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Hunnebeck BOSTA User Manual

Reinforcement installation scaffolds
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REINFORCEMENT
INSTALLATION SCAFFOLDS
User guide

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Summary of Contents for Hunnebeck BOSTA

  • Page 1 REINFORCEMENT INSTALLATION SCAFFOLDS User guide...

  • Page 2: Table Of Contents

    System overview .....................10 3.1 BOSTA standard configurations ..................11 3.2 MODEX standard configurations ..................17 Components ......................27 Basic cross-system components ..................27 4.2 BOSTA system ........................30 4.3 MODEX components ......................36 4.4 System-free accessories ....................39 Preparation for assembly ..................41 Complying with regulations ....................41 5.2 Planning principles ......................
  • Page 3 Reinforcement installation scaffolds Checks before use ....................78 Moving the scaffold with a crane ................. 78 9.1 Moving the MODEX scaffold .....................78 10 Temporary storage of the scaffold ............... 79 Dismantling the scaffolds ..................80 11.1 Dismantling the BOSTA reinforcement installation scaffold ........80 11.2 Dismantling the MODEX reinforcement installation scaffold ........80 Unless stated otherwise, all dimensions in mm.

  • Page 4: Introduction

    Introduction Introduction About this user guide This user guide describes the safe assembly and use of reinforcement installation scaf- folds from the BOSTA and MODEX systems. The reinforcement installation scaffolds are referred to as "scaffolds" in this user guide. The activities described in this user guide include the erection of scaffolds with up to two levels and a level height of two metres. Scaffolds that exceed this are possible after consultation with HÜNNEBECK. This user guide is intended for commercial users with appropriate technical training. The information and procedures described here comply with the laws and the occupa- tional health and safety regulations of Germany and Austria.

  • Page 5: Safety

    The equipment may be used only by properly trained personnel under the authority of qualified supervisors. The work on the reinforcement installation scaffolds must be supervised by a properly qualified supervisor, specified by the contractor, who ensures that the work is carried out safely. Only the use of components from the MODEX and BOSTA 70/100 systems described in this user guide is considered intended. Extensions, deviations or changes are only per- mitted with separate proof. This proof must be requested from the manufacturer. All other uses are considered to be unintended. This applies in particular to additions, deviations or changes to this user guide without the consent of HÜNNEBECK.

  • Page 6: General Safety Information

    Safety 2.2 General safety information 2.2.1 Risk of fatal injury Risk of fatal injury from using damaged or unsuitable components! Damaged components may result in a diminished load-bearing capacity or failure of components of the scaffold. • Check that all components are in flawless condition before use and at the specified intervals. • Do not use damaged or unsuitable components. • Contact HÜNNEBECK if there are any doubts about potentially harmful factors.
  • Page 7 Reinforcement installation scaffolds Risk of fatal injury in the event of falling from the scaffold due to missing compo- nents or mounting parts! Missing, damaged, incorrectly or inadequately fastened mounting parts may cause the scaffold to fall due to a diminished load-bearing capacity. • Do not use any damaged components. • Ensure that all barriers, decks and guard rails are fitted to the scaffold as described and illustrated in this user guide. • Ensure that all mounting parts are securely attached. Risk of fatal injury in the event of falling from the scaffold due to missing or incor- rectly mounted fall protection! A guard rail attached to the scaffold may exceed the load limits of the scaffold.

  • Page 8: Obligations Of The Operator

    Safety 2.3 Obligations of the operator The operator must ensure that only personnel with knowledge and experience in the use of the scaffold and all relevant safety regulations work on and with the scaffold. All other persons may only access the scaffold under the direct supervision and instruction of a person with this knowledge. 2.3.1 Responsible supervisor The operator must ensure that all work is carried out under the supervision of a spe- cially trained person. This person must have knowledge and skills in the following areas: • Accident prevention measures • Determination and estimation of the load limits of the scaffold, taking into account all...

  • Page 9: Structure And Characteristics Of The Information On Hazards To Persons

    Reinforcement installation scaffolds 2.5 Structure and characteristics of the information on hazards to persons DANGER! DANGER DANGER indicates a hazardous situation that, if not avoided, will cause death or serious injury. WARNING! WARNING WARNING indicates a hazardous situation that, if not avoided, can cause death or serious injury.

  • Page 10: System Overview

    • Safety glasses • Safety gloves • Safety shoes, class 3 The operator must specify further components of the PPE in the assembly instructions for the specific application and the work to be performed. System overview The HÜNNEBECK scaffold systems BOSTA 70, BOSTA 100 and MODEX meet the requirements of DIN 4420, DIN EN 12810 and DIN EN 12811 as working and protective scaffold. BOSTA 70, BOSTA 100 and MODEX each have a German technical approval for the standard configuration as working and protective scaffolds according to the German Institute for Structural Engineering ("Deutsches Institut für Bautechnik", DIBt) approval guidelines.

