306031 6,54 3040306030 6,82 3040307501 7,01 Bracket for Realpont system 1050 material 3600 3040604020 41,84 3600 IT/EN 3040604021 43,50 5000 IT/EN 3040601031 52,82 5400 3040604040 60,66 material 5400 IT/EN 3040604041 63,06 1050...
  • Page 14 Instruction manual Prefabricated frames •...
  • Page 15 Description Tel Dal T5/Uniform system Prefabricated frames: Tel Dal T5/Uniform system Tel Dal system T5 - Components Uniform System - Components Instruction manual Prefabricated frames •...
  • Page 16 Prefabricated frames: Tel Dal T5/Uniform system System with 105 cm frames with pawl 1050 mm deep/wide frame • Painted protection by immersion • Erection of 1800 mm mixed bay structures • Pawl fittings SUPPLY Sales, rent. UPRIGHTS MATERIAL - Steel grade S235JR - Steel tubes: 48.3 mm outside diameter, 2.9 mm nominal gage PROTECTION - Painting performed by immersion with resistance tested to ASTM D...

  • Page 17: Tel Dal System T5 Components

    Tel Dal system T5 - Components Base plate Half-frame Tel Dal T5 material cod. 3030100006 0,92 material cod. Adjustable base jack 1330x1050 3040104010 14,26 1330x1050 3040104011 14,30 Spigot pin material cod. 3040701006 0,12 material cod. 3040501062 2,42 Double guardrail P22 1000 3040501012 4,69...
  • Page 18 Ledger P11 Side fencing structure with toeboard T5 material cod. 3040204020 2,42 3040204021 2,76 material cod. Vertical-diagonal brace 3040206120 12,05 3040206121 12,39 Steel plank with trapdoor material cod. 3040204000 2,99 3040204001 3,06 Horizontal-diagonal brace material cod. 1800x500x50 3070100011 28,68 Toeboard material cod.
  • Page 19 Ladder Upright TD4 material cod. 2000 3070300130 6,05 2000 3070300131 7,35 material cod. Compensation frame ladder 3040404020 7,07 3040404021 7,42 Reinforcement upright RP12 material cod. 1330 3070300160 3,96 1330 3070300161 4,15 Ladder handrail material cod. 2000 3040406030 8,26 2000 3040406031 8,58 material cod.
  • Page 20 Guardrail ledger Vertical-diagonal brace for walkthrough passage for walkthrough passage with forged with forged connection device connection device material cod. material cod. 3040204105 4,26 3040204115 5,03 Horizontal-diagonal brace Lower support Tel Dal for walkthrough passage with forged connection device material cod.
  • Page 21 Upper support Tel Dal Street protection fan material cod. 3040104030 25,32 3040104031 26,25 material cod. 3040301050 9,19 3040301051 9,65 Inside bracket Bridging ledger material cod. 3040304050 4,29 3040304051 4,43 Bracket for non axial piers material cod. 3600 3040604000 24,39 material cod.

