Cuplok Manual 20 - Draft06 - Web18

CUPLOK Scaffolding System
Boral Formwork & Scaffolding

ACROW CYCLONE
Issue 2 Nov 2007
CUPLOK Functional design with simplicity of connection
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:

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.
CUPLOK Easy to erect

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
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
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
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 Boral 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
The product codes are shown on pages 3 to 8.
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
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 Boral 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, Boral 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 Boral Formwork & Scaffolding outlet.
General Technical and Application Manual

Product
Description

Product
Code
Mass
kg
80 500
500
500
500
500
420 150
CUPLOK Spigotted Standards
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
high-quality 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
CS05
CS10
CS15
CS20
CS25
CS30
3.5
7.4
10.5
13.6
16.7
19.9
CSOE08
CSOE13
CSOE18
CSOE23
CSOE28
5.8
8.8
11.9
15.0
18.2
CT031
CT061
CT083
CT10
CT13
CT18
CT24
2.6
5.0
6.6
7.9
9.7
13.7
22.4
80
500
500
500
500
500
220
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 Transoms
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

Product
Description

Product
Code
Mass
kg
CUPLOK Ledgers
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.
gth
en
eL
ac
Height
Br
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
1.2
1.6
2.6
3.4
4.2
4.8
5.5
6.9
9.1
11.5
CB16
CB17
CB18
CB20
CB24
CB27
CB30
CB32
CB35
CB37
6.8
7.2
7.8
8.2
9.9
10.9
11.4
12.5
13.7
13.9
CHUB1
CHUB2
CHUB3
2.3
7.8
8.3
CUPLOK Diagonal Braces

Bay Length
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
1.83 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
1P
lan
2P
lan
3P
lan
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 2.37m
CUPLOK Brace 2.71m
CUPLOK Brace 2.86m
CUPLOK Brace 3.16m
CUPLOK Brace 3.49m
CUPLOK Brace 3.65m
CUPLOK Platform Brackets
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

Product
Description

Product
Code
Mass
kg
CUPLOK Tie Bars
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 Tie Bar 0.61m
CTB06
CTB08
CTB105
CTB13
CTB18
CTB24
CTB30
1.8
2.4
3.0
3.7
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
CUPLOK Transom Beam
Transom Beams are designed for special duty load

applications. Allows high deck capacity and large
grid patterns.
CUPLOK Transom Beam 1.83m
CUPLOK Transom Beam 2.44m
CUPLOK Transom Truss
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 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
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

Product
Description

Product
Code
Mass
kg
Adjustable Base
Adjustment range
50mm to 450mm
The Adjustable Base is a generic BF&S product

which is used with all scaffold systems and some
BF&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.
Adjustable Base (Solid) Form/Scaf
18
0
ABSFS
7.1
AUHSFS
11.1
CFGB
10.7
CFGT
5.9
CDA
1.7
180
8mm plate
Adjustable U-Head
83
20
23
Adjustment range
50mm to 450mm
Holes
for nailng
The Adjustable U-Head is a generic BF&S

product which is used with scaffold systems and
BF&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 into the
Standard of 150mm.
The U-Head is capable of accepting twin 100mm
wide bearers.
Adjustable U-Head (Solid) Form/Scaf
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 BF&S Engineering
Department for load capacity details.
CUPLOK Fan Guard Bearer
CUPLOK Fan Guard Tie

m
1.8
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
CUPLOK Deck Adaptor
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

Product
Description

Product
Code
Mass
kg
CUPLOK Steel Planks
61
221
Typical Plank Section
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.
Cuplok Steel Planks 0.83m Bay
SPC083
SPC105
SPC13
SPC18
SPC24
SPC30
5.0
7.2
8.5
11.5
15.5
19.5
CSS
31.5
CST15
26.0
CSB
3.5
CPSTH
15.0
CSST
11.3
CUPLOK Stair Stringer
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.
CUPLOK Stair Stringer 2m rise x 2.4m go
CUPLOK Aluminium Stair

Holes
provided
for
attachment
of handrail
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 Aluminium Stair 1.5m
CUPLOK Step Bracket -1 Plank
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.
CUPLOK Step Bracket - 1 Plank
CUPLOK Aluminium Stair Handrail
The Stair Handrail follows the slope of the