  • Page 11: Bosta Standard Configurations

    Page 47 Compression Bearing Page 40 Page 64 Cross Pipe Page 40 – Vertical Frame BOSTA 70: Page 32 Page 44 BOSTA 100: Page 33 Double Rail BOSTA 70: Page 32 Page 51 BOSTA 100: 34 Base Jack Securing Page 27...
  • Page 12 Secure the base jacks with the base jack securing device to prevent them from falling out. Secure the base jacks used on stage brackets with wing nuts to prevent them from falling out. The vertical frames of the BOSTA 100 scaffolds must be connected with 12 mm frame pins or M12 screws. The vertical frames of the BOSTA 70 scaffolds must be connected with 8 mm frame pins or M8 screws.
  • Page 13 Reinforcement installation scaffolds Type 1 Required materials: Part code Component Quantity Part code Component Quantity 144131 Base Jack 50/3.3 426545 Wing Nut 30/150 652044 Vertical Frame 200/70, light 651762 Base Jack Securing Device 116370 Half Coupler 48/G w.a.f. 22 422753 Ladder Lock 2113 Guard Rail 250 652880 Twin-Railing Post 70 Trans, light 110020 Diagonal 200 652114 Railing Post 70N, light...
  • Page 14 System overview Type 2 With two-part side protection for the interior plane! Required materials: Part code Description Quantity Part code Description Quantity 144131 Base Jack 50/3.3 422753 Ladder Lock 652044 Vertical Frame 200/70, light 652880 Twin-Railing Post 70 Trans, light 116370 Half Coupler 48/G w.a.f. 22 133120 Single Post 70 2113 Guard Rail 250 417348...
  • Page 15 Reinforcement installation scaffolds Type 3 Required materials: Part code Description Quantity Part code Description Quantity 144131 Base Jack 50/3.3 651762 Base Jack Securing Device 652044 Vertical Frame 200/70, light 422753 Ladder Lock 116370 Half Coupler 48/G w.a.f. 22 652880 Twin-Railing Post 70 Trans, light 2113 Guard Rail 250 652114 Railing Post 70N, light 110020 Diagonal 200 534419...
  • Page 16 System overview Type 4 With two-part side protection for the interior plane! Required materials: Part code Description Quantity Part code Description Quantity 144131 Base Jack 50/3.3 422753 Ladder Lock 652044 Vertical Frame 200/70, light 652880 Twin-Railing Post 70 Trans, light 116370 Half Coupler 48/G w.a.f. 22 652114 Railing Post 70N, light 2113 Guard Rail 250 534419...

  • Page 17: Modex Standard Configurations

    Reinforcement installation scaffolds 3.2 MODEX standard configurations 3.2.1 System overview Item number Component Description Assembly Side protection Page 37 Page 66 Plank Page 27 Page 70 Tube Ledger / Com- Page 27 Page 64 pression Bearing Transom U Page 37 Page 66 Base Jack Securing Page 27 Page 70 Device V-diagonal...
  • Page 18 System overview 3.2.2 Standard configurations Type Interior side protection Height Length Width Load-bearing capacity Without 2000 4000 LC 3 With 2000 4000 LC 3 Without 2000 4000 1130 LC 3 With 2000 4000 1130 LC 3 Without 4000 4000 LC 3 With 4000 4000...
  • Page 19 Reinforcement installation scaffolds Type 1 Required materials: Part code Component Quantity Part code Component Quantity Alu Passage Plank 250/70 with 470907 Vertical Post 300 465031 Ladder 470892 Vertical Post 200 651742 Steel Plank 82/15 Trans 470940 Tube Ledger 250 470962 Transom 82U 651472 Side Protection 250 479047 Lifting Retainer 82* 470930 Tube Ledger 82 424226...
  • Page 20 System overview Type 2 With two-part side protection for the interior plane! Required materials: Part code Component Quantity Part code Component Quantity Alu Passage Plank 250/70 with 470907 Vertical Post 300 465031 Ladder 470892 Vertical Post 200 651742 Steel Plank 82/15 Trans 470940 Tube Ledger 250 470962 Transom 82U 651472 Side Protection 250...
  • Page 21 Reinforcement installation scaffolds Type 3 Required materials: Part code Component Quantity Part code Component Quantity Alu Passage Plank 250/70 with 470907 Vertical Post 300 465031 Ladder 470892 Vertical Post 200 651741 Steel Plank 113/15 Trans 470940 Tube Ledger 250 476043 Transom 113U 651472 Side Protection 250 479091 Lifting Retainer 113* 475760 Tube Ledger 113 424226...
  • Page 22 System overview Type 4 With two-part side protection for the interior plane! Required materials: Part code Component Quantity Part code Component Quantity Alu Passage Plank 250/70 with 470907 Vertical Post 300 465031 Ladder 470892 Vertical Post 200 651741 Steel Plank 113/15 Trans 470940 Tube Ledger 250 476043 Transom 113U 651472 Side Protection 250...
  • Page 23 Reinforcement installation scaffolds Type 5 Required materials: Part code Component Quantity Part code Component Quantity Alu Passage Plank 250/70 with 470918 Vertical Post 400 465031 Ladder 470907 Vertical Post 300 651742 Steel Plank 82/15 Trans 470892 Vertical Post 200 470962 Transom 82U 470940 Tube Ledger 250 479047 Lifting Retainer 82* 651472 Side Protection 250 424226...
  • Page 24 System overview Type 6 With two-part side protection for the interior plane! Required materials: Part code Component Quantity Part code Component Quantity Alu Passage Plank 250/70 with 470918 Vertical Post 400 465031 Ladder 470907 Vertical Post 300 651742 Steel Plank 82/15 Trans 470892 Vertical Post 200 470962 Transom 82U 470940 Tube Ledger 250...
  • Page 25 Reinforcement installation scaffolds Type 7 Required materials: Part code Component Quantity Part code Component Quantity Alu Passage Plank 250/70 with 470918 Vertical Post 400 465031 Ladder 470907 Vertical Post 300 651741 Steel Plank 113/15 Trans 470892 Vertical Post 200 476043 Transom 113U 470940 Tube Ledger 250 479091 Lifting Retainer 113 651472 Side Protection 250 424226...
  • Page 26 System overview Type 8 With two-part side protection for the interior plane! Required materials: Part code Component Quantity Part code Component Quantity Alu Passage Plank 250/70 with 470918 Vertical Post 400 465031 Ladder 470907 Vertical Post 300 651741 Steel Plank 113/15 Trans 470892 Vertical Post 200 476043 Transom 113U 470940 Tube Ledger 250...