  • Page 22: Uniform System Components

    Uniform System - Components Base plate Half-frame Uniform material cod. material cod. 3030100006 0,92 1330x1050 3040102010 14,79 Adjustable base jack Spigot pin material cod. 3040701006 0,12 Side fencing truss Uniform material cod. 3040501062 2,42 1000 3040501012 4,69 Frame Uniform material cod.
  • Page 23 Vertical and Steel plank horizontal-diagonal brace with trapdoor Uniform material cod. material cod. 1800x490x50 3070100011 28,68 3040202000 2,68 Toeboard Transom Uniform material cod. material cod. 1800x200 3070200001 5,02 3040202030 1,82 Ladder Side fencing structure with toeboard Uniform material cod. material cod.
  • Page 24 Compensation frame ladder Top end double element Uniform material cod. 1330 3070300160 3,96 material cod. 1330 3070300161 4,15 3040402010 9,00 Ladder handrail Lower support Uniform material cod. 2000 3070300141 2,78 material cod. Top guardrail 3040102030 17,10 upright Uniform Upper support Uniform material cod IT daN IT...
  • Page 25 Bracket for non axial Bridging ledger piers Realpont/Uniform material cod. 3600 3040604000 24,39 material cod. 3600 3040604001 25,08 1050 3040306000 8,50 5400 3040601020 50,70 1050 5400 3040306001 8,82 3040601021 52,32 Bracket brace Bridging ledger junction material cod. material cod. 1050 3040605010 8,47 1050...
  • Page 26 Instruction manual Prefabricated frames •...
  • Page 27 Description Tube-coupler system Tube-coupler system - Components Manufacturing standards - Aut. Min. 15/VI/2702/14.03.01.01 del 12/02/2009 - Est. 15/VI/11535/14.03.01.02 del 24/06/2009 - UNI EN 74, EN 39 - Decreto legislativo 9 Aprile 2008 n. 81 - Disciplinare UNICMI sul marchio SQ Instruction manual Prefabricated frames •...
  • Page 28 Tube-coupler system - Components Base plate 4-bolts right angle coupler material cod. material cod. 3030100006 0,92 3020300006 1,42 3020300032 1,35 Adjustable base jack Simple 4-bolts coupler material cod. 3040800902 2,49 material cod. 1000 3040501012 4,69 3020200006 1,93 2-bolts right angle coupler Swivel coupler material cod.
  • Page 29 Pivot coupler material cod. material cod. 3020000006 1,73 3030000001 0,63 Simple coupler Anchoring screw material cod. material cod. 3030200000 1,68 3020500006 0,69 Steel caster Head coupler material cod. material cod. 3020100006 0,94 3030300000 10,00 Scaffold tube S235JR material cod. 3010800035 3,45/ml Instruction manual Prefabricated frames...
  • Page 30 Instruction manual Prefabricated frames •...

  • Page 31: Instructions For Use Pre-Erection

    Instructions for use Pre-erection Erection Dismantling Transport Instruction manual Prefabricated frames •...
  • Page 32 Pre-erection Clothing CHECKING THE TECHNICAL DOCUMENTATION Working attire - overalls, gloves, shoes and all clothing must bear the The documentation described in the following sections must be availa- CE mark and comply with EN 510 Cat.II. Standards. ble on the work site at all times. Other provisions Some of the documentation will be provided by the scaffolding ma- nufacturer and some by the authorized technician from the Company...

  • Page 33: Erection

    Erection During the erection stage, the mounting designs and the prescriptions issued by the Site Engineer must be scrupulously followed. As regards the stages of scaffolding erection, adhere to local regulations. The main areas on which to focus attention during the erection stages follow.
  • Page 34 other than those foreseen in the dimensional allowance designs of the • truss beams system’s elements are not permitted. • hoisting connections In the event that uprights are not parallel to a plumb line, they must be • anchorages dismantled and erected again, if possible, or alternatively appropriate static verifications must be carried out that will guarantee that the The checks must be carried out periodically, even while the scaffol- specific scaffolding is suitable to fulfill the requirement for which it...
  • Page 35 Winches and Pulleys Overlapping of personnel When winches or pulleys – even temporary – are used, the parts of the Organize the erection teams in such a way that they are never positio- scaffolding affected by such equipment must be checked. ned one above the other on the same part of the scaffolding.

  • Page 36: Dismantling

    Dismantling Transport During dismantling, as during the erection stage, all precautions re- Transport must be organized in detail analogous to the preceding phases quired by the regulations in force relating to safety equipment must be and, as a minimum, paying particular attention the areas described taken.

  • Page 37: Anchorages General Characteristics

    Anchorages General characteristics Tie anchorage Ring anchorage Screw-down anchorage Bracing anchorage Truss beam in tube-coupler anchorages Anchorage with reinforced rod for reinforced concrete Anchorage with steel structural plate Instruction manual Prefabricated frames •...
  • Page 38 General characteristics JOINT CREEP STRENGTH SPLIT RINGS The extraction strength of the split rings must be provided by the manu- During static checks, creep strength must be considered and determined facturer and in any case it is a good rule to apply a safety factor of ϒ=1,5. through crimp tests in officially and legally recognized laboratories: Ring properties to be requested from the manufacturer: •...

  • Page 39: Tie Anchorage

    Tie anchorage ERECTION PLAN Effected according to the following layouts: metal decking metal decking scaffolding frame scaffolding frame metal decking scaffolding frame Instruction manual Prefabricated frames •...
  • Page 40 Tie anchorage CHECKING THE ANCHORAGE SUBJECT TO AN F LOAD WARNINGS Checks to be carried out are the following: When using tie anchorages, it is recommended to carry out the fol- lowing: • joint creep check: • check the correct hold of the anchorage joints to ensure creep resistan- <...

