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PT.

CIPTAMEGA ARIEFSEJATI
Ringlock Scaffold
Structural Design and Calculation

Coal Storage, Indocement Project


Indonesia
March 2014

Ringlock Scaffold
Structural Design and Calculation
-- Content --

1Check Bearing Load of Scaffolding

2Design and Calculation of Plywood

3Design and Calculation of Second Bearer

4Design of Main Bearer...

APPENDIX

APPENDIX

12

APPENDIX

13

APPENDIX

14

Ringlock Scaffold
Structural Design and Calculation
Design Scope
1.Scaffolding TypeRinglock Scaffold
1-1Property
Vertical

: Q345Fy=3600kg/cm2E=2100000kg/cm2

Horizontal : Q235Fy=2520kg/cm2E=2100000kg/cm2
Diagonal : Q235Fy=2520kg/cm2E=2100000kg/cm2
1-2Dimension
Vertical

: 60.2mm T:3.2mm

Horizontal : 48.2mm T:2.5mm


Diagonal : 42.3mm T:2.5mm
1-3Minimum Failure Load74.77 ton (refer to Appendix )
2Formwork typePlywood
2-1PropertyE= 70000kg/cm2Fb= 140kg/cm2Fv= 12kg/cm2
2-2DimensionL:1000mm T:18mm
3Second Bearer TypeTimber
3-1PropertyE= 70000kg/cm2Fb= 140kg/cm2Fv= 12kg/cm2
3-2Dimension120mm 80mm
3-3Spacing 50cm under 0.6m slab
4Main BearerH-Beam
4-1PropertyE= 2100000kg/cm2Fb= 1512kg/cm2Fv= 12kg/cm2
4-2Dimension200mm 100mm

DESIGN CALCULATION SHEET


1Check Bearing Load of Scaffolding
Design Assumption
Dead Load (concrete wight)
Live Load(labors) (LL1)
Live Load(equipments) (LL2)

SHEET NO.

2.5ton/m3
0.35ton/m2
0.15ton/m2

1-1Take Section as following to consider :

To calculate maximum bearing load of a leg:


DL =

2.50

ton/m3

1.35

m3

3.38

ton/m

LL1 =

0.35

ton/m2

2.25

m2

0.79

ton/m

0.15

2.25

0.34

ton/m

4.50

ton/m

LL2 =

ton/m

Maximum bearing load of a leg =

4.50

ton/m

Referring to test report of a tower -------------Appendix


Use May 17,2013 material testing report sheet------ 74.77
Assume the Safety Factor is 2.5
74.77 ton /
2.5
= 29.9 ton
29.91 ton /
4
= 7.48 ton
Allowable bearing load of a leg = 7.48 ton
Check bearing load of scaffolding
7.48 ton
OK!
<
4.50 ton

ton

DESIGN CALCULATION SHEET

SHEET NO.

1-2 Check Bearing Load of Ring System Scaffolding by AISC Code


Material and Sectional properties of Scaffolding member:
Vertical
Q345 60.2T3.2
E=2100000( kg/cm2 )

Fy = 3058 ( kg/cm2 )

Horizontal

Q345 48.2T2.5

E=2100000( kg/cm )

Fy = 2089 ( kg/cm2 )

Diagonal

Q345 42.3T2.5

E=2100000( kg/cm2 )

Fy = 2089 ( kg/cm2 )

Allowable load of buckling theory by AISC Code


Claculate Allowable axial force Pa of Vertical, Horizonal and Diagonal
L non-brace length
K=1
r = rotate radius

non-elastic buckled

Allowable compression stress

elastic buckled
Allowable compression stress

Allowable axial force

P a = Fa A

Calculate allowable axial force as below


re
ri
t
A
5.38
0.32
5.73
Vertical 6.02
4.32
0.25
3.59
Horizontal 4.82
4.23
3.73
0.25
3.13
Diagonal
Cc
Vertical 107.3
Horizontal 120
Diagonal 128

R
0.69
0.77

FS
1.88
1.90

L
150
150
212
Fa
1233.14
771.713
478.342

r
KL/r
2.018 74.33
1.618 92.71
1.41 150.35
Pa (ton)
7.07
2.77
1.50

By above list:
Vertical and Horizontal are non-eleastic buckled ; Diagonal is eleastic buckled.
Allowable axial force of Vertical Pa = 7.07 ton
Allowable axial force of Horizonal Pa = 2.77 ton
Allowable axial force of Diagonal Pa = 1.5 ton
Check bearing load of Scaffolding
4.50 ton <
7.07 ton

OK!

DESIGN CALCULATION SHEET

SHEET NO.

