You are on page 1of 33

STEKIZ ENGINEERING

CONSULTANTS PTY LTD

LOAD TESTING OF
STATIC MODULAR ALUMINIUM SCAFFOLD
FOR

NCS WHOLESALERS PTY LTD

ORIGINAL TESTING CONDUCTED:


FURTHER TESTING CONDUCTED:

13 & 14 December 2011


27 June 2012

TESTING CONDUCTED BY:

Steve Pratt
Civil / Structural Engineer
Stekiz Engineering Consultants Pty Ltd

ORIGINAL REPORT PREPARED:


REVISED REPORT PREPARED:

February 2012
July 2012

REPORT PREPARED BY:

Steve Pratt
Civil / Structural Engineer
Stekiz Engineering Consultants Pty Ltd

Stekiz
ABN:
P:
M:
E:

Engineering Consultants Pty Ltd


77116912255
121 Date St, Adamstown NSW 2289
0419 161933
stekizeng@bigpond.com

NCS WHOLESALERS PTY LTD

CONTENTS
1. INTRODUCTION
2.

TESTING PROCEDURE & RESULTS


2.1
2.2
2.3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
2.4.8
2.4.9
2.4.10
2.4.11
2.4.12
2.4.13
2.4.14
2.4.15
2.4.16
2.4.17

Vertical Load-Carrying Capacity of an assembled static


Modular Scaffold - 25 metre Design height [ 2.4m Bay ]
Vertical Load-Carrying Capacity of an assembled static
Modular Scaffold - 40 metre Design height [ 2.4m Bay ]
Vertical Load-Carrying Capacity of an assembled static
Modular Scaffold - 25 metre Design height [ 3.0m Bay ]
Test on Load Bearing Components
1.2m Transom Heavy Duty
1.0m Transom Heavy Duty
0.8m Transom Medium Duty
0.5m Transom Light Duty
1.8m Transom Heavy Duty
2.4m Transom Heavy Duty
3.0m Transom Heavy Duty
2.4m Transom Truss Hoarding Loading (10kPa)
1.8m Transom Truss Hoarding Loading (10kPa)
1.8m Transom Truss Further testing
3.0m Transom Truss Hoarding Loading (10kPa)
3.0m Transom Truss Further testing
3.0m Steel Board to Failure.
2.0m Standard to Failure.
2-board Hop-up Medium Duty.
2.4m Ledger Mid-span Load.
2.4m Infill Ledger
3.0m Ledger Mid-span Load.
3.0m Infill Ledger

3. CONCLUSIONS

4.2
4.3

Certifiers Insurance - Certificates of Currency

4.1.1
4.1.2

6
8

10
11
12
13
14
15
16
17
18
18
19
19
20
21
22
23
23
24
24

25

4. APPENDICES
4.1

Professional Indemnity
Public Liability

Certifiers Qualifications (copies)


LoadCell Calibration Certificate

STEKIZ ENGINEERING CONSULTANTS PTY LTD

26

30
33

Page 2

NCS WHOLESALERS PTY LTD

INTRODUCTION

This Report presents the details and results of the testing of static modular
aluminium lightweight Scaffold.
The testing was requested by NCS Wholesalers Pty Ltd.
The objectives of the testing were to determine:

Compliance with the requirements of relevant Australian Standards for


Scaffolding.

Determination of compliance with Design Load Duty requirements.

Design Serviceability installed height of the modular Scaffold.


Testing was undertaken using the procedures detailed in:
AS/NZS 1576.3:1995 Scaffolding

Part 3: Prefabricated and tube-and-coupler scaffolding

Testing was undertaken on 13 & 14 December 2011 at the workshop of NCS


Wholesalers Pty Ltd, and was supervised by Steve Pratt of Stekiz Engineering
Consultants Pty Ltd.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 3

NCS WHOLESALERS PTY LTD

TESTING PROCEDURE & RESULTS

2.1

Vertical Load-Carrying Capacity of an assembled static Modular


Scaffold

Heavy Duty Scaffold (675kg/Bay) 25 metre Design height [ 2.4m Bay ]


Scaffold Design criteria:

Scaffold 25.0 metres to top handrail.

