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Alsina 84067 Use And Safety Instructions

Alupercha system
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ALUPERCHA
SYSTEM
CE 0158 - EN 795:2012 B / D / E
Assembly, Use and Safety
Instruction Manual
www.alsipercha.com
Code
6490063ENLZ / 6790063ENLZ
►

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  • Page 1 ALUPERCHA SYSTEM CE 0158 - EN 795:2012 B / D / E Assembly, Use and Safety Instruction Manual www.alsipercha.com Code 6490063ENLZ / 6790063ENLZ ►...
  • Page 2 This documentation provides the basis for the evaluation of specifi c risks in the works, and Alsina’s Instruction Manuals may in no case be regarded as a substitute. Sets of vertical formwork equipment, as systems, are made up by joining different components.
  • Page 3 ISO 9001:2015 Certifi cation The Alsina Group is ISO 9001:2015 certifi ed. The Alsina Group has been granted the ISO 9001:2015 certifi cation for their sales and rental service of concrete formwork equipment. The certifi cate was granted by BVQI, an institution of renowned prestige and worldwide experience, under UKAS accreditation.

  • Page 4: System Description

    - Before fi rst use and subsequent use. - If the product is activated by a fall, it must be withdrawn Max.: STRUCTURAL ANCHORS/SUPPORTS: REVIEW 0158 REF. N.: 84067 YEAR EN 795 Type B EN 795 Type E EN 795 Type D from service inmediatley and replaced.
  • Page 5 • Many fall accidents occur from a low height. • When referring to included components not produced by Alsina or offi cial distributors, please refer to the specifi c user guide / manual for that specifi c item.
  • Page 6 System description Alupercha System Technical data Attachments Alupercha (Art. 84067) The Alupercha has been tested and approved to be used together with the The Alupercha is designed to be a lightweight product that can be folded following described attachments. for easy relocation, transport and space-saving storage. To secure both the...

  • Page 7: Component Description

    (mm) weight (kg) code dimensions (mm) weight (kg) 84423 1,500 0.31 84067 3,100 x 2,000 84474 0.15 HOOK HARNESS Description: Component used to reach the Description: Device anchoring the worker to the subsequent Alupercha to change the achor Alupercha fall arrest system.

  • Page 8: Assembly Process

    Always check that the security seal of the energy-absorber is not broken Leveller detail. or missing, before use. Withraw the Alupercha from service and contact Alsina technical department or offi cial distributor in case of doubts. 6490063ENLZ / 6790063ENLZ ►...
  • Page 9 Under no circumstances should a Lock Pin other than the the Alupercha brace, during fi nal unfolding, to avoid contact/ ones provided by Alsina be used. impact with the head or other parts of the body. The Alupercha should be able to rotate freely after installation, make sure that nothing prevents the rotation.
  • Page 10 Assembly process Alupercha System Dismantling Working with the Alupercha System The installation procedure should be performed in the reverse order when dismantling. Step 4/5 - Repositioning the Alupercha The Alupercha allows the worker to change anchorings before First, locate the embedded tubes in the columns where the Fall Arrest unhooking from the fi...
  • Page 11 Assembly process Alupercha System The work should carried out in such a way, Extended user equipment for Alupercha as to minimise both the potential for falls and potential fall distance. (Optimisation to reduce When all the boards, handrails, netting for perimeter and openings the possible fall distance to the minimum.) have been put in place and the perimeter boards have been nailed and watered (dry climate), the Alupercha Body can be removed.
  • Page 12 Precautions: Warning Precautions: - Use the slings supplied by Alsina. - Do not allow loads to rest on the sling if they could damage it. - Protect the sling against adverse weather conditions. - Each sling should be examined before use. Remove the sling if it presents cuts, especially at the edges.
  • Page 13 1. - Alupercha with housing tube Alupercha System Employment and Loading of the system Table of minimum concrete strengths Shown below are the time periods for use (the time between pouring column concrete and when the Alupercha can be used) depending on ambient temperature and column cross-section.
  • Page 14 - EUROCODE 2: Design of concrete structures. Part 1-1: General rules reinforced concrete columns by the use of the Fall Arrest System and rules for buildings. UNE-EN 1992-1-1:2013 developed by ENCOFRADOS J. Alsina, S.A. - EUROCODE 3: Design of steel structures. Part 1-1: General rules (.../...) and rules for buildings.
  • Page 15 (mm) weight (kg) 83426 154 Ø65 1.24 code dimensions (mm) weight (kg) 84067 3100 x 2,000 HOOK Description: Component used to reach the subsequent Alupercha to change the achor point. code dimensions (mm) weight (kg) 83068...
  • Page 16 1.- A set of Alupercha system with column clamps will be made of: hitting the end nut hard (up to 50 Nm). 1 Alupercha body (84067), 2 column clamps (83424) and 1 column Note: The clamp which has the column sleeve connected must be clamp sleeve (83426).
  • Page 17 (mm) weight (kg) to the following steps: To be installed following the use of crane assembly model (refer to 84067 3,100 x 2,000 step 5/5 of the "Move by crane section" on Page 12) HOOK Description: Component used to reach the subsequent Alupercha to change the anchor point.
  • Page 18 3. - Alupercha with tripod Alupercha System TRIPOD Option of anchoring to steel plate Description: Element that supports and - Place the tripod on a steel plate that has the following characteristics stabilizes the Alupercha. as a minimum: measurements of 300 x 300 cm and 4 cm thickness, with three M18 previously-bored threaded holes through which the anchors will pass (in this case it will be an 8.8 quality M18x50 DIN933 code...
  • Page 19 Step 3 Step 6 Secure it in the open position by placing the pin in the R position. ALSINA TRIPOD in the working position. Step 7 On the HA25 concrete sole plate, drill with an 18 mm - diameter bit to a depth of 140 mm.
  • Page 20 Other spare parts that are not supplied with the system must not be used. Check all the parts of the Alsina unloading system components before installing. Never use the equipment if it is damaged or rusty, as this may affect its safety.

