TG25:21

Scaffold Tube Storage Racks

INTRODUCTION

Scaffold tube storage racks are a common feature of every scaffolding contractor’s yard and many long-
term live sites. Whilst tube racks are usually constructed as basic birdcage-like structures, they generally
support many tonnes of equipment, so their design needs special consideration. This guidance note therefore
considers the design, use and maintenance of scaffold tube storage racks.

For the purpose of this guidance, all tube is assumed to be Type 4 steel tube to BS EN 39:2001 with a self-
weight of 4.37 kg/m. All tube is assumed to be in ‘as new’ condition. Scaffold coupler permissible values are in
accordance with BS EN 74:2005.

This guidance does not cover the storage of scaffold couplers or other storage facilities.

A ‘typical’ generic design for an unclad scaffold tube rack is included within this guidance, which can be used
to negate the requirement for a bespoke design, provided that it is situated in an area where the basic wind
velocity (Vb,map) does not exceed 25.75 m/s. (This essentially covers all mainland UK areas excluding the
northern areas of both Scotland and Northern Ireland). Please refer to Figure 4.1 of the TG20 Design Guide
for further detail. Any storage rack or structure which does not comply with the requirements of this guidance
note requires a bespoke design by a competent engineer.

Where temporary roof structures are erected to form storage sheds, guidance can be found in the latest edition
of NASC guidance TG9 “Guide to the design and construction of temporary roofs and buildings”.

DESIGN CRITERIA

To ensure that scaffold tube storage racks remain safe and stable, they should be subject to calculation and
design.

The method of loading, especially if by mechanical means, should be taken into consideration. If the top level
of the storage rack is to be boarded and accessed by workers or used as a working platform, then it must
be fitted with guardrails, toeboards, a staircase or access ladder(s), in compliance with the Work at Height
Regulations 2005.

Tube storage racks are generally erected with traditional tube & fitting scaffolding components as a series of
birdcage lines to cater for varied lengths of tube. Generally the length of bay lines range from 1m to 6m to cater
for 1.2m (4ft) to 6.4m (21ft) tubes respectively.

A typical example consists of a 1m x 1m grid on plan and 0.6m lift heights and should be constructed, modified
and dismantled by adopting a safe system of work in compliance with NASC guidance SG4.

The stored tubes rest on structural transoms fixed directly above ledgers, both fixed to standards using right
angle couplers. The SWL of the storage rack is limited to the safe slip capacity of the transom and ledger to
standard connection. The allowable quantity of tubes should be limited to ensure no additional supplementary
couplers are required to minimise equipment and subsequent labour time.

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 FOUNDATIONS

Prior to erecting a storage rack, the foundations must be prepared to ensure that they are firm & level and
capable of withstanding the loads imposed by the scaffold. A check should also be made to ensure that the
rack is not positioned over any underground services which could be damaged by the additional imposed
loading. Suitable steel base plates and timber sole boards should be positioned below scaffold standards,
as detailed in Chapter 5 of the TG20 Operational Guide. The design drawing and calculations should state
maximum anticipated leg loads, from which the resulting ground bearing pressure and the required sole plates
can be determined.

As some racks may be in place for many years, timber sole pads could deteriorate and rot. Consideration
should therefore be given to siting racks with base plates supported directly on suitably constructed concrete
bases or pads where possible.

DIAGONAL BRACING

Due to the fact that rotational stiffness of couplers is not generally considered in scaffold design, all tube &
fitting scaffolds require diagonal bracing for rigidity and storage racks are no exception.

Sway bracing should be installed in accordance with the design to cater for horizontal environmental loads and
dynamic forces during loading.

Typically, in the case of storage racks, it is not desirable to install ledger/section bracing as this would hinder
storage. Assuming class ‘B’ couplers are used throughout, ledger bracing may be omitted under certain
circumstances, such as demonstrated in the generic design provided.

Plan bracing should be installed as required at vertical intervals not exceeding 2m.

All diagonal bracing within the racking structure should be capable of resisting 5% of vertically imposed load,
acting in any horizontal direction.

For added stability, scaffold tube racks should be tied and/or butted to existing permanent structures where
possible. These permanent structures should be checked for suitability and ensure they are capable of
withstanding any additional loads imposed by the scaffold at all times.

