Scaffold Couplers

General Technical and Application Manual

Boral Know How
Formwork &
Scaffolding
ACROW CYCLONE
2 3 Scaffold Couplers General Technical and Application Manual

Product Description
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Mass

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Introduction
Scaffold couplers are essentially the fundamental component that is used to assemble tube-and-coupler
scaffolding as encompassed by AS1576. Tube-and-coupler scaffolding is defned in AS1576.3 as 'a scaffold in
which individual circular tubes serving as standards, braces or ties are joined together by means of purpose
designed couplers'.
This basic ftting that is designed to join two scaffold tubes can be used to create a diverse range of scaffolding
structures or used as an accessory to prefabricated scaffolding systems.
This manual includes basic types of scaffold couplers which join two tubes together as well as special couplers
used to connect scaffold tube to other components, equipment or structures.
Important
The technical and application guidelines contained in this booklet are recommended methods to be used with
scaffold couplers supplied by Boral Formwork & Scaffolding Pty Ltd.
Recommendations and technical details must be accurately followed to obtain the correct performance of the
product. Deviation from the recommended usage will require a separate engineering design and/or verifcation
by the Boral Formwork & Scaffolding Engineering Department.
The use and application of scaffold couplers must be in compliance with the requirements of Statutory
Regulations and Australian Standards for Scaffolding (AS/NZS1576 'Scaffolding' and AS/NZS 4576 'Guidelines
for Scaffolding') as applicable.
The illustrations of the assembly confgurations are guidelines only.
Site specifc Hazard and Risk assessments may need to be generated for specifc projects.
As part of the risk management processes, we draw your attention to the requirement that scaffolders must, as
part of their competency, be competent in manual lifting techniques. Therefore, scaffolders erecting, altering
or dismantling scaffolding must follow the manual handling guidelines published by Regulatory Authorities or
other guidelines and codes of practice recognised as being acceptable by such Regulatory Authorities.
Personnel who erect, alter or dismantle scaffolding over 4m in height must hold a current National, State or
Territory Certifcate in Scaffolding to the appropriate class.
Working Load Limits
Working Load Limits (WLLs) are given for couplers that are covered by AS1576.2 and comply to that standard.
WLLs for couplers shown may be limited by components to which they are attached. Hence, load capacity of
such components must be checked for suitability to support resultant loads.
Product Codes
The product codes shown on the following pages are sales codes.
To determine the hire code for the product remove the Z prefx.
Example: Sale code for Double Coupler is ZDC
Hire code for Double Coupler is DC.
Disclaimer
1 Photographs/illustrations shown within this brochure are intended as expressing the diversity and possible applications of the product and as
such must not be used as assembly instructions.
2 In line with Boral Formwork & Scaffoldings commitment to continuous product development and improvement, the information contained in
this brochure may be changed without notice.
3 Every effort has been made to give appropriate guidelines for the use of this product, however, Boral Formwork & Scaffolding Pty Ltd accepts
no responsibility for any loss or damage suffered by any person acting or refraining from action as a result of this information.
Should the users require any further information or guidance, they are encouraged to contact their local Boral Formwork & Scaffolding outlet.
2 3 Scaffold Couplers General Technical and Application Manual

Product Description
Code

Mass

Number

Kg


ZDC 1.05 Double Coupler
Joins two scaffold tubes having outside
diameter of 48.3mm at right angles.
Tightening nuts suit standard Scaffold Spanner
(23mm A/F).
Replaceable 'T' bolts, nuts and washers.
Robust design made from drop forged steel for
durability and reliability.
Hot dip galvanised fnish for corrosion resistance.
Complies with the requirements of AS1576.2.
Typical working load limit of 6.25kN against slip
at tightening torque of 54 Nm.
Can be used to resist tension or compression loads.
Swivel Coupler
Joins scaffold tube having outside diameter of
48.3mm at any angle.
Each half of the Coupler is interconnected with
a swivel pin.
Typically used for connecting bracing members.
Also used for tension splicing of scaffold tubes.
Tightening nuts suit standard Scaffold Spanner
(23mm A/F).
Replaceable 'T' bolts, nuts and washers.
Robust design made from drop forged steel for
durability and reliability.
Hot dip galvanised fnish for corrosion resistance.
Complies with the requirements of AS1576.2.
WLL = 6.25 kN against slip at tightening torque
of 54 Nm.
Can be used to resist tension or compression
loads in bracing.
Should not be used to support primary members.
(Refer Clause 3.2.2 of AS1576.2-1991)
Reduction Double Coupler
Similar to Double Coupler except that it
connects 48 O.D. tube to 60 O.D.
Reduction Swivel Coupler
Similar to Swivel Coupler except that it connects
48 O.D. tube to 60 O.D.
ZSC 1.18
ZRDC 1.80
ZRSC 2.20
4 5 Scaffold Couplers