Scaffold 24.0 metres to top working deck.

Intermediate decks at 2.0m height intervals.

Scaffold made up of maximum 2.4m long bays.

Scaffold 1.2m (5-boards) wide.

Working deck edge protection double handrail & kickboard.

Scaffold to be rigidly tied to a supporting structure at every other standard, and at


vertical intervals not exceeding 4.0m.

Screw base jacks are to be used with spindle extension not exceeding 450mm.

Face bracing to full height to every third Bay.


This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix B.
Three (3) modular Scaffold bays were assembled to a testing height of 6.2m in the normal use
configuration. The Loads were applied to the ends of the Scaffold standards at the 6.2m test
height, and maintained in place for 15 minutes.
The Design height of the Scaffold, in this instance, is to be 25 metres.
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load B1
B1 = (2G-W)/2 + (2 x 0.7Q)

where

G = Self weight of Scaffold Bay at its Design height of 25m


W = Self weight of Scaffold Bay as tested (6.2m)
Q = Design Live Load on working platform

=
=
=

1442.3 kg
382.6 kg.
675 kg.

B1 = ((2 x 1442.3) 382.6)/2 + (2 x (0.7 x 675))

2196 kg

1656 kg

Test Load B2
B2 = (2G-W)/2 + (2 x 0.3Q)
B2 = ((2 x 1442.3) 382.6)/2 + (2 x (0.3 x 675))

The total test load used was 3852 kg.


Test Load B1 was applied to one standard in a set of transverse standards, while Test Load
B2 was applied to the other standard in the same set of transverse standards.
The test loads were maintained in place for 15 minutes, and then removed. The Scaffold
structure was then examined for evidence of permanent deformation and/or component
failure.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 4

NCS WHOLESALERS PTY LTD

Observations revealed no evidence at all that the Scaffold structure exhibited permanent
deformation.
The Scaffold structure was sound, with no damage to any of the Scaffolds components.
It can be concluded that this Scaffold passed this test satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 5

NCS WHOLESALERS PTY LTD

2.2

Vertical Load-Carrying Capacity of an assembled static Modular


Scaffold

Heavy Duty Scaffold (675kg/Bay) 40 metre Design height [ 2.4m Bay ]


Scaffold Design criteria:

Scaffold 40.0 metres to top handrail.

Scaffold 39.0 metres to top working deck.

Intermediate decks at 2.0m height intervals.

Scaffold made up of maximum 2.4m long bays.

Scaffold 1.2m (5-boards) wide.

Working deck edge protection double handrail & kickboard.

Scaffold to be rigidly tied to a supporting structure at every other standard, and at


vertical intervals not exceeding 4.0m.

Screw base jacks are to be used with spindle extension not exceeding 450mm.

Face bracing to full height to every third Bay.


This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix B.
Three (3) modular Scaffold bays were assembled to a testing height of 6.2m in the normal use
configuration. The Loads were applied to the ends of the Scaffold standards at the 6.2m test
height, and maintained in place for 15 minutes.
The Design height of the Scaffold, in this instance, is to be 40 metres.
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load B1
B1 = (2G-W)/2 + (2 x 0.7Q)

where

G = Self weight of Scaffold Bay at its Design height of 40m


W = Self weight of Scaffold Bay as tested (6.2m)
Q = Design Live Load on working platform

=
=
=

2362.9 kg
382.6 kg
675 kg.

B1 = ((2 x 2362.9) 382.6)/2 + (2 x (0.7 x 675))

3117 kg

2577 kg

Test Load B2
B2 = (2G-W)/2 + (2 x 0.3Q)
B2 = ((2 x 2362.9) 382.6)/2 + (2 x (0.3 x 675))

The total test load used was 5694 kg.