WORK ON SITE

Storage racks should be of suitable base dimensions to ensure sufficient stability or tied/butted to an adequate
adjacent structure. Tubes should not be stacked above a height which is accessible to operatives when standing
on the ground, unless a safe system for loading/unloading above this height is devised and implemented. The
design should address all possible load combinations that could destabilise the structure which may include
those resulting from cladding and sheeting etc.

Where access to the top level of the rack is required, and so constitutes work at height, it should be close
boarded with suitable access/egress provided. Double guardrails and toe boards should be installed to all
sides where there is a risk of a fall and loading gates, complete with up and over restraints, should be fitted
where required, if the rack is to be loaded by forklift. All users should be briefed on safe loading & unloading
procedures.

All protruding tubes and trip hazards should be eliminated where possible. Where this is not practicable, they
should be clearly marked with high visibility tube caps or foam padding.

The safe working load (SWL) of the rack (and the top storage platform, if boarded) should be simply and clearly
stated using appropriate signage and communicated to all relevant parties. For avoidance of any doubt, a
common solution is to state the allowable quantity of tubes rather than a specific load.

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 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

600
600
2600

600
600

SCAFFOLD TUBE STANDARDS FOUNDED PLAN BRACING FIXED TO STANDARDS

ON STEEL BASE PLATES & SUITABLE USING RIGHT ANGLE COUPLERS AT LEVELS
ALL COUPLERS TO BE CLASS 'B', TIMBER SOLEBOARDS AS REQUIRED. SHOWN. FIX BRACE HARD UP TO
SWL = 9.1 kN EACH
ELEVATION A-A UNDERSIDE OF RACKING LEVEL ABOVE.
1:40

SCAFFOLD TO BE ERECTED IN
ACCORDANCE WITH NASC TECHNICAL LOCATION OF LADDER ACCESS
GUIDANCE, TG20 & SG4. ERECTION SAFE WORKING LOAD CAPACITY OF SCAFFOLD C/W SAFETY GATE TO BE
AIDS OMITTED FOR CLARITY. RACKED TO BE CLEARLY SHOWN ON STRUCTURE. DETERMINED ON SITE.

IN ACCORDANCE WITH WORKING AT

HEIGHT REGULATIONS 2005, DOUBLE
ALL TUBE & FITTING COMPONENTS & TIMBER NO CLADDING TO BE FIXED TO SCAFFOLD RACK GUARDRAILS & TOEBOARDS ARE
BOARDS TO BE TG20 COMPLIANT. WITHOUT PRIOR ENGINEERING ADVICE. REQUIRED ON ALL WORKING PLATFORMS.

LOADING GATES C/W UP & OVER RESTRAINT TO BE SCAFFOLD RACK TO BE TIED TO ADJACENT MIN. STORAGE RACK OVERALL PLAN
INSTALLED AS REQUIRED. ALL USERS TO BE BRIEFED STRUCTURES WHERE POSSIBLE. PERMANENT AREA DIMENSIONS = 4.0 x 4.0m
ON LOADING / UNLOADING PROCEDURES. STRUCTURES SHOULD BE CHECKED FOR SUITABLITY.

LONGITUDINAL BRACING FROM DIAGONAL BRACING FIXED USING

GROUND LEVEL TO FULL HEIGHT LOAD BEARING COUPLERS WITHIN
OF SCAFFOLD. 300mm OF NODE POINTS.
B CONTINUE AS REQUIRED
-
1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
1000
1000
RANGE = 1000-6000mm

1000
1000
1000

MAX.
1000

1000

A A
- -
1000
SCAFFOLD TUBE STANDARDS PLAN BRACING FIXED TO STANDARDS GRID EXTENDED AS REQUIRED. MAX. MAX.
FOUNDED ON FIRM & LEVEL USING RIGHT ANGLE COUPLERS AT LEVELS BAY DIMENSIONS = 1000x1000mm.
B FOUNDATIONS. SEE DETAIL. SHOWN. FIX BRACE HARD UP TO (BRACING OMITTED FOR CLARITY).
-
UNDERSIDE OF RACKING LEVEL ABOVE

