for HACA stationary fixed two rail ladders with / without safety cage

Transcription

1 Instructions for assembly and use for HACA stationary fixed two rail ladders with / without safety cage Please read before assembly! Caution: incorrect assembly can lead to a risk of death! Please contact our head office in Bad Camberg if you have any queries regarding assembly. 1. General information under consideration of regulations English 1.1 Fixed ladders must be securely attached to the building. The foundation must be sufficiently stable. Proof of this and of correct assembly must be provided separately for each building project and must be checked and approved by an expert for structural stability. The anchor bolt extraction forces can be seen in Tables 5 and 6. The statics calculations for the individual components are available on request. We recommend involving the responsible authorities at the earliest possible stage when planning fixed ladders. 1.2 Planning aid The planning aid (Table 1) provides guidance and help when designing the ladder with/without safety cage under consideration of standards. The manhole standard EN is included in the planning aid, but is described in more detail in the separate assembly instructions MA Labelling An identification plate (Fig. 2) must be attached and legibly filled out on every access level of fixed ladders with fall protection that can be reached without this fall protection system. If the ladder has been designed in accordance with DIN 18799, the class according to which the ladder has been designed must additionally be made clear. The user (A, B, C) can then see whether he is permitted to use the ladder before climbing it. This is achieved using the identification plate (Fig. 3). The plate must be labelled in the national language. Identification plates may be applied as adhesive film or can be screwed on. Fig. 1: Multi-section ladder with safety cage acc. to DIN and DIN Fig. 2: Example of identification plate Fig. 3: Example of identification plate acc. to DIN Stand 08/2017

2 On a recovery platform there is space for more than 1 person. A recovery platform is required if there is more than 1 person on the ladder. 2

3 1.4 Examples of designs 100 Exit platform English Fig. 4: Single section ladder without safety cage with transition piece acc. to DIN / EN ISO Fig. 5: Single section ladder with safety cage, drop > 5 m < 10 m DIN Safety cage Pivoting entry aid Ladder hook Model Platform grating Intermediate platform Model Folding rest platforms; spacing: see planning aid Fall protection Model Waiting platform Safety cage Fig. 6: Single section ladder with Fig. 6a: Single section ladder fall arrest rail, drop > 5 m on double T-girder with wall DIN mounting, Model Fig. 7: Multi-section ladder with platforms acc. to and Model and DIN

4 2. Assembly 2.1 General information Start from the top when dividing the ladder, so that the top rung is level with the exit level and under no circumstances lies above the exit level. Assembly of the ladder can start from the bottom, but should be conducted from the exit level to avoid subsequent differences in level. The shorter, retracted end of the rail should be at the bottom (Fig. 12). (Fig. 13) should be followed where there are staggered sections of ladder or where platforms are mounted. The various long standard ladder parts can be assembled in any order. Basic ladder parts have the following standard sizes: 4, 7, 10, 13 (see Fig. 12 for working lengths). The distance (GD) from the top edge of the bottom rung to the ground depends on the standard according to which the ladder is assembled (Fig. 14). Intersections should generally be coated with zinc thick film coating Type It is important to ensure an even rung spacing of 280 mm at the transition point from one ladder section to another. We recommend inserting two spacers between the last and first rung when combining the individual ladders so that rungs are 280 mm apart. This guarantees the precise rung spacing and the required air gap between the separate ladder elements. The purpose of this air gap is to compensate for length when the material expands due to temperature fluctuations. Edge of building Fig. 8: Ladder hook with short side piece Edge of building Fig. 9: Ladder hook with long side pieces Ladder hook with short side pieces max.185 Ladder hook with long side pieces max. 472,5 2.2 Transition pieces LW 500 Transition pieces are available in sizes 4,5,6,7,10 and 13. Ladder They are assembled in the same grid dimension as the standard ladder elements (Fig. 12). The assembly of the transition pieces guarantees the Edge of building clear 500 mm exit opening required under DIN and EN ISO (Fig. 10). According to these standards, the last rung must be at the same height as the edge of the building. The Size 4 ladder section adapter has always to be attached with at least two pairs of wall mounts. If ladder hooks with long side pieces are used (Model ), the first must be no more than mm below the building edge (Fig. 9). When using ladder hooks with short side pieces, (Model ), the first s may be Fig. 10: Ladder exit acc. to DIN Table 2: Attachment points of size 4 ladder section Ladder hook used Max. distance of top Distance to the second wall mount from from the building edge top to the top of the building edge 01/ (long) max. 472,5 mm Flush above 1st rung trans. piece 01/ (short) max. 185 mm Flush above 1st rung trans. piece

