SCAFFOLDING PRODUCT

TECHNICAL GUIDE

Acrow Cuplok
Scaffolding System
General Technical and Application Manual

Genuine Safety.
Outstanding Service.

CUPLOK Scaffolding System

General Technical and Application Manual

Product

Description

Code No.

Mass kg (nom.)

CS05
CS10
CS15
CS20
CS25
CS30

3.9
6.9
9.9
13.0
16.0
19.1

CSOE08
CSOE13
CSOE18
CSOE23
CSOE28

5.2
8.2
11.3
14.3
17.3

CT031
CT061
CT083
CT10
CT13
CT15
CT18
CT24

2.6
5.0
6.6
7.9
9.7
11.5
13.7
22.4

CUPLOK Functional design with simplicity of connection

500

500

500

Speed of assembly
Versatility of application
Simplicity of components and their connection
Galvanised components improve corrosion resistance
Elimination of loose wedges
No special tools required for assembly (hammer and spirit level only)
Low maintenance.

500

420 150

The CUPLOK system has been designed to meet the requirements of the Australian
construction and housing industries.
The success of CUPLOK lies in its principal design features:

CUPLOK Easy to erect

80 500

No wedges just a simple locking cup at each node point on the Standards enables connection
of the ends of up to four members in one locking action. With all four members attaching at the
same level the system is ideal for birdcage construction as well as conventional face scaffolding.

CUPLOK Versatile in use

220

It is suitable for access or formwork support with an extensive range of special applications. The
horizontal members can be angled to suit many different applications. The system has been
used in triangular, trapesium and is ideal for curved surfaces.

CUPLOK Proven design with safety accessories

500

500

The CUPLOK system has a proven performance history on an extensive number of sites,
meeting the requirements of the various statutory bodies. A comprehensive range of accessories
is available to cater for safety requirements such as guardrails, mesh panels, ladder access, stair
access and components to provide overhead protection.

Important

80

500

500

500

The assembly guidelines contained in this booklet are the recommended methods to be used
for CUPLOK products and must be accurately followed to achieve the correct function of the
product. Seek advice from the Acrow Formwork & Scaffolding Engineering Department should
you need to deviate from the recommendations and technical detail given in this manual.
Use and application of the CUPLOK system must be in accordance with AS1576, AS4576,
AS3610, Occupational Health & Safety Regulations of the regulatory authorities and approved
industry codes of practice. The illustrations in these assembly instructions are recommended
guidelines only.

Product Codes
Safety Warning
It is recommended that users of the CUPLOK system employ and implement appropriate
procedures and control measures to eliminate or control any risk of possible musculoskeletal
disorder/injury while manually handling CUPLOK components. Refer to your local regulatory
authority for Codes of Practice on manual handling or other approved and recognised guidelines
for correct and appropriate manual handling procedures.

Disclaimer

3
1 The 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 Acrow 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, Acrow 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 Acrow Formwork & Scaffolding outlet.

CUPLOK spigotted Standards are principally

used in access scaffolding applications and
also as a base structure for formwork support
applications. They have cup joints at 500mm
intervals. The captive mobile top cups are
designed to endure rough site handling and
welded bottom cups are made from highquality steel. Integral spigots, 150 mm long, are
provided at the top of each Standard for making
vertical connections. The spigots and the base
of each Standard incorporate 16mm dia. holes
to enable use of locking pins to join Standards
where necessary.
CUPLOK Standard 0.5m
CUPLOK Standard 1.0m
CUPLOK Standard 1.5m
CUPLOK Standard 2.0m
CUPLOK Standard 2.5m
CUPLOK Standard 3.0m

CUPLOK Open Ended Standards

CUPLOK open ended Standards are principally
used in falsework or formwork support
applications in conjunction with Spigotted
Standards or as a single height unit. The
open ended design allows the insertion of an
Adjustable Base or Adjustable U-Head to provide
the final support to the soffit formwork. The base
of each Standard has a 16mm dia through hole
to enable the use of locking pins to join it to a
Spigotted Standard when required.
CUPLOK open ended Standard 0.8m
CUPLOK open ended Standard 1.3m
CUPLOK open ended Standard 1.8m
CUPLOK open ended Standard 2.3m
CUPLOK open ended Standard 2.8m

CUPLOK Transoms

The product codes are shown on pages 3 to 8.

CUPLOK Spigotted Standards

Transoms are fabricated from twin structural

angles fixed back to back with a drop forged
blade attached to each end. The 2.44m Transom
has an additional web member welded below
the flange section for added strength. The
transom blade locates into a bottom cup and is
locked in position by the top cup. The outward
standing bottom leg of the angles supports
the steel planks in a captive manner. Available
in various lengths to suit scaffolding and
formwork applications.
CUPLOK Transom 0.31m
CUPLOK Transom 0.61m
CUPLOK Transom 0.83m
CUPLOK Transom 1.05m
CUPLOK Transom 1.27m
CUPLOK Transom 1.52m
CUPLOK Transom 1.83m
CUPLOK Transom 2.44m

CUPLOK Scaffolding System

Product

Description

gth

en

L
ce

General Technical and Application Manual

Height

Bra

Code No.

Mass kg (nom.)

Product

CUPLOK Ledgers

CUPLOK Tie Bars

The Ledgers are manufactured from 48.3 mm

O.D. tube with forged steel blade ends which
locate into bottom cups of the Standards and are
locked in place by the the corresponding top cups.
Ledgers are available in various lengths to provide
the desired grid dimension for scaffolding or
formwork. Production of the Ledger since 1997
has been from thinner high grade steel tube. This
contributes to a lighter Ledger for easier handling.
Ledgers manufactured prior to 1997 are made
from the thicker wall tube and weigh approx.
20% heavier than the weights stated below.

Tie bars are used to interlock the ends of

Platform Brackets and to provide a means of
preventing the Planks from sliding off the end of
the bracket. The studs at the end of the tie locate
into slots in the Platform Brackets.

CUPLOK Ledger 0.22m

CUPLOK Ledger 0.34m
CUPLOK Ledger 0.61m
CUPLOK Ledger 0.83m
CUPLOK Ledger 1.05m
CUPLOK Ledger 1.27m
CUPLOK Ledger 1.52m
CUPLOK Ledger 1.83m
CUPLOK Ledger 2.44m
CUPLOK Ledger 3.05m

CL022
CL034
CL061
CL083
CL105
CL13
CL15
CL18
CL24
CL30

CUPLOK Tie Bar 0.61m

CUPLOK Tie Bar 0.83m
CUPLOK Tie Bar 1.05m
CUPLOK Tie Bar 1.27m
CUPLOK Tie Bar 1.52m
CUPLOK Tie Bar 1.83m
CUPLOK Tie Bar 2.44m
CUPLOK Tie Bar 3.05m

1.2
1.7
2.6
3.4
4.2
5.0
5.9
7.0
9.2
11.4

Bay Length x
Height (m)

Brace Centres
(m)

