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HAKI AB 2010

SAFETY GUIDE

HAKISCAFFOLD SYSTEMS

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Important information

The HAKI Group is certified in accordance with ISO 9001:2000

Copyright HAKI AB, 2010The reproduction of text and pictures/illustrations without HAKIs permission is prohibited.

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Contents

Safety guide HAKI scaffold systems ..................................................... 1 Why is a Safety Guide needed? ......................................................... 4 Strength ........................................................................................... 4 HAKI contra hook-on ......................................................................... 4 What is HAKI? .................................................................................. 5 Why is it important to use only HAKI components and not other hook-on components? ................................................................... 5 How do you distinguish between HAKI and other hook-on systems? ......... 6 Standards ................................................................................... 6 Ledger beam ............................................................................... 7 Single tube beam ......................................................................... 8 Frame ......................................................................................... 9 Guardrail frame ........................................................................... 10 Marking ........................................................................................... 11 Corrosion ......................................................................................... 12 Corrosion of scaffold components in marine environments ................. 12 Corrosion in other environments ..................................................... 12 Effect of heat on materials .................................................................. 13 Steel ........................................................................................... 13 Aluminium ................................................................................... 13 Fatigue ............................................................................................. 14

Steel ........................................................................................... 14 Aluminium ................................................................................... 14 Surface treatment .............................................................................. 15 What type of surface treatment should you choose? ......................... 15 Painted material ...................................................................... 15 Hot-dip galvanized material ..................................................... 15 Aluminium .............................................................................. 15 Inspection ........................................................................................ 16 Repairing ......................................................................................... 16 Repairing damaged material .......................................................... 16 Steel ...................................................................................... 16 Aluminium .............................................................................. 16 Examples of other hook-on components ................................................ 17 Ergonomics ...................................................................................... 18 Notes .............................................................................................. 19 Checklist for scaffold inspection .......................................................... 20

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Why is a Safety Guide needed?In the first instance, erecting and using scaffolds is about creating a safe workplace both forthe people erecting and taking down the scaffold and for the people working on it.To this end, there is an EU directive and a standard that regulate this field in combination

with national safety regulations (AFS).In order to help create a safe workplace, all manufacturers must have checked their scaffoldcomponents and scaffold configurations so that they comply with the regulations.The creation of a safe workplace also involves not mixing different scaffold components fromdifferent manufacturers in any way you choose, since they may have completely differentmaterial properties despite the fact that they look deceptively similar at a first glance.Another part of the responsibility for safety rests with the scaffold erector, who nowadays musthave proper training to do the work.

StrengthThe load-bearing capacity of a scaffold system/component is arrived at by testing and/orcalculation.On the basis of the result obtained, you work out the permitted load for the scaffold system/component. This value must not be exceeded.The overcapacity consists of two safety factors. These are known as partial coefficients.The first partial coefficient or safety factor is 1.5 this is to cover any overloading, faults inthe welding or material, changes in loading conditions, etc.To this is added a partial coefficient (safety factor) of 1.1 to cover the uncertainty in thecalculations.

HAKI contra hook-onIn order to clear up any misunderstandings, we must first distinguish between HAKI scaffoldsystems and other hook-on systems. The HAKI scaffold system is an original system in thatthe design with catches and pockets was first produced and marketed by HAKI in Sibbhult,Sweden. Since its inception in 1956, HAKI has pursued an active development process in

order to place HAKI scaffold systems at the forefront as far as safety and user-friendliness areconcerned.Other makers of hook-on systems have not been interested in promoting development.Instead, they have quite simply devoted themselves to copying an existing design, whichmeans that they are always a step behind with respect to both design and choice of material.

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What is HAKI?

Why is it important to use only HAKI components and not other hook-oncomponents?

HAKI scaffold components are made of specially selected materials and put together inthe course of carefully monitored processes. They are designed so as to work together inharmony.As part of HAKIs ambition to focus on both the user and the scaffold erector, HAKIcomponents are made of high tensile steel in order to achieve maximum strength with theleast possible weight. HAKI carries out continual checks on the quality of its products and hasfull traceability for the material used.All HAKI products are manufactured in accordance with EN 12811 and EN 12810 and arealso type-inspected by the SP Swedish National Testing and Research Institute.All this helps to ensure the user the greatest possible degree of safety at his or her workplaceand to improve the working environment for the scaffold erector as far as is possible.