Test Load B1 was applied to one standard in a set of transverse standards, while Test Load
B2 was applied to the other standard in the same set of transverse standards.
The test loads were maintained in place for 15 minutes, and then removed. The Scaffold
structure was then examined for evidence of permanent deformation and/or component
failure.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 6

NCS WHOLESALERS PTY LTD

Observations revealed no evidence that the Scaffold structure exhibited permanent


deformation.
The Scaffold structure was sound, with no damage to any of the Scaffolds components.
It can be concluded that this Scaffold passed this test satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 7

NCS WHOLESALERS PTY LTD

2.3

Vertical Load-Carrying Capacity of an assembled static Modular


Scaffold

Heavy Duty Scaffold (675kg/Bay) 25 metre Design height [ 3.0m Bay ]


Scaffold Design criteria:

Scaffold 25.0 metres to top handrail.

Scaffold 24.0 metres to top working deck.

Intermediate decks at 2.0m height intervals.

Scaffold made up of maximum 3.0m long bays.

Scaffold 1.2m (5-boards) wide.

Working deck edge protection double handrail & kickboard.

Scaffold to be rigidly tied to a supporting structure at every other standard, and at


vertical intervals not exceeding 4.0m.

Screw base jacks are to be used with spindle extension not exceeding 450mm.

Face bracing to full height to every third Bay.


This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix B.
Three (3) modular Scaffold bays were assembled to a testing height of 6.2m in the normal use
configuration. The Loads were applied to the ends of the Scaffold standards at the 6.2m test
height, and maintained in place for 15 minutes.
The Design height of the Scaffold, in this instance, is to be 25 metres.
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load B1
B1 = (2G-W)/2 + (2 x 0.7Q)

where

G = Self weight of Scaffold Bay at its Design height of 25m


W = Self weight of Scaffold Bay as tested (6.2m)
Q = Design Live Load on working platform

=
=
=

1704 kg
452 kg
675 kg.

B1 = ((2 x 1704) 452)/2 + (2 x (0.7 x 675))

2423 kg

1883 kg

Test Load B2
B2 = (2G-W)/2 + (2 x 0.3Q)
B2 = ((2 x 1704) 452)/2 + (2 x (0.3 x 675))

The total test load used was 4306 kg.


Test Load B1 was applied to one standard in a set of transverse standards, while Test Load
B2 was applied to the other standard in the same set of transverse standards.
The test loads were maintained in place for 15 minutes, and then removed. The Scaffold
structure was then examined for evidence of permanent deformation and/or component
failure.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 8

NCS WHOLESALERS PTY LTD

Observations revealed no evidence that the Scaffold structure exhibited permanent


deformation.
The Scaffold structure was sound, with no damage to any of the Scaffolds components.
It can be concluded that this Scaffold passed this test satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 9

NCS WHOLESALERS PTY LTD

2.4

Test on Load-Bearing Components

2.4.1

Heavy Duty (675kg/Bay) 1.2m Transom Test

Design

criteria:
Scaffold made up of maximum 3.0m long bays.
Scaffold 1.2m (5-boards) wide.
Kickboard included in Dead Load.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom (using 300mm spreader blocks).
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

108 kg
675 kg.

L = 2 x (108 + 675)

1566 kg

The total test load used was 1566 kg.


The test load was maintained in place for 15 minutes, and then removed. The transom &
Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
Observations revealed no evidence of the Transom or the Scaffold structure exhibiting
permanent deformation.
The Transom was sound, with no damage to its structural integrity.
It can be concluded that the 1.2m Transom passed this test (Heavy Duty) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 10

NCS WHOLESALERS PTY LTD

2.4.1
Design

Heavy Duty (675kg/Bay) 1.0m Transom Test


criteria:
Scaffold made up of maximum 3.0m long bays.
Scaffold 1.0m wide.
Kickboard included in Dead Load.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom (using 300mm spreader blocks).
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

108 kg
675 kg.

L = 2 x (108 + 675)

1566 kg

The total test load used was 1570 kg.