0.61 x 1.5

1.62

0.83 x 1.5

1.71

1.05 x 1.5

1.83

1.27 x 1.5

1.97

1.52 x 1.5

2.14

1.52 x 2.0

2.51

1.83 x 1.5

2.37

1.83 x 2.0

2.71

2.44 x 1.5

2.86

2.44 x 2.0

3.16

2.44 x 2.5

3.49

3.05 x 2.0

3.65

CUPLOK Transom Beam 1.83m

CUPLOK Transom Beam 2.44m

lan

2P

lan

3P

lan

1.8
2.4
3.0
3.7
4.5
5.3
7.0
10.8

CTBEAM18
CTBEAM24

21.2
27.0

CTT18
CTT24
CTT30

40.1
52.4
55.7

CTRET13

10.3

CTLA105
CTLA13
CTLA18
CTLA24

10.6
12.6
15.2
18.0

The Transom Truss is designed for high capacity

loading platforms and overhead protective
structures. Connects at 4 points, enhancing the
rigidity of the scaffold.
CUPLOK Transom Truss 1.83m
CUPLOK Transom Truss 2.44m
CUPLOK Transom Truss 3.05m
CB16
CB17
CB18
CB20
CB21
CB24
CB25
CB27
CB30
CB32
CB35
CB37

6.8
7.2
7.8
8.2
8.8
9.9
10.0
10.9
11.4
12.5
13.7
13.9

Platform Brackets enable 1, 2 or 3 plank wide

platforms to be placed between the scaffold and
the workface. The blade end locates into the cup
on the Standard and the ends of the brackets are
connected to each other with Tie Bars.
CUPLOK Platform Bracket 1 Plank
CUPLOK Platform Bracket 2 Plank
CUPLOK Platform Bracket 3 Plank

CTB06
CTB08
CTB105
CTB13
CTB15
CTB18
CTB24
CTB30

CUPLOK Transom Truss

CUPLOK Return Transom

The Return Transom is used at the end of a
scaffold run where it meets another scaffold
running at right angles to it.
The U-shaped return section of the transom
hooks over the ledger of the adjacent
scaffold, closing off the gap between the the
two scaffolds.
CUPLOK Return Transom 1.3m

CUPLOK Ladder Access Transom

CUPLOK Platform Brackets

1P

Mass kg (nom.)

Transom Beams are designed for special duty

load applications. Allows high deck capacity and
large grid patterns.

Diagonal Braces are made from 48.3mm dia tube

with a swivel blade at each end. Their function is
to provide transverse and longitudinal bracing to
scaffold structures.
The brace is available in various lengths to suit
the combination of bay widths and heights.
CUPLOK Brace 1.62m
CUPLOK Brace 1.71m
CUPLOK Brace 1.83m
CUPLOK Brace 1.97m
CUPLOK Brace 2.14m
CUPLOK Brace 2.37m
CUPLOK Brace 2.51m
CUPLOK Brace 2.71m
CUPLOK Brace 2.86m
CUPLOK Brace 3.16m
CUPLOK Brace 3.49m
CUPLOK Brace 3.65m

Code No.

CUPLOK Transom Beam

CUPLOK Diagonal Braces

Bay Length

Description

5
CHUB1
CHUB2
CHUB3

2.1
5.8
7.8

The Ladder Access Transom is used to provide

an opening in a bay allowing a ladder to pass
through it. The L.A. Transom is attached to
and spans between the Ledgers in the bay.
CUPLOK Ladder Access Transom 1.05m
CUPLOK Ladder Access Transom 1.27m
CUPLOK Ladder Access Transom 1.83m
CUPLOK Ladder Access Transom 2.44m

CUPLOK Scaffolding System

Description

18

18
0

Code No.

Mass kg (nom.)

Product

Adjustable Base

CUPLOK Steel Planks

The Adjustable Base is a generic AF&S product

which is used with all scaffold systems and
some AF&S formwork systems.
It has a solid stem of 36mm nominal diameter
which has a nut restraint to ensure the stem
always has a minimum engagement of 150mm
into the Standard.

Planks to suit CUPLOK are formed from

galvanised steel sheet with a perforated tread
to provide a non-skid surface. Perforations
are taken close to the ends and edges of the
Plank to provide even coverage over the whole
assembled deck.

Adjustable Base (Solid) Form/Scaf

221

ABSFS

Typical Plank Section

7.1

Adjustable U-Head
Holes
for nailng

20

30

Adjustment range
50mm to 450mm

83

Description

61

450
Adjustment range

Product

General Technical and Application Manual

The Adjustable U-Head is a generic AF&S

product which is used with scaffold systems
and some AF&S formwork systems.
It has a solid stem of 36mm nominal diameter
which has a nut restraint to ensure the stem
always has a minimum engagement of 150mm.
The U-Head is capable of accepting twin
100mm wide bearers.
Adjustable U-Head (Solid) Form/Scaf

Cuplok Steel Planks 0.83m Bay

Cuplok Steel Planks 1.05m Bay
Cuplok Steel Planks 1.27m Bay
Cuplok Steel Planks 1.83m Bay
Cuplok Steel Planks 2.44m Bay
Cuplok Steel Planks 3.05m Bay

Code No.

Mass kg (nom.)

SPC083
SPC105
SPC13
SPC18
SPC24
SPC30

5.0
7.2
8.5
11.5
15.5
19.5

CSS

31.5

CST15

26.0

CSBMK2

3.6

CPSTH

15.0

CSST

11.3

CUPLOK Stair Stringer

AUHSFS

The Stair Stringer is a steel frame used in pairs in

conjunction with Steel Planks to form a full width
access stair 1.27m wide. Planks are retained in
place by built-in retaining clips. Stair Stringers are
designed to be used in 2.44m bays to provide a
rise of 2m vertical between Transoms.

11.1

CUPLOK Stair Stringer 2m rise x 2.4m go

CUPLOK Fan Guard Bearer

m
1.3

Fan Guard Bearer is used to provide an angled

external platform for protection against falling
debris. The lower end connects to a cup on the
Standard whilst the top end is supported by
the Fan Guard Tie. Consult AF&S Engineering
Department for load capacity details.
CUPLOK Fan Guard Bearer

CUPLOK Aluminium Stair

CFGB

Holes
provided
for
attachment
of handrail

10.7

CUPLOK Fan Guard Tie

1.8

CUPLOK Aluminium Stair 1.5m

Fan Guard Tie is used to support the end

of the Fan Guard Bearer. The tie connects
to the cup of a Standard and the twin plate
end connects over the hook on the Fan
Guard Bearer.
CUPLOK Fan Guard Tie

The Aluminium Stair enables a stairway to be

assembled within a 2.44m x 1.27m bay. Each
end of the Stair is supported by a Transom. The
width of the unit is half the bay width enabling
two units to sit on a Transom, thus a continuous
staircase can be built up the full height of the
scaffold. Vertical height of the unit is 1.5m.

CUPLOK Step Bracket -1 Plank

CFGT

The Step Bracket enables a step down of 0.25m

which is mid height between adjacent platforms
which have a 0.5m height difference. Useful for
Birdcage scaffold and stair landings.

5.9

CUPLOK Step Bracket - 1 Plank

CUPLOK Deck Adaptor

CUPLOK Aluminium Stair Handrail

The Deck Adaptor is attached to the top

Standard in birdcage scaffolds to enable a
flush top deck to be assembled. The top
cup is screwed down to capture Ledgers
and Transoms.
CUPLOK Deck Adaptor

The Stair Handrail follows the slope of the

Aluminium Stair and is bolted to the inside face
of the Aluminium Stair side member.