5 Ladder spacing See table Last rung flush with the building edge 1200 max.185 Size (working length) 4 ( 1120 mm), 5 ( 1400 mm), 6 ( 1680 mm), 7 ( 1960 mm), 10( 2800mm), 13 ( 3640 mm) Rung at same height English Fig. 11: Side view of ladder hook 280 Fig. 12: Working lengths Detail A mounted up to 185 mm below the building edge (Fig. 8). The bottom two s must be flush with the first rung of the transition piece (Fig. 8, 9). Refer also to Table Wall s in general (Fig ) The s must be clamped directly under the rungs at a max. distance of 1.96 to the rail of the ladder. The angled ends of the can face inwards or outwards. There are fixed and adjustable s. With adjustable s, the desired distance to the wall must be set (see Tab. 5, 6 for the adjustment range). Here the wall mounting parts must be joined to the ladder connection parts using the two M10 screwed joints. The bottom s may be mounted at a max. distance of 750 mm from the exit level. The bottom ladder section must be secured at least twice and every further section at least once. Alternatively, the bottom ladder section can be secured using a and a pair of base plates. If this is the case, the wall must be mounted at a distance of 1.96 m to the ground (attachment point of the base plates). The top s may be mounted a max. of 185 mm from the top edge of the building if subsequent accessories are mounted (Point ). For static reasons it is necessary to attach the ladder to the ground by base plates in case of using wall fastenings , , and Alternatively a wall mount , , or can be assembled as bottom. If ladder hooks shall be applied, a top has to be mounted as well. Please observe the possible combinations. A Transition point Fig. 13: Distances ladder/platform Exit platform Fig. 14: Mounting distances Ladder spacing Ladder with safety cage and platform grating 760 mm 1000 x 1300 to platform centre 880 mm 1000 x 1000 to platform centre 880 mm 800 x 800 to platform centre 780 mm 600 x 800 to platform centre 680 mm 500 x 1300 to platform centre 630 mm 500 x 1000 to platform centre 630 mm Platform walkway at least 760 mm Standard Wall Shorten here if necessary GD (Ground distance) Exit platform DIN mm 380 mm No DIN mm 380 mm Yes EN ISO mm Yes 5

6 2.3.1 Wall for ladders with/without safety cage The top s may be mounted a max. 750 mm from the top edge of the building if no subsequent accessories are mounted (Point ) Wall for ladders with fall protection The top s may be mounted a max. of 500 mm from the top edge of the building if no subsequent accessories are mounted (Point ). The bottom must be fitted with tie bars or a reinforced wall fastening (Fig.15) if the ladder does not rest on the floor or no base plates are mounted. At least 4 pairs of wall s must be mounted on ladders with fall protection. 2.4 Assembly of the wall s, e.g. concrete wall, grade > B25 < B55 The ladder and the preassembled s should be posiioned in the intended place. Holes in the wall should be drilled through the slotted holes of the. It is essential to heed the assembly instructions of the anchor bolt manufacturer. Table 3: Anchor bolt requirement for the wall Fig. 15: Wall mounting reinforced by a pair of tie bars and wall Anchor base Hole connection Hole connection Per wall (Fig. 16 and 18) (Fig. 19 to 20) (Fig. 17) Concrete B 25 B 55 1 or 2 units 4 units 2 units masonry 1 or 2 units 4 units Not applicable Ladder mount - ing screws Fig. 16 Fig. 17 Ladder mounting screws Rail 48.3 galv. steel DIN 603 M 10 x 80 Rail 37.7 galv. steel DIN 603 M 10 x 65 Rail 48 aluminium and VA stainless steel DIN 931 M 10 x 80 Fig. 18 Fig. 19 6