The values given in HAKI erection instructions apply only to HAKI components. Using thesevalues for hook-on components in general involves exposing both the scaffold erector andthe user to serious safety risks.In a study carried out by HAKI AB with the aid of the SP Swedish National Testing andResearch Institute in Bors, Sweden, it was shown that other hook-on components had as lowas half the load-bearing capacity as corresponding HAKI components.

Consider the fact that no chain is stronger than its weakest link.

The diagram shows the joint strength for other hook-on components, 53 65%, compared with HAKI,

100%.

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How do you distinguish between HAKI and other hook-on systems?

Standards

1956 The original standard was available as BS (bottom standard) and FS (extension

standard) with three pockets.

1962 Pressure welded pockets introduced.1971 65 mm 34 mm spigot introduced on standard.

1980 Automated production with new bayonet plate.

1983 Sleeve joint arrived for standard.

Standard FSSH,

todays design

Standard FS, todays design

HAKI standards with

reshaped spigots formaximum material

strength without risking

weakness due to welds.

Pressure welded

pockets for controlled

strength in the welded

joints of the pockets.

Marking Sticker

Standard in high tensile steel

Press welded

pockets

Sticker

Cold shaped spigot

without any HAZ by

welding

Rounded spigot

for easier fitting

Pockets at

same level

Marking

Press welded pockets

HAKIs characteristic bayonet

plate with cut corners

Rounded spigot

for easier fittingRobot-welded details to

secure high and even

quality

Cold shaped spigot

without any HAZ by welding

High tensile steel

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1993 Marking with logo and S 93 or O 93 introduced, where 93 specifies the year of

manufacture and reshaping of the spigot of the FS standard L=110 mm 38 mm.

2001 Weight reduced FSSH standard with reshaped spigot, L=160 mm 38 mm andpockets at same level.

Ledger beam

1956 HAKI launched its ledger beam, consisting of two tubes connected by flat steel bars.

The design was optimized for longitudinal or transverse plank decking.

1983 Marking with HAKI-logo and 83, the year of manufacture, on the backside of thelocking catch.

1987 The middle steel bar was removed from the LB 3000 and the beam gained a design

that was more optimized for strength.

2001 The ledger beam was provided with a patented spring locking catch.

2003 The ledger beam became 15% lighter, but with the same load-bearing capacity.

Ledger beam, todays design

No middle flat bar for better handlingMarking

Placement of verticals

optimized for strength

Sticker

Marking before

weight reductionMarking

after weightreduction

Rounded corners

for better

handling

Patented spring locking catch

High tensile steel

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Single tube beam

1989 Patented pear-shaped tube.

1997 TUE introduced.

1997 TUD introduced.

2001 ERB-S introduced to the French market.

2004 Introduction of the new ledger beam with spring locking catch and same structural

height as ledger beam with 15% weight reduction.

Single tube beam, todays design

MarkingSticker

Recess that provides flat bed

Made of high tensile steel,which reduces weight

Patented pear shape for

maximum strength

Patented spring locking catch

Rounded corners

for better handling

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Frame

1978 Type approved and introduction.

1982 Aluminium decking unit.1983 Frames without spigot for toeboard.

1983 Guardrail frame type SKRD.

1995 Frames marked with year of manufacture and HAKI logotype without hook for

diagonal brace.

2005 Double holes introduced on the spigot joint.

Frame, todays design

Marking Sticker

Pressure welded

pocketsAll loadbearing components in high tensile steel

Double holes in order to be able to fullyutilize verstility of HAKI Scaffold System

Rounded spigot for

easier fitting

Cold shaped spigot

without any HAZ by welding

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Guardrail frame

Guardrail frame, here type SKRH, todays design

Sticker

Marking

Reshaped tube to meet European standardHeigh tensile steel

Robot-welded details to

secure high and even quality

Patented

spring locking

catch

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MarkingThe marking of HAKIs products has varied over the years.This is a guide to help you identify it.

1983-1993 Marking with logo + year on the back of the catch on beams and on the base plate of the standard.