CDA

1.7

CUPLOK Aluminium Stair Handrail

CUPLOK Stairway Trimming

Standard
The Stairway Trimming Standard is used in
conjunction with Aluminium Stair to provide an
access/egress point. The top and bottom of the
Standard is captured between Ledgers. Additional
Ledgers are used to connect the Stairway
Trimming Standard to the adjacent Standard.
CUPLOK Stairway Trimming Standard

CUPLOK Scaffolding System

Product

General Technical and Application Manual

Description

Code No.

Mass kg (nom.)

CUPLOK Transoms

Mesh Guards
Mesh Panels are hung from the guardrail to
provide a full protection screen 1 metre high
along the length of the platform. The unit
incorporates a built in kick plate and typically
a midrail is not used when mesh guards are in
place. Available in the nominal bay lengths.
Mesh Guard 1.27m
Mesh Guard 1.83m
Mesh Guard 2.44m
Mesh Guard 3.05m

MP12
MP18
MP24
MP30

10.8
14.6
18.4
22.2

Cross Section of Transoms

Working Load Limits
Duty Live Load to AS1576.1
0.61 - 1.83m Transom

CUPLOK Corner Platforms

Corner Platforms are designed to fill the gap
left where two runs of Platform Brackets
intersect on an internal corner of the building.
The Platforms attach to the corner Standard
and are connected to adjacent Platform
Bracket by Tie Bars. (See page 23)
CUPLOK Corner Platform 1 x 1
CUPLOK Corner Platform 2 x 2
CUPLOK Corner Platform 2 x 1
CUPLOK Corner Platform 1 x 2

2.44m Transom

Bottom web n

CCB1
CCB2
CCP2x1
CCP1x2

5.0
11.5
9.5
9.5

Toe boards are secured using the generic Toe

Board Clamp which locks around the Standard
with its protruding prong holding the toe board
Plank or Planks in place.
TBC

W (kN)

P (kN)

0.61

Light (2.2kN UDL)

1.0

0.83

Heavy (6.6kN UDL)

2.0

1.05

Heavy (6.6kN UDL)

2.0

1.27

Heavy (6.6kN UDL)

2.0

1.52

Medium (4.4kN UDL)

1.5

1.83

Medium (4.4kN UDL)

1.5

2.44

Medium (4.4kN UDL)

1.5

Notes:

Toe Board Clamp

Toe Board Clamp

L (m)

0.8

= Working Load Limit for Point Load

W = Working Load Limit for Uniformly Distributed Load

Loads W and P shown are not simultaneous loads. Refer AS/NZS1576.1-2010, Clause 2.5.3.1.2

The Transom Working Load Limits shown in the table above are governed by the Operational requirements of AS/NZ1576.1
Section 3. Typically, this limitation applies to working platform widths equal to transom size 'L' shown.

Where Special Duty design load is required or design loads exceed Duty Live Load shown then contact your local AF&S
Engineering department for design advice.

Working Load Limits (P & W) may be limited by other components or assemblies.

CUPLOK Return Toeboards

CUPLOK Transom Beams and Transom Trusses

CUPLOK Return Toeboards are typically used

at the end of a bay or return and installed
parallel to the Transom. They are held captive
between Standards by means of a set screw
at one end and U-bracket arrangement at the
other end.

CUPLOK Return Toeboard 0.61m

CUPLOK Return Toeboard 0.83m
CUPLOK Return Toeboard 1.05m
CUPLOK Return Toeboard 1.27m
CUPLOK Return Toeboard 1.83m
CUPLOK Return Toeboard 2.44m

For load ratings and applications contact the AF&S Engineering Department
Transom Truss
Transom Beam

CRTB061
CRTB083
CRTB105
CRTB13
CRTB18
CRTB24

4.2
5.2
6.3
7.3
9.9
15.0

1.83m & 2.44m

3.05m

Transom
Section

Section
for all
Transom Trusses

CUPLOK Scaffold Castor

The Scaffold Castor is designed to fit into
the bottom of a Standard. It features a swivel
facility and a dual function locking mechanism
which locks both swivel and rolling motion of
the Castor.
CUPLOK Scaffold Castor - 200mm

1.83

2.44m

Transom Beams and Transom Trusses impose additional loads on the scaffold structure requiring the overall design of the
scaffold to be checked and verified.
CC200

4.5

CUPLOK Scaffolding System

General Technical and Application Manual

CUPLOK Planks

Formwork Support (Falsework) Applications

1.27

4.1

1.83

2.8

2.44

2.1

3.05

2.0

General

221

All Planks meet point load requirement specified for Heavy Duty Loading to AS1576.1
The sum of individual loads applied to planks must not exceed the Duty Live Load for the platform per bay.

Shear Capacity of Bottom Cup

4.4kN

Bracing

P = 17kN

CUPLOK Platform Brackets

P = 2.0kN

P = 2.0kN

P = 2.0kN

Maximum load per blade must not exceed 17kN

and total load applied to a bottom cup must not
exceed 34kN.
The total load from multiple cups on the
Standards load capacity must also be considered.
1 Plank

2 Plank

3 Plank

CUPLOK Stair Stringer (used in pairs)

CUPLOK Aluminium Stair Unit

W
2.0m

1.5m

Stair Width

Stair Tread Width

1.27m

10

2.44m

W = 2.5kPa
Total = 7.7kN

0.59m
2.44m

W = 2.5kPa
Total = 3.6kN

11

Bracing shall satisfy two conditions:

(1) Provide nodal restraint.
(2) Transfer transverse forces to supports.
AS3610-1995 requires that each restraining element be designed to transfer
a transverse load equal to the sum of 0.025 times the axial force in the
compression member at the location of the restraint and an additional load
equal to half that value for each additional compression member being
restrained, up to a maximum of seven members. This load shall be assumed to
act in addition to other loads.
All nodal points which are considered in defining lift heights shall be restrained.
The correct amount of bracing shall be calculated, however a minimum amount
must always be used. This requires every row of standards to have a top to
bottom bracing system installed at a maximum of 4 bays apart along its length.
This applies in both directions.
Bracing can be provided externally (for example, using the permanent structure
to act as a brace, in this case it shall be stated in the project documentation
with the magnitude of the force) or internally by the bracing system.
Bracing shall be installed immediately after each lift has been erected, and as
close as possible to the node points (not more than 100mm from the node point).
Transverse loads must act at node points on the Standards where Ledgers/
Transoms are fitted (no secondary bending moments are permitted).
If any brace is not continued to the support and is terminated within the
structure, the vertical compression component of the bracing force must be
added to all other vertical compression forces and the total shall not exceed the
published WLL. The horizontal component of the force must also be transferred
to a suitable support, ie via butting/tying to a suitable structure or other suitable
bracing system as required.
When the formwork deck is not restrained (for example, no permanent structure
like walls or columns to provide lateral restraint) particular care shall be taken in
the design to restrain the formwork deck and top Adjustable U-Heads.
Individual towers or narrow falsework systems shall be fully and effectively
braced and the stability of the system be investigated in the design. The slenderness
ratio of the system as a whole shall not be greater than that of the individual
compression members.