7 Fig. 20 English Fig. 21 Fig. 22 Table 4: Distances between holes (in mm) for wall s Ladder Rail Ø B L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 model , , , , , , , , , , , ,5,6,7er * 48,3 450/ / / / / / / / / / / / /377 4,5,6,7er * 33,7 434/ / / / / / / / / / / / /343 * With assembly of the 4 transition pieces for the ladder hook with long side pieces, the top s are arranged in the incline of the ladder. This distance between holes must be determined on site. 7

8 Distance between holes 110 mm mm mm mm mm mm mm mm optimized for Concrete foundation No. of anchor bolts Rail Ø 48mm Steel Stainless steel Tension [KN] - 0,31 0,23 0,23 0,24 0,23 0,26 Shearing [KN] - 1,30 1,30 1,30 1,30 1,30 1,30 Torque [KNm] - -0,35-0,51-0,51-0,61-0,99-1,20 Rail Ø34mm Steel Stainless steel Tension [KN] 0,27 0,31 0,23 0,23 0,24 0,23 0,26 Shearing [KN] 1,40 1,30 1,30 1,30 1,30 1,30 1,30 Torque [KNm] 0-0,35-0,51-0,51-0,61-0,99-1,20 Distance between holes 200mm Tie bar Tie bar insulation 0-180mm mm mm mm mm mm mm optimized for Masonry foundation No. of anchor bolts Rail Ø48mm Steel Stainless steel Tension [KN] 1,50 1,50 0,31 0,23 0,23 0,24 0,23 0,26 Shearing [KN] 3,20 3,20 1,30 1,30 1,30 1,30 1,30 1,30 Torque [KNm] -0,71-0,71-0,35-0,51-0,51-0,61-0,99-1,20 Rail Ø34mm Steel Stainless steel Tension [KN] 1,50 1,50 0,31 0,23 0,23 0,24 0,23 0,26 Shearing [KN] 3,20 3,20 1,30 1,30 1,30 1,30 1,30 1,30 Torque [KNm] -0,71-0,71-0,35-0,51-0,51-0,61-0,99-1,20 Table 5 8

9 Distance between holes 110 mm Tie bar Tie bar insulation 0-180mm Tie bar Reinforced, wall distance 200 mm Bracket, wall distance 200mm Bracket, wall distance 200mm optimized for Concrete foundation for No. of anchor bolts Rail Ø48mm Steel Stainless steel AL Tension [KN] 1,50 1,50 0,9 1, ,31 Shearing [KN] ,20 3,20 2,60 2,60 1,41 Transverse shearing [KN] ,40 0,40 - Torque [KNm] -0,71-0, Rail Ø34mm Steel Stainless steel Tension [KN] 1,50 1,50 0,9 1,20 1,20 0,31 Shearing [KN] 3,20 3,20 3,20 2,60 2,60 1,41 Transverse shearing [KN] ,40 0,40 - Torque [KNm] -0,71-0, English Anchoring forces of the top mounting point for ladders with transition piece and accessories attached at the top (e.g. ladder hook) Up to a = 200 Up to a = 400 Up to a = 945 Tension [KN] 1,00 0,70 0,90 Transverse shearing [KN] 0,40 0,40 0,40 Shearing [KN] 1,50 1,50 1,50 Torque [KNm] 0 0,40 0,30 Transverse torque [KNm] 0 0,10 0,11 All forces are per wall. All forces are calculated values. All wall mounts can be used on any kind of ground. The assembly material yet has to bear the required loads. 9