1993-2004 Marking is done using the logo + letter of the alphabet + year. All components are marked.

2004- Introduction of marking that provides full traceability for components.

Example of marking of beam or rail of high tensile steel.

Reshaped spigot, punched holes in top and bottom and HAKIs

special corner cut for bayonet plate.

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CorrosionThe rate at which scaffold components corrode varies greatly depending on thesurroundings.Factors that play a role are degree of exposure, pH, salinity, temperature, etc.

In general, corrosion may be seen as decreasing the safety factor of 1.5.

Corrosion of scaffold components in marine environments

The layer of zinc on HAKI hot-dip galvanized components has an average thickness of atleast 70 micrometres.The rate of corrosion is difficult to determine, since it depends on a number of differentfactors such as degree of exposure, pH, salinity and temperature.According to the Swedish Corrosion Research Institute, the rate of corrosion of hot-dipgalvanized components in Swedish marine environments (west coast) is 4-8 micrometres peryear. However, if we look at warmer climates it increases dramatically. A study in Chile showsa decrease of 8-12 micrometres per year.This means that the layer of zinc will last 9 years in a Swedish climate and 6 years in atropical climate.The rate of corrosion of untreated steel in Swedish maritime environments is 80-200micrometres. This means that 10% of the material will have corroded away after 1 year in theworst case.

Corrosion in other environments

Since corrosion varies very greatly with the environment in which the component is placed,we cannot provide any general recommendations for service life. This must be done by theuser for each specific application.For values for the corrosion of zinc coatings in various environments, we refer the reader tothe SIS handbook number 160.

Reduction of safety factor owing to corrosion

Unaffected

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Effect of heat on materials

Steel

Load-bearing components such as standards and beams in HAKI scaffold systems are madeof tubes of cold-formed steel. Cold-formed steel whose strength has increased during coldforming risks losing this increase during a fire. In order to ascertain whether or not thestrength of the steel has decreased, an extensive testing procedure must be carried out.

We therefore recommend that all HAKI scaffold material that has been exposed to fire bescrapped.

AluminiumIn order to raise the strength of aluminium, the material is thermally aged to state T6. Thismeans that it is heated up under controlled conditions to 175 C for a specific length of timeand is then allowed to cool.

The time factor is what decides whether or not the material reaches T6 or is aged past thisstate to become over-aged with resultant lower strength.

At 100 C, the time for thermal ageing is measured in years, but rises quickly to become amatter of hours at higher temperatures.

In the light of this, HAKI AB cannot guarantee the strength of any material that has been

exposed to temperatures above 100 C. Our recommendation is that such material bescrapped.

If the material must be used temporarily, it must under no circumstances whatsoever beloaded to more than 50% of the nominal load-bearing capacity for after-heat effects ofbetween 100 and 200 C. Up to 250 C, this limit is reduced to 33% of normal bearingcapacity.

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FatigueSteelHAKI Steel has a favourable tolerance towards fatigue and will not be affected by this duringits normal service life.

AluminiumHas a lesser degree of tolerance towards fatigue and may suffer brittle fractures after as fewas 5000 cycles slightly below the yield point.

The fracturing process occurs in three stages: - initiation - crack growth

- brittle fracture

Initiation may be caused by something such as a scratch, the edge of a weld or an impurityin the material, which begins the emergence of a crack. The growth of the crack occurs at anaccelerating rate with a brittle fracture as the final phase.

In connection with the testing of steps, SS-EN 12810-1 has assessed that a reasonable valuefor the acceptance of load changes is 300,000. This corresponds to loads that continuallyreach approximately 2/3 of the yield point.

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Surface treatmentWhat type of surface treatment should you choose?

The choice of surface treatment is strongly dependent on the environment in which thecomponent is to be used. Another important factor to consider when choosing a component

is the total cost of the component over its entire service life.

Painted materialHAKIs painted material has only a limited protection against corrosion.This provides sufficient protection under favourable circumstances.In harsher environments, HAKI recommends that you choose hot-dip galvanized products,which also provide better overall economy despite their slightly higher price.Since 2005, we have only produced hot-dip galvanized materials.