Applied Load < WLL

Adjustable
U-Head

190

P = 17kN

CUPLOK
Open Ended
Standard

Top lift

For all standard sizes

Node
Main lift

P=

Spigot
Joint

Main lift

CUPLOK Diagonal Braces

Footings and/or foundation shall be satisfactory to support the imposed loads and prevent differential settlement.
All Standards shall be erected plumb.
After squaring up the initial Standards on the first bay, plan bracing is helpful to maintain squareness.
Each bay must have Ledgers/Transoms connected at the cup positions nearest the Adjustable Bases or
Adjustable U-Head Assemblies, for example at top and bottom of each leg (and at intermediate positions at
design lift heights).
The most recommended type of falsework is built by having continuous lines of Ledgers or transoms in both directions.
When very long runs of falsework are to be constructed consideration shall be given to dividing the structure into
smaller sections to avoid the build up of adverse tolerances.
No more than one spigot joint per Standard is allowed between vertical lifts of Ledgers/Transoms.
Spigot Joints must be avoided in Base Lifts.
Joints in Standards should be staggered if possible.

CUPLOK
Spigotted
Standard

Base lift

P (kN)

110

L (m)

61

CUPLOK
Standard

CUPLOK
Standard

Notes:

P = Working Load Limit for Point Load

Working Load Limits (P & W) may be limited by other components or assemblies.

Adjustable Base

W = Working Load Limit for Uniformly Distributed Load

Suitable footing and foundation

CUPLOK
Ledger/Transom

Internal Standard

External Standard
Plan View

CUPLOK Scaffolding System

General Technical and Application Manual

CUPLOK Standards
Formwork Applications

CUPLOK Assembly Recommendations

Maximum Bay Size 1.8 m X 1.3 m

The following scaffold Assembly Recommendations provide guidance on how to assemble a basic scaffold structure. Through
experience with the system, different and more complex configurations can be assembled.

Working Load Limits for internal Standards

For assistance with these recommendations contact your local Acrow Formwork & Scaffolding Branch.

CUPLOK 2.0m Lift

30

Working Load Limit (kN)

Persons erecting or dismantling the components should be competent in this type of work.
For safety reasons, we recommend that no less than two erectors work as a team to erect CUPLOK.

Notes:

Where assistance is required in erecting more complex designs other than Standard faade type independent
scaffolding and configurations not shown in these recommendations, contact your local Acrow Formwork & Scaffolding
representative.

In certain areas scaffolding may be exposed to high winds and as such special precautions regarding tying in and
cladding removal can apply. For assistance with design of scaffolding that may be exposed to high winds contact your
local Acrow Formwork & Scaffolding Engineering office.

In some cases, particular configurations of scaffolds and particular sites may require scaffolders to use safety harnesses
and lanyard systems to provide protection against a fall when erecting the scaffold over a void or lean out from the
scaffold or supporting structure without the protection of a guardrail. In such cases do not attach harness systems to
scaffolding supplied by Acrow Formwork & Scaffolding unless attachment points for such systems are approved by
Acrow Formwork & Scaffolding Engineers.

25

2.0m Lift
20

15

10
0

100

200

300

400

500

Adjustable Base/Adjustable U-Head Extension (mm)

30

Working Load Limit (kN)

Compliance to Statutory Regulations

CUPLOK 1.5m Lift

Scaffolding must be erected in compliance with the requirements of Statutory Regulations and Australian Standards for
Scaffolding (AS/NZS1576 and AS/NZS4576 'Guidelines for Scaffolding') as applicable.
The following are some additional points, which should also be considered:

1.5m Lift

25

20

1.5m Lift

15

100

200

300

400

500

Adjustable Base/Adjustable U-Head Extension (mm)

Working Load Limit (kN)

Manual Handling
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.

CUPLOK 1.0m Lift

40

Risk Management
When planning the erection of any scaffolding, a site specific Risk Assessment process must be carried out.
Generic Hazard Identification/Risk Assessments/Control method profiles and Safe Work Methods Statements for
the erection, dismantling and the usage of scaffolding equipment are available from Acrow Formwork & Scaffolding
Branches. Site specific Hazard Identification and Risk assessments and Recommended Work Methods Statements
would need to be generated for specific projects.

10
0

1.0m Lift
35

Simple Method of Component Connection

1.0m Lift

30

25

1.0m Lift

Locking Bar

20

Top Cup

12

Erection of scaffolding over 4 metres in height

Personnel who erect, alter or dismantle scaffolding having a working deck at greater than 4m in height must hold a
current National, State or Territory Certificate in Scaffolding to the appropriate class.

100

200

300

400

500

Adjustable Base/Adjustable U-Head Extension (mm)

If higher leg loads are required we recommend the use of the AF&S SUPERCUPLOK system

13
Bottom Cup

Notes:

These graphs give Working Load Limits for internal Standards which are erected plumb, loaded concentrically and
effectively braced in the major directions.
For external Standards reduce Working Load Limits by 15%.
These graphs must be read in conjunction with the Guidance Notes on page 11.

Blade ends of horizontal members (Ledgers or Transoms)

are located in the bottom cup. The top cup is then slid
down over the top of the blades and is rotated until it
engages the locking bar.

The top cup is tightened by striking its lugs with a scaffold

hammer. The inclined spiral top edge of the top cup acts
against a fixed locking bar on the Standard to wedge the
top cup tightly around the blades providing a positive and
firm connection.

CUPLOK Scaffolding System

General Technical and Application Manual

CUPLOK Assembly Recommendations (cont)

CUPLOK Assembly Recommendations (cont)

Before commencing the erection of any CUPLOK scaffold, care should

be taken to check that the ground is suitable and clear of loose rubble to
provide a stable base and clear access for erection. The scaffold must be

Figure 1

erected on adequate soleplates and the foundation on which the soleplates

are placed must have sufficient bearing capacity to support the imposed

If the Standards are moved an appreciable distance in the squaring up process,

then recheck the levels. Refer Figure 8.

loads transferred from the scaffold. As a general rule, each soleplate

should be long enough so that it supports at least two Standards. Bricks or

The first bay of CUPLOK is completed by locating the upper Ledgers

and Transoms.

Check whether or not platform brackets are required adjacent to the

workface. If so, you will need to make allowance for the width of the

Top cups can now be tightened in this first bay.

No need for heavy hammering.

platform brackets and increase the distance between the workface and the

Start here at top

closest adjacent Standard to the workface.

Figure 7

Fix a Diagonal Brace to the outer face and end face of the first bay. Always start by
fixing the top end of brace to the upper cup first: this makes for safer handling.

masonry blocks are not suitable and must not be used. Refer Figure 1.

The bay should now be squared in plan and correctly located in relation to the
structure being scaffolded. Check squareness across the diagonally opposite
Standards. Checking squareness is assisted by placing the recommended number
of Planks between Transoms and ensuring that Planks sit correctly with an even
gap between the ends of the Planks and the supporting Transom. Refer Figure 7.

Figure 2

Commence erection - where possible - on the highest point of the ground

and work down the incline - this will make levelling easier as the scaffolding

Now it is a simple matter to extend the scaffold structure by connecting Ledgers,

Transoms and Standards to the existing bay checking the alignment of the
Standards as the scaffold progresses.

