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İskeleler İçin İş Güvenliği-

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İGY Zirve
İGY Zirve

Ankara Congresium Angora Salonları'nda 23 Ekim 2014 Perşembe günü gerçekleşen 7. İGY-İş, Güvenlik Yaşam Zirvesi'nde Layher İskele Yönetim Direktörü Helmut Kreller, İskeleler için İş Güvenliği konulu bir sunum yaptı.

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Occupational safety related to Scaffolds Ankara, 23.10.2014
Layher | 2 OCCUPATIONAL SAFETY RELATED TO SCAFFOLDS Dr. Helmut Kreller - Managing Director of Layher GmbH & Co.KG, Germany •Chairman of the Subgroup “German Producers” at the German Scaffolding Association •Member of the “Committee of Experts” at “German Institute for Building Technology” •Former member of CEN/TC 53 – European Standards EN12810 and EN 12811 Topics: Brief introduction of company Layher Some pictures of Layher scaffolding applications worldwide German/European normative requirements for scaffolds Approval procedure – Examples how to fulfil requirements
Layher | 3 LAYHER – WORLD MARKET LEADER IN SYSTEM SCAFFOLD 1945 Wilhelm Layher founds the company nearby Stuttgart 2014 Still family owned company in 3rd Generation Production only in Germany! 2 km Headquarters Eibensbach 250,000 m² factory premises – steel parts Plant 2 Gueglingen 68,000 m² factory premises – aluminium & wooden parts
Layher | 4 TWO PRINCIPLE SYSTEMS – UNLIMITED APPLICATIONS SPEEDYSCAF – frame system for façade scaffolds ALLROUND SYSTEM – modular system for industrial use Completed by a range of supplements (roofs, cladding, stairs etc.)
Layher | 5 Branches in 37 countries and more than 50 additional trading contacts worldwide: LAYHER WORLDWIDE  EUROPE Austria, Belgium, Bulgaria, Denmark, France, Greece, Hungary, Italy, Kazakhstan, Lithuania, the Netherlands, Norway, Poland, Romania, Russia, Serbia, Spain, Sweden, Switzerland, Turkey, UK  SOUTH AMERICA Argentina, Brazil, Chile, Colombia, Ecuador, Peru  AFRICA Morocco, South Africa  NORTH AMERICA USA (Alabama, Florida, Maryland, Texas), Canada (Alberta), Mexico  OCEANIA Australia (New South Wales, Queensland, Western Australia), New Zealand  ASIA India, Singapore  MIDDLE EAST United Arab Emirates
Layher | 6 LAYHER PRODUCTION OUTPUT 2013 Annual loading in Eibensbach More than 140,000 t scaffolding material 7,300 trucks (à 18 t) = up to 67 trucks daily 900 containers are sent overseas Layher’s efficiency is not only reflected in its products, but also in some impressive production figures. Annual processing More than 21,000,000 m steel tubes = Flight distance Frankfurt – Rio de Janeiro – round-trip More than 1,700,000 m² scaffolding decks = 275 football pitches
Layher | 7 AWARDS AND CERTIFICATES Innovation-Award Construmat 2011 Spanien Innovation-Award BATIMAT 2011 / Frankreich Certificate for Reduction of CO2 Emission, signed by German Minister for Environment Award for Innovation und Quality Baden-Württemberg
Layher | 8  Swiss, Bern, Wankdorf City, facade scaffold
Layher | 9 PRODUKTGRUPPE ALLROUND  Italien, Bologna, Basilika San Petronio
Layher | 10  Swiss, Zurich, zoo, new house for elephants, dome shaped roof
Layher | 11 PRODUKTGRUPPE ALLROUND  Finland, Oulu, water tower renovation
Layher | 12 PRODUKTGRUPPE ALLROUND  England, power-lining
Layher | 13 PRODUKTGRUPPE ALLROUND  Germany, Bremerhaven, Lloyd Wharf, ship repair
Layher | 14 PRODUKTGRUPPE  Argentina, airplane maintenance dock
Layher | 15  Deutschland, Mylau, Göltzschtal-bridge renovation
Layher | 16  Italy, renovation of bridges
Layher | 17 PRODUKTGRUPPE ALLROUND  Luxemburg, street crossing bridge
Layher | 18 PRODUKTGRUPPE ALLROUND  Kasachstan, Astana, Abu Dhabi Tower
Layher | 19 WHOLE RANGE OF PRODUCTS TO SURROUND SCAFFOLDING STRUCTURES Berlin “Gedächtniskirche”
Layher | 20 PRODUKTGRUPPE ALLROUND  USA, Florida, Kennedy Space Center
Layher | 21  Industrial facilities, power plants, refineries
Layher | 22 PRODUKTGRUPPE ALLROUND  Finland, Kuopio, Tikkalansaari-bridge, shoring scaffold
Layher | 23 PRODUKTGRUPPE ALLROUND  Germany, Dillingen, steel casting line, access and shoring scaffold
Layher | 24  Sochi, Olympic winter games 2014
Layher | 25  Australia, Gold coast, 3.200 seats stand
Layher | 26 Precondition for a safe –and efficient- work during construction is a scaffold with high quality standard and proofed stability. What is the procedure to generate such a scaffold?
Layher | 27 MAIN GERMAN NORMATIVE REQUIREMENTS ON SCAFFOLDS According to the European Act 305/2011 scaffolds are no building product → they belong to the non-harmonized area, scaffolds underlie national regulations. Therefore the European Codes DIN EN 12810 – façade scaffolds made by prefabricated parts and DIN EN 12811 - working scaffolds has been worked out on a “voluntary” basis and transferred into national law - partly with additional regulations. (Germany: working & protection scaffolds) In Germany each federal state (16) has an own “Landesbauordnung” (state building regulation) which state that scaffolds are “building structures”, the stability against collapse has to be approved by: a) A General Building Supervisory Approval (“Zulassung”) or a b) Static calculation for every single application (time consuming) The execution is checked by the Governmental Building Inspection