MIN. STORAGE RACK OVERALL PLAN
AREA DIMENSIONS = 4.0 x 4.0m
ENSURE FIRM AND LEVEL FOUNDATIONS
PLAN VIEW ENGINEERING ADVICE SHOULD BE SOUGHT
WHERE THE GROUND BEARING PRESSURE
1:40
CAPABLE OF WITHSTANDING LOADS IMPOSED EXCEEDS THE FOUNDATION CAPACITY OR
BY SCAFFOLD AT ALL TIMES WITHOUT UNDUE WHERE THERE IS ANY DOUBT REGARDING THE
SETTLEMENT OR DEFLECTION. SUITABILITY OF THE EXISTING FOUNDATIONS.

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 IDENTIFICATION OF RESIDUAL HAZARDS
1000 1000 1000 1000 1000 1000 ! THIS SYMBOL DENOTES WHERE RESIDUAL
HAZARDS REMAIN ON THE SCAFFOLD.

STRUCTURAL TRANSOM FIXED TO DOUBLE GUARD RAILS & TOE

STANDARDS USING RIGHT ANGLE BOARDS FIXED TO PERIMETER
COUPLERS DIRECTLY BELOW
BOARDED PLATFORM LEDGER.
OF ALL WORKING PLATFORMS.
PRELIMINARY
ISSUED FOR GUIDANCE
BS 2482 225x38mm TIMBER BOARD BEARING TRANSOMS
BOARDS SUPPORTED BY TUBE AT STANDARDS & BOARD
TRANSOMS AT MAX. 1000mm C/C. ENDS.
600
600
2600

600
600

DIAGONAL BRACING FIXED USING

LOAD BEARING COUPLERS WITHIN
300mm OF NODE POINTS AT ENDS.
ELEVATION B-B
1:40

SITE TRAFFIC MANAGEMENT SHOULD BE IN PLACE SCAFFOLD ONLY TO BE ALTERED BY AUTHORISED

TO AVOID COLLISION WITH SCAFFOLD. PERSONNEL WITH ADEQUATE TRAINING.
! ALL PROTRUDING TUBES AND CLEARLY MARKED. ! NO BRACES OR GUARD RAILS TO BE REMOVED
WITHOUT PRIOR ENGINEERING NOTICE.

ENSURE FIRM & LEVEL FOUNDATIONS CAPABLE OF ALL WORKING AT HEIGHT TO BE SUSPENDED AT
! WITHSTANDING THE IMPOSED LOADS BY THE SCAFFOLD.
! GUST VELOCITIES ABOVE 40mph (18m/s).
SCAFFOLD TO BE INSPECTED PRIOR TO USE
FOLLOWING ADVERSE WEATHER CONDITIONS.

DURING WINTER MONTHS SNOW MANAGEMENT MUST DESIGN CRITERIA

BE IN PLACE TO AVOID SLIPS, TRIPS, FALLS AND
! OVERLOADING THE SCAFFOLD. ! MAX. Vb,map = 25.75 m/s
MAX. PEAK VELOCITY PRESSURE, qp = 0.87 kN/m²

WHERE LOADING BAY GATES C/W UP & OVER DESIGN LOADINGS:

RESTRAINTS ARE UTILISED, ALL USERS TO BE MAX. NO. OF TUBES PER CELL = 200No.
! BRIEFED ON LOADING / UNLOADING PROCEDURES. ! (i.e 800No. TUBES PER BAY)
TOP BOARDED PLATFORM @ 5.00 kN/m²

1000 1000

ALL COUPLERS TO BE CLASS 'B',

600

SWL = 9.10 kN EACH.

STRUCTURAL TRANSOM FIXED

600

DIRECTLY TO STANDARD USING

RIGHT ANGLE COUPLER.
600

LEDGER FIXED TO STANDARD

DIRECTLY BELOW TRANSOM.