10 The slotted hole (16x25mm) of the wall must be covered by a large washer. For a Model stud anchor, HACA provides a Ø35 x Ø13 x min. 4 mm thick washer in stainless steel V4A / ST-tZn. The nut must be tightened to the torque specified by the anchor bolt manufacturer. The holes can also be drilled in advance using a drill template. The distances between holes required can be found in Table 4. Fig. 23: Base plate The tightening torque of the M10 screwed joints on the ladder and are as follows: Steel version 35 Nm Stainless steel version 40 Nm. Fig. 24: Connecting 2.5 Base plates Base plates are required when using extra-long wall s of more than 400 mm, and assembling fall protection as from a wall distance of 200mm. If it is not possible for the ladder to go right down to the ground, a pair of tie rods or a wall fastening can be mounted to the bottom s as reinforcement. The tube on the base plates can be shortened during assembly, thereby enabling the height to be adapted to the ladder. The measurement of the first rung stipulated by the standard must be taken into consideration (Fig )! The base plates must be secured firmly to the ground and may not merely rest on the ground. 2.6 Connecting These are used to connect a section of ladder that does not end at an access level. The connecting is no wall fastening and therefore has no structural load-bearing function. The ladder must be assembled as described under Point 2.3 Wall s. 2.7 Safety cage in general (Fig. 27) Assemble the back guard hoops a max. of 1.5 m apart. The top back guard hoop must be mounted so that the opening points to the platform or to the building edge, presenting no risk of falls (e.g. Fig. 26 & 27). When ladder hooks are used, the back guard hoop must be attached 100 mm below the top edge of the ladder hook (Fig. 5). The vertical back guard tubes must be screwed inside the back guard hoops at the pre-punched points using the U-bolts and M8 nuts (Fig.27). The nuts should always be on the outside because of the risk of injury. Where necessary, the back guard tubes are delivered in partial lengths and must be joined together using the connectors supplied. The height of the joints is vertically offset, i.e. the joints must be arranged between different back guard hoops. They must not lie between the two bottom and the two top back guard hoops. For safety reasons, back guard tubes must finish flush with the top and bot- Fig.25: Safety cage assembly Fig. 26: Safety cage with a transfer platform acc. to EN ISO 141 Fig. 27: Safety cage with a transfer platform acc. to DIN ,1m 5 4 1,60m 1,68m 7 1,1m 2,2m to 3m 2,2m to 2,3m

11 tom back guard hoop and shortened where necessary. The top open tube ends must be closed with plastic caps. The bottom ends should be left open to prevent water collecting in the tube. All intersections must be coated with zinc thick film coating Type to prevent corrosion. Important: At least 3 back guard hoops must always be installed irrespective of the length of the safety cage. 2nd rung 2.8 Safety cage with exit on the side or transfer point For side exits or transfer points along the ladder, space for 1st rung a back guard tube must created in the area of the exit or Fig. 28: Platform grating for safety cage Model transfer point. For side exit, a Model platform grating is needed, while for the transfer point a Model transfer platform is required when moving to a different section of the ladder. With a side exit, guards are to be mounted that close the gap between the safety cage and the railing (Fig. 29, 30/ 8 Pos 2). These supports must be adapted for mounting and holes drilled. At the exit points to the next adjacent platform or ladder section on the right or left, an opening must be made for the inner back guard connecting tubes up to the lower edge of the back guard hoop positioned at 5 least 2.2 m and at most 2.3 m above the platform (Fig. 29 / 2 Pos.8). The back guard connecting tubes are screwed directly to the platform grating using the U-bolt 2 4 (Fig.30/Pos.10) and nuts. With multi-section ladders, the safety cage must be joined together at the transfer point (Fig.26, 29/Pos.2). For this, 1 3/4 back guard hoops of individual ladder sections are secured to each other using a Model connecting plate and M8 screwed Fig. 29 Bottom end acc. to DIN 14122, DIN joints. 2,2 m to 2,3 m English Fig. 29a Fig. 30 Bottom end acc. to DIN