The test load was maintained in place for 15 minutes, and then removed. The transom &
Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
Observations revealed no evidence of the Transom or the Scaffold structure exhibiting
permanent deformation.
The Transom was sound, with no damage to its structural integrity.
It can be concluded that the 1.0m Transom passed this test (Heavy Duty) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 11

NCS WHOLESALERS PTY LTD

2.4.3
Design

Medium Duty (450kg/Bay) 0.8m Transom Test


criteria:
Scaffold made up of maximum 3.0m long bays.
Scaffold 0.8m (3-boards) wide.
Kickboard included in Dead Load.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom (using 300mm spreader blocks).
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

72 kg
450 kg.

L = 2 x (72 + 450)

1044 kg

The total test load used was 1044 kg.


The test load was maintained in place for 15 minutes, and then removed. The transom &
Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
Observations revealed no evidence of the Transom or the Scaffold structure exhibiting
permanent deformation.
The Transom was sound, with no damage to its structural integrity.
It can be concluded that the 0.8m Transom passed this test (Medium Duty) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 12

NCS WHOLESALERS PTY LTD

2.4.4
Design

Light Duty (225kg/Bay) 0.5m Transom Test


criteria:
Scaffold made up of maximum 3.0m long bays.
Scaffold 0.5m (2-boards) wide.
Kickboard included in Dead Load.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom.
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

54 kg
225 kg.

L = 2 x (54 + 225)

558 kg

The total test load used was 558 kg.


The test load was maintained in place for 15 minutes, and then removed. The transom &
Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
Observations revealed no evidence of the Transom or the Scaffold structure exhibiting
permanent deformation.
The Transom was sound, with no damage to its structural integrity.
It can be concluded that the 0.5m Transom passed this test (Light Duty) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 13

NCS WHOLESALERS PTY LTD

2.4.5
Design

NOTE:

Heavy Duty (675kg/Bay) 1.8m Transom Test


criteria:
Scaffold made up of maximum 3.0m long bays.
Scaffold 1.8m (7-boards) wide
Simple transom (not a transom truss).
This is not a 10kPa Hoarding loading.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom (using 1.0m spreader blocks).
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

126 kg
675 kg.

L = 2 x (126 + 675)

1602 kg

The total test load used was 1602 kg.


The test load was maintained in place for 15 minutes, and then removed. The transom &
Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
Observations revealed no evidence of the Transom or the Scaffold structure exhibiting
permanent deformation.
The Transom was sound, with no damage to its structural integrity.
It can be concluded that the 1.8m Transom passed this test (Heavy Duty) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 14

NCS WHOLESALERS PTY LTD

2.4.6
Design

NOTE:

Heavy Duty (675kg/Bay) 2.4m Transom Test


criteria:
Scaffold made up of maximum 2.4m long bays.
Scaffold 2.4m (10-boards) wide
Simple transom (not a transom truss).
This is not a 10kPa Hoarding loading.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom (using 1.0m spreader blocks).
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

180 kg
675 kg.

L = 2 x (180 + 675)

1710 kg

The total test load used was 1710 kg.


The test load was maintained in place for 15 minutes, and then removed. The transom &
Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
Observations revealed no evidence of the Transom or the Scaffold structure exhibiting
permanent deformation.
NOTE:

Transom deflected approx. 15mm under load.

The Transom was sound, with no damage to its structural integrity.


It can be concluded that the 2.4m Transom passed this test (Heavy Duty) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 15

NCS WHOLESALERS PTY LTD

2.4.7
Design

NOTE:

Heavy Duty (675kg/Bay) 3.0m Transom Test


criteria:
Scaffold made up of maximum 2.4m long bays.
Scaffold 3.0m (13-boards) wide
Simple transom (not a transom truss).
This is not a 10kPa Hoarding loading.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom (using 1.0m spreader blocks).
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

234 kg
675 kg.

L = 2 x (234 + 675)

1818 kg

The total test load used was 1818 kg.