  • Page 21: Final Assembly

    3. - Alupercha with tripod Alupercha System Trucks that are 6 m long To unload the 6-metre platform of a truck, only one Alupercha system will need to be used. When parking the truck, the rear box/platform must be situated according to the distances shown in the following illustration: 3000 mm 3000 mm...
  • Page 22 3. - Alupercha with tripod Alupercha System Trucks that are 12 m long As the image below shows, when a 12-metre truck is loaded and unloaded, two Alupercha systems must be used simultaneously. When parking the truck, the rear box/platform must be situated according to the distances shown in the illustration below.
  • Page 23 (mm) weight (kg) Designed and tested in compliance to EN:795:2012 and ANSI/ASSE 84067 3,100 x 2,000 Z359.18-2017. the MF Counterweight solution can be used on a site or in a loading yard and can be moved to alternative locations HOOK as the needs arise.
  • Page 24 4. - Alupercha with counterweight MF Alupercha System D/20X130 MF NUT ALUPERCHA MF AXIS SUPPORT Description: Component connection. Connector to the central support Description: axis. code dimensions (mm) weight (kg) code dimensions (mm) weight (kg) 33701 142 x 30 0.32 83039 200 x 150 x 250 ALUPERCHA MF STRENGTHENER...
  • Page 25 4. - Alupercha with counterweight MF Alupercha System Assembly instructions Step 1 Step 3 On a fl at surface, must be placed the 2UPN 4.97M MF GIRDER The ALUPERCHA MF AXIS (Code 84044) must be connected to the (Code 3490497). Then, the ALUPERCHA MF AXIS (Code 83039) has ALUPERCHA MF AXIS SUPPORT (Code 83039), by using the M to be installed over the girder, by using the 6th and 7th hole from the 20X120 DIN931 8.8 ZN SCREW (Code 83046), and the M 20 DIN985...
  • Page 26 4. - Alupercha with counterweight MF Alupercha System Step 4 Step 5 The PULLPROP 1,50-2,25 MF (Code 34603), has to be joined to The ALSIP. MF TRUCK WHEEL BASE (Code 83034) has to be put the ALUPERCHA MF AXIS (Code 84044), and to the two kind of over the 2UPN 4,97M MF GIRDER (Code 3490497) at a distance GIRDERS (Codes 3490122 and 3490497), by using the D/20X130 between 0,85m and 1,00m from the ALUPERCHA MF AXIS...
  • Page 27 ALUPERCHA FALL PREVENTION SYSTEM (Code 84067) has to be installed inside the ALUPERCHA MF AXIS (Code 84044 or 84059), to adopt its fi nal confi guration. 2000 mm Warning - Prepare and adapt the ground/surface where the system is intended to be installed, in order to ensure a 0º % of unevenness.

