Scaffolding procedure

LANXESS India Scaffold Lanxess India Private Limited, Address: Plot no A-162, A-163, A-164 Road No 27, Opposite ITI College, MIDC, SG Brave, Wagle Estate, Rd Number 16, Wagle Industrial Estate, Thane West, Thane, Maharashtra 400604, India Phone: +91 22 2587 1000 Fax : 00 971 3474725 E-Mail: LANXESS India Contents Purpose: Scope: Responsibilities: Error! Bookmark not defined Abbreviations: Reference: Definitions: Scaffolding image with components name & Terminology: Scaffold Contractor/ Inspector/ Erectors: Training: 10 10 Competent Persons: Error! Bookmark not defined 11 General Requirements (Scaffold Erection): 10 12 Loads, calculation According Code OF Federal Regulations - (29 CFR 1926.1) 10 13 Capacity and Foundations: 11 14 Scaffold Tube and Fitting Specification: 11 15 Ladders: 12 16 Lifting Rope: 13 17 Base Plates and Sole Plates: 13 18 Standards or upright: 13 19 Ledgers: 14 20 Transom: 14 21 Bracing: 14 22 Ties or Stability: 18 23 Platforms: 20 LANXESS India 24 Guardrails and Toe boards: 22 25 Gin Wheels: 23 26 Tube and Coupler Hanging Scaffolding: Error! Bookmark not defined 27 Clearance between Scaffold & Power lines: 24 28 Steps for Erection of scaffolding: 25 29 Tube and coupler scaffold Erection Diagram 26 30 Scaffold Inspection & Tag 30 31 Scaffold dismantling 32 32 High Wind & Work over water: 24 33 Complex Scaffolding Requirement: 24 34 Scaffold Check list for user: 31 35 Request for Scaffolding Template: 33 LANXESS India Purpose: The purpose of this document is to comply with LANXESS Directives and local regulatory requirements and to ensure safety in various types of steel tubular scaffolds while erecting, installing, using, re-positioning, altering(As per structural engineer recommendations) and dismantling scaffolds with access ladders, which is an integral part of scaffold Scope: These requirements and standards shall apply to the entire LANXESS India Private Limited for scaffolding erection, installation, re-positioning, alteration and dismantling by LANXESS employees and contract employees Abbreviations: LIPL : LANXESS India Private Limited SWL : Safe Working Load OSHA: Occupational Safety and Health Administration PPE : Personal Protection Equipment BS : British Standards HSE : Health safety & Environment IS : Indian Standard PFAS : Personal Fall arrest system EHS : Environment Health & safety IOSH : Institution of Occupational Safety and Health Reference: IS 2750:1964, 1991, and 1995 – This standard lays down the requirements for materials, fabrication and performance of steel scaffoldings IS :3696 (Part 01) – 1987, 1996 - This standard (Part 1) lays down the safety requirements for the erection, use and dismantling of scaffolds for providing access and for supporting workmen, equipment and materials for any construction work including maintenance, repairs and demolition IS: 3696 (Part 02) – 1991, 1996 - This standard (Part 2) lays down the safety requirements for ladders used for various jobs in general construction work IS: 4014 (Part 01)1967 – 2006 This code (Part I) covers common definitions and general guidance in regards to selection of materials for tubular scaffoldings IS: 4014 (Part 02) 1967 – 2005 This code (Part II) covers safety regulations that shall be observed in the design and construction of scaffolding IS 1161: 2006 Steel tubes for structural purposes – specification LANXESS India OHSA Standard on scaffold (CFR1926.452) BS EN 74-1:2005 (Steel Couplers) Definitions: Scaffold : A temporary elevated platform (supported or suspended) and its supporting structure (including points of anchorage) used for supporting employees, materials, or both Sole Board : Sole Plate - A timber, concrete or metal spreader used to distribute the load from a standard or base plate to the ground At least 225 mm (9”) wide , 38 mm (1-1/2”) thick and 765 mm (30”) long Base Plate : A plate for distributing the load from a standard At least 150 x 150mm & 6mm thick Adjustable Base Plate : A base plate embodying means of vertical adjustment At least 150 x 150mm & 6mm thick, Standard Spacing (Or Bay Length) : is the distance between standards, Measured along the face of scaffold Foot Tie or Kicker Lift : These are the ledger and transoms that are fixed near to the bottom of standards, approximately 150 from ground Lift Height & Ledger Spacing: is the distance between ledgers, Measured up the face of the scaffold Base lift or First Lift : is the first lift above ground level, other than foot tie or kicker lift Scaffold width : is the distance between standards measured at the shortest point, also known as the board width Brace or bracing : means a tube incorporated diagonally across two or more members in a scaffold and fixed to them to afford stability Coupler: A fitting by which a grip is applied to the external surfaces of two tubes and which thereby holds them together Coupler, Double (Right Angled) : A coupler for connecting a tube at right angle Coupler Putlog - A non-load bearing coupler used for fixing a putlog or transom to a ledger Coupler, Swivel - A coupler for connecting two tubes at any angle other than a right angle LANXESS India Scaffolding spanner - A 21millimetres box spanner head with a levered 25 centimetres (10 inches) long handle These dimensions are recommended by the coupler manufacturers to ensure the scaffolding coupler is tightened to the correct tension Scaffold level - A Spirit level designed specifically for scaffolding that enables the scaffolder to accurately plum components horizontally and vertically Typically max 25 centimetres (10 inches) in length with a magnetic surface along the base Joint Pin -Joint pins fit internal of scaffold tubes to provide an end to end connection Joint pins are compression joints and must not be used in tension unless the joint is spliced Sleeve Couplers - An external coupler used for joining tubes together end to end Sleeve Couplers may be used in joints that are subject to both compression and tension Hanging scaffold- A suspended scaffold supported from an overhead structure by means of vertical 'hanging' scaffolding tube Ledger - A tube spanning horizontally and tying a scaffold longitudinally, which may act as a support for putlogs or transoms Transom - A tube spanning across ledgers to tie a scaffold transversely Gin Wheel - a simple form of tackle block, having one wheel, over which a pulley rope runs The device is used to lift or lower lightweight properly secured materials and/ or object Outrigger - The structural member of a supported scaffold used to increase the base width of a scaffold in order to provide support for and increased stability of the scaffold Safe Working Load (SWL) - The maximum load calculated in accordance with sound and acceptable engineering practice, which can be supported safely under normal operating conditions as per standard OSHA Rated Load- The manufacturer’s specified maximum load to be lifted by a hoist or to be applied to a scaffold or scaffold component (Pipe ,Gin wheel, coupler) Scaftag - A specific tag holder and card, that, when fixed to a scaffold, identifies the status of the scaffold Working Platform – That part of a scaffolding on which workers and/ or materials are supported for the purpose of carrying out construction works and other work 'T'-Step - 'T' Step is provided on the vertical members for enabling the movement of scaffold during erection and dismantling of scaffold It is an 18" long scaffolding pipe LANXESS India tightened with fixed clamp It can also be used for anchoring safety harness lanyard while working at lower elevations.(Photo to be attached) Three Points of Contact : Term used for a method of safe ladder climbing where between a climber’s two hands and two feet, at least three of them are in contact with the ladder rungs/rails at all times while ascending or descending the ladder Reveal Tie : A tube which is jacked (wedged) between two opposing surfaces, for example, window reveal (opening) to tie a scaffold to a building Guardrail : A barrier secured to uprights and erected along the exposed sides and ends of platforms to prevent falls Toe Board : A Barrier (Height 150 mm) placed along the edge of scaffold platform and secured there to guard against the falling of material and equipment.(IS standard same as OSHA) Authorized Scaffolder – An experienced person who thoroughly trained and is capable of erecting, moving, modifying and dismantling scaffold Scaffolding images with components name & Terminology: LANXESS India This diagram is intended for illustrating the various parts/components of scaffold Responsibilities : Scaffold Contractor : No scaffold shall be erected, installed, re-positioned, altered or dismantled except by an experienced and authorized scaffold contractor Scaffold contractor shall only deploy trained and experienced scaffold supervisor and scaffold erectors Details of training and experience requirements are given below Scaffold Contractor shall ensure the statutory payments under – The Employees Provident Funds and Misc Provisions Act, 1952 The Employees State Insurance Act, 1948 The Minimum Wages Act, 1948 Scaffold contractor shall fully understand and comply with the LIPL site HSE rules/requirements Scaffold contractor will only use good quality scaffolding materials and shall construct the scaffolds in line with LIPL Scaffold standard Scaffold contractor shall produce his credential list (companies where the contractor has worked) related to experience in scaffold erection, dismantling and correction LANXESS India Scaffold contractor shall provide a list of people authorized as “Supervisor” and “Erectors Scaffold contractor shall a demo for scaffold erection and HSE Department representative to certify the scaffold for suitability After fulfilling all requirements, scaffold contractor shall be authorized by the HSE/Engineering Department in writing to carry out scaffolding work within the site Scaffold Supervisor : Every scaffold work shall have to be 100 % supervised by the competent scaffold supervisor If work is to be carried out in more than one location, every location should have a