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General Technical and Application Manual

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ZEJCP 1.37 Expanding Joint Pin
Joins 48 O.D. scaffold tube standards end to
end internally.
Fits inside scaffold tubes.
Expands to ft internal diameter of scaffold tube
when bolt tightened.
Tightening bolt suits standard Scaffold Spanner
(23mm A/F).
Made from forged steel.
Hot dip galvanised fnish.
Under compression loading this Joint Pin
is capable of taking the full capacity of the
scaffold tube.
Not to be used for tension loads. Under tension
loading, it is necessary to splice the joint with
another scaffold tube and Swivel Couplers
(tension load check required).
Not to be used for end to end joining of tube
ledgers.
(Refer Clause 3.2.2 of AS/NZS1576.6-2000).
This Joint Pin must only be used to join
scaffold tube with the same internal diameter,
ie, the same wall thickness.
Typical scaffold tube sizes are:
48.3mm O.D. x 40.3mm I.D. (4.00mm wall
thickness tube) or
48.3mm O.D. x 38.5mm I.D. (4.88mm wall
thickness tube).
External Sleeve Coupler
Joins 48 O.D. scaffold tubes end to end
externally.
Used for end to end joining of scaffold tube
standards.
Locates on outside diameter of scaffold tube
members.
Tightening bolt suits standard Scaffold Spanner.
Made from high quality pressed steel.
Hot dip galvanised fnish.
Under compression loading this Coupler
is capable of taking the full capacity of the
scaffold tube.
Not to be used for tension loads. Under tension
loading, it is necessary to splice the joint with
another scaffold tube and Swivel Couplers
(tension load check required).
Can be used for end to end joining of tube
ledgers.
(Refer Clause 3.2.2 of AS/NZS1576.6-2000).
This Coupler must only be used to join scaffold
tube with the same external diameter.
Typical scaffold tube sizes are:
48.3mm O.D. x 40.3mm I.D. (4.00mm wall
thickness tube) or
48.3mm O.D. x 38.5mm I.D. (4.88mm wall
thickness tube).
ZESCG 1.20
4 5 Scaffold Couplers

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General Technical and Application Manual

Product Description
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Putlog Coupler
(Standard Double Flap Type)
Joins 48 O.D. scaffold tubes at right angles.
Used for fxing putlog tubes onto ledger tubes.
Tightening nut suits standard Scaffold Spanner
(23mm A/F).
Replaceable 'T' bolt, nut and washer.
Pressed steel faps and drop forged steel cap.
Hot dip galvanised fnish for corrosion
resistance.
Complies with the requirements of AS1576.2.
Typically used for securing guardrails and
midrails at right angles to standards. Other uses
can distort the coupler so that tube retention is
not effective and WLL does not apply.
Not to be used for connecting putlog tubes to
ledger tube in tube-and-coupler scaffolding.
Only use Right Angle Couplers for this purpose.
Refer AS/NZS1576.6 for guidance on tube-and-
coupler scaffolding.
WLL = 0.62 kN against slip of tube through faps
of coupler at tightening torque of 54 Nm.
Putlog Coupler - Wrapover
(Standard Wrapover single type)
Joins 48 O.D. scaffold tubes at right angles.
Used for positioning putlog tubes onto ledger
tubes.
Tightening nut suits standard Scaffold Spanner
(23mm A/F).
Replaceable 'T' bolt, nut and washer.
Pressed steel body and drop forged steel cap.
Hot dip galvanised fnish for corrosion
resistance.
Complies with the requirements of AS1576.2.
Typically used for securing guardrails and
midrails to standards at right angles.
Other uses can distort the Coupler so that tube
retention is not effective and WLL does not apply.
Not to be used for connecting putlog tubes to
ledger tube. Only use Right Angle Couplers for
such purpose.
Refer AS/NZS1576.6 for guidance on tube-and-
coupler scaffolding.
WLL = 0.62 kN against slip of tube through faps
of coupler at tightening torque of 54 Nm.
Putlog Coupler - Hook Type
Joins 48 O.D. scaffold tubes at right angles.
Not recommended for fxing of putlog tubes to
ledger tubes for working decks.
Putlog Head
Used for single pole putlog scaffolding.
Fits 48 O.D. scaffold tube.
WLL = 6.25 kN (resistance to tube slip where nuts
tightened to 54 Nm torque).
WLL = 2.25 kN (bending of blade).
ZPC 1.0
ZPCSW 0.7
ZPCHT 0.4
ZPH 1.23
Putlog Coupler - Hook Type
Putlog Coupler - Wrapover
Putlog Coupler
Putlog Head
6 7 Scaffold Couplers