Layher | 28 MAIN GERMAN NORMATIVE REQUIREMENTS ON SCAFFOLDS The German federal states transferred the responsibility for granting General Approvals to the „German Institute for Building Technology“ DIBt in Berlin. Besides statically requirements there are additional occupational challenges: Since scaffolds are also technical working equipment according to the “Industrial Safety Regulations” BetrSichV and the “Equipment and Product Safety Law” GPSG, they have to fulfill also the requirements of that bylaws. In addition, inspectors of the “Building Trade Association” check the compliance with this regulations.
Layher | 29 SCAFFOLDING APPROVALS IN GERMANY (IN ACCORDANCE WITH EN 12810 AND 12811) According to the German Law for Building and Construction System Scaffolds need an official Approval Procedure: German Institute for Structural Technology (DIBt, Berlin) This is the only body in Germany that officially grants Approvals General Building Supervisory Approval E & D Manual is a mandatory part of the approval! Scaffold Manufacturer Has to provide comprehensive documents: ( Static calculations, test reports, expert opinions )
Layher | 30 30  By Conformity Check Testing of the scaffold components: • a first extensive component test, carried out by an independent external supervision • self-controlled production of components • regular external supervision (carried out by an independent institute) Production The compliance of scaffold components with the approval specifications has to be proven (for each production site separately) Conformity certificate HOW? If everything is fulfilled FORMAL PROCEDURE AFTER GETTING THE APPROVAL
Layher | 31 31 Approval (document) The approval requires: Inspection certificates for all semi- finished products (tubes, sheets,…) Inspection certificates according to EN 10204 are required. Inspection certificates confirm material specifications; e. g. higher yield stress of 320 N/mm2. Layher asks suppliers for material certificates for each charge. ContEeXntA oMf PthLeE aSp pOroFv AalP PROVAL REGULATIONS I
Layher | 32 32 Inspection Certificate: Round Tube 48.3 x 3.2 with increased yield stress fy,k = 320 N/mm2 Additionally internal tests for each material delivery are worked out ADDITIONAL INTERNAL MATERIAL TESTS
Layher | 33 33 Approval (document) The approval specifies marking of each scaffolding part with: Identifier of material supplier, producer (Layher), month or day of production, approval number, Ü – sign for “conformity” ContEeXntA oMf PthLeE aSp pOroFv AalP PROVAL REGULATIONS II
Layher | 34 34 The track from the approval to the scaffold component Ü 64 (shortcut) is the mark of the approval Z-8.22-64 for Layher Allround scaffold Allround Rosette Allround wedge Allround ledger wedge head EXAMPLES FOR MARKING OF SCAFFOLDING PARTS
Layher | 35 35 Quality assurance in production Steel deck Day Year Machine number Automated date embossing on machines: • Welding of end profiles • Welding of ledgers • Welding of standards • Crimping of spigots • Lattice girder/standard • Diagonals machine • Welding of base collars EXAMPLES FOR MARKING OF SCAFFOLDING PARTS
Layher | 36 36 Further requirements set in the approval FURTHER REQUIREMENTS FOR PRODUCING STEEL PARTS Certificates for welding according to DIN 18800-7 (Factory Requirement) The factory and the workers must be proven acc. to the standard to be allowed to produce welded constructions in steel and aluminium. This includes: - regular tests and certificates for welders - nomination of a responsible (and skilled) supervisor for welding
Layher | 37 CONTINUOUS TESTING DURING PRODUCTION
Layher | 38 38 All approved decks must have passed the drop test acc. to EN 12810-2: A 100 kg- sphere drops down to the deck from 2.5m height  The deck must be able to hold the sphere ! Two drop positions must be tested: middle of the deck and at the end support. IMPACT TESTS FOR DECKS
Layher | 39 What are the Requirements on a “safe” Scaffold? What does that mean? High quality of each single scaffolding component (exact measurement, no risk of injury during handling and use) “Self-explanatory” erection sequences – easy to train (even unskilled workers cannot do things wrong) Versatile and adaptable to given building geometries (no uncovered holes, no fall traps) Sturdy design + hot dip galvanizing = long life time (> 30 years!) Low maintenance (robust in use, no losable parts) The scaffolding system must supply a maximum on safety to workers during erection, use and dismantling SUMMARY
Thank you very much for your attention! Safety and efficiency are not a contradiction More efficiency – through safety