separate supervisor Scaffold contractor deputes the Scaffold supervisor Scaffold supervisor should be trained from a government recognized institute The minimum working experience of the scaffold supervisor should be years He should be well aware of site HSE requirements and erection/dismantling of Scaffolds as per LIPL scaffold standard He should have good communication skills especially in Hindi / Gujrati Scaffold supervisor shall always ensure that his “Erectors” comply with site HSE conditions/ requirements Scaffold supervisor approves and certify the scaffold after scaffold construction Scaffold inspectors will be trained in the following areas, as applicable: Nature of potential scaffold hazards (such as falls, falling objects) Procedure for erecting, maintaining, inspecting, and dismantling scaffolds as per LIPL scaffold standard and associated fall hazards Design criteria and load carrying capacities Scaffold Erectors: Scaffold erectors will have to undergo medical assessment before working at LIPL site and they will be re-examined yearly thereof Scaffold contractor shall depute the erectors Scaffolding erectors should have years of experience and trained on scaffolding erection Scaffold erectors should comply with all site HSE requirements of LIPL No scaffold erection work will be done by erectors, in the absence of an authorized scaffold supervisor LANXESS India Only erectors authorized by the contractor, having minimum of 05 years working experience will be allowed to work inside the premises LIPL will, organize yearly training programmes on scaffolding by Govt recognized scaffold institutes and the cost of such training shall be borne by the scaffold contractor It is mandatory for all erectors to attend such training when organized Final Check : After approving the scaffold by scaffold supervisor , Scaffold shall be checked by Respective BU Mechanical engineers as a final check before stating the activity Site SIS shall authorize their Civil/Mechanical engineers as backup All BU/SIS mechanical engineers and civil engineers shall undergo the training training by Govt recognized institute every year Training: Scaffold Erectors, supervisors, and authorizers shall undergo the scaffold training every year Scaffold Erection: Scaffolds must be constructed, modified, and altered in a systematic manner only with knowledge of the maximum intended load and in accordance with the design criteria Scaffolds are classified according to their intended use as: Light Duty, Medium duty and Heavy Duty scaffolds Loads, calculation According Code OF Federal Regulations - (29 CFR 1926.1) Light Duty Maximum intended load Posts, runners, braces & Bearers Maximum Bay length & Width Medium Duty Heavy Duty 25 p.s.f or 11.33 kg/ft2 75 p.s.f or 34 kg/ft2 50 p.s.f or 22.67 kg/ft2 ( 326 kg)Considering 6x6 bay and ( 856 kg) Considering 6x6 bay ( 652 KG) Considering 6x6 bay and tube thickness 4mm and tube thickness 4mm tube thickness 4mm Nominal in (1.90 inches) OD steel tube or pipe (wall thickness 04mm) Post spacing Longitudinal 9ft and Post spacing transverse 4-6 ft Light Duty Nominal in (1.90 inches) OD steel tube or pipe (wall thickness 04mm) Post spacing Longitudinal 07ft and Post spacing transverse -6 ft Medium Duty 10 Nominal in (1.90 inches) OD steel tube or pipe (wall thickness 04mm) Post spacing Longitudinal 06ft and Post spacing transverse 06 ft Heavy Duty LANXESS India Ties or guys shall be spaced vertically every m (26’) (4 lifts) or less Ties or guys shall be installed on both ends of the scaffold and at horizontal intervals not to exceed m (30’) measured from one end toward the other All ties will prevent both inward and outward movement of the scaffold Ties may only be removed by trained and qualified scaffolding personnel under direct supervision Alternative replacement ties must always be in place before a tie is removed Only tubes will be used for tying 19 LANXESS India 18 Platforms: Every working platform from which a person is liable to fall more than m shall be: closely boarded, planked, or plated; If the front edge of a working platform is less than 360 mm (14”) from the face of the wall or structure, guardrails not need to be erected from that edge For medium-duty and more heavily loaded scaffolds, at least one board bearer (intermediate transom) shall be used in every bay at each platform level Planks should be secured on both ends by using fiber rope/wire lashing, clamped toe boards or other equivalent means Planks & toe boards should not be nailed Scaffold platforms, landings, and walkways should be at least 675 mm (27”) (3planks) wide, including during erection, dismantling and alteration Scaffold materials shall not be thrown or dropped from heights Gaps between platform units shall be less than 25 mm (1”) wide When larger gaps are unavoidable, they shall be covered as follows: 20 LANXESS India Gaps less than 600 mm (2’) in width shall be covered at least 20 mm (1”) thick, exterior grade plywood Plywood covering shall be overlapped with at least the width of the gap, 12” min., on both