Product Description
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General Technical and Application Manual

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RSJ Clamp N2
RSJC2
Hire Only
1.07
RSJ Clamp N3
RSJC3
Hire Only
1.20
RSJ Clamp N1
RSJC1
Hire Only
1.05 RSJ Clamps
Joins 48 O.D. scaffold tube to Tapered or Parallel
Flange steel beams at 90
0
.
Size 1 suitable for RSJ fange thickness up to 19mm.
Size 2 suitable for RSJ fange thickness of 19-38mm.
Size 3 suitable for RSJ fange thickness of 38-57mm.
Note:
RSJ Clamps must be used in pairs each side of
the fange. Minimum tightening torque = 54 Nm.
WLL =
15.0 kN
RSJ Girder Clamp
WLL = 6.25kN
Resistance to slip along
tube or along flange of beam
Steel
Beam
48 O.D. scaffold tube
48 O.D.
scaffold tube
Gravlock Girder Clamp
Joins 48 O.D. scaffold tube to Tapered or Parallel
Flange steel beams at 90
0
.
Suitable for girder fange thickness up to 44mm.
ZGGC 1.50
Note:
Gravlock Girder Clamps must be used in pairs
each side of the fange.
Minimum tightening torque = 54 Nm.
WLL = 6.25kN
Resistance to slip along
tube or along flange of beam
48 O.D.
scaffold
tube
WLL =
15.0 kN 48 O.D. scaffold tube
Steel
Beam
Gravlock
Girder Clamp
Note:
RSJ Swivel Clamps must be used in pairs each
side of the fange.
Minimum tightening torque = 54 Nm.
RSJ Swivel Clamp
Joins 48 O.D. scaffold tube to Tapered or Parallel
Flange steel beams at various angles.
Suitable for girder fange thickness up to 44mm.
RSJSC
Hire Only
1.45
WLL =
15.0 kN
WLL = 6.25kN
Resistance to slip along
tube or along flange of beam
Steel
Beam
48 O.D. scaffold tube
48 O.D.
scaffold
tube
RSJ Swivel Clamp
6 7 Scaffold Couplers

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General Technical and Application Manual

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Board Clamp
Retains timber scaffold planks to 48 O.D. putlog/
transom tubes.
Suitable for plank thickness range of 35 to 38mm.
Rafter Coupler
Used for clamping scaffold tube to timber runners.
Suitable for timbers 50mm wide.
Wall Tie Bracket
Wall Tie Brackets are an alternative tying method
and they are used where it is not possible or
convenient to tie through windows or around
columns.
Wall Tie Brackets supplied by BF&S comprise a
half Swivel Coupler attached to an angle section
with a pin allowing it to rotate. The angle section
contains an 18mm dia hole for a 16mm dia
fastener or anchor for securing the bracket to the
face of a building wall or similar structure. The
swivel pin attachment enables the Half Coupler to
rotate through 360
0
.
Notes:
The load capacity of the selected anchor and
the structure to which the bracket is attached
must be verifed as having suitable capacity to
sustain the Working Load Limit of the bracket.
When determining anchor forces, prying forces
must be considered where they may occur.
Stated WLL is applicable where the following
types of Swivel Coupler is used:
- Boral/Euro
- Boral/Burtons
- Boral/SGB
- Acrow.
Australian Standards for Scaffolding provide
guidance on Anchorage and Tie Assemblies.
In particular refer to Clause 2.8 of AS1576.1 and
Clause 8.5 of AS4576.
ZSBCP 0.60
RC
Hire Only
1.5
ZWTB 2.0
Suitable anchor
to structure
WLL = 6.25kN