12 2.8.1 Safety cage acc. to EN ISO 14122, DIN Bottom end (Fig.29) At the start of a section of ladder with side access, the railing must be continued. For this, 2 x 3/4 back guard hoops must be assembled at knee level (Pos.4) and at the height of the hand rail (Pos.5). The first complete back guard hoop (Pos.8) must be assembled with sufficient headroom and must be at least 2.2 and a max. 3 m above the platform grating (Pos.1). Transfer platform (Fig.26) The bottom safety cage must be stabilised using a complete back guard hoop at the height of the transfer platform (Pos.7). The last back guard hoop is a 3/4 hoop and must be assembled at least 1.6m above the transfer platform (Pos.1). A further 3/4 back guard hoop is positioned between the two. Two 3/4 back guard hoops must likewise be assembled in the following ladder section at the height of the two 3/4 back guard hoops (Pos.4, 5) and joined using the connecting plate (Fig.26/Pos.2). The first complete back guard hoop in the following ladder section (Pos.8) must be assembled with sufficient headroom and must be at least 2.2 and max. 2.3 m above the transfer platform (Pos.1). The top edge of the last rung of the next ladder section may only end 1.68 m (6 rungs) above the transfer platform Safety cage acc. to DIN Bottom end (Fig.30) At the start of a section of ladder with side access, the hand rail on the railing must be continued. For this, a 3/4 back guard hoop must be assembled at the height of the hand rail (Pos.4) and joined using the connecting plate (Fig.27/Pos.2). The first complete back guard hoop (Pos.8) must be assembled with sufficient headroom and must be at least 2.2 and max. 3 m above the platform grating (Pos.1). Transfer platform (Fig.27) The bottom safety cage must be stabilised using a complete back guard hoop at the height of the transfer platform (Pos.7). The last back guard hoop is a 3/4 hoop and must be assembled at least 1.1m above the transfer platform (Pos.1). A 3/4 back guard hoop must likewise be assembled in the following ladder section at the height of the 3/4 back guard hoop (Pos.5). The first complete back guard hoop in the following ladder section (Pos.8) must be assembled with sufficient headroom and must be at least 2.2 and max. 3 m above the transfer platform (Pos.1). The top edge of the last rung of the next ladder section may only end 1.12 m (4 rungs) above the transfer platform Aluminium safety cage (Model 6290) (Fig.29a) In the case of an aluminium safety cage, a Model reinforcement set must be mounted to the bottom back guard hoop on each ladder section. The reinforcement set is screwed to the back guard hoop using the M8 U-bolt provided and clamped to the ladder using the clamping on the ladder rail Safety cage on large combustion plants acc. to DIN The assembly is conducted as set out under Point The back guard connections or overlaps are arranged on the inside of the back guard hoop. 2.9 Assembly of transfer platform or platform grating (Fig. 28) The bottom end of a section of ladder has a platform grating or transfer platform (Fig.26, 27, 29, 30 / Pos 1). The ladders must be assembled so that the platform grating / the platform (1) is hooked in to the 2nd rung from the bottom. The support is secured one rung lower down. Insert M 10 x 50 mm screws (2) into the holes on the U- shaped rail and screw tight with nuts (3). Place the support (4) with the U-shaped rail over the bottom rung. Press the crossbeam (5) of the support against the underside of the platform grating until the platform grating is lying horizontally. Place retaining plates (6) from above into the mesh of the grating over the slotted holes of the support. Push M 8x45 mm screws (7) through from above and secure with washers and nuts (8) Exit platform Under DIN and EN ISO 14122, an exit platform must be mounted to the last rung. The clear space between building and ladder must not exceed 75 mm. 12