  • Page 28: Safety Warnings

    Alupercha + Wall Brackets Alupercha System Description Always remember: - Plan fall prevention at an early stage, this will benefi t everyone. The Alupercha + Wall Brackets system, designed and tested - Use only safety-checked products. in compliance to EN:795:2012 and ANSI/ASSE Z359.18-2017, - Restrict access below and around installation and working area to consist of a pair of connectors (upper bracket + lower bracket), prevent injury to others from any fall hazard.
  • Page 29 BRACKETS on the wall. the wall brackets system. Code Dimensions (mm) Weight (kg) Code Dimensions (mm) Weight (kg) 84067 3,100 x 2,000 83855 27.4 x 3 0.010 ALUPERCHA HOOK DIN 125 - M16 WASHER Description: Component used to reach the...
  • Page 30 Alupercha + Wall Brackets Alupercha System SLING (3M) Description: An essential component used to move the system with a crane or remove it once the work is complete. Code Dimensions (mm) Weight (kg) 84414 3,000 0.62 6490063ENLZ / 6790063ENLZ ► ◄...
  • Page 31 Alupercha + Wall Brackets Alupercha System Dimensions with Alupercha UPPER WALL BRACKET 2000 mm Dibujado por Fecha creación Fecha revisión Material Part Number SOPORTE_2 FALLPROTEC Número plano Calvet i Pintò - Nave 4 08339 Vilassar de Dalt Revisión Escala Hoja LOWER WALL BRACKET Barcelona 1 /1...
  • Page 32 Alupercha + Wall Brackets Alupercha System Resulting actions on the anchors: Anchoring requirements Reactions to the anchor (kN) - Calculation method: ETAG BOND Guide (EOTA TR029) Shear load: (+Traction, -Compression) - Anchor base: Regular concrete, C25/30, EN 206 - Condition of concrete: Compressed, dry perforation - Edge reinforcement: No Reinforcement.
  • Page 33 Alupercha + Wall Brackets Alupercha System Assembly process 6.- Proceed to install the upper Wall Bracket (above the lower Wall bracket) and the lower Wall Bracket (below the upper Wall The following sequence of steps must be taken in order to correctly Bracket), through the anchors.
  • Page 34 Alupercha + Wall Brackets Alupercha System 8.- By the use of an appropiate lifting equipment, proceed to insert the Alupercha through the central holes of the wall brackets, starting with the upper Wall Bracket, and ending with the lower Wall Bracket. Installation elements Epoxy resin for chemical blocks.
  • Page 35 Alupercha + Post for reduced spaces (PRS) Alupercha System Description Always remember: - Plan fall prevention at an early stage, this will benefi t everyone. The Alupercha + Post for reduced spaces system (PRS), designed - Use only safety-checked products. and tested in compliance to EN:795:2012 and ANSI/ASSE Z359.18-2017, - Restrict access below and around installation and working area to has a base of mínimum dimensions (just 350 mm diameter), providing...
  • Page 36 Alupercha + Post for reduced spaces (PRS) Alupercha System Dimensions with Alupercha Sizes of the PRS base 2000 mm 5300 mm 3000 mm 350 mm 6490063ENLZ / 6790063ENLZ ► ◄...
  • Page 37 Alupercha + Post for reduced spaces (PRS) Alupercha System Resulting actions on the anchors: Anchoring requirements Reactions to the anchor (kN) - Calculation method: DITE 001 Guide, TR 029, Appendix C, Shear load: (+Traction, -Compression) Method A - Anchor base: Normal concrete, C25/30, EN 206 - Condition of concrete: Compressed, dry perforation Anchor Nr.
  • Page 38 Code Dimensions (mm) Weight (kg) Code Dimensions (mm) Weight (kg) 84067 3,100 x 2,000 84414 3,000 0.62 ALUPERCHA HOOK Description: Component used to reach the subsequent Alupercha, if required, to change the anchor point.
  • Page 39 Alupercha + Post for reduced spaces (PRS) Alupercha System 7.- Tighten up the 6 anchors. Warning - Prepare and adapt the ground/surface where the system is intended to be installed, in order to ensure a 0º % of unevenness. Assembly process The following sequence of steps must be taken in order to correctly assembly the anchoring system: 1.- Clean and clearance the area where is planned to install the PRS.
  • Page 40 Alupercha + MBU Alupercha System Description - Under no circumstances shall any item other than those provided with the system be used either in replacement or through preference as this may affect the performance of the product. The engineered MOBILE BASE UNIT designed for the Alupercha, - The equipment must be inspected before each use.
  • Page 41 Alupercha + MBU Alupercha System Components of the system Dimensions with Alupercha The system consists of a base, a post for housing the Alupercha unit, and manual counterweights, that will provide the stability to the 2000 mm whole system in case of a fall. The base is made by a circular steel plate with a 1320 mm diameter, with four star-shaped extensions to house the support levelling feet (maximum width 2240 mm).