The test load was maintained in place for 15 minutes, and then removed. The Transom &
Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
Observations revealed no evidence of the Transom or the Scaffold structure exhibiting
permanent deformation.
NOTE:

Transom deflected approx. 25mm under load.

The Transom was sound, with no damage to its structural integrity.


It can be concluded that the 3.0m Transom passed this test (Heavy Duty) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 16

NCS WHOLESALERS PTY LTD

2.4.8
Design

NOTE:
Truss.

Hoarding Load (10kPa) 2.4m Transom Truss


criteria:
Scaffold made up of maximum 2.4m long bays.
Scaffold 2.4m (10-boards) wide.
This is a 10kPa Hoarding loading.
One (1) diagonal plan brace was installed at the level of the bottom of the Transom

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom Truss (using 1.0m spreader blocks).
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

180 kg
2400 kg.

L = 2 x (180 + 2400)

5160 kg

The total test load used was 5160 kg.


The test load was maintained in place for 15 minutes, and then removed. The Transom Truss
& Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
Observations revealed no evidence of the Transom Truss or the Scaffold structure exhibiting
permanent deformation.
The Transom Truss was sound, with no damage to its structural integrity.
It can be concluded that the 2.4m Transom Truss passed this test (Hoarding Load)
satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 17

NCS WHOLESALERS PTY LTD

2.4.9
Design

NOTE:
Truss.

Hoarding Load (10kPa) 1.8m Transom Truss


criteria:
Scaffold made up of maximum 2.4m long bays.
Scaffold 1.8m (7-boards) wide.
This is a 10kPa Hoarding loading.
One (1) diagonal plan brace was installed at the level of the bottom of the Transom

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom Truss (using 1.0m spreader blocks).
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

126 kg
2400 kg.

L = 2 x (126 + 2400)

5052 kg

The total test load used was 5052 kg.


The test load was maintained in place for 15 minutes, and then removed. The Transom Truss
& Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
NOTE: Under load, the strap diagonals within the 1.8m Transom Truss, in compression,
deflected out of conformance limits.
Observations revealed no evidence of the Transom Truss or the Scaffold structure exhibiting
permanent deformation.
The Transom Truss was sound, with no damage to its structural integrity.
However, it is highly recommended that the 1.8m Transom Trusss structure is re-designed to
minimise the deflection under load of the truss straps in compression.

FURTHER TESTING
Further testing was undertaken on the newly-designed 1.8m Transom Truss with tubular
diagonals, rather than strap diagonals.
An identical testing regime was undertaken total test load 5050kg.
Observations revealed no evidence of the Transom Truss or the Scaffold structure exhibiting
permanent deformation.
The Transom Truss was sound, with no damage to its structural integrity.
It can be concluded that the newly-designed 1.8m Transom Truss passed this test (Hoarding
Load) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 18

NCS WHOLESALERS PTY LTD


2.4.10 Hoarding Load (10kPa) 3.0m Transom Truss
Design

NOTE:
Truss.

criteria:
Scaffold made up of maximum 2.4m long bays.
Scaffold 3.0m (13-boards) wide.
This is a 10kPa Hoarding loading.
One (1) diagonal plan brace was installed at the level of the bottom of the Transom

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Transom Truss (using 1.0m spreader blocks).
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

234 kg
2400 kg.

L = 2 x (234 + 2400)

5268 kg

The total test load used was 5268 kg.


The test load was maintained in place for 15 minutes, and then removed. The Transom Truss
& Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
NOTE: Under load, the strap diagonals within the 3.0m Transom Truss, in compression,
deflected out of conformance limits.
Observations revealed no evidence of the Transom Truss or the Scaffold structure exhibiting
permanent deformation.
The Transom Truss was sound, with no damage to its structural integrity.
However, it is highly recommended that the 3.0m Transom Trusss structure is re-designed to
minimise the deflection under load of the truss straps in compression.

