BOTHWELL ALUMINUM PLANK AND DECK SYSTEM USERS MANUAL AND GUIDELINES 2015
TABLE OF CONTENTS 3 Introduction 4 General Use of Product 5 Use of Float Bars 4 Visual Inspection 5 Product List 6 Installing Float Bars 7 Installing Diamond Plate 8 Wind Clips 9 Net Clips 10 Replacing End Connectors 11 Replacing Tac Strip 12 Inserting Spring Pins 13 Modifying Plank Length 2 > TABLE OF CONTENTS
INTRODUCTION The Bothwell Aluminum Plank and Deck system is a new innovative scaffold plank system that is engineered, designed and compatible with most existing scaffolding frames and bracing world wide. This system is designed and developed to eliminate problems and troubles associated with the use of filler boards in the Nuclear and Petro Chem Industries. Utilizing the planks as filler boards uses less labor, eliminates tripping hazards and creates a much safer working environment. When using the Bothwell Plank and Deck System to it s fullest capability you can save up to 30% in labor and 80% of diamond plate. By greatly reducing #9 tie wire, screws and nails, plus reducing the chance of F.M.E. (Foreign Material Exclusion) makes this a safer and more cost effective alternative to the old style filler board solutions. This 21st century system is designed to make your scaffold program safer, smarter and run more efficient. INTRODUCTION > 3
GENERAL USE OF PRODUCT All material must be inspected before use! All Bothwell products have been designed, engineered and developed to be compatible with most existing scaffolding frames and systems including tube and clamp components. All Bothwell products meet or exceed both OSHA and CAL OSHA standards and has a (4:1) safety factor. OSHA requires that inspections must be made by the scaffold builder and end user. Bothwell products are not designed to be loaded in excess of OSHA and ANSI requirements. Bothwell planks are intended to be exclusively for scaffold planks. Other uses may cause damage that will make the planks unsafe for their intended use. Do not overload planks: Refer to span charts for loading capacity. Immediately remove planks that have been overloaded and inspect and evaluate before reuse. Do not throw scaffold planks: Throwing planks from scaffolding may cause damage. A thrown plank must be inspected and evaluated before reuse. Do not use excessive force or stomp on planks when installing. Planks must be the correct span length when installed. When using or handling any or all of Bothwell products all personal MUST wear required PROTECTIVE SAFETY GEAR at all times! All users of Bothwell products MUST follow all common safety guidelines. All end users must review this Users Manual and Guidelines booklet before using any Bothwell products. 4 > GENERAL PRODUCT USE
USE OF FLOAT BARS The scaffold designer and/or user must review the actual live loads and the interaction between the live loads and plank in combination with the recommendations of the Bothwell Seismic Engineering Calculations report. The Float Bars can span from 6 to 18 depending on the width of planks that are being installed. The following illustrations show four combinations utilizing the Float Bars. USE OF FLOAT BARS > 5
VISUAL INSPECTION All Bothwell products must be visually inspected before and after each set up. The most subjectable component of the Bothwell system to sustain damage is the end connectors as planks often get dropped on the ends causing damage. Figure 1 shows an undamaged end connector. Figures 2 & 3 show the left and the right fingers damaged as indicated by the red circles. ALL END CONNECTORS MUST BE VISUALLY INSPECTED BEFOR AND AFTER EACH USE! FIGURE 3 Any end connector that is cracked or broken MUST be removed and replaced. (See page 12) DO NOT USE A PLANK WITH A DAMAGED OR BROKEN END CONNECTOR! 6 > INSPECTION PROCEDURE
A B C A 6 Perforated Plank w/aluminum End Caps (Includes Tac Strips) D E B 6 Perforated Plank w/aluminum Hook Ends (Includes Wind Clips & Tac Strips) C 6 Aluminum End Caps D 6 Aluminum Plank Segments FC G H E F 6 Aluminum End Connector 9 Perforated Plank w/aluminum End Caps (Includes Tac Strips) I J G 9 Perforated Plank w/aluminum Hook Ends (Includes Wind Clips & Tac Strips) H 9 Aluminum End Caps I 9 Aluminum Plank Segments K L J 9 Aluminum End Connector K Aluminum Tack Strips (Blue or Pink) L Two Hook Aluminum Net Clip M N M 6 or 9 Field Jig N Steel Float Bar (Various Sizes) PRODUCT LIST > 7