  • Page 27: Components

    Reinforcement installation scaffolds Components Basic cross-system components 4.1.1 Base jacks Component Part code Weight [kg] Base Jack 45/3.8 551234 3.10 Adjustment range 6.5 cm – 26.5 cm Base Jack 70/3.8 540575 4.00 Adjustment range 6.5 cm – 50.0 cm Base Jack 50/3.3 144131 3.00 Adjustment range 6.5 cm –...
  • Page 28 Components Component Part code Weight [kg] Alu Passage Plank 300/70 with Ladder 492910 26.80 (2.0 kN/m², LC 3) 3000 Alu Passage Plank 250/70 with Ladder 465031 23.70 (2.0 kN/m², LC 3) Aluminium-plywood design with integrated folding ladder. 2500 Hollow Box Plank 300/32 531323 17.60 (2.0 kN/m², LC 3) 3000 Hollow Box Plank 250/32 531334 15.10...
  • Page 29 Toe Board 82/15 Trans 651992 3.00 Secure the MODEX scaffold at the end faces. Toe Board 70/15 Trans 651991 2.40 1010 Steel Toe Board 70/15 Trans 652002 2.40 Secure the BOSTA 70 scaffold at the end faces. Toe Board 100 554512 3.30 1010 Steel Toe Board 100 Trans 534279 2.50 Secure the BOSTA 100 scaffold at the end faces. Steel Toe Board 300/15 531437 9.00...

  • Page 30: Bosta System

    Base Plate 428533. Swivel Castor 200/10 481780 4.80 Screwed to base plate in conjunction with Roller Spindle 25186 4.2 BOSTA system 4.2.1 Combination components BOSTA 70 / BOSTA 100 Component Part code Weight [kg] Railing AGR 70 Trans 651926 12.50...
  • Page 31 W = 74 cm Ø 8 mm Frame Pin 061312 0.10 Ø 8 mm steel wire. Secures the butt joints at BOSTA. Wing Nut 30/150 426545 0.40 Secures the Base Jack to Stage Brackets. Unless stated otherwise, all dimensions in mm.
  • Page 32 Components 4.2.2 BOSTA 70 components Component Part code Weight [kg] Vertical Frame 200/70, light 652044 18.20 For storey heights of 2.00 m. Connection points for guard rail, toe board and diagonal. 2000 Double Rail 70 Trans 534419 3.40 For securing the scaffold levels at the end faces.
  • Page 33 1120 Single Post 70 133120 5.30 For use with Stage Bracket 35 or 70. Used to support the side protection. Secured with Ø 8 mm Frame Pin. 1120 4.2.3 BOSTA 100 components Component Part code Weight [kg] Vertical Frame 200/100 129429 27.40 For storey heights of 2.00 m. Connection points for guard rail, toe board and diagonal.
  • Page 34 Component Part code Weight [kg] Railing AGR 100 Trans 651936 15.50 Used to erect a temporary rail to secure the end face of the scaffold at the next highest scaffold level. For BOSTA 100 2040 Double Rail Transverse 100 534441 4.30 l = 101 cm For securing the scaffold at the end faces. B-Railing Post 100 129392 8.40...
  • Page 35 Reinforcement installation scaffolds Component Part code Weight [kg] Twin-Railing Post 100 Trans 452969 14.80 H = 100 cm Placed at the end of the upper scaffold level at the end faces. 1165 Railing Post 136410 3.90 H = 100 cm Can be used with Stage Bracket 35 or 70. Used to support the side protection.