FURTHER TESTING
Further testing was undertaken on the newly-designed 3.0m Transom Truss with tubular
diagonals, rather than strap diagonals.
An identical testing regime was undertaken total test load 5270kg.
Observations revealed no evidence of the Transom Truss or the Scaffold structure exhibiting
permanent deformation.
The Transom Truss was sound, with no damage to its structural integrity.
It can be concluded that the newly-designed 3.0m Transom Truss passed this test (Hoarding
Load) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 19

NCS WHOLESALERS PTY LTD


2.4.11 3.0m Steel Board to failure
Design

criteria:
Scaffold made up of maximum 3.0m long bays.
Single steel board supported by 1.2m transoms.
Steel board was loaded to failure.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the midpoint
of the Steel Board.

The midspan load was increased over a period of 10 minutes, until the Steel Board failed by
creasing under the midspan load.
Ultimate Test Load was 450 kg.
This Ultimate Test Load well exceeds the Design Load (225kg) of a 2.4m Steel Board.
This is an excellent result considering the Steel Board is spanning 3.0m.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 20

NCS WHOLESALERS PTY LTD

2.4.12 2.0m Standard to failure


Design

criteria:
Scaffold made up of maximum 2.4m long bays.
Standard was central of two (2) bays.
2.0m standard was loaded to failure.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied as an axial
vertical load to the top of the standard.

The axial load was increased over a period of 10 minutes, until the 2.0m standard failed in
bending at its midpoint.
Ultimate Test Load was 5300 kg.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 21

NCS WHOLESALERS PTY LTD

2.4.13 2-board Hop-up Light Duty (225kg/Ba)


Design criteria:

Scaffold made up of maximum 2.4m long bays.

Hop-up was fixed with 2.4m tie-bars both sides.


This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied at the hop-ups
extremity.
Test loads were determined in accordance with AS/NZS 1576.3:1995 Appendix B as follows:
Test Load L
L = 2(G + Q)

where

G = Dead Load to be supported on the component


Q = Design Live Load on the component

=
=

36 kg
225 kg.

L = 2 x (36 + 225)

522 kg

The total test load used was 522 kg.


The test load was maintained in place for 15 minutes, and then removed. The 2-board Hop-up
& Scaffold structure were then examined for evidence of permanent deformation and/or
component failure.
Observations revealed no evidence of the 2-board Hop-up or the Scaffold structure exhibiting
permanent deformation.
The 2-board Hop-up was sound, with no damage to its structural integrity.
It can be concluded that the 2-board Hop-up passed this test (Light Duty) satisfactorily.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 22

NCS WHOLESALERS PTY LTD

2.4.14 2.4m Ledger Midspan Load Test


Design criteria:

Scaffold made up of maximum 2.4m long bays.

Ledger was within a central bay of three (3) bays.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied as a vertical
load at the Ledgers midspan.
The midspan load was increased over a period of 10 minutes.
Maximum Test Load was 85 kg.
A midspan deflection of 15mm was observed under load.
Observations revealed no evidence of the Ledger exhibiting permanent deformation.
The Ledger was sound, with no damage to its structural integrity.
It can be concluded that the 2.4m Ledger passed this midspan Load test satisfactorily.

2.4.15 2.4m Infill Ledger Midspan Load Test


Design

criteria:
Scaffold made up of maximum 3.0m long bays.
Ledger was within a central bay of three (3) bays.
Test was undertaken to determine the Infill Ledgers suitability as a Stretcher Stair
Stringer.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied as a vertical
load at the Ledgers midspan.
The midspan load was increased over a period of 10 minutes.
Maximum Test Load was 630 kg.
A midspan deflection of 14mm was observed under load.
Observations revealed no evidence of the Ledger exhibiting permanent deformation.
The Ledger was sound, with no damage to its structural integrity.
It can be concluded that the 2.4m Infill Ledger passed this midspan Load test satisfactorily,
and its section could serve as a Stretcher Stair Stringer.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 23

NCS WHOLESALERS PTY LTD

2.4.16 3.0m Ledger Midspan Load Test


Design criteria:

Scaffold made up of maximum 3.0m long bays.