Figure 8

progresses.
Set the nut on the first Adjustable Bases to close to the bottom of the stem

10 The Working Platform can now be constructed

to allow maximum adjustment as the scaffold progresses to lower levels.

using Scaffold Planks as decking and toeboards.

Refer Figure 9.
Planks are supported by the flanges of
Transomes and Toeboards are attached to
Standards using Toeboard clamps.

Figure 3

Refer Figure 2
If the scaffold is founded on sloping ground, then the ground should be
benched to provide a level surface for soleplates.
If the scaffold is founded on sloping solid foundation,
eg concrete, then adjustable bases should be wedged.

Lay out the Adjustable Bases, Ledgers and Transoms for the first bay in

Inside
2m

Outside
3m

horizontally, levelling and and positioning each

bay as you go before tightening cups. Continue
the 2m and 3m Standard combination for the
full run. Refer Figure 10.

Figure 4

Connect the Standards with a Transom in the lowest cup joint, by inserting

bays should be carried out from a fully decked

platform or as required by Code of Practice
published by local Statutory authorities.
Refer to local statutory regulations for
further requirements.

or lowering the Adjustable Base. Always start the scaffold with a 3 metre
Standard on the outside face and a 2 metre Standard on the inside.
Refer Figure 4.
Do not tighten top cups - yet.
With one erector still holding the first pair of Standards, the second erector
first pair with a Ledger. The top cups can then be dropped temporarily into
the locking position. The structure is now self supporting and the fourth

14

which incorporates a toeboard 1m high can be used in lieu of a midrail and toeboard.
Figure 5

bay levelled. Refer Figure 5.

Figure 10

12 Planks are now moved up to fully deck out the the first lift. Refer Figure 11. When these Planks remain in place as a
Working Platform, Ledgers are positioned at 0.5m and 1m above the planked level to form a guardrail and mid
rail on the outer face. For working platforms, toeboards on the outer face are also required. A Mesh Panel

inserts an Adjustable Base into the third Standard and connects it to the

Standard can now be connected by a further Ledger and Transom and the

The height of the

Standards has
been reduced in
the diagram

Note: Erection and dismantling of scaffold

the blades into the bottom cups. Approximately level the transom by raising

Face of
building /
structure

11 Now complete the base layout by adding bays

Refer Figure 3

Outside

Figure 9

their approximate positions. Then insert an Adjustable Base into each of the
first pair of Standards and position Adjustable Bases onto the soleplates.

Inside

15

The bay can now be levelled. Starting from the highest point use a spirit
level to adjust the bases so that Ledgers and Transoms are level. Accuracy
in levelling at this stage makes for a good start. Refer Figure 6.

Figure 6
Figure 11

Do not tighten top cups - yet.

Level both ways

Figure 12

CUPLOK Scaffolding System

General Technical and Application Manual

CUPLOK Assembly Recommendations (cont)

CUPLOK Assembly Recommendations (cont)

13 Additional lifts can now be constructed by adding further Standards into spigots of the Standards of the lower lift and

15 TIES

staggering joints wherever possible. Transoms and Ledgers are placed at platform levels.
Refer Figure 13.

It is essential that scaffolds be tied to the building or suitable structure to resist a minimum design force 6kN
(600kg) to prevent inwards or outwards movement of the scaffold. As such they provide stability and enable
effective performance of the scaffold structure as it grows in height and length. As general rule, ties need to
commence where the scaffold height exceeds 3 times its least width. Typically ties comprise scaffold tube and
right angle scaffold couplers and are connected to the Standards with right angled scaffold couplers. Care must
be taken that ties do not obstruct clear access along the full length of the working and access platforms.
The scaffold must not be built to allow it to cantilever more than 4m without cladding beyond the last level of ties
(refer Figure 20). If cantilevered section is clad, then consult AF&S Engineering for limits on cantilever height. The
following examples show tie configurations for assembling around columns and through openings.
Note: In the examples shown, tie tubes are not connected direct to Standards but to horizontal tubes spanning
between Standards, as shown in Figure 18.

Working levels should be fully decked out and the outside face fitted with guardrails, midrails and toeboards (or Mesh
Guards) at the required positions.
Fully complete the longitudinal erection of a lift before progressing to the next lift.
Stagger joints in Standards wherever possible.

Figure 13

Figure 15

Figure 16

Figure 17

14 Face Bracing
All scaffolds require a certain amount of diagonal face bracing to eliminate any tendency for the scaffold to distort
or sway.

Double Lip or U Tie

Box Tie

Plan View

Before the scaffold goes beyond the second lift, Bracing should be added to the outside face and on the ends. Braces
attach to the outward facing of the cup on the Standard.
Tie Tubes

Further bracing must be placed on the scaffold as it progresses in length and height. Braces should span from lift level to
lift level and cross over joints in Standards and be positioned all the way to the top of the scaffold.
Refer Figure 14.

Column Tie with

Butt transom

Note:
Where it is not possible to use the typical tie
configurations, other tie methods are available.
These methods have certain restrictions for
use so, contact your local Acrow Formwork
& Scaffolding Engineering Representative
for assistance.
Figure 19

Warning:

max Lift height (typical)

Figure 18

16

Through Ties should be placed as

close as possible to the window
reveal and secured with right angle
couplers.

Tie Configuration
Figure 14

2.0m
Typical 'Zig Zag'
Longitudinal Bracing
along external face

Tie tubes must not be attached to Ledgers.

Tie tubes must be attached directly to
Standards, if this is not possible then scaffold
tube must be fixed between Standards with
right angled couplers and the tie tube is
attached to this scaffold tube.

Alternative 'Node to Node'

type Longitudinal Bracing
pattern along external face

3 Bays max
Unbraced

Transverse
Bracing
at ends

Diagonal Braces provide stability to the scaffold and are used to brace adjacent Standards longitudinally or transversely.
Face Diagonal Braces are positioned in the end bays of a scaffold run on the external face of the scaffold. They extend
from the first cup near ground level to the top working level. They are typically arranged in an alternating (zig-zag) manner
to provide more stability to the scaffold. For scaffold runs exceeding 5 bays in length, intermediate bracing is required
where a maximum of 3 bays can be left unbraced. Variations to this spacing must be checked by the appropriate
designer and specified in the design layout.
End Diagonal Braces are used between end pair of Standards in the transverse direction. They extend from the first cup
near ground level to the top working level in an alternating manner.

17

Figure 20 shows an example

of staggered tie configuration
for scaffolding assembled
with 2m lifts and without any
cladding, such as shade cloth
or other semi or non porous
material. Ties are installed at
no more than 3 bays apart
for a maximum bay length
of 2.44m in the longitudinal
direction and 2 bays apart for
bay lengths of 3.05m. Ties
should have a 4m overlap in
the vertical direction. Cladding
the scaffold will cause wind
loads to increase and tie
spacings may need to reduce
accordingly. Contact your local
Acrow Formwork & Scaffolding
Engineering Representative for
assistance with tie spacing for
clad scaffolds.

Figure 20

Note: When using 3.05m ledgers the max distance between ties is 2 Bays.