13 3 Anchor bolts Anchor bolt parameters can be found in Table 7. When using different anchor bolts to those recommended by HACA, the specifications of the anchor bolt manufacturer must be heeded! If Model / stud anchors are used, hot dip galvanised or stainless steel V4A washers Ø 35 x Ø 13 x a thickness of least 4 mm are enclosed (Fig. 31). Model stainless steel anchor bolts made of V4A are suitable for damp rooms, outdoor and indoor use (not for indoor swimming pools, road tunnels, seawater environments etc.). Model galvanised anchor bolts are suitable for indoor use (with the exception of damp rooms). The anchor bolts are approved for cracked and noncracked concrete. Requirements for correct assembly in accordance with the anchor bolt approval: Installation must be carried out by appropriately trained personnel and supervised by the construction manager. The components may only be installed as supplied by HACA, without replacing individual parts. The stability of the assembly foundation must be checked. The suitable materials for assembly can then be selected. Take care that the anchor base is not weakened by radiators, hollow areas or similar. In this case the anchoring points must be moved. Alternatively, an engineered support structure can be used. Correct assembly must be checked and approved by a responsible expert for structural stability. The foundation must be checked to ascertain whether there are any significant hollow areas. The drill dust must be removed from the drill hole The effective anchor depth must be complied with. This condition is met if the position mark on the anchor bolt does not protrude beyond the concrete surface. The specified distances of the stud anchors to the edge and axis must be complied, without any minus tolerances. The drill holes must be arranged without damaging the reinforcement. The nuts are to be tightened using a tested torque spanner and tightened to the torque set out in Table 7. A hammer drill»suitable for anchor bolts«must be used. Hard metal hammer drills with the sign should be used. If a mistake is made when drilling a hole, the new hole must drilled at a distance that corresponds to at least twice the depth of the faulty hole. If the distance is less, the faulty hole must be filled with high strength mortar. This also applies where the transverse or diagonal pull does not lie in the direction of the applied load. Obtain written confirmation that the corresponding assembly instructions have been read, understood, and that assembly has conducted accordingly. Stud anchor Fig. 31: Anchor bolt with washer 35 x 13 x 4 Washer 35 x 13 x 4 English Table 7: Anchor bolt parameters for anchor bolt Model and for establishing the connection to HACA anchor bolt units for Model , Model and Model wall s Anchor Anchor Drill hole Drill Torque Component Axis/edge distance 1 ) Axis/edge distance 1 ) bolt bolt depth at rated Nm thickness for cracked concrete for cracked concrete length working least Ø (thickness of at least mm at least mm ca. mm length mm mm anchor base) max. mm at least mm ) NB: The respective combinations of axis/edge distance are decisive. Cracked concrete is standard and includes non-cracked concrete 13

14 4. Accessories 4.1 Platforms and supplementary platforms See MA Retractable ladders Provision to prevent climbing. See MA Climbing guard plate Provision to prevent unauthorised climbing See MA 3700 Fig. 32 Fig. 33 Fig Ladder hook See MA Ladder hook See MA Exit element See MA 5059 Fig. 35 Fig. 36 Fig Crossing element See MA Gate (self-closing) See MA 5076 Fig. 38 Fig

15 4.9 Model folding rest / Model climbing guard (Fig. 38, 39) Rests may only be installed if the safety cage has at least four back guard hoops in this area. The back guard connecting tubes must not be interrupted over this length (approx. 6 m). It then makes no difference which hoop the rest is mounted on. The support is secured from the outside of the back guard hoop to the two neighbouring back guard connecting tubes. English Fig Rest platforms See MA 5101 Fig. 41 Using screws, secure the mounting to the reinforced platform side and place over the intended ladder rung. Secure screws to the inside of the platform with hex nuts Model platform Fig Fall protection equipment Fall arrest rail connector and fall arrest rail See MA 5017 Fig. 43 Fig

16 5. Model 5289, Model 9289, 5284, Model 9284, Model manhole ladders The same assembly principles apply to manhole ladder assembly as to fixed ladders. See MA 5068 for further assembly instructions. General information on manhole ladder assembly 1. Wastewater manholes are classed as potentially explosive atmospheres (Zone 0) 2. Permit to work must be present prior to access 3. Aluminium components must not be installed in the EX area 4. Safety cages in manholes are not permitted 5. At least one holding device must be present for entry and exit 6. Fall protection should preferably be taken into consideration (heed DIN EN 365) Fig. 45 Wall Ø 800 support Ø 600 support Fig Information about the regular inspection of fall protection equipment and guided type fall arresters: According to the German Ordinance on Industrial Health and Safety, the operating company must define the appropriate inspection intervals based on a hazard assessment. We are happy to provide free checklists on request. 7. Standards and regulations DIN Teil 1 DIN EN ISO Part 1, 2, 3 u. 4 DIN Part 1 DIN EN DIN DIN BGI 691 ArbStättV BetrSichV Fixed ladders for construction works- Part 1: Ladders with two uprights; safety requirements and tests Safety of machinery Permanent means of access to machinery Firefighting and fire protection Metal escape ladder installations Fixed ladders for manholes Handholds for entrance into accessible manholes Wind turbines Regulations for equipping step irons and vertical ladders for fall protection systems on chimneys German regulations governing the workplace German Ordinance on Industrial Health and Safety 16