2Design and Calculation of Plywood


Consider :

Concrete Unit Load D/L


2.5ton/m3
Impact Load(pouring concrete)
0.35ton/m2
LiveLoad(equipments and labors etc.) L/L 0.15ton/m2

Thickness
D/L =
Impact Load =
L/L =

Unit load w

Span of Plywood
Total Weight

0.60 m
2.50 ton/m3
0.35 ton/m2
0.15 ton/m2

ton/m2

2.00

0.50
20.0

L1 =
W =

Check the strength of plywood :


Calculate bending moment
20.0
wL2
M
=
=
10
Check bending stress
M
5000
=
=
BS
Z
54.0
92.6

0.60

m =
kg/cm

Test
L 100
cm
Plywood characters as fallowing :
Section Modulus (Z) bh2/6 = 100
Moment of Inertia ( I ) bh3/12 = 100
Section Area (A)
bh
= 100
Mod of Elasticity (E)
70000
=
(Fb)
140
=
(Fv)
12
=

kg/cm
10

1.50
0.35
0.15
2.00

=
=

ton/m2
ton/m2
ton/m2
ton/m2

2.00
20.0

50 cm
50 cm =

1.8

1.8
1.8
1.8
kg/cm2
kg/cm2
kg/cm2

=
=
=

cm
/
/

6 =
12 =
180

(50 cm )

ton/m
kg/cm

1000 kg
Plywood

54.0
48.6
cm2

cm3
cm4

5000

kg- cm

kg-cm
kg/cm2
kg/cm2

<

140

kg/cm2

OK!

DESIGN CALCULATION SHEET


Check shear stress
0.5W
SS
=
A

1000 kg

180 cm2
kg/cm2

SHEET NO.

0.5

<

kg/cm2

2.78

12

20 kg/cm
1
128 70000 kg/cm2

(50 cm ) 4
48.6 cm4

0.30

OK!

Check deflection
Def

Use

wL4
128EI

100
cm
Span

0.29

1.8
T
0.50 m

cm

<

cm

Choose spacing of timber beam = 0.50

cm

Plywood

OK!

DESIGN CALCULATION SHEET

SHEET NO.

3Design and Calculation of Second Bearer


Use timber 12 x 8 cm as second bearer.
Consider :

Concrete Unit Load D/L


2.5ton/m3
Impact Load(pouring concrete)
0.35ton/m2
LiveLoad(equipments and labors etc.) L/L 0.15ton/m2

Spacing of timber beam = 0.5 m


0.60 m
thickness
D/L = 2.50 ton/m3
Impact Load = 0.35 ton/m2
L/L = 0.15 ton/m2
1.000 ton/m

12

cm

m
m
m

0.60

=
=
=

0.75
0.18
0.08
1.00

ton/m
ton/m
ton/m
ton/m

10.00 kg/cm

1.5
Span of timber beamL2 =
m
Total Weight W = 10.00 kg/cm
Unit weight
w = 1500 kg
Test

0.50
0.50
0.50

/
cm

150
150
150

cm
cm =
cm =

1500 kg
10.00 kg/cm

Timber

Timber beam characters as following :


192 cm3
Section Modulus (Z) =
1152 cm4
Moment of Inertia ( I ) =
96 cm2
Section Area (A)
=
Broad-Leaved Trees More Appropriate
Mod of Elasticity (E)
= 70000 kg/cm2
(Fb)
kg/cm2
= 140
(Fv)
kg/cm2
= 12
Check the strength of timber beam :
Calculate bending moment
10.00
wL2
M
=
=
10

kg/cm
10

(150 cm )

22500.0

kg- cm

DESIGN CALCULATION SHEET


BS

M
Z

=
=

Check shear stress


0.5W
SS =
A

22500.0
192

SHEET NO.

kg-cm
kg/cm2

117.2 kg/cm2

1500 kg
96 cm2

7.8

kg/cm

<

140

kg/cm

OK!

12

kg/cm2

OK!

0.5

<

Check deflection
Def

wL4
128EI

1 10.00 kg/cm (150 cm ) 4


128 70000 kg/cm2 1152.0 cm4
=

Use

timber

12

cm

0.490

cm

<

0.625 cm

cm @ 50cm

L
240

OK!

DESIGN CALCULATION SHEET

SHEET NO.

4Design of Main Bearer


Use H-beam 2001005.58mm as main bearer.
Consider :

Concrete Unit Load D/L


2.5ton/m3
Impact Load(pouring concrete)
0.35ton/m2
LiveLoad(equipments and labors etc.) L/L 0.15ton/m2

Spacing of main beam = 1.5 m


0.60 m
thickness
D/L = 2.50
Impact Load = 0.35
L/L = 0.15
3.000 ton/m

ton/m3
ton/m2
ton/m2
=

1.50
1.50
1.50

0.60

= 2.250 ton/m
= 0.525 ton/m
= 0.225 ton/m
3.000 ton/m

30.00 kg/cm

1.5
Span of H-beam
m =
L3 =
Total Weight: W = 30.00 kg/cm
4500
Unit weight: w =
kg /
Test

m
m
m

150
150
150

cm
4500
cm =
kg
cm = 30.00 kg/cm

H-2001005.58mm

H-beam characters as following :