MAX. NO. OF SCAFFOLD TUBES PER

CELL MUST NOT EXCEED 200No.
STORAGE RACK DETAIL
1:20

TUBE LEDGER FIXED TO STANDARD HARD STRUCTURAL TRANSOMS FIXED

UP TO UNDERSIDE OF TRANSOM DIRECTLY TO STANDARDS USING
COUPLER ACTING AS CHECK COUPLER. CLASS 'B' RIGHT ANGLE COUPLERS.
USE CLASS 'B' COUPLER, SWL = 9.10 kN.

43.34 KN
(UNF)
KICKER LIFT FIXED TO
STANDARDS USING RIGHT ANGLE
COUPLERS AT BASE. TYPICAL SCAFFOLD
STANDARDS TO BE FOUNDED ON
TUBE STORAGE RACK
STEEL BASE PLATES UPON MIN.
225x38x450mm TIMBER SOLE BOARDS.

REQUIRED GROUND BEARING

FOUNDATION DETAIL PRESSURE = 628.12 kN/m². NODE DETAIL
1:20 1:5 (STORAGE LEVELS)

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 INSPECTION CRITERIA

Where the storage rack can be accessed by operatives and subsequently includes a working platform, the
structure should be inspected by a competent person every 7 days.

Where the structure is located in a scaffolding contractor’s yard and consists of tube storage levels only, with no
upper storage or access platform, the frequency of inspections may be extended. This should be determined
via risk assessment and should consider things like location (sheltered or fully exposed to the elements) the
risk of being struck by a vehicle and the security of the foundations. It may, however, be difficult to justify any
case where inspection intervals are in excess of one month.

In addition to scheduled inspections, racks must also be inspected immediately after any event has taken
place, which is suspected or likely to have affected their strength or stability (e.g. severe weather, collision of
vehicle, nearby excavations etc.)

When the storage rack has been completed and passed the initial inspection, it should be formally handed over
(via a hand over certificate or ‘permit to load’) to show that the structure has been constructed to the design
drawing and that it is now available for use.

The results of all inspections, including any defects and remedial action, shall be recorded in a ‘scaffold’
register and retained until the rack is dismantled. It is also recommended that a Scafftag system is put in place
to assist with on-going inspections and alerting users as to the current status of the structure.

For racks which remain in situ for long periods of time and any defects (such as excessive corrosion of scaffold
tubes or fittings or rot/splitting of boards) are noticed, it may be necessary to remove stored materials and
change out individual components or strip and re-erect the whole rack.

RISK ASSESSMENT

The designer of any storage rack should complete a design risk assessment as part of the design process.

Risk assessments must also be produced for its erection, continued use and maintenance.

Potential hazards should be identified and measures put in place to eliminate or control risks. Any residual
risks or hazards should be identified and clearly communicated to all responsible persons.

For the purpose of a scaffold storage rack, the following potential hazards may be considered:
• Traffic management resulting in impact or collision with scaffold.
• Protruding tubes
• Existing foundations
• Ties to adjacent structures
• Overloading
• Snow management.

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 REFERENCES, FURTHER READING AND GUIDANCE

BS EN 39:2001 Loose steel tubes for tube and coupler scaffolds – Technical delivery conditions.
BS EN 74:2005 Couplers, spigot and baseplates for use in falsework and scaffolds. Part 1: couplers
for tubes – requirements and test procedures.
BS 5975:2019 Code of practice for the procedural control of temporary works and the permissible
stress design of falsework.
BS EN 12811-1-1:2003 Temporary works equipment – Part 1 Scaffolds, Performance requirements and
general design.
HSG76 Warehouse and storage: A guide to health and safety.
NASC TG9 Guide to the design and construction of temporary roofs and buildings.
NASC TG20 Design Guide – Technical guidance on the use of BS EN 12811-1.
The Provision and Use of Work Equipment Regulations (PUWER) 1998.
The Work at Height Regulations 2005.
The Construction Design and Management Regulations (CDM) 2015.

Whilst every effort has been made to provide reliable and accurate information, we would welcome any corrections to information provided by the author which may
not be entirely accurate, therefore and for this reason, the NASC or indeed the author cannot accept any responsibility for any misinformation posted.
© 2021 NASC. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording or otherwise, without the prior permission of the publisher and copyright owner.

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Tel: 020 7822 7400 Fax: 020 7822 7401
enquiries@nasc.org.uk www.nasc.org.uk
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