  • Page 42 Mobile Base Unit. Code Dimensions (mm) Weight (kg) Code Dimensions (mm) Weight (kg) 84067 3,100 x 2,000 84832 370 x 80 x 18 ALUPERCHA HOOK 5.5M RETRACTABLE DEVICE EN360 Description: Component used to reach the Description: Retractable component that locks subsequent Alupercha, if required, to change on a sudden acceleration.
  • Page 43 Alupercha + MBU Alupercha System 4.- Position and fasten the Alupercha to the MBU, by using an Assembly process auxiliar equipment. The following sequence of steps must be taken in order to correctly assembly the anchoring system: 1.- Ensure that the level of the surface where the System is intended to be installed is = 0º.
  • Page 44 Alupercha + MBU Alupercha System Relocation and locking system 6.- Place the 40 manual counterweights in their positions (total 1000 kg.).. It is possible to move the entire system without having to dismantle the components, bearing in mind the following aspects: 1.- Adjust the 2 handles on the locking system until they are fully closed (1 on each side): Fig.
  • Page 45 Alupercha + MBU Alupercha System 3.- Once located in the required position and ensuring the system is correctly level, the locking system can be disabled and the system will be ready for use. If you prefer, it can also be used with the locking system activated, without the Alupercha rotating.
  • Page 46 Alupercha + RAIL Alupercha System Description The Alupercha + RAIL, designed and tested in compliance to EN:795:2012, CEN/TS 16415:2013 and ANSI/ASSE Z359.18-2017, is an overhead anchor system, comprising an Alupercha anchor and a rigid lifeline RAIL, that protect workers against falls from heights, especially during the work over vehicles, trailers or machinery.
  • Page 47 Alupercha + RAIL Alupercha System Free-fall height The free-fall height must be bigger than the free-fall distance, so that user do not impact any obstacles in case of fall. It is essential that enough free distance is verifi ed to closest underlying object.
  • Page 48 Alupercha + RAIL Alupercha System Components of the Alupercha + RAIL system Confi guration Alupercha The total length of the Alupercha + RAIL combination, will depend on the total length intended to protect workers. Below are the suggested The Alupercha consists of a 3.10 m tall mast and an arm with a radius confi...
  • Page 49 RAIL lifeline and use most of the many different accessories/supports in the Alupercha range. Code Dimensions (mm) Weight (kg) Code Dimensions (mm) Weight (kg) 84067 3,100 x 2,000 83052 300 x 200 0.10 ALUPERCHA HOOK RETRACTABLE ADVANCING CARRIAGE Description: Component used to reach the...
  • Page 50 Alupercha + RAIL Alupercha System Assembly Step 2 For the step by step installation procedure of the Alupercha system, Proceed to assemble and joint the set of 2 rails (83051) for 12m, please refer to the specifi c chapter for each type of Alupercha by using the reinforcement joint (83057).
  • Page 51 Alupercha + RAIL Alupercha System Step 3 Step 7 Fit the round-head bolts (M12 DIN603 A2) as shown in the following Fasten all joint/supports (83047) nuts and screws, and proceed to picture (4 units per Alupercha): install the SRL trolley. Step 8 Installation of the STEEL/NYLON RAIL BUFFER (83049).
  • Page 52 Control guidelines Procedure As explained in Alsina's Alupercha Assembly and Safety Manual, Place the item on an stable surface, to: this review does not replace the visual inspection that the user should perform each time before using the Fall Arrest System.
  • Page 53 - Check that there is no washer. Verify the Alsina Service the level. Check that the leveller is not Department. broken. Textile Components review procedure:...

  • Page 54: Maintenance And Safety

    Background Training and Standards After more than 60 years in the Spanish market, the Alsina Group has Above all, the purpose of this Assembly and Safety Manual is to assist become one of the largest companies in the formwork sector, with whoever works with our products.
  • Page 55 2. Alsina is absolved of all responsibility if the system components are substituted with other, similar components supplied by another company.

  • Page 56: Inspection And Maintenance

    Inspection and maintenance Alupercha System DEVICE IDENTIFICATION SHEET (A) Distributor / Reseller / Details Encofrados J. Alsina S.A. Pol. Ind. Pla d’en Coll (B) Manufacturer Camí de la Font Freda, 1 08110 - Montcada i Reixac (Barcelona - Spain) (C) Product (type, model, code)

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