Section Modulus (Z) =
Moment of Inertia ( I ) =

Section area (A) =


Mod of Elasticity (E) =
(Fb)
=
(Fv)
=

181
1810
11
2100000
1512
1008

Calculate bending moment:


30.00
wL2
M
=
=
10

cm3
cm4
cm2
kg/cm2
kg/cm2
kg/cm2

kg/cm
10

(150 cm )

67500.0

kg-cm

DESIGN CALCULATION SHEET

Check bending stress:


M
BS =
Z

=
=

Check shear stress:


0.5W
SS =
A

67500.0
181.0

SHEET NO.

kg-cm
kg/cm2

372.9 kg/cm2

<

4500 kg
11 cm2

204.5 kg/cm2

1
128

1512

kg/cm2

OK!

1008

kg/cm2

OK!

0.5

<

Check deflection:
Def

wL4
128EI

Use

30.00 kg/cm
(150 cm ) 4
2100000 kg/cm2 1810 cm4

0.031

cm

H-2001005.58mm

<

0.625

cm

L
240

OK!

APPENDIX

A. Construction Procedures and Dismantling


1. Site Inspection
(1) Before working, check first if the construction site is flat and ready.
(2) Then see if there is any deformation or shortage of material.
(3) Finally the supervisor arranges all sling equipment, transportation route and workers.

2. Installation
(1) Check if the position is correct.
(2) Put steel piles in the right way according to structural drawing.
(3) Start installation.
(4) Height control.
(5) Check if all wedges are fixed.
(6) Check various supporting beams.
(7) Check safety net.
(8) Check randomly if there is any deformation of scaffold or loose wedge.

3. Dismantling
(1) Arrange dismantling tools, sling equipment, route.
(2) Step by step to prevent inappropriate hit.
(3) Release U-Head Jack to tear down the plywood. Remove timber and H-Beam, then
take out U-Head Jack, Diagonal, Horizontal, Vertical. According to shape and size,
put everything in order aside (convenient for moving in or coming out).
(4) Count every item.

B. Safety Inspection Procedures after Scaffold Installation.


1Vertical/Basic Socket must be fully assembled on Handle Nut to ensure the axial force,
ref. the illustration below

2. Before concreting, make sure that Horizontal and Diagonal are indeed fixed to Ring.
3. Check if all the relevant fulcrums are enhanced with Diagonal according to structural drawing.
4. Claws are required to fix U-Head Jack and H-Beam, at least 2pcs at each side.
5. Foundation is solid (Plywood, H-Beam or Steel Pile in between with Jack Base) to prevent any
spacing.
6. In rainy season, make sure that foundation is not damaged (no safety concern) before concreting.
7. After earthquake, check if there is any deformation, damage or loose wedge.
8. Any deformation on Vertical shape in construction way.
9. After installation, there should be no deformation or bending of Vertical.
10. Check if the actual installation is in accordance with structural drawing. Otherwise it should be
corrected immediately to prevent jerry-building that causes danger, unnecessary trouble or cost
increasing.

C. Cross Sectional functions of Ring System Scaffold


No.

I
.
6
.
29

Area
2
A ( cm )

Maximum distance
to center
e, e 1 ( cm )

Moment of Inertia
4
I ( cm )

( D 2 -d 2 )
4

D
2

( D 4 -d 4 )
64

( D 4 -d 4 )
32D

64

( 6.02 4 -5.38 4 )
32D

6.022 + 5.382
4

= 7.756

= 2.018

(4.82 4 -4.32 4 )
32D

4.822 + 4.322
4

= 3.900

= 1.618

(4.82 4 -4.32 4 )
32D

4.822 + 4.322
4

= 2.938

= 1.410

(4.232-3.732)
32D

4.232 + 3.732
4

= 6.656

= 1.538

sketch of cross section

Vertical
Sub-Vertical
(60.2mm t 3.2mm)

= 5.730

(6.02 2 -5.38 2 )

(4.82 2 -4.32 2 )

(4.82 2 -4.32 2 )

4.82
2

= 23.345

64

(4.82 4 -4.32 4 )

D +d
4

= 2.410

4.82
2

= 9.398

64

(4.82 4 -4.32 4 )

Diagonal
(42.3mm t 2.5mm)
= 3.126

= 3.010

( 6.02 4 -5.38 4 )

Rotation Radius
i ( cm )

Horizontal
(48.2mm t 2.5mm)
= 3.589

60.2
2

Section Modulus
3
Z ( cm )

(4.232-3.732 )

= 2.115

4.23
2

= 6.214

64

(4.232-3.732)

Jack Base, U-Head Jack


(48.2mm t 5.0mm)
= 6.786

= 2.410

= 16.042

APPENDIX

APPENDIX

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