INSTALLING FLOAT BARS 1 > Place planks on both size of obstacle. (Fig 1) 2 > Using the correct length Float Bar, twist into position. (Fig 2) 3 > Place the correct length Filler Plank into position hooking on the Float Bar first (Fig 3) and then setting plank into position on ledger bar. (Fig 4) FIGURE 3 FIGURE 4 8 > INSTALLING FLOAT BARS
INSTALLING DIAMOND PLATE When Float Bars are not the best solution for decking around piping, interior structures or any other obstacles, Diamond plate or other material may be used and attached to decking. USING SCREWS > 1 self tapping screws are recommended ONLY SCREW INTO TAC STRIP! 1 > Place diamond plate or other material used as filler boards into position to fill gap. (Fig 1) 2 > Using a 1 self tapping screw, screw filler board to Tac Strip on top of plank. (Fig 2) USING ZIP TIES 1 > After pre drilling, place diamond plate or other material used as filler boards into position to fill gap. (Fig 1) 2 > Using nylon zip ties use the water holes in top of plank to attach filler board, top of plank. (Fig 2) INSTALLING DIAMOND PLATE > 9
LOCKING DOWN WIND CLIPS LOCK > Using a flat head screw driver, push completely down and twist until clip is locked into position. (Fig 1,2, 3) FIGURE 3 UNLOCK > Using a flat head screw driver, push completely down and twist until clip releases and reloads into original position. (Fig 4) FIGURE 4 10 > LOCKNG DOWN WIND CLIPS
ATTACHING NET CLIPS & NETTING CLIP 1 > With the hooks pointing down, set Net Clip into position inserting the bottom of clip into bottom plank channel. (Fig 1) 2 > Holding clip in position, (using a small hammer) tap the center of the clip until it pops in. Make sure clip can slide either direction to ensure proper installation. (Fig 2) CLIP SLIDES LEFT & RIGHT NETTING 1 > Zip tie net to upper hand rail or overhead horizontal ledger letting the net hang down below plank. (Fig 1) 2 > Using both hands, stretch net semi tight and hook net on to net clips. (Fig 2) 3 > Make sure net grabs net clip hooks and release, net is installed. Attach netting every 6 inches. ATTACHING NET CLIPS & NETTING > 11
REPLACING END CONNECTORS REMOVING END CONNECTOR 1 > Using both hands as illustrated in (Fig 1,2), push spring pins in as far as able and tug on connector until it slides out. If buttons won t retract using fingers a screwdriver can be used to push pins in. INSERTING END CONNECTOR 1 > Slide Connector into the planks until the spring pins touch the end of the plank. (Fig 1) 2 > Using both hands (Fig 2), use index fingers to push spring pins on both sides and slide connector into plank until Spring pin locks into position. BUTTON EXTENDS 1/8 FROM SURFACE 3 > Make sure spring pins (buttons) extend approximately 1/8 from surface. END CONNECTORS MUST BE INSPECTED BEFORE AND AFTER EACH USE. 12 > REPLACING END CONNECTORS
REPLACING TAC STRIP REMOVING TAC STRIP 1 > Using both hands as illustrated in (Fig 1), pull tac strip out of plank gently while keeping the Tac Strip straight. 2 > If Tac Strip will not come out, use channel locks or plyers to grab the Tac Strip (Fig 2) and using continuous tugs work the Tac Strip out of plank. DO NOT BEND TAC STRIP! INSERTING TAC STRIP & 2 1 > Cut Tac Strip to correct length. (Fig 1) 2 > Gently Slide Tac strip into the Tac Strip channel on top of plank. (Fig 2) 3 > Make sure that Tac Strip does not extend out of either end of plank. DO NOT FORCE TAC STRIP INTO PLANK! IF TAC STRIP IS BENT OR DAMAGED DO NOT USE. REPLACING TAC STRIP > 13
SPRING PIN ASSEMBLY 1 > Combine spring and male end of spring clip. (Fig 1) INSTALLING SPRING PIN 2 > Place spring assembly parts in hand as seen in. (Fig 2 ) 3 > Using both hands as illustrated in (Fig 3), position the spring clip long end to insert into the outside of connector. FIGURE 3 4 > Using your thumb, press the other end downwards and snap into place. (Fig 4) FIGURE 4 5 > Push in and out 3-4 times to make sure it installed properly. (Fig 5) FIGURE 5 14 > SPRING PIN ASSEMBLY
MODIFYING PLANK LENGTH CUTTING PLANK TO LENGTH 1 > Measure correct length of plank. (Fig 1) 2 > Place plank square and level underneath saw blade and cut plank. (Fig 2) NOTE: IF PLANK IS NOT CUT SQUARE AND DRILLED LEVEL END CONNECTOR PINS WILL NOT LOCK INTO POSITION. USING FIELD DRILL JIG 1 > Place plank perfectly level into Field Drill Jig. (Fig1 ) 2 > A shim is needed to compensate for the height of the jig. (Fig 2) SHIM SHIM FIGURE 3 3 > Make sure plank in square and all the way in the jig and clamp jig handles down. (Fig 3) MODIFYING PLANK LENGTH > 15
The 21st Century Plank and Deck System Bothwell Enterprises, Inc. 446 North Austin Drive Chandler, Arizona 85226 951.255.8733 BothwellPlank.com bothwellplank.com