Occupational

safety related

to Scaffolds

Ankara, 23.10.2014

Layher | 2

OCCUPATIONAL SAFETY RELATED TO SCAFFOLDS

Dr. Helmut Kreller - Managing Director of Layher GmbH & Co.KG, Germany

• Chairman of the Subgroup “German Producers” at the German Scaffolding Association

• Member of the “Committee of Experts” at “German Institute for Building Technology”

• Former member of CEN/TC 53 – European Standards EN12810 and EN 12811

Topics:

Brief introduction of company Layher

Some pictures of Layher scaffolding applications worldwide

German/European normative requirements for scaffolds

Approval procedure – Examples how to fulfil requirements

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LAYHER – WORLD MARKET LEADER IN SYSTEM SCAFFOLD

1945 Wilhelm Layher founds the company nearby

Stuttgart

2014 Still family owned company in 3rd Generation

Production only in Germany!

2 km

Headquarters Eibensbach 250,000 m² factory premises – steel parts

Plant 2 Gueglingen 68,000 m² factory premises – aluminium & wooden parts

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TWO PRINCIPLE SYSTEMS – UNLIMITED APPLICATIONS

SPEEDYSCAF –

frame system for

façade scaffolds

ALLROUND SYSTEM –

modular system for industrial use

Completed by a range of supplements (roofs, cladding, stairs etc.)

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Branches in 37 countries and more than 50 additional trading contacts worldwide:

LAYHER WORLDWIDE

EUROPE Austria, Belgium, Bulgaria, Denmark, France, Greece, Hungary,

Italy, Kazakhstan, Lithuania, the Netherlands, Norway, Poland, Romania,

Russia, Serbia, Spain, Sweden, Switzerland, Turkey, UK

SOUTH AMERICA Argentina, Brazil, Chile,

Colombia, Ecuador, Peru

AFRICA Morocco, South Africa

NORTH AMERICA USA (Alabama, Florida, Maryland,

Texas), Canada (Alberta), Mexico

OCEANIA Australia (New South Wales,

Queensland, Western Australia),

New Zealand

ASIA India, Singapore

MIDDLE EAST United Arab Emirates

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LAYHER PRODUCTION OUTPUT 2013

Annual loading in Eibensbach

More than 140,000 t scaffolding material

7,300 trucks (à 18 t) = up to 67 trucks daily

900 containers are sent overseas

Layher’s efficiency is not only reflected in its products,

but also in some impressive production figures.

Annual processing

More than 21,000,000 m steel tubes

= Flight distance Frankfurt – Rio de Janeiro – round-trip

More than 1,700,000 m² scaffolding decks

= 275 football pitches

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AWARDS AND CERTIFICATES

Innovation-Award

Construmat 2011 Spanien

Innovation-Award

BATIMAT 2011 / Frankreich

Certificate for Reduction of CO2

Emission, signed by

German Minister for Environment

Award for Innovation und Quality

Baden-Württemberg

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Swiss, Bern, Wankdorf City, facade scaffold

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PRODUKTGRUPPE ALLROUND

Italien, Bologna, Basilika San Petronio

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Swiss, Zurich, zoo, new house for elephants, dome shaped roof

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PRODUKTGRUPPE ALLROUND

Finland, Oulu, water tower renovation

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PRODUKTGRUPPE ALLROUND

England, power-lining

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PRODUKTGRUPPE ALLROUND

Germany, Bremerhaven, Lloyd Wharf, ship repair

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PRODUKTGRUPPE

Argentina, airplane maintenance dock

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Deutschland, Mylau, Göltzschtal-bridge renovation

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Italy, renovation of bridges

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PRODUKTGRUPPE ALLROUND

Luxemburg, street crossing bridge

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PRODUKTGRUPPE ALLROUND

Kasachstan, Astana, Abu Dhabi Tower

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WHOLE RANGE OF PRODUCTS TO SURROUND SCAFFOLDING

STRUCTURES

Berlin “Gedächtniskirche”

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PRODUKTGRUPPE ALLROUND

USA, Florida, Kennedy Space Center

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Industrial facilities, power plants, refineries

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PRODUKTGRUPPE ALLROUND

Finland, Kuopio, Tikkalansaari-bridge, shoring scaffold

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PRODUKTGRUPPE ALLROUND

Germany, Dillingen, steel casting line, access and shoring scaffold

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Sochi, Olympic winter games 2014

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Australia, Gold coast, 3.200 seats stand

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Precondition for a safe –and efficient-

work during construction

is a scaffold with high quality standard

and proofed stability.

What is the procedure to generate

such a scaffold?

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MAIN GERMAN NORMATIVE REQUIREMENTS ON SCAFFOLDS

According to the European Act 305/2011 scaffolds are no building product →

they belong to the non-harmonized area, scaffolds underlie national regulations.