NEW SOUTH WALES
Email: bfs.nsw@boral.com.au
SYDNEY (REVESBY)
Telephone (02) 9780 6577
Facsimile (02) 9780 6499
BROOKVALE
Telephone (02) 9905 1142
Facsimile (02) 9905 1109
COFFS HARBOUR
Telephone (02) 6653 1390
Facsimile (02) 6658 2377
NEWCASTLE
Telephone (02) 4961 4315
Facsimile (02) 4961 5582
NORTH WYONG
Telephone (02) 4352 2272
Facsimile (02) 4351 5115
ORANGE
Telephone (02) 6362 4195
Facsimile (02) 6361 3215
PORT MACQUARIE
Telephone (02) 6581 0366
Facsimile (02) 6581 2488
TAMWORTH
Telephone (02) 6765 7474
Facsimile (02) 6765 2704
WOLLONGONG
Telephone (02) 4227 3211
Facsimile (02) 4227 1114
CANBERRA ACT
Email: bfs.nsw@boral.com.au
CANBERRA
Telephone (02) 6260 2558
Facsimile (02) 6260 2559
VICTORIA
Email: bfs.vic@boral.com.au
MELBOURNE
Telephone (03) 8311 5100
Facsimile (03) 9310 2977
TRARALGON
Telephone (03) 5174 5616
Facsimile (03) 5174 8522
TASMANIA
Email: bfs.tas@boral.com.au
HOBART
Telephone (03) 6272 6775
Facsimile (03) 6272 3647
LAUNCESTON
Telephone (03) 6334 5484
Facsimile (03) 6334 5494
QUEENSLAND
Email: bfs.qld@boral.com.au
BRISBANE
Telephone (07) 3265 2266
Facsimile (07) 3865 0277
CAIRNS
Telephone (07) 4035 4886
Facsimile (07) 4035 4870
GLADSTONE
Telephone (07) 4972 3685
Facsimile (07) 4972 7903
GOLD COAST
Telephone (07) 5593 5850
Facsimile (07) 5593 4203
MACKAY
Telephone (07) 4952 2204
Facsimile (07) 4952 2938
MAROOCHYDORE
Telephone (07) 5445 3233
Facsimile (07) 5445 3099
ROCKHAMPTON
Telephone (07) 4928 3666
Facsimile (07) 4926 1590
TOOWOOMBA
Telephone (07) 4632 1536
Facsimile (07) 4639 3764
TOWNSVILLE
Telephone (07) 4779 3255
Facsimile (07) 4725 1119
SOUTH AUSTRALIA
Email: bfs.sa@boral.com.au
ADELAIDE
Telephone (08) 8359 1033
Facsimile (08) 8359 1366
NORTHERN TERRITORY
Email: bfs.nt@boral.com.au
DARWIN
Telephone (08) 8984 4414
Facsimile (08) 8984 4060
WESTERN AUSTRALIA
Email: bfs.wa@boral.com.au
PERTH
Telephone (08) 9302 8900
Facsimile (08) 9302 1744
KALGOORLIE
Telephone (08) 9021 8642
Facsimile (08) 9021 5220
KARRATHA
Telephone (08) 9144 1010
Facsimile (08) 9144 1709
KWINANA
Telephone (08) 9419 7806
Facsimile (08) 9419 4024
Your local contact from our national network of branches
BORAL FORMWORK &
SCAFFOLDING PTY LTD
ACN 004 284 806
ABN 35 004 284 806
National Head Offce:
2A Mavis Street
Revesby NSW 2212
Telephone: (02) 9780 6555
Facsimile: (02) 9780 6444
Email: bfs@boral.com.au
Web: www.boral.com.au
Formwork &
Scaffolding
ACROW CYCLONE
Broch 031 Mar 03
Boral Know How