  • Page 41: Ring Anchorage

    Ring anchorage ERECTION PLAN Effected according to the following layouts metal decking metal decking ring scaffolding frame scaffolding frame metal decking metal decking scaffolding frame ring scaffolding frame ring Instruction manual Prefabricated frames •...
  • Page 42 Ring anchorage CHECKING THE ANCHORAGE SUBJECT TO AN F LOAD CHECKING THE ANCHORAGE SUBJECT TO AN F LOAD The checks to be carried out are the following: loads as calculated in the ‘Loads’ section is divided on n number of C or D type anchorages.

  • Page 43: Bracing Anchorage

    Anchorage with force screw Ancoraggio a sbadacchio ERECTION PLAN ERECTION PLAN Effected according to the following layout A monolateral constraint, resistant only to erected compression as laid out in the following diagrams. metal metal decking decking scaffolding frame scaffolding frame In special cases, when other types of anchorages are not permitted, force LOADS screws can be used, provided their working is checked and monitored...
  • Page 44 Bracing anchorage λ = _____ from which ω is derived from the tables of existing standards and regulations. Checking instability σ = ω x _____ < σ1 • compressive strength check of the regulating screw Limit the screwing out of the screw within a maximum of 15 ÷ 20 cm in order to omit factors of instability and only carry out resistance checks.

  • Page 45: Truss Beam In Tube-Coupler Anchorage

    Truss beam in tube-coupler anchorage ERECTION PLAN OF HORIZONTAL BEAMS ERECTION PLAN OF VERTICAL BEAMS For buildings under construction with framed structures in reinforced Truss beams can be erected on every bay or on alternate bays to act as concrete or steel, or for building maintenance with large areas of glass, loads.
  • Page 46 Truss beam in tube-coupler anchorage LOADS CHECKING THE TRUSS BEAMS The wind pressure (Pw) is calculated according to the regulations and Having defined the acting loads and the static diagrams as explained in standards in force and the project diagrams applicable to the scaffolding the previous section, proceed with defining the truss beams using the surface exposed to the wind.