  • Page 36: Modex Components

    Components 4.3 MODEX components Component Part code Weight [kg] Starting Piece 470929 2.00 H = 37.5 cm For installing the lowest vertical posts. Vertical Post 400 470918 20.20 H = 400 cm Vertical Post 300 470907 15.30 H = 300 cm Vertical Post 200 470892 10.40...
  • Page 37 Reinforcement installation scaffolds Component Part code Weight [kg] Transom 82U 470962 4.10 l = 82 cm Transom 113U 476043 7.10 l = 113 cm Standard planks from the HÜNNEBECK scaffold range are placed on top of the Transom U. Lifting Retainer 113 479091 6.70 l = 113 cm Lifting Retainer 82 479047 4.80 l = 82 cm...
  • Page 38 Components Component Part code Weight [kg] Lifting Retainer Tube 113 651431 2.00 l = 113 cm Lifting Retainer Tube 82 651430 1.40 l = 82 cm Plank Retainer for planks placed on top of Transoms U. Secured with the Connection Part (part code: 651440).

  • Page 39: System-Free Accessories

    Reinforcement installation scaffolds 4.4 System-free accessories Component Part code Weight [kg] Ø 12 mm Frame Pin 129473 0.20 Ø 12 mm steel wire. Secures the butt joint. Ladder 200 A 136318 9.80 For interior ascent at storey height of 2.0 m. Ladder Lock 422753 2.20 Rigid Coupler 48/48 w.a.f.
  • Page 40 Components Component Part code Weight [kg] Scaffold Tube 48.3 x 50 169001 1.90 l = 50 cm Scaffold Tube 48.3 x 100 169012 3.81 l = 100 cm Scaffold Tube 48.3 x 150 169023 5.72 l = 150 cm Scaffold Tube 48.3 x 200 169034 7.62 l = 200 cm Scaffold Tube 48.3 x 250 169045 9.53 l = 250 cm Scaffold Tube 48.3 x 300 169056 11.43...

  • Page 41: Preparation For Assembly

    Reinforcement installation scaffolds Preparation for assembly Complying with regulations Step 1 Ensure that the rules and regulations applicable at the place of use are observed and followed. This applies in particular to the following regulations: • Occupational safety regulations • Safety rules of the employers' liability insurance association and the applicable regu- lations for work safety • Regulations of the German ordinance on industrial safety and health • German technical rules on operational safety 2121 (TRBS 2121)

  • Page 42: Preparing The Ground

    Preparation for assembly The following points must be checked: • Completeness of the components • Flawless condition of the components • Stability of the scaffold • Occupational health and operational safety aspects of the scaffold Step 1 Verify that the scaffold and all components are in flawless condition. Step 2 Only use undamaged original HÜNNEBECK parts. Step 3 Visually inspect all components for origin and damage before installation. Step 4 Replace damaged parts and parts from other manufacturers with original parts.

  • Page 43: Erecting Bosta Reinforcement Installation Scaffolds

    Reinforcement installation scaffolds Erecting BOSTA reinforcement installation scaffolds The following order is ideal when assembling the reinforcement installation scaffold: • Erect the first scaffold bay • Add further scaffold bays to the side of the first scaffold bay • Erect the upper level scaffold bays one after the other. Tip! It is also possible, but more complicated, to attach scaffold bays laterally to a finished scaffold on both levels. This procedure is therefore not described in this user guide. Creating connections using drop latches Drop latches are attached to the exterior of the vertical frames. Additional drop latches can be attached to the vertical frame with Half Couplers 48/G w.a.f. 22 (116370). Up to two components can be attached to each drop latch. Follow these steps: Step 1 Raise the drop latch (1) in line with the clevis pin.

  • Page 44: Preparing The First Scaffold Bay

    Erecting BOSTA reinforcement installation scaffolds 6.2 Preparing the first scaffold bay 6.2.1 Preparing the base frame Tip! Begin assembly at the highest point of the ground. Otherwise, the reinforcement instal- lation scaffold may need to be levelled several times. Step 1 Place two base jacks at a distance of one vertical frame width from the highest point of the planned scaffold surface.
  • Page 45 Reinforcement installation scaffolds 6.2.2 Stabilising the scaffold bay Follow these steps to stabilise the scaffold bay: The diagonal brace must be mounted on scaffolds with several scaffold bays in such a way that the highest point is on the common vertical frame. To use the temporary rail on exterior vertical frames, the diagonal braces have to be fastened to the inner of the two recesses. Step 1 Insert the connecting hook (1) of the diagonal brace (3) into the inner recess (2) on the vertical frame. Step 2 Connect the diagonal brace on the lower clevis pins (4) to the second vertical frame. To stabilise the vertical frame, a cross pipe must be secured as far down as possible on the vertical frame.
  • Page 46 Erecting BOSTA reinforcement installation scaffolds Step 3 Fix the cross pipe (1) to the vertical frame using two swivel couplers (2). Step 4 Secure the second cross pipe to the other vertical frame in the same way. Unless stated otherwise, all dimensions in mm.