sides of the opening and held with cleats If an internal ladder is used, opening shall be at least 675mm (27”) (3 planks) wide & not less than 900mm (36”) deep The slope of scaffold platform units shall not exceed vertical to horizontal All scaffold boards used in the construction of the working platform will rest firmly and evenly on all of their transom supports and will be firmly secured against movement or tipping, preferably using board retaining couplers at each end of the boards All material will be uniformly distributed on platforms and will not be stored above the toe board Where storage above the toe board is necessary, mesh guards will be installed All platforms will be kept free from unnecessary obstructions and from materials, rubbish and projecting nails Platforms, which have become slippery with oil or other substance, should be immediately replaced 21 LANXESS India Scaffolder in the process of erecting or dismantling scaffolds will ensure that the platform they are working from is a minimum of three boards wide at all times All decking units, where possible, extend a maximum of 15 centimeters (6 inch) past the centre of the end transom At least 6.6’ X feet length and width if the platform is used for the support of any higher platform and is one upon which stone is dressed or roughly shaped 19 Guardrails and Toe boards: Guardrails will be installed on every platform from which it is possible for a person to fall Guardrail system shall be able to withstand a force of at least 90kg (200 lbs.) It consists: (As per OHSA Guide lines) The minimum permitted height is 950 mm (37 inch) and the maximum is 120 mm (47 inch) as measured from the top of the working platform Midrails – installed approximately halfway between the walking/working surface and top rail Guardrails shall be installed on all sides of a working platform Guardrails shall be fixed to the inside of the standards with right angle (Double) couplers All toe boards must be placed on the inside of uprights Every open side of a working platform will be fitted with toe boards (or other barriers) which must be a minimum of 150 mm (6 inch) high Toe boards must be fixed to all exposed edges where there is risk of fall or risk of falling materials There should be no gaps larger than 25 mm (1 inch) other than at access points 22 LANXESS India 20 Gin Wheels: Rope and gin wheels will be provided where required The gin wheel shall be certified for use with the SWL clearly visible The lifting rope shall be of good quality and 18millimeters or 20millimeters in diameter The gin wheel will be suspended no greater than 750 mm (30 inches) from the supporting tubes and load bearing fitting will be used on each side of the gin wheel on the horizontal support tube Personnel operating a Gin wheel appropriate PPE with good quality gloves and shall be trained in how to use a scaffolding Gin wheel, including how to correctly tie all knots required The maximum amount of material to be lifted or lowered x metal board (Will use a hook connection where practicable) scaffolding tube up to 6.4 meters (21 feet) scaffolding tubes up to 3.1 meters (10 feet) scaffolding tubes up to 2.4 meters (8 feet) Once raised, lower as soon as possible, load will not leave suspended or unattended 23 LANXESS India All Gin Wheels and Safety Pulleys will be inspected by the user before use at the start of the working shift 21 Clearance between Scaffold & Power lines: Scaffold operations adjacent to overhead power lines are prohibited unless one of the following conditions are satisfied: The power line has been de-energized, relocated, or protective coverings installed to prevent accidental contact with the lines It should be lockout/ tag out 22 High Wind & Work over water: Personnel shall not be on any scaffold or other temporary elevated work area during storms or high winds (sustained winds more than 65 kph (40 mph) 23 Complex Scaffolding Requirement: A qualified structural engineer shall provide scaffolding designs and technical calculations to prove the designs structural capacity for the following scaffold types: Hanging scaffolding up to meters (20 feet) wide Cantilever Scaffolding over 1.8 meters (6 feet) wide Complex Scaffolding 38 meters (height 125 feet and more) as per OSHA 24 LANXESS India 24 Steps for Erection of scaffolding: Sr No Steps Description 01 Obtain necessary work permit, Duly signed by issuer (Competent Persons) Understand RA and follow mitigation plan Also Identify the scaffolding requirement and exact location where platform is desired and plan for erection 02 Shift Material to site Shift and store scaffold tube in stand or laterally, close to the scaffold erection site Do not obstruct escape route or access to emergency vehicle also not store below under erection scaffolding 03 Delivering Tool box talk Explain the fire risk, Associated with scaffold erection 04 Barricaded scaffolding and provided signage Clear off the area, barricade & display warning signs/ notification for “SCAFFOLDING – WORK IN PROGRESS” 05 Inspection Check the components and