Ledger was within a central bay of three (3) bays.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied as a vertical
load at the Ledgers midspan.
The midspan load was increased over a period of 10 minutes.
Maximum Test Load was 85 kg.
A midspan deflection of 15-20mm was observed under load.
Observations revealed no evidence of the Ledger exhibiting permanent deformation.
The Ledger was sound, with no damage to its structural integrity.
It can be concluded that the 3.0m Ledger passed this midspan Load test satisfactorily.

2.4.17 3.0m Infill Ledger Midspan Load Test


Design

criteria:
Scaffold made up of maximum 3.0m long bays.
Ledger was within a central bay of three (3) bays.
Test was undertaken to determine the Infill Ledgers suitability as a Stretcher Stair
Stringer.

This test was completed using the basis of the procedure outlined in:
AS/NZS 1576.3:1995 Appendix C.
The test was assembled in a low height lift of Scaffold. The Load was applied as a vertical
load at the Ledgers midspan.
The midspan load was increased over a period of 10 minutes.
Maximum Test Load was 630 kg.
A midspan deflection of 18mm was observed under load.
Observations revealed no evidence of the Ledger exhibiting permanent deformation.
The Ledger was sound, with no damage to its structural integrity.
It can be concluded that the 3.0m Infill Ledger passed this midspan Load test satisfactorily,
and its section could serve as a Stretcher Stair Stringer.

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 24

NCS WHOLESALERS PTY LTD

CONCLUSIONS

Vertical load-carrying capacity tests, along with load-bearing components testing


were undertaken on assembled static Modular Aluminium Scaffold.
Testing was undertaken using the procedures detailed in:
AS/NZS 1576.3:1995 Scaffolding

Part 3: Prefabricated and tube-and-coupler scaffolding

Test results are detailed in this Report.


After extensive testing on the static Modular Aluminium Scaffold, the following
conclusions may be drawn:
Notwithstanding Australian Standard & WorkCover NSW regulations, the test
results on the static Modular Aluminium Scaffold (installed with 2.4m max. long
Bays) reveal that it can be safely installed to a height of 40 metres in Heavy Duty
mode (675kg/Bay).
Notwithstanding Australian Standard & WorkCover NSW regulations, the test
results on the static Modular Aluminium Scaffold (installed with 3.0m max. long
Bays) reveal that it can be safely installed to a height of 25 metres in Heavy Duty
mode (675kg/Bay).
Testing found that the 1.8m Transom Truss, along with the 3.0m Transom Truss,
requires structural design modifications.
Although both these components supported their respective Design Test Loads, the
deflection of their truss straps, under load, exceeded compliance limits.
Further testing on newly-designed Transom Trusses (both 1.8m and 3.0m), with a
tubular lattice structure rather than a strap lattice structure, revealed that both
Transom Trusses supported their respective Design Test Loads, with deflections
within compliance limits.
Based on the results of the testing, it can be concluded that the static Modular
Aluminium Scaffold, along with its individual components, satisfies compliance
with:
AS/NZS 1576.3:1995 Scaffolding

Part 3: Prefabricated and tube-and-coupler scaffolding

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 25

NCS WHOLESALERS PTY LTD

APPENDICES
4.1

Certifiers Insurance - Certificates of Currency


4.1.1
4.1.2

Professional Indemnity
Public Liability

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 26

NCS WHOLESALERS PTY LTD

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 27

NCS WHOLESALERS PTY LTD

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 28

NCS WHOLESALERS PTY LTD

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 29

NCS WHOLESALERS PTY LTD

4.2

Certifiers Qualifications (copies)

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 30

NCS WHOLESALERS PTY LTD

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 31

NCS WHOLESALERS PTY LTD

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 32

NCS WHOLESALERS PTY LTD

4.3

LoadCell Calibration Certificate

STEKIZ ENGINEERING CONSULTANTS PTY LTD

Page 33