CUPLOK Scaffolding System

General Technical and Application Manual

CUPLOK Assembly Recommendations (cont)

CUPLOK Assembly Recommendations (cont)

15 TIES (cont)
Tying to Standards

16 Access and Egress Methods

Every working platform level must be provided with a safe and suitable access. This can be achieved by means of a builtin ladder or stair access tower or by direct access from within the building or structure. Stair access can be constructed
with either Aluminium Stair units or steel Stair Stringers as outlined on the following pages:

Ties tubes must be connected to Standards and be parallel to transoms at a position adjacent to the junction of the
Transom and Ledgers, with the following restrictions:
(a) Within 300mm from the underside of the cup at the junction - connected to the front Standard with addition of a
Check Coupler.
(b) Further than 300mm from underside of the cup at the junction - Tie connected to both front and rear Standards.
(c) If unable to connect to two Standards then reinforce front Standard for the full height of the lift with scaffold tube and
swivel couplers with couplers attached at 900mm centres.
(d) If tying is to a Standard with a spigot within the lift then the Standard needs to be reinforced using a verticle tube or
alternatively, if space permits, by installing an extra transom adjacent to the joint.

Ladder Access

(i)

Ladder access is typically used where only a few persons need access to the working platform and where tools
and equipment can be delivered separately to the working platform (such as by rope and gin wheel, materials hoist
or crane).
Ladder access bays can be constructed within the main run of the scaffold, however, where space permits it is
preferable that a separate ladder access bay be placed adjacent to the main run.
Single ladders need to extend at least 0.9m above the landing level, secured at top and base and successive landing
levels should be vertically spaced at no more that 6m.

Note:
The 300mm distance given in (a), (b) and (c) may need to be reduced, subject to the amount of tie force.

More than
300mm

More than
300mm

Tie

Tie

Important:

Tie
Connect
to both
Standards

Add Check
Coupler

Add Check
Coupler

Reinforce
Tied Standard

Reinforce
Tied Standard

(a)

Ensure that guarding and edge protection is installed around openings in Ladder Access Bays that are in or beside
working platforms.

Joint in Standard
Alternatively
a transom
adjacent to
the joint could
be used

Ladder Access
1.3m Planks x 2

2.44m

Figure 21

(c)

(d)

Ladder secured
to alternate
each side of Bay

Increased distance between tie points

In cases where ties cannot be placed in the correct position, where ties have to be removed, where tie spacings
exceed those given in these assembly recommendations or in scaffolds which extend above the building, with the
result that typical tie spacings given in these Assembly Recommendations cannot be achieved, then consult your
local Acrow Formwork & Scaffolding Engineering Representative for technical design assistance with tie
spacing and configurations to suit your specific needs.

Install guarding
& edge protection
around opening
1.3m Transoms
1.27m

Maximum Height of Scaffold

Ladder Access Transom

secured between Ledgers

When determining the maximum height of a scaffold, a number of factors must be considered.
Live load of working platforms, for example Heavy Duty, Medium Duty or Light Duty.
Number of Working Platforms.
Live load of Platform Brackets.
Dead load of scaffold, for example Standards, Transoms, Ledgers, Guardrails, Mesh Guards, Platform
Brackets, Planks, Bracing, shadecloth and chainwire mesh.
The position of the top tie in relation to the top of the scaffold.
Wind Loading (in relation to tie forces).
Strength of the supporting structure for the scaffold.

18

Note:
Any additional equipment such as additional planked levels, Working Platforms, Platform Brackets, spurs or the like
will increase leg load and hence reduce the maximum height of the scaffold. Therefore, where assessment shows
that scaffold configuration exceeds the above conditions, consult your local Acrow Formwork & Scaffolding
Engineering Representative for technical design assistance with the maximum heights of CUPLOK and
tying configurations to suit your specific needs.

2.4m Planks x 3

2.4m Ledgers

3.2m Braces
Tie Ladder
Access Bay
at Standards
every 4.0m max

Ladder Access Bay

Plan View

6.0m max

Scaffolding configurations can vary greatly, so for a CUPLOK scaffold of typically 1.27m wide, constructed using 2m
lifts, braced and tied in accordance with patterns given in these recommendations, without cladding, with a maximum
of two Heavy Duty Working Platform levels (6.6kN as per AS4576 and AS/NZS1576.1), two levels of Planks and
Platform Brackets, guardrails at the outside face at 1m vertical spacing for full height of scaffold, diagonal bracing for
full height, the maximum height of the scaffold constructed with bay lengths of 3.05m or less is 45m.

Ladders inclined at
slope of between
1 to 4 and 1 to 6

Standard

1.27m

(b)

0.9 m min

Add Check
Coupler

Tie

CUPLOK Ladder Access Transoms are used to enable the formation of an opening within the deck through which
the ladder can pass. These Transoms span between Ledgers and are typically positioned at mid-span of the Ledgers
or at the appropriate position to support two shorter length Planks. The remaining bay width is decked out with
Planks that span between Transoms in the usual manner.

19

Figure 22

4.0m max

Within
300mm

Pitch ladders at a horizontal to vertical slope of not less than 1 to 4 or more than 1 to 6.

Denotes Transom/Ledger
positions

1.27m

2.44m

End View

Elevation

CUPLOK Scaffolding System

General Technical and Application Manual

CUPLOK Assembly Recommendations (cont)

CUPLOK Assembly Recommendations (cont)

16 Access and Egress Methods (cont)

16 Access and Egress Methods (cont)

(b) CUPLOK Stair Stringers

(ii) CUPLOK Stair Access Systems

Typically, a 12 Standard configuration is used to assemble the stairway giving overall plan dimensions
of 2.54m x 4.98m. This bay can either be incorporated within the main run of scaffold or adjacent to the
run. Where the stair access bay shares common Standards with the main run, the loading on the shared
Standards needs to be checked during the scaffold design phase as height conditions and wind loading
can vary from site to site and may limit the height of the stair access bay. Contact your Acrow Formwork
& Scaffolding Representative for assistance with establishing maximum stair heights.
CUPLOK Stair Stringers are designed to fit within the Standard 1.27m x 2.44m bay and are often used
as a stretcher stair access bay. Each Stair Stringer assembly is nominally 1.27m wide and rises 2.0m
over the bay length of 2.44m. The 12 Standard configuration is based out in the position required and
the first 2m lift is erected so that Stair Stringers can be installed. Ensure that Transoms and Ledgers are
in the correct positions as shown on the Plan and Elevation views, as this will avoid clashes between
components. Each end of the Stair Stringer is hooked over 1.3m Ledgers positioned at the top of each
2m lift. Once hooked over the Ledgers, Stair Stringers are then moved to within 0.15m of the Standard
so that they are approximately 1.0m apart. Using the clamps incorporated in the Stair Stringer, CUPLOK
Planks are clamped between the two Stair Stringers thus forming the stair treads.
Once the Stair Stringers are installed, Landings for the stair access are assembled within the 1.27m
square bays at each end of the Stair Stringer bays using CUPLOK 1.27m Planks supported between
Transoms. Once landings are in place the next lift can be installed making sure that guardrail and midrails
are installed at 1.0 and 0.5m above landing levels as each lift is assembled. Standard 3.2m Face Braces
(2.44 x 2.0m) are installed as handrails at approx 0.5m and1.0m above the Stair Stringer. Continue
building the stair access bay making sure that each end of the bay is tied into a suitable structure at no
more that 4.0m vertical intervals.