Hot-dip galvanized materialHot-dip galvanized components are required for fully adequate protection against corrosionin aggressive environments.HAKI hot-dip galvanized material receives its surface treatment in one of Europes mostmodern surface treatment plants.This ensures the provision of the high and uniform quality that HAKI requires.The service life of the galvanization varies with the environment in which it is used and you

should look out for corrosion as indicated by streaks of red rust.

AluminiumAluminium has completely different properties from steel. In contact with oxygen, it oxidizesvery quickly. The difference compared with steel is that the oxide forms an impervious layerthat protects against further corrosion. In most cases, this constitutes adequate protectionagainst corrosion, but there is a risk of further corrosion, particularly in environments wherethe component is exposed to water and salt without access to oxygen from the air, which cancreate a new protective oxide protection layer. Examples of such environments are beneathcouplers or in joints. If the scaffold is in an environment where there is such a risk and itremains there for a prolonged period, you should loosen a few couplers after a couple ofmonths to see if white oxide has been produced under them. If so, measures must be taken.

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InspectionHAKI recommends that the material be periodically inspected.

Some examples of ways of doing this are as follows: Examine used material on arrival before it is put into store or goes to the next

job. Code the material, using coloured paint for instance, and then carefully inspect it regularly, e.g. once a year. The code allows you to quickly see whether or not the material has been checked during the period.

Repairing

Repairing damaged material

SteelDamaged material must under no circumstances be repaired using heat, since the strengthof the material may be radically affected.Cold repairing may be carried out, but only to a limited extent.If the material is deformed or fails to fully return to its original form, it should be scrapped.Buckling of standards by hammer blows or by other means is damage that cannot berepaired and the standard should be scrapped.

Seriously damaged material should be destroyed to prevent re-use by less responsible peopleresulting in serious risk of personal injury.

AluminiumMost of the aluminium used in scaffold components is of a quality that makes repairunsuitable.You must not repair parts by welding, since this may seriously change the strength of theparts.Our recommendation, therefore, is that the parts are scrapped.

If you are unsure, please contact HAKI AB for advice.HAKI has no objection to the exchange of locking pins or similar repairs.

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Examples of other hook-on components

Examples of hook-on components that fail to meet HAKI standard. These exhibit weldingspatter that poses a risk of injury, and hand-welded pockets and tongues with sharp corners

that pose an increased risk of injury.

Hand-welded pockets

Welding spatter that poses a risk of injury

Tongues with sharp corners

Tongues with sharp corners

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Ergonomics

Before you lift:1. Assess the weight of the material with regard to the table below2. Can you handle the material by yourself? If NO: Obtain the help of other people or use lifting aids3. Do you need to carry the material far? If YES: Obtain the help of other people or use a trolley or cart4. Is the way clear to where you want to carry the material? If NO: Make sure that it is clear before you lift

Close to your body* Forearms lengthabout 30 cm

arms lengthabout 45 cm

50 kg

30 kg

15 kg

11 kg

7 kg

3 kg

REDHarmful strain.

Must not be lifted without help Obtain help of other people or

use lifting aids

YELLOWStrain acceptable underideal conditions. If conditions are not ideal- Obtain help of otherpeople or use lifting aids

YELLOWRisk of harmful strain. In the case of repeated lifts- Obtain help from other

people

YELLOWThere must be a numberof exacerbating factors forthe lift to be consideredharmful

GREENThe strain is not normally harmful.

* Loads are seldom lifted close to the body, except when harnesses and other lifting aids areused.

The table does not include lifts made at distances of greater than arms length from theback. Such lifts normally pose a risk of strain injury and must always be specially assessed.

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Notes

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H

AKIINT201011

P000082

HAKI ABSE-280 63 Sibbhult, SwedenTel +46 44 494 00 Fax +46 44 494 72info@haki se HAKI com

SAFETY CHECKLIST

1. Supporting surface checked with regard to load-bearingcapacity

2. Distance to wall or similar as short as possible

3. Scaffold aligned correctly horizontally and vertically

4. Components correctly fitted and locked

5. Bracing correctly fitted

6. Anchoring with right number and placing of ties

7. Decking correctly fitted

8. Guardrail with toeboard if drop is two metres or more

9. Suitable means of access to scaffold

10. Scaffold erected for correct class of load

The HAKI Group is certified according to ISO 9001:2000