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

Product
Description

Product
Code
Mass
kg
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
CCB1
CCB2
CCB21R
CCB21L
5.0
11.5
9.5
9.5
TBC
0.8
CRTB061
CRTB083
CRTB105
CRTB13
CRTB18
CRTB24
4.2
5.2
6.3
7.3
9.9
15.0
CC200
4.5
CUPLOK Corner Brackets
Corner Brackets are designed to fill the gap left

where two runs of Platform Brackets intersect on
an internal corner of the building. The Brackets
attach to the corner Standard and are connected
to adjacent Platform Bracket by Tie Bars.
(See page 23)
CUPLOK Corner Bracket 1 Plank
CUPLOK Corner Bracket 2 Plank
CUPLOK Corner Bracket 2 x 1 Plank - Right
CUPLOK Corner Bracket 2 x 1 Plank - Left
Toe Board Clamp
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.
Toe Board Clamp
CUPLOK Return Toeboards
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 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

CUPLOK Transoms
W**
P**
Cross Section of Transoms

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

L (m)
2.44m Transom
Bottom web fin
W (kN)**
P (kN)**
0.61
Light (2.2kN UDL)
1.0
0.83
Light (2.2kN UDL)
1.0
1.05
Heavy (6.6kN UDL)
2.0
1.27
Heavy (6.6kN UDL)
2.0
1.83
Medium (4.4kN UDL)
1.5
2.44
Medium (4.4kN UDL)
1.5
** Note:
Loads W and P shown are not simultaneous loads. Refer AS1576.1, Clause 2.4.3.2
The Transom Working Load Limits shown in the table above are governed by the Operational requirements of
AS1576.1 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 BF&S Engineering department for design advice.
CUPLOK Transom Beams and Transom Trusses

For load ratings and applications contact the BF&S Engineering Department
Transom Truss
Transom Beam
1.83m & 2.44m

3.05m
Transom
Section
Section
for all
Transom Trusses
2.44m
1.83
Transom Beams and Transom Trusses impose additional loads on the scaffold structure requiring the overall
design of the scaffold to be checked and verified.
P = Working Load Limit for Point Load
W = Working Load Limit for Uniformly Distributed Load
General Notes:
1 Working Load Limits (P & W) may be limited by other components or assemblies.
10
CUPLOK Planks
L (m)
P (kN)
1.27
4.1
1.83
2.8
2.44
2.1
3.05
2.0
221
61
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.
CUPLOK Diagonal Braces
Shear Capacity of Bottom Cup

P=
4.4kN
For all standard sizes
P = 17kN
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 Tread Width
Stair Width
0.59m
1.27m
2.44m
W = 2.5kPa
Total = 7.7kN
P = Working Load Limit for Point Load
2.44m
W = 2.5kPa
Total = 3.6kN
W = Working Load Limit for Uniformly Distributed Load
General Notes:
1 Working Load Limits (P & W) may be limited by other components or assemblies.
11

Formwork Support (Falsework) Applications
General

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 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.
Bracing
CUPLOK
Standard
CUPLOK
Standard
190
Top lift
CUPLOK
Open Ended
Standard
Node
Spigot
Joint
Main lift
Adjustable
U-Head
Main lift
Applied Load < WLL
CUPLOK
Spigotted
Standard
Base lift
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.
110
CUPLOK
Ledger/Transom
Internal Standard
External Standard
Plan View
Adjustable Base
Suitable footing and foundation
12
CUPLOK Standards
Formwork Applications
Maximum Bay Size 1.8 m X 1.3 m
Working Load Limit (kN)
Working Load Limits for internal Standards

CUPLOK 2.0m Lift
30
25
2.0m Lift
20
15
10
0
100
200
300
400
500
Adjustable Base/Adjustable U-Head Extension (mm)
CUPLOK 1.5m Lift
30
1.5m Lift
25
20
1.5m Lift
15
10
0
100
200
300
400
500
CUPLOK 1.0m Lift
40
1.0m Lift
35
1.0m Lift
30
1.0m Lift
25
20
0
100
200
300
400
500