Two types of stair access systems are available with CUPLOK:

CUPLOK Aluminium Stairs
CUPLOK Stair Stringer System

(a) CUPLOK Aluminium Stair

CUPLOK Aluminium Stair units fit within the Standard 1.27m x 2.44m bay. Each Stair unit is 0.6m wide
and rises 1.5m over the bay length of 2.44m and incorporates a landing at top and base of the unit.
A 1.27m x 2.44m bay needs to be dedicated as the stair access bay. This bay can either be incorporated
within the main run of scaffold or adjacent to the run. The stair access bay typically shares common
Standards with the main run, however this detail needs to be checked during the scaffold design phase as
height conditions and wind loading can vary from site to site.
The stair access tower should be constructed with 2.44m Ledgers and 1.27m Transoms at 1.5m vertical
intervals, except at entrance and exit points to the stairs where head clearance of 2m (nom) is required.
Lift the first Stair unit into place such that it is supported between the Transoms spaced at 1.5m vertical
intervals and position the Stair unit adjacent to the Standard. Note that stair landings need to be adjacent
to access/egress landing points at working platforms.
Install Ledgers at 0.5m and 1.0m above the landing level in both transverse and longitudinal directions
to act as midrails and guardrails respectively. Ledgers can be installed at 0.5m intervals on the exposed
faces of the bay for the full height of the bay.
Install the second Stair unit such that its bottom landing commences from the Transom that supports the
top landing of the lower Stair unit. A zigzag pattern of Stairs should now be established.
Where it is necessary to construct a stair access as a bay independent of the scaffold, then, ensure that
the stair access bay is adequately braced and tied to the main scaffold or other support structure.
Subject to space required to handle the Stair units within the bay during installation, the Stair Handrails are
to be installed at the earliest opportunity. The Handrails bolt to the stair unit with M12 x 50 long bolts and
nuts. The Handrail should be bolted through the holes provided to the inside face of the stringer part of the
Stair units. Holes are located towards the top and bottom of the Stair unit.
Continue to build the scaffold tower framework so that the last level of Ledgers and Transoms is 2 metres
past the top landing of the uppermost Stair unit. Once the uppermost Stair unit is installed, a Trimming
Standard will need to be installed between the Ledgers at 2m above the top stair landing and the Ledger
adjacent to the uppermost stair landing and positioned to be 0.6m away from the corner Standard next to
the intended opening. 1.8m Ledgers are then attached between to the Trimming Standard and the corner
Standard to give a 0.6m opening to the work platform. Planks can be installed to occupy the gap between
the edge of the Stair unit at the top landing and the edge of the bay.

Note:

Edge protection (guardrails, midrails and toeboards) is required at access and egress points of working platforms.
Care is to be taken to ensure that head clearance of 2m (nom) is maintained at these points.
Gaps between the stair access landing and working platform levels may occur and these should be kept to a
minimum. Suitable infill should be installed.
Access/Egress
Point

Denotes Transom/Ledger positions

Note:

0.6m

1.27m

Stair Handrail
bolted to stairs

2.44m

2.0m Lifts

1.27m

1.27m

2.44m

1.27m

1.27m

Elevation

1.27m

End View

Stair Handrail

21

Aluminium Stair
Units supported
on Transoms

1.3m Ledgers

1.27m

End View

Access/Egress
Point

Standards

2.4m Ledgers

Access/Egress
Point

Access/Egress
Point

Access/Egress
Point

2.4m Ledgers
at 2.0m Lifts
(Top & Bottom of Stringers)

1.3m Ledgers at 2.0m Lifts

(Landings) and at 0.5m
& 1.0m above Landing for
Midrails & Guardrails

1.27m

Figure 23

1.3m Planks
for Stair Treads
secured to Stringers

2.0m Stair Stringers

(Two per Bay within
150mm of Standards)

Stair Stringer Bay

12 Standard configeration
Plan View
Figure 24

Standards Typical

3.2m Braces

Plan View

1.3m Transom at
2.0m Lifts (Landings)

1.27m

20

Trimming
Standard
between
Ledgers

Tie Stair
Bay at
Standards
every
4.0 max.

3.2m Braces
as Handrails
at 0.5m centres

1.27m

Tie Stair Bay

1.8m Ledgers
at Standards
every 4.0m max

Trimming
Standard
between
Ledgers

2.0m Rise/Lift

Tie Stair
Bay at
Standards
every
4.0m

1.8m Ledgers

1.5m Rise/Lift

Denotes Transom/Ledger positions

Edge protection (guardrails, midrails and

toeboards) is required at access and egress
points of working platforms.
Care is to be taken to ensure that head
clearance of 2m (nom) is maintained at these
points.
Gaps between the stair access landing and
working platform levels may occur and these
should be kept to a minimum. Suitable infill
should be installed.

4.0m max

1.27m

2.44m

1.3m Planks at Landings

2.44m

1.27m
Entrance to Stairs
(typical)

CUPLOK Scaffolding System

General Technical and Application Manual

CUPLOK Assembly Recommendations (cont)

CUPLOK Assembly Recommendations (cont)

17 Platform ('Hop Up') Brackets

18 Configurations of Corner Platforms

Platform brackets (also known as Hop Up brackets) are used to enable a platform to be placed between the scaffold and
the building or structure and are therefore attached to the Standard closest to that workface. Widths vary from one to
three planks wide. Platform Brackets are usually installed such that they provide a platform at the same level as the work
platform or 500mm below the work platform. The outer edge of the platform provided by the Platform Brackets must be
within 225mm from the workface.
When installing Platform Brackets, make sure that they are interconnected with a Tie Bar and that the open side of the
Tie Bar angle faces inwards, enabling the steel plank to sit in the angle. This prevents accidental dislodgment of the
Tie Bar.

Figure 26 below shows plan view of the various sizes of Corner Platforms. Tie bars, which are used to interconnect
Platform Brackets, are also used to interconnect ends of Corner Platforms to each other or to adjacent Platform
Brackets. In the diagrams below, Tie bars and planks are not shown for clarity.

Corner Platforms
interconnected with
Tie bars (typical)

Corner Brackets are also available to enable continuity of Platform Brackets around the internal corners of buildings.
These units are attached to the Standard and connect to adjacent Platform Brackets with Tie Bars.