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İskeleler İçin İş Güvenliği-

  • 1. Occupational safety related to Scaffolds Ankara, 23.10.2014
  • 2. Layher | 2 OCCUPATIONAL SAFETY RELATED TO SCAFFOLDS Dr. Helmut Kreller - Managing Director of Layher GmbH & Co.KG, Germany •Chairman of the Subgroup “German Producers” at the German Scaffolding Association •Member of the “Committee of Experts” at “German Institute for Building Technology” •Former member of CEN/TC 53 – European Standards EN12810 and EN 12811 Topics: Brief introduction of company Layher Some pictures of Layher scaffolding applications worldwide German/European normative requirements for scaffolds Approval procedure – Examples how to fulfil requirements
  • 3. Layher | 3 LAYHER – WORLD MARKET LEADER IN SYSTEM SCAFFOLD 1945 Wilhelm Layher founds the company nearby Stuttgart 2014 Still family owned company in 3rd Generation Production only in Germany! 2 km Headquarters Eibensbach 250,000 m² factory premises – steel parts Plant 2 Gueglingen 68,000 m² factory premises – aluminium & wooden parts
  • 4. Layher | 4 TWO PRINCIPLE SYSTEMS – UNLIMITED APPLICATIONS SPEEDYSCAF – frame system for façade scaffolds ALLROUND SYSTEM – modular system for industrial use Completed by a range of supplements (roofs, cladding, stairs etc.)
  • 5. Layher | 5 Branches in 37 countries and more than 50 additional trading contacts worldwide: LAYHER WORLDWIDE  EUROPE Austria, Belgium, Bulgaria, Denmark, France, Greece, Hungary, Italy, Kazakhstan, Lithuania, the Netherlands, Norway, Poland, Romania, Russia, Serbia, Spain, Sweden, Switzerland, Turkey, UK  SOUTH AMERICA Argentina, Brazil, Chile, Colombia, Ecuador, Peru  AFRICA Morocco, South Africa  NORTH AMERICA USA (Alabama, Florida, Maryland, Texas), Canada (Alberta), Mexico  OCEANIA Australia (New South Wales, Queensland, Western Australia), New Zealand  ASIA India, Singapore  MIDDLE EAST United Arab Emirates
  • 6. Layher | 6 LAYHER PRODUCTION OUTPUT 2013 Annual loading in Eibensbach More than 140,000 t scaffolding material 7,300 trucks (à 18 t) = up to 67 trucks daily 900 containers are sent overseas Layher’s efficiency is not only reflected in its products, but also in some impressive production figures. Annual processing More than 21,000,000 m steel tubes = Flight distance Frankfurt – Rio de Janeiro – round-trip More than 1,700,000 m² scaffolding decks = 275 football pitches