Therefore the European Codes DIN EN 12810 – façade scaffolds made by

prefabricated parts and DIN EN 12811 - working scaffolds has been worked

out on a “voluntary” basis and transferred into national law - partly with additional

regulations. (Germany: working & protection scaffolds)

In Germany each federal state (16) has an own “Landesbauordnung” (state building

regulation) which state that scaffolds are “building structures”, the stability against

collapse has to be approved by:

a) A General Building Supervisory Approval (“Zulassung”) or a

b) Static calculation for every single application (time consuming)

The execution is checked by the Governmental Building Inspection

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MAIN GERMAN NORMATIVE REQUIREMENTS ON SCAFFOLDS

The German federal states transferred the responsibility for granting General

Approvals to the „German Institute for Building Technology“ DIBt in Berlin.

Besides statically requirements there are additional occupational challenges:

Since scaffolds are also technical working equipment according to the “Industrial

Safety Regulations” BetrSichV and the “Equipment and Product Safety Law” GPSG,

they have to fulfill also the requirements of that bylaws.

In addition, inspectors of the “Building Trade Association” check the compliance with

this regulations.

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SCAFFOLDING APPROVALS IN GERMANY (IN ACCORDANCE WITH EN 12810 AND 12811)

According to the German Law

for Building and Construction

System Scaffolds need an official Approval

Procedure:

German Institute for Structural Technology

(DIBt, Berlin)

This is the only body in Germany that officially

grants Approvals

General Building Supervisory Approval

E & D Manual is a mandatory part of the approval!

Scaffold Manufacturer

Has to provide comprehensive documents:

( Static calculations, test reports, expert opinions )

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By Conformity Check

Testing of the scaffold components:

• a first extensive component test, carried out

by an independent external supervision

• self-controlled production of components

• regular external supervision (carried out by an independent institute)

Production The compliance of scaffold components

with the approval specifications

has to be proven (for each production site separately)

Conformity certificate

HOW?

If everything is fulfilled

FORMAL PROCEDURE AFTER GETTING THE APPROVAL

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Approval (document)

The approval requires: Inspection certificates for all semi- finished products (tubes, sheets,…)

Inspection certificates

according to EN 10204

are required.

Inspection certificates

confirm material

specifications; e. g.

higher yield stress of

320 N/mm2.

Layher asks suppliers

for material certificates

for each charge.

Content of the approval EXAMPLES OF APPROVAL REGULATIONS I

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Inspection Certificate:

Round Tube 48.3 x 3.2

with increased yield stress

fy,k = 320 N/mm2

Additionally internal tests for each

material delivery are worked out

ADDITIONAL INTERNAL MATERIAL TESTS

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Approval (document)

The approval specifies marking of each scaffolding part with:

Identifier of material supplier, producer (Layher), month or day of

production, approval number, Ü – sign for “conformity”

Content of the approval EXAMPLES OF APPROVAL REGULATIONS II

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The track from the approval to the scaffold component

Ü 64 (shortcut) is the mark of the approval Z-8.22-64 for Layher Allround scaffold

Allround Rosette Allround wedge Allround ledger wedge head

EXAMPLES FOR MARKING OF SCAFFOLDING PARTS

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Quality assurance in production

Steel deck

Day Year Machine number

Automated date embossing on machines:

• Welding of end profiles

• Welding of ledgers

• Welding of standards

• Crimping of spigots

• Lattice girder/standard

• Diagonals machine

• Welding of base collars

EXAMPLES FOR MARKING OF SCAFFOLDING PARTS

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Further requirements set in the approval FURTHER REQUIREMENTS FOR PRODUCING STEEL PARTS

Certificates for welding according to

DIN 18800-7 (Factory Requirement)

The factory and the workers must be proven

acc. to the standard to be allowed to produce

welded constructions in steel and aluminium.

This includes:

- regular tests and certificates for welders

- nomination of a responsible (and skilled)

supervisor for welding

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CONTINUOUS TESTING DURING PRODUCTION

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All approved decks must have passed the drop test acc. to EN 12810-2:

A 100 kg- sphere drops down to the deck from 2.5m height

The deck must be able to hold the sphere !

Two drop positions must be tested:

middle of the deck and at the end support.

IMPACT TESTS FOR DECKS

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What are the Requirements on a “safe” Scaffold?

What does that mean?

High quality of each single scaffolding component (exact measurement, no risk of injury during handling and use)

“Self-explanatory” erection sequences – easy to train (even unskilled workers cannot do things wrong)

Versatile and adaptable to given building geometries (no uncovered holes, no fall traps)

Sturdy design + hot dip galvanizing = long life time (> 30 years!)

Low maintenance (robust in use, no losable parts)

The scaffolding system must supply a maximum on

safety to workers during erection, use and dismantling

SUMMARY

Thank you very much

for your attention!

Safety and efficiency

are not a contradiction

More efficiency –

through safety