  • Page 47: Attaching The Plank

    Reinforcement installation scaffolds 6.3 Attaching the plank In order to completely stabilise the scaffold bay, the plank has to be put into place. Tip! To access the upper scaffold bays, a passage plank is required in a scaffold bay. Step 1 Hook the plank (1) into the U-profiles (2) of both vertical frames using the claws (3). The scaffold bay is now sufficiently stable. The plank is only securely fastened when twin-railing posts or other vertical frames are attached to the vertical frames (Refer to page 51). Step 2 Turn up the base jacks until the upper edge of the guard rail and the crossbars of the vertical frames are horizontal.

  • Page 48: Attaching The Base Jack Securing Device

    Erecting BOSTA reinforcement installation scaffolds 6.4 Attaching the Base Jack Securing Device Step 1 Attach the Base Jack Securing Device (2) to all base jacks (3) as shown. Step 2 Tighten the screw (1) in the coupler with 50 Nm. Unless stated otherwise, all dimensions in mm.

  • Page 49: Increasing Stability

    Reinforcement installation scaffolds 6.5 Increasing stability If the ratio of the width to the height of the reinforcement installation scaffold exceeds 1:3, the width of the scaffold has to be increased. In the case of BOSTA 70 scaffolds, the Stage Bracket must always be used. Follow these steps: Step 1 Place the stage bracket (2) on the base jack (4). Step 2 Hook the stage bracket to the exterior of the vertical frame and align it at a right angle to the long side. Step 3 Tighten the screw (1) in the coupler with 50 Nm. Step 4 Unscrew the base jack of the stage bracket so that there is no clearance between the base jack and the ground or substructure.

  • Page 50: Attaching The Scaffold Bay At The Side

    Erecting BOSTA reinforcement installation scaffolds 6.6 Attaching the scaffold bay at the side Step 1 Position two base jacks (5) next to the existing scaffold bay, at a distance of approxi- mately the size of a frame, spacing them to suit the scaffold bay depth. Step 2 Place the additional vertical frame (1) on the base jacks (5). Step 3 Connect the additional vertical frame to the existing vertical frame by inserting the guard rail (4) that will later be on the exterior into the lower drop latches (3). Step 4 To level the scaffold bay, turn up the base jacks until the upper edge of the guard rails and the crossbars of the vertical frames are horizontal. Step 5 Insert the diagonal brace (2) into the recess on the common vertical frame. Step 6 Connect the diagonal brace to the additional vertical frame using the drop latches.