If higher leg loads are required we recommend the use of the BF&S SUPERCUPLOK system
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.
13
CUPLOK Assembly Recommendations

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.
For assistance with these recommendations contact your local Boral Formwork & Scaffolding Branch.
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 Boral 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 Boral 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 Boral Formwork & Scaffolding unless attachment points for
such systems are approved by Boral Formwork & Scaffolding Engineers.
Compliance to Statutory Regulations
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:
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.
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 Boral Formwork &
Scaffolding Branches. Site specific Hazard Identification and Risk assessments and Recommended Work
Methods Statements would need to be generated for specific projects.
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.
Simple Method of Component Connection
Locking Bar
Top Cup
Bottom Cup
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.
14
CUPLOK Assembly Recommendations (cont)

1 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 erected on adequate soleplates
and the foundation on which the soleplates are placed must
have sufficient bearing capacity to support the imposed 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 masonry blocks are not suitable and must
not be used. Refer Figure 1.
Figure 1
2 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 platform brackets and increase the distance
between the workface and the closest adjacent Standard to
the workface.
Start here at top

Figure 2
3 Commence erection - where possible - on the highest point of

the ground and work down the incline - this will make levelling
easier as the scaffolding progresses.
Set the nut on the first Adjustable Bases to close to the bottom
of the stem to allow maximum adjustment as the scaffold
progresses to lower levels. 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.
4 Lay out the Adjustable Bases, Ledgers and Transoms for
the first bay in their approximate positions. Then insert an
Adjustable Base into each of the first pair of Standards and
position Adjustable Bases onto the soleplates. Refer Figure 3
5 Connect the Standards with a Transom in the lowest cup joint,
by inserting the blades into the bottom cups. Approximately
level the transom by raising 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.
Figure 3
Inside
2m
Outside
3m
Figure 4
6 With one erector still holding the first pair of Standards,

the second erector inserts an Adjustable Base into the third
Standard and connects it to the 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
Standard can now be connected by a further Ledger and
Transom and the bay levelled. Refer Figure 5.
7 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.
Do not tighten top cups - yet.
Figure 5
Figure 6
Level both ways
15

8 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.

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

process, then recheck the levels. Refer Figure 8.
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.
The first bay of CUPLOK is completed by locating the upper Ledgers

and Transoms.
Top cups can now be tightened in this first bay.

No need for heavy hammering.
Figure 7
9 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.
10 The Working Platform can now be constructed
using Scaffold Planks as decking and toeboards.
Refer Figure 9.
Planks are supported by the flanges of
Face of
Transomes and Toeboards are attached to
building
Standards using Toeboard clamps.
/structure
11 Now complete the base layout by adding
bays 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.
Note:
Erection and dismantling of scaffold 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.
Figure 8
Inside
Outside
Figure 9
The height of the

Standards has
been reduced in
the diagram
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 midrail on the outer face. For working platforms, toeboards on the outer face are also required.
A Mesh Panel which incorporates a toeboard 1m high can be used in lieu of a midrail and toeboard.
Figure 11
Figure 12
16

13 Additional lifts can now be constructed by adding further Standards into spigots of the Standards of the lower
lift and staggering joints wherever possible. Transoms and Ledgers are placed at platform levels.
Refer Figure 13.

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

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.
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.
2.0m
max Lift height (typical)
Figure 14
Typical 'Zig Zag'

Longitudinal Bracing
along external face
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

15 TIES
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 BF&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.
Figure 15
Figure 16
Double Lip or U Tie
Figure 17
Box Tie
Column Tie with

Butt transom
Plan View
Note:
Tie Tubes
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 Boral Formwork & Scaffolding
Engineering Representative for assistance.
Warning:
Figure 18
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.
Figure 19
Through Ties should

be placed as close
as possible to the
window reveal and
secured with right
angle couplers.
4.0m max
Tie Level
height of first
4.0m max
between
staggered
Ties
max Lift height (typical)