CCB2

CCB2

CCB1

CCB1

CUPLOK Plank Arrangement

The diagrams below show typical plank quantities for various bay widths. Various combinations of Bay width and
Platform Bracket size are achievable, however, care must be taken to ensure that the combination does not adversely
affect the stability of the scaffold.
2 planks
plus
toeboard

10 planks plus toeboard

1 plank
platform bracket
Corner Platforms
1x1

2.44m Bay

Corner Platforms
2x2

0.61m
Bay

2.44m

0.61m
CCB2

CCB2

7 planks plus toeboard

2 plank
platform bracket

Cuplok Tie Bar

interconnecting
Platform or
Corner Brackets
(typical)

1.83m Bay

CCB1

CCB1
3 planks
plus toeboard

CCP1x2

0.83m Bay

CCP2x1

0.83m

1.83m

Workface

5 planks plus toeboard

3 plank
platform bracket

4 planks
plus toeboard

Corner Platforms
1x2

Corner Platforms
2x1

1.27m Bay

22

1.05m Bay

1.27m

Less than
225mm (typical)

1.05m

23
CCP2x1

CCP1x2

Figure 25
Figure 26

CUPLOK Scaffolding System

General Technical and Application Manual

CUPLOK Assembly Recommendations (cont)

CUPLOK Assembly Recommendations (cont)

19 Dismantling

26 Scaffold Safety Rules

The following are some common sense rules designed to promote safety in the use of scaffolding. These rules do

Care must be taken when dismantling scaffold as the stability of the scaffold must be maintained at all times.
After removal of materials and equipment from the working platforms, dismantle the scaffolding generally in the
reverse order of the erection sequence.
Avoid accidents and damaging material by appropriately lowering materials and not dropping them (bombing)
when dismantling.
Removal of ties to the permanent structure should progress at the same rate as the dismantling process.
Do not remove ties until dismantling of the scaffold reaches the level of the ties.
Do not remove diagonal braces until it is necessary to remove the Standard to which it is attached.
Ledgers should not be removed from any working level before the removal of scaffold planks from the same level.
Localised overloading by stacking of dismantled equipment on partially dismantled scaffold must be avoided.
Stack materials neatly in the appropriate stillages or on pallets.

not purport to be all inclusive or to supplant or replace other additional safety and precautionary measures. They are not
intended to conflict with or supersede the requirements of statutory or government regulations; reference to such specific
authorities should be made by the user.

Inspect all equipment before using. Never use any equipment that is damaged or deteriorated in any way. If in doubt
contact your supplier.

Ensure that personnel erecting, altering or dismantling the scaffold are certified to the appropriate level.

Inspect erected scaffolds regularly to ensure that they are maintained in a safe condition.

Consult Acrow Formwork & Scaffolding when in doubt. Dont Take Chances.

Always check foundations and use adequate soleplates. Foundations for a scaffold must have adequate bearing
capacity to carry imposed loads.

Use Adjustable Bases instead of packing to adjust uneven grade conditions.

When scaffolds are to be partially or fully enclosed, specific precautions must be taken to check the frequency and
adequacy of ties attaching to the building due to increased load conditions resulting from effects of wind and rain.
The scaffolding components to which the ties are attached must also be checked for additional loads. Consult your
Acrow Formwork & Scaffolding Engineering Representative.

Equip all planked or working levels with proper edge protection (guardrails, midrails and toeboards or guardrails and
mesh guards) along all open sides and ends of scaffold platforms.

Ensure that buildup of debris on working or access platforms is removed.

Power lines near scaffolds are dangerous - use caution and consult the power authorities and local Regulatory
Authorities for advice and local requirements.

Do not use ladders or makeshift devices on top of scaffolds or place planks on guardrails/midrails to gain extra
access height.

Do not overload scaffolds.

Planking

20 Transportation

Loose items are to be stacked in Stillages and be secured in such a way that they are able to be contained within
the vehicle during transport.
Materials are to be secured for transport in such a way that the securing process (stacking, strapping, tying down)
does not damage or deform them.
Care must be taken during unloading such that release and removal of load restraints does not allow the materials to
fall out of their containment or Stillages fall off the transport.

21 Storage

Materials are to be stored in Stillages and on Pallets as appropriate and in a manner that prevents damage.
Avoid injury and damage to materials by taking care when releasing strapping such that materials do not fall out of
their containment.
Components must not be stacked higher than the top of the Stillage to enable proper stacking.
AF&S Stillages (tubular or enclosed) must not be stacked more than FIVE high.

22 Maintenance

Acrow Formwork & Scaffolding Branches have in place a quality system, which includes inspection and maintenance
procedures in accordance with the AF&S Inspection and Maintenance Manual to ensure all scaffolding returned from
hire is inspected prior to being returned to stock. Any damaged or non-conforming components are removed and
isolated for repair or scrapped where appropriate.
Maintenance of Acrow Formwork & Scaffolding equipment is only to be carried out by
Acrow Formwork & Scaffolding and its authorised repairers.

(a) Use CUPLOK Steel Planks wherever possible.

(b) Timber scaffold planks may be used if intermediate putlogs are attached to CUPLOK Ledgers on either side
of the Standards to provide adequate support within plank span limit requirements. Timber planks must be
provided with intermediate supports between CUPLOK Transoms.

23 Working Platform Duty Loading

Duty Live Loads for Working Platforms are typically dependent on Platform Width and Length as specified in
AS/NZS1576.1. For Cuplok Scaffolding Duty Live Loads are shown on page 9 of this brochure and are for platforms
lengths of up to 3m.
Where design loads exceed Duty Live Loads specified herein or greater that two working platform levels is required
then consult with AF&S Engineering for design guidance.

24 Number of Working Platforms

The maximum number of Working Platform levels within a bay is two. A bay is typically "the enclosed spaced
between four standards" and this space extends from ground to top working platform for the full height of scaffold.
Where greater than two working platform levels or greater than two levels of planks is required, consult with AF&S
Engineering for design guidance.

24

Whilst Cuplok has been previously approved for a maximum height of 45m, where the scaffold exceeds 30m height
from ground or base support to top of scaffold, consult AF&S Engineering for design advice.
Maximum height applies to scaffold without cladding (sheeting, shadecloth and the like). Where such cladding is required
to be attached to the scaffold then consult with AF&S Engineering for design guidance.

Consultation with AF&S Engineering should done during design of the scaffold,
prior to erecting the scaffold.

Do not hesitate to contact our Branch outlets

for assistance with supply of scaffolding equipment and associated services.

Adjustable Bases when fully extended shall have a minimum engagement of 150mm length of the spindle remaining
inside the Standard tube. In any case, the maximum extension from the baseplate to the bottom of the Standard
shall not exceed 450mm.

Connections between components should be firmly secured.

All scaffolding and accessories shall be installed in accordance with the recommendations of Acrow Formwork &
Scaffolding Pty Ltd

Important! Always ensure that any joints in standards are below the last transom position.
Under no circumstances are guardrails to be attached to a standard cantilevering from a joint above the
platform level.

25 Maximum Height

25

When a scaffold has been completely erected it must be fully inspected by a qualified Scaffolder and a handover
Certificate issued to the user verifying the scaffold is complete and safe to use.
See your local Acrow Formwork & Scaffolding Branch for further details.

Note:

The term ENGINEER referred to herein is in accordance with the definition of a person qualified for corporate
membership of the Institute of Engineers, Australia, and with experience in the area of Scaffolding.
The term COMPETENT PERSON referred to herein refers to a person who has been adequately trained, has a number of
years practical experience in the Scaffolding construction industry and is capable of interpreting and applying the design
requirements as specified in the Scaffolding documentation.

Alteration of an Existing Scaffold by Unqualified Personnel

is a Safety Hazard and must not be undertaken.

Updated October 2011

Formwork
Scaffolding
Industrial & Mining Scaffolding

Contact
Phone: 1300 138 362
or contact your business
development manager.
www.acrow.com.au