  • Page 51: Attaching The Upper Scaffold Bay

    Reinforcement installation scaffolds Attaching the upper scaffold bay 6.7.1 Attaching the temporary rail The temporary rail is used to provide protection against falling during the attachment of the upper scaffold bay. As soon as the guard rails are securely fastened, the temporary rail can be removed. Risk of serious and fatal injury due to falling from the scaffold! WARNING Working on an unsecured scaffold can lead to falls. • Do not access the upper scaffold level until the guard rail has been securely fas- tened. Attaching the Double Rail A double rail has to be attached to all vertical frames on the end faces of each level for assembly.
  • Page 52 Erecting BOSTA reinforcement installation scaffolds Step 5 Hook the upper fastening brackets (1) on the AGR railing into the outer recesses on the end face of the vertical frame (3). Step 6 Push the AGR railing upwards until the lower fastening brackets (2) fit over the double rail. Unless stated otherwise, all dimensions in mm.
  • Page 53 Reinforcement installation scaffolds Step 7 Move the AGR railing downwards until the lower fastening brackets hook into the dou- ble rail. Step 8 Attach the second AGR railing to the other end face vertical frame in the same way. Unless stated otherwise, all dimensions in mm.
  • Page 54 Erecting BOSTA reinforcement installation scaffolds Attaching Guard Rails and AGR Posts Step 1 Hook the upper fastening bracket (1) of the AGR post over the upper U-profile of the Vertical Frame 200/70, working from below. Unless stated otherwise, all dimensions in mm.
  • Page 55 Reinforcement installation scaffolds Step 2 Position the AGR post vertically, such that the lower fastening bracket rests against the vertical outer tube of the Vertical Frame 200/70. Step 3 Rest the lower fastening bracket of the AGR post on the clevis pin. Unless stated otherwise, all dimensions in mm.
  • Page 56 Erecting BOSTA reinforcement installation scaffolds Step 4 Pass a guardrail (2) of an appropriate length along one side on the hook (1) of the AGR post. Unless stated otherwise, all dimensions in mm.
  • Page 57 Reinforcement installation scaffolds Step 5 Attach the other end of the guard rail to the hook of the second AGR post as shown. Unless stated otherwise, all dimensions in mm.
  • Page 58 Erecting BOSTA reinforcement installation scaffolds Step 6 Slightly screw in the upper fastening bracket of the second AGR post on the upper U-profile of the Vertical Frame 200/70, working from below. Step 7 Position the second AGR post vertically, such that the lower fastener rests lightly against the vertical outer tube of the second Vertical Frame 200/70. Step 8 Place the lower fastener of the second AGR post on the clevis pin of the second Verti- cal Frame 200/70. Step 9 Attach the second guard rail to the second AGR post as described in step 4. Step 10 Attach the second guardrail for the second scaffold bay to the hook of the third AGR post as described in step 5. Step 11 Install the third AGR post in the third Vertical Frame 200/70 as described in step 6. Unless stated otherwise, all dimensions in mm.
  • Page 59 Reinforcement installation scaffolds 6.7.2 Securing the scaffold level Step 1 Push the Ladder Lock (2) over the lower tube of the second Vertical Frame 200/70. Then hook the U-profile of the Ladder Lock to the lowest rung of the ladder and secure with the Wedge (1) Step 2 Open the hatch in the Alu Passage Plank 300/70 with Ladder. Step 3 Step onto the plank of the second scaffold level. Unless stated otherwise, all dimensions in mm.
  • Page 60 Erecting BOSTA reinforcement installation scaffolds Step 4 Insert a Twin-Railing Post 70 Trans (1) in each vertical tube of the lower Vertical Frame 200/70. Step 5 Secure the twin-railing posts on both sides through the bore holes (2) using a Ø 8 mm Frame Pin or a screw 8x80 (with nut). Step 6 Insert Railing Posts 70 in the vertical tube of the lower middle Vertical Frame 200/70. Step 7 Secure the twin-railing posts as described in step 5. The twin-railing posts prevent the plank from lifting off at the top level of the scaffold. To create an additional scaffold bay above, the twin-railing posts have to be replaced with vertical frames and double rails. Tip! When multiple scaffold bays are erected next to one another, the twin-railing posts only have to be inserted at the ends. Unless stated otherwise, all dimensions in mm.
  • Page 61 Reinforcement installation scaffolds 6.7.3 Installing Guard Rails Step 1 Attach the guard rails (3) to the upper (1) and middle (2) clevis pin of the Twin-Railing Posts 70 Trans (Railing Post 70) to serve as handrail and knee rail. Attach the drop latches on the twin-railing posts as described beginning on page 44. Tip! This user guide describes only the erection of scaffolds up to two levels. To erect higher scaffolds, follow the instructions in the user guide for the respective scaffold system. In particular, the deviations in individual cases have to be proven safe. Scaffolds with more than two levels must always be tied as described in the user guide. Unless stated otherwise, all dimensions in mm.
  • Page 62 Erecting BOSTA reinforcement installation scaffolds Step 2 Attach suitable toe boards (2) to the lower clevis pins (1) on the outside of the twin-rail- ing posts (railing posts). Step 3 Secure toe boards (4) of an appropriate width to the twin-railing posts using the brack- ets (3) on the end faces. Step 4 Secure the outer sides and end faces of all scaffold bays with toe boards in this way. Unless stated otherwise, all dimensions in mm.
  • Page 63 Reinforcement installation scaffolds Step 5 Reverse the order of the steps from the assembly procedure to remove the temporary railing (Refer to page 51 ff). 6.7.4 Assembling the second scaffold level The second scaffold level is assembled in the same way. Follow these steps on all scaf- fold bays: Step 1 Put the vertical frames on the existing vertical frames. Step 2 Connect the vertical frames using frame pins or screws. Step 3 Stabilise the scaffold bay as described beginning on page 45. Step 4 Attach the plank as described beginning on page 47.

  • Page 64: Installing Compression Bearings

    Erecting BOSTA reinforcement installation scaffolds 6.8 Installing Compression Bearings The Compression Bearing braces the scaffold against the formwork. This ensures the specified distance of the scaffold from the reinforcement. The Compression Bearing consists of scaffold tubes, which are fixed to all vertical posts of the uppermost level using rigid couplers. The Compression Bearing is always attached to the interior as far up as possible. Step 1 Attach a scaffold tube (2) of an appropriate length with a Rigid Coupler 48/48 w.a.f. 22 (1) as high up as possible on the vertical posts. Step 2 Repeat step 1 for all posts on the reinforcement side of the top level. Unless stated otherwise, all dimensions in mm.