2.0m
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 Boral Formwork & Scaffolding
Engineering Representative for
assistance with tie spacing for clad
scaffolds.
4.0m max
beyond
tied level
Tie Configuration
3 Bays max (7.32m)

between ties or
from a tied return
Staggered
Tie Points
Figure 20
Staggered
Tie Points
One Bay max between Ties at ends with no returns
Note: When using 3.05m ledgers the max distance between ties is 2 Bays.
18

15 TIES (cont)
Tying to Standards
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.
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
Within
300mm
Add Check
Coupler
Tie
More than
300mm
Tie
Tie
Tie
Connect
to both
Standards
Add Check
Coupler
Add Check
Coupler
Reinforce
Tied Standard
Reinforce
Tied Standard
Joint in Standard
Alternatively
a transom
adjacent to
the joint could
be used
(a)
(b)
Figure 21
(c)
(d)
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 Boral Formwork & Scaffolding Engineering Representative for technical
design assistance with tie spacing and configurations to suit your specific needs.
Maximum Height of Scaffold
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.
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 AS1576.1),
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 scaffold constructed with
bay lengths of 3.05m or less is 45m.
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 Boral
Formwork & Scaffolding Engineering Representative for technical design assistance with the maximum
heights of CUPLOK and tying configurations to suit your specific needs.
19

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 built-in 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:

(i) Ladder Access

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.
Pitch ladders at a horizontal to vertical slope of not less than 1 to 4 or more than 1 to 6.
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 midspan 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.
Important:
Ensure that guarding and edge protection is installed around openings in Ladder Access Bays that are in
or beside working platforms.
Ladders inclined at
slope of between
1 to 4 and 1 to 6
Ladder Access
2.44m
1.3m Planks x 2
Standard
Install guarding
& edge protection
around opening
0.9 m min
1.27m
Ladder secured
to alternate
each side of Bay
1.3m Transoms
1.27m
Ladder Access Transom
secured between Ledgers
2.4m Planks x 3
2.4m Ledgers
3.2m Braces
Tie Ladder
Access Bay
at Standards
every 4.0m max
4.0m max
6.0m max
Ladder Access Bay

Plan View
Figure 22
Denotes Transom/Ledger
positions
1.27m
End View
2.44m
Elevation
20

16 Access and Egress Methods (cont)
(ii) CUPLOK Stair Access Systems

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:
Tie Stair Bay

1.8m Ledgers
at Standards
every 4.0m max
Trimming
Standard
between
Ledgers
0.6m
Aluminium Stair
Units supported
on Transoms
1.27m
Stair Handrail
bolted to stairs
2.4m Ledgers
2.44m
Plan View
Tie Stair
Bay at
Standards
every
4.0 max.
Access/Egress
Point
Stair Handrail
Access/Egress
Point
Standards
1.3m Ledgers
Trimming
Standard
between
Ledgers
2.0m Rise/Lift
Denotes Transom/Ledger
1.8m Ledgers
positions
1.5m Rise/Lift
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
Access/Egress
Point
3.2m Braces
Figure 23
1.27m
2.44m
21

16 Access and Egress Methods (cont)
(b) CUPLOK Stair Stringers
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 Boral 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 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 less that 4.0m vertical intervals.
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
Elevation
Denotes
Transom/Ledger
positions
Figure 24
1.27m
End View
1.3m Transom at
2.0m Lifts (Landings)
Access/Egress
Point
1.27m
1.3m Planks
for Stair Treads
secured to Stringers
2.44m
1.27m
1.27m
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
2.0m Stair Stringers

(Two per Bay within
150mm of Standards)
Stair Stringer Bay

12 Standard configeration
Plan View
Figure 25
Standards Typical
1.3m Planks at Landings
1.27m
2.44m
1.27m
End View
1.27m
1.27m
3.2m Braces
as Handrails
at 0.5m centres
1.27m
Tie Stair
Bay at
Standards
every
4.0m
2.0m Lifts
1.27m
Entrance to Stairs
(typical)
22