scaffold tube 06 Layout the scaffold & place the Sole plate and base plate & Adjust the base plate according the requirement 07 08 09 10 Position first pair of standards Fixed first ledger with right angle coupler Position second pair of standard Ledgers and transoms shall be securely fixed to the inside of each standard with right angle coupler Bearers (transoms), including board bearers, shall extend at least 150 mm (6”) beyond the runner centerline Level the bay Fix foot tie ledger and transom with right angle coupler Approx 150 mm from ground Attach braces and check structure is plumb and level 11 12 13 14 25 LANXESS India 25 Tube and coupler scaffold Erection Diagram 26 LANXESS India 27 LANXESS India 28 LANXESS India 29 LANXESS India 26 Scaffold Inspection & Tag Subject to provisions of this regulation no scaffold shall be used unless: It has been inspected by a qualified and authorised safety engineer before using; also it has been inspected by a trained and qualified scaffold inspector Before the scaffold is first used At least once every days After any modifications to the structural components of the scaffold After any severe weather that may have damaged the scaffold All scaffold inspections will be recorded on the Scaftag and in the scaffolding register on the day of the physical inspection 30 LANXESS India Scaffolds that are approved as safe for use by the scaffold inspector will be have a GREEN tag placed at each access point to clearly show the scaffold users that the scaffold is safe to use Scaffold Read Tag - Indicates the scaffold has not been inspected or is not safe for use (by anyone other than the scaffold erector 27 Scaffold Check list for user: Only work on GREEN Tagged Scaffolds Never work on RED tagged scaffolds 31 LANXESS India Scaffolds that not have a tag must be considered to be RED tagged and must never be used Visually inspect the scaffold before you use it, if your believe it to be unsafe in any way inform your supervisor before using the scaffold Never replace, remove, add or alter a scaffold tag in any way, this is the sole responsibility of the scaffold inspector Never alter or modify scaffolding in any way, this includes modifications to handrails and toe boards Only trained and approved scaffolder may alter or modify scaffolding in any way Never climb bracing or climb under or over a guardrail of any type to gain access onto or off of a scaffold Keep only the tools and materials necessary to perform the task on the platform Control slipping and tripping hazards by removing or securing tools or materials Use fall protection systems when working 1.8m (6feet) or more above a lower level Maintain a clean and tidy work area on the scaffold; not allow loose materials to build up on the platforms and remove all tools and materials that are finished at the end of your shift Never use a scaffold as a lifting support unless it has been designed for that purpose, check with your supervisor if you are unsure Never store materials near the edge of a scaffold higher than the height of the toe board 28 Scaffold dismantling All scaffolds must be dismantled only under the supervision or direction of a competent person The work will be organized and executed in an orderly manner The scaffold will be RED tagged Dismantling will progress one complete lift at a time from top to bottom working towards the ladder access Ties and bracing will not be removed until as late as possible I.e they will not be removed early 32 LANXESS India The top guardrail will be left in place until as late in the dismantle process as is reasonably practicable All components will be passed down to the ground as soon as they are removed from the structure All items will be stored and stacked tidily, segregated by size and type, ready for immediate removal to an approved storage facility Always dismantle the scaffold from the top down Lower all components to the ground by rope, hoist or man Never throw the parts to the ground Post warning sign /notices at each point of access Erection & dismantling must not be conducted during high winds and storms Check to ensure that the scaffold has not been structurally altered in a way which would make it unsafe 29 Request for Scaffolding Template: Request for scaffolding Erection by Lanxess Engineer I hereby requested that the scaffolding of size - - - - - Long Width height feet for purpose of be erected the duty (select from load table as given below M/S (Scaffold Contractor) 33 ... capacity for the following scaffold types: Hanging scaffolding up to meters (20 feet) wide Cantilever Scaffolding over 1.8 meters (6 feet) wide Complex Scaffolding 38 meters (height 125 feet and more)... way which would make it unsafe 29 Request for Scaffolding Template: Request for scaffolding Erection by Lanxess Engineer I hereby requested that the scaffolding of size - - - - - Long Width... materials for tubular scaffoldings IS: 4014 (Part 02) 1967 – 2005 This code (Part II) covers safety regulations that shall be observed in the design and construction of scaffolding IS 1161: 2006