  • Page 47: Anchorage With Reinforced Rod For Reinforced Concrete

    Anchorage with reinforced rod for reinforced concrete ERECTION PLAN CHECKING THE ANCHORAGE SUBJECT TO AN F LOAD The checks to be carried out are the following: • joint creep check: < R reinforcing rod sunk in the casting reinforced concrete wall •...
  • Page 48 Anchorage with structural steel plates In general and in particular for the layout shown in ‘ A nchorage with ERECTION PLAN structural steel plate’ , the vertical load applied by the scaffolding uprights In the event of there being a particular geometry to the scaffolding must be added to the wind element.
  • Page 49 Erection sequence Instruction manual Prefabricated frames •...
  • Page 50 Connection elements Instruction manual Prefabricated frames •...
  • Page 51 Erection sequence 1 • positioning the base 4 • inserting the ledger 2 • positioning the frames 5 • erection second frame with guardrail 3 • leveling the base 6 • erecting the second ledger Instruction manual Prefabricated frames •...
  • Page 52 Erection sequence 7 • erecting the vertical-diagonal brace 10 • checking the level 8 • checking the level 11 • erecting the next modules 9 • checking the distance from the facade 12 • erecting the next modules Instruction manual Prefabricated frames •...
  • Page 53 Erection sequence 13 • erecting the next modules 16 • erecting metal ledger boards 14 • inserting the anchorage 17 • erecting metal ledger boards 15 • inserting the anchorage 18 • erecting plank with trapdoor Instruction manual Prefabricated frames •...
  • Page 54 Erection sequence 19 • erecting plank with trapdoor 22 • first level 20 • ladder of the plank with trapdoor 23 • passage to the upper level 21 • inserting the ladder of the plank with trapdoor 24 • attaching the holding cable before mounting the bay Instruction manual Prefabricated frames •...
  • Page 55 Erection sequence 25 • closing the trapdoor 28 • erecting level 1 frame 26 • start of frame erection of level 1 29 • erecting frame pins 27 • erecting level 1 frame 30 • erecting the level 1 ledger Instruction manual Prefabricated frames •...
  • Page 56 Erection sequence 31 • erecting 1st level guardrail 32 • erecting the level 1 vertical-diagonal brace Instruction manual Prefabricated frames •...
  • Page 57 Erection sequence 33 • erecting the next level 1 modules 36 • level 1 toeboard detail 34 • erecting the level 1 rear ledger 37 • level 1 toeboard detail 35 • erecting the level 1 toeboard 38 • erecting the level 1 toeboard Instruction manual Prefabricated frames •...
  • Page 58 Erection sequence 39 • erecting 1st level side fencing 42 • erecting the level 2 planks 40 • erecting 1st level side fencing 43 • erecting the level 2 planks 41 • erecting an anchorage on level where needed 44 • erecting the level 2 planks with trapdoor Instruction manual Prefabricated frames •...
  • Page 59 Erection sequence 45 • erecting the level 2 planks with trapdoor 48 • erecting top upright joint on level 2 46 • erecting planks on all level 2 modules 49 • passage to the level 2 47 • erecting top upright on level 2 50 •...
  • Page 60 Erection sequence 51 • erecting 2nd level side fencing 54 • street protection guard detail 52 • erecting street protection guard 55 • erecting street protection guard planks 53 • street protection guard detail 56 • erecting street protection guard planks Instruction manual Prefabricated frames •...
  • Page 61 Erection sequence 57 • street protection guard planks detail 60 • erection of the plank with bracket brace 58 • erecting bracket brace 61 • erecting the planks on the brackets 59 • erecting plank bracket brace 62 • erecting the planks on the brackets Instruction manual Prefabricated frames •...
  • Page 62 Erection sequence 63 • erecting the connections of the pedestrian walk-through frame 66 • erecting carriage beam connecting beams 64 • erecting the planks on the pedestrian walk-through frame 67 • erecting decking on the carriage beam 65 • erecting carriage beams 68 •...
  • Page 63 Erection sequence 69 • erecting the vertical-diagonal brace above the carriage beams 70 • end of erection above the carriage beams Instruction manual Prefabricated frames •...
  • Page 64 Instruction manual Prefabricated frames •...
  • Page 65 Certifications Instruction manual Prefabricated frames •...
  • Page 66 CNAS - MCC ICECON Tube-coupler system Test report Certificat no. 2009-52558 de conformitate nr. 0835/2017 Steel tube scaffold Schele de fațadă, couplers din oțel T/C China Romania Technischen Universität München Certificati di prodotto P021A Prüfbescheinigung gemäß DIN EN 74 Ponteggio metallico fisso Rohr-Kupplungs- a tubi e giunti System 9466...
  • Page 67 ICECON Certificat de conformitate Certificato nr. 0834/2017 di prodotto P021I Schele de fațadă, Realpont 75 a telai din oțel RP 75 prefabbricati Romania Italy CNAS - MCC ICECON Prefabricated frames: Test reports no. TC-JG1- Certificat de conformitate Realpont 105/EU92 system Q-2009-08;...
  • Page 68 ICECON Prefabricated frames: Certificat de conformitate Certificati di prodotto P021D Tel Dal T5/Uniform system nr. 459/2007 Schele de fațadă, Tel Dal 3, Tel Dal 5 bis, din oțel T5 Tel Dal 5 ter Romania Italy ICECON Certificat de conformitate Certificati nr.
  • Page 69 Prefabricated frames Certificati di prodotto Certificati di prodotto P021B P021C HTP a telai PRATICUS a telai prefabbricati prefabbricati Italy Italy Certificati di prodotto Certificati di prodotto P021M P021N RP 390 a telai RP 490 a telai prefabbricati prefabbricati Italy Italy Certificati di prodotto P021O T5-SX a telai...
  • Page 70 CNAS - MCC CNAS - MCC Deck planks Test report Test report no. TC-JG1-Q-2009-10 no. TC-JG1-Q-2009-11 Metal plank mm 330x1800 Metal plank mm 330x2500 China China CNAS - MCC CNAS - MCC Test report Test report no. TC-JG1-Q-2009-12 no. TC-JG1-Q-2009-13 Metal plank mm 490x1800 Metal plank mm 490x2500 China...
  • Page 72 Construction equipment division Divisione cantieristica edile via Giovanni della Casa, 12 20151 Milano - Italy Tel. +39 . 02 30 704 1 Fax +39 . 02 33 402 706 cantieristica@marcegaglia.com www.marcegagliabuildtech.com...

This manual is also suitable for:

Tel dal t5/uniform systemRealpont system 105

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