17 Platform ('Hop Up') Brackets
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.
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.
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
2.44m Bay
0.61m
Bay
2.44m
1 plank
platform bracket
0.61m
2 plank
platform bracket
Cuplok Tie Bar

interconnecting
Platform or
Corner Brackets
(typical)
1.83m Bay
1.83m
3 planks
plus toeboard
0.83m Bay
0.83m
Workface
3 plank
platform bracket
4 planks
plus toeboard
1.27m Bay
1.05m Bay
1.27m
Less than
225mm (typical)
Figure 26
1.05m
23

18 Configurations of Corner Brackets

Figure 27 below shows plan view of the various sizes of Corner Brackets. Tie bars, which are used to
interconnect Platform Brackets, are also used to interconnect ends of Corner Brackets to each other or to
adjacent Platform Brackets. In the diagrams below, Tie bars and planks are not shown for clarity.
Corner brackets
interconnected with
Tie bars (typical)
CCB2
Planks span between

Corner Brackets
(typical)
CCB2
CCB1
CCB1
1 x 1 Plank
Corner Brackets
2 x 2 Plank
Corner Brackets
CCB2
CCB2
CCB1
CCB1
CCB21L
CCB21R
2 x 1 Plank - Left
2 x 1 Plank - Right
Corner Brackets
Corner Brackets
CCB21R
CCB21L
Figure 27
24

19 Dismantling
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 evel.
Localised overloading by stacking of dismantled equipment on partially dismantled scaffold must be avoided.
Stack materials neatly in the appropriate stillages or on pallets.
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.
BF&S Stillages (tubular or enclosed) must not be stacked more than FIVE high.
22 Maintenance
Boral Formwork & Scaffolding Branches have in place a quality system, which includes inspection and
maintenance procedures in accordance with the BF&S Inspection and Maintenance Manual to ensure
all scaffolding returned from hire is inspected prior to being returned to stock. Any damaged or nonconforming components are removed and isolated for repair or scrapped where appropriate.
Maintenance of Boral Formwork & Scaffolding equipment is only to be carried out by
Boral Formwork & Scaffolding and its authorised repairers.
23 Working Platform Duty Loading
Duty Live Loads for Working Platforms are typically dependent on Platform Width and Length as
specified in AS1576.1. 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 BF&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 BF&S Engineering for design guidance.
25 Maximum Height
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 BF&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 BF&S Engineering for design guidance.
Consultation with BF&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.
25

26 Scaffold Safety Rules
The following are some common sense rules designed to promote safety in the use of scaffolding. These
rules do 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 Boral 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 Boral 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

(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.
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 Boral
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.
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 Boral 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.
Boral Formwork & Scaffolding

ACROW CYCLONE
BORAL FORMWORK & SCAFFOLDING PTY LTD

ACN 004 284 806
ABN 35 004 284 806
National Head Office:
2A Mavis Street
Revesby NSW 2212
Telephone: (02) 9780 6555
Facsimile: (02) 9780 6444
Email: [email protected]
Web: www.boral.com.au
Your local contact from our national network of branches

NEW SOUTH WALES
SYDNEY (REVESBY)
Scaffolding
Telephone (02) 9780 6577
Facsimile (02) 9780 6499
SYDNEY (REVESBY)
Formwork
Telephone (02) 9780 6411
Facsimile (02) 9780 6463
NEWCASTLE
Telephone (02) 4961 4315
Facsimile (02) 4961 5582
GOSFORD
Telephone (02) 4324 9929
Facsimile (02) 4324 9512
PORT MACQUARIE
Telephone (02) 6581 0366
Facsimile (02) 6581 2488
TAMWORTH
Telephone (02) 6765 7474
Facsimile (02) 6762 0208
WOLLONGONG
Telephone (02) 4271 3688
Facsimile (02) 4271 3622
CANBERRA ACT
CANBERRA
Telephone (02) 6260 2558
Facsimile (02) 6260 2559
VICTORIA
MELBOURNE (Sunshine)
Scaffolding
Telephone (03) 8311 5100
Facsimile (03) 9310 2977
MELBOURNE (Sunshine)
Formwork
Telephone (03) 8311 5100
Facsimile (03) 8311 5131
TRARALGON
Telephone (03) 5174 5616
Facsimile (03) 5174 8522
TASMANIA
HOBART
Telephone (03) 6272 6775
Facsimile (03) 6272 3647
LAUNCESTON
Telephone (03) 6334 5484
Facsimile (03) 6334 5494
QUEENSLAND
SOUTH AUSTRALIA
BRISBANE
Scaffolding
Telephone (07) 3265 4703
Facsimile (07) 3265 4896
ADELAIDE
Telephone (08) 8359 1033
Facsimile (08) 8359 1366
BRISBANE
Formwork
Telephone (07) 3265 2266
Facsimile (07) 3865 0277
CAIRNS
Telephone (07) 4035 4886
Facsimile (07) 4035 4870
GLADSTONE
Telephone (07) 4972 3685
Facsimile (07) 4972 7903
GOLD COAST
Telephone (07) 5593 5850
Facsimile (07) 5593 4203
MACKAY
Telephone (07) 4952 2204
Facsimile (07) 4952 2938
MAROOCHYDORE
Telephone (07) 5445 3233
Facsimile (07) 5445 3099
NORTHERN TERRITORY
DARWIN
Telephone (08) 8984 4414
Facsimile (08) 8984 4060
WESTERN AUSTRALIA
PERTH (Bassendean)
Scaffolding
Telephone (08) 9373 7200
Facsimile (08) 9378 2376
PERTH (Bassendean)
Formwork
Telephone (08) 9373 7200
Facsimile (08) 9379 3488
KARRATHA
Telephone (08) 9144 1010
Facsimile (08) 9144 1709
TOOWOOMBA
Telephone (07) 4632 1536
Facsimile (07) 4639 3764
TOWNSVILLE
Telephone (07) 4779 3255
Facsimile (07) 4725 1119
Broch 028 Nov07

eBC 02602 Nov07

Cuplok Manual 20 - Draft06 - Web18

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CUPLOK Scaffolding System

Boral Formwork & Scaffolding

Issue 2 Nov 2007

CUPLOK Scaffolding System

CUPLOK Functional design with simplicity of connection

CUPLOK Easy to erect

CUPLOK Versatile in use

It is suitable for access or formwork support with an extensive range of special

CUPLOK Proven design with safety accessories

The product codes are shown on pages 3 to 8.

General Technical and Application Manual

CUPLOK Spigotted Standards

CUPLOK spigotted Standards are principally used in

CUPLOK Open Ended Standards

CUPLOK open ended Standards are principally

Transoms are fabricated from twin structural angles

CUPLOK Scaffolding System

The Ledgers are manufactured from 48.3 mm

CUPLOK Ledger 0.22m

CUPLOK Diagonal Braces

Diagonal Braces are made from 48.3mm dia tube

CUPLOK Platform Brackets

Platform Brackets enable 1, 2 or 3 plank wide

General Technical and Application Manual

CUPLOK Tie Bars

Tie bars are used to interlock the ends of

CUPLOK Transom Beam

Transom Beams are designed for special duty load

CUPLOK Transom Truss

The Transom Truss is designed for high capacity

CUPLOK Return Transom

The Return Transom is used at the end of a

CUPLOK Ladder Access Transom

The Ladder Access Transom is used to provide

CUPLOK Scaffolding System

The Adjustable Base is a generic BF&S product

The Adjustable U-Head is a generic BF&S

CUPLOK Fan Guard Bearer

Fan Guard Bearer is used to provide an angled

CUPLOK Fan Guard Tie

Fan Guard Tie is used to support the end of the

CUPLOK Deck Adaptor

The Deck Adaptor is attached to the top Standard

General Technical and Application Manual

CUPLOK Steel Planks

Typical Plank Section

Planks to suit CUPLOK are formed from

CUPLOK Stair Stringer

The Stair Stringer is a steel frame used in pairs in

CUPLOK Aluminium Stair

The Aluminium Stair enables a stairway to be

CUPLOK Step Bracket -1 Plank

The Step Bracket enables a step down of 0.25m

CUPLOK Aluminium Stair Handrail

The Stair Handrail follows the slope of the

CUPLOK Stairway Trimming Standard

The Stairway Trimming Standard is used in

CUPLOK Scaffolding System

Mesh Panels are hung from the guardrail to