  • Page 65: Erecting The Modex Reinforcement Installation Scaffold

    Reinforcement installation scaffolds Erecting the MODEX reinforcement installation scaffold The following order is ideal when assembling the reinforcement installation scaffold: • Erect the first scaffold bay • Add further scaffold bays to the side of the first scaffold bay • Erect the upper level scaffold bays one after the other. Tip! It is also possible, but more complicated, to attach scaffold bays laterally to a finished scaffold on both levels. This procedure is therefore not described in this user guide. Creating connections with the MODEX node The horizontal tube ledgers and the diagonals are connected with the joint connectors to the attachment rosettes on the vertical posts with the MODEX system nodes. Several components can be secured to each rosette.

  • Page 66: Preparing The Ground

    Erecting the MODEX reinforcement installation scaffold Preparing the ground 7.2.1 Connecting starting pieces to base jacks Step 1 Place four starting pieces (1) on four base jacks (2). Step 2 Position the base jacks with starting pieces according to the approximate frame dimen- sions. 7.2.2 Connecting starting pieces to the base frame Step 1 Connect two starting pieces (1) each to the joint connections with tube ledgers (4) of the desired width. Step 2 Attach the two connected starting pieces to the joint connections with tube ledgers (2) of the desired length. Step 3 Turn up the base jacks until the base frame is horizontal.

  • Page 67: Assembling The Scaffold Bay

    Reinforcement installation scaffolds Tip! To brace the prepared base frame, place a horizontal diagonal of the appropriate length horizontally between two starting pieces. The horizontally mounted diagonal is not absolutely necessary. It facilitates right-an- gled alignment of the scaffold, increases stability and can be removed after completion of the scaffold. Assembling the scaffold bay Step 1 Insert four Vertical Posts 300 (3) into the starting pieces (4). Step 2 Align the vertical posts such that the bore holes (1) for securing the butt joints are ori- ented in the longitudinal direction.
  • Page 68 Erecting the MODEX reinforcement installation scaffold Unless stated otherwise, all dimensions in mm.

  • Page 69: Attaching The Scaffold Bay At The Side

    Reinforcement installation scaffolds Attaching the scaffold bay at the side The scaffold can be extended by attaching further elements to the end faces. Step 1 Prepare two additional starting pieces as described beginning on page 66. Step 2 Connect the starting pieces to the end faces of the existing scaffold using tube ledgers of the desired length. Step 3 Erect the scaffold bay as described in the previous section. Step 4 Repeat the steps for the other required scaffold bays. Tip! A complete scaffold in the desired width can also be erected. The procedure is identi- cal. Increasing stability If the ratio of the planned width to the height of the reinforcement installation scaffold exceeds 1:3, the width of the scaffold has to be increased. Step 1 Position the base jack (4) on the exterior of the scaffold in front of the vertical post. Step 2 Place the Stage Bracket 70 (2) with the sleeve (3) on the base jack. Step 3 Connect the Stage Bracket to the Vertical Post at right angles to the exterior. Step 4 Tighten the screw (1) in the coupler with 50 Nm.

  • Page 70: Attaching The Base Jack Securing Device

    Erecting the MODEX reinforcement installation scaffold Attaching the Base Jack Securing Device Step 1 Attach the base jack securing device (2) to all base jacks as shown. Step 2 Tighten the screw (1) of the coupler by hand. Step 3 Use the wing nut (3) to secure the base jack in the Stage Bracket 70. Attaching planks Planks can be either fixed planks or a passage plank with a hatch and a ladder. Depending on the scaffold width, one or more planks may be required per level. Risk of serious and fatal injury due to falling from the scaffold! WARNING Unsecured plank elements can shift when subjected to load. This can lead to falls. Gaps between displaced plank elements can cause injuries due to tripping or buckling. • Verify that all the plank elements are installed properly.
  • Page 71 Reinforcement installation scaffolds Step 1 Hang the plank or passage plank(1) at the height of the scaffold level between the tran- soms U (3) at the end faces using the claws (2). Step 2 Fold out the ladder (4) from the passage plank. Step 3 Press the Ladder Lock (2) over the bottom Tube Ledger 82. Then place the U-profile of the Ladder Lock on the bottom rung of the ladder and secure it to the tube ledger with the wedge (6). Step 4 Open the hatch in the passage plank. Unless stated otherwise, all dimensions in mm.

  • Page 72: Installing The Guard Rails

    Erecting the MODEX reinforcement installation scaffold Installing the guard rails Risk of serious and fatal injury due to falling from the scaffold! WARNING The upper level of the scaffold is only temporarily secured during the assembly of the guard rails. • Exercise caution when moving about on the scaffold. • If necessary, use fall protection. • Observe and follow the regulations applicable at the place of use. Step 1 Open the hatch in the passage plank. Step 2 Standing on the ladder, attach a tube ledger (2) to the upper rosettes of the vertical posts at the nearest end face. Step 3 Attach a Guard Rail 82 (1) to the upper rosettes.

  • Page 73: Attaching Toe Boards And Lifting Retainers

    Reinforcement installation scaffolds Attaching toe boards and lifting retainers 7.9.1 Attaching lifting retainers Step 1 Attach the hook (2) of the lifting retainer (3) to the inside of the transom U with the legs. Step 2 Move the lifting retainer inwards to the toe board fastening limit stop (1). Step 3 Fold over the joint latch (4) until it rests firmly on the transom U fixing wedge. Unless stated otherwise, all dimensions in mm.
  • Page 74 Erecting the MODEX reinforcement installation scaffold 7.9.2 Attaching toe boards Step 1 On the exterior, hook a long toe board (2) into the fastenings (1) on both sides with the brackets (3). Step 2 Attach additional toe boards to the exterior of the remaining scaffold bays. Unless stated otherwise, all dimensions in mm.
  • Page 75 Reinforcement installation scaffolds Step 3 Hook a short toe board into the vertical posts with the brackets (1) at each end face. Unless stated otherwise, all dimensions in mm.

  • Page 76: Attaching The Upper Scaffold Bay

    Erecting the MODEX reinforcement installation scaffold 7.10 Attaching the upper scaffold bay Risk of serious and fatal injury if the scaffold tips over! WARNING Incorrectly assembled scaffolds can tip over. • Verify that the ratio between width and height does not exceed 1:3. • Ensure that the maximum loads are not exceeded. Step 1 Place additional vertical posts on the vertical posts (2) of the end faces of the lower scaffold bay. Step 2 Verify that the bore holes (1) in the butt joints of the vertical posts are aligned. Step 3 Complete the scaffold bay as described beginning on page 67. Step 4 Attach the planks and guard rails as described beginning on page 72. Step 5 Ensure that all butt joints are secured in the bore holes. Always use Ø 12 mm frame pins or a screw M12x75 4.6 to secure. Tip! This user guide describes only the erection of scaffolds up to two levels. To erect higher scaffolds, follow the instructions in the user guide for the respective scaffold system. In particular, the deviations in individual cases have to be proven safe. Unless stated otherwise, all dimensions in mm.

  • Page 77: Installing Compression Bearings

    Reinforcement installation scaffolds 7.11 Installing Compression Bearings The Compression Bearing braces the scaffold against the formwork. It is made up of Tube Ledgers 25 attached to the uppermost plank. The compression bearing is always attached as high up as possible. Step 1 Install the compression bearing (1) with Tube Ledgers 25 to the rosette (2) at the upper- most platform. Step 2 Repeat step 1 for all posts on the reinforcement side of the top platform. Step 3 Verify that all compression bearings touch the formwork. Unless stated otherwise, all dimensions in mm.

  • Page 78: Checks Before Use

    Checks before use Checks before use Step 1 Check that the scaffold is in flawless condition. Step 2 Check that all components are securely connected. Step 3 Check that the position of the planks is correct. Step 4 Post a sign to indicate that the scaffold is safe to use. Step 5 Attach a sign to the scaffold to indicate that the reinforcement installation scaffold is safe to use. Once the reinforcement installation scaffolds have been approved for use, no changes may be made to them, in particular no parts may be removed. Moving the scaffold with a crane The scaffold does not have to be dismantled to move it to create another reinforce- ment.

  • Page 79: Temporary Storage Of The Scaffold

    Reinforcement installation scaffolds Step 5 Attach the lifting gear to the lifting points on the four vertical posts of the end faces of the scaffold. Step 6 Move the scaffold to the desired position. Step 7 Remove the vertical diagonal and additional tube ledgers on the reinforcement side. 9.1.2 Aligning the scaffold After each move, the scaffold has to be re-aligned, including the stage bracket.

  • Page 80: Dismantling The Scaffolds

    Dismantling the scaffolds Dismantling the scaffolds 11.1 Dismantling the BOSTA reinforcement installation scaffold 11.1.1 Releasing the connections with drop latches  Step 1 Fold up the drop latch. Step 2 Remove the component. 11.1.2 Dismantling the scaffolds Step 1 Reverse the order of the steps from the assembly procedure to dismantle the scaffold. Step 2 Check that the dismantled components are in flawless condition. Step 3 Clean any dirty components. Step 4 Store the dismantled components on pallets such that they are protected from moisture and dirt.
  • Page 81 Reinforcement installation scaffolds Unless stated otherwise, all dimensions in mm.
  • Page 82 Unless stated otherwise, all dimensions in mm.
  • Page 83 Reinforcement installation scaffolds Unless stated otherwise, all dimensions in mm.
  • Page 84 HÜNNEBECK Deutschland GmbH Rehhecke 80 D-40885 Ratingen +49 2102 9371 info_de@huennebeck.com www.huennebeck.com The copyright in these instructions for assembly and use belongs to BrandSafway. All the trademarks named in these instructions for assembly and use are the property of BrandSafway, unless marked as third- party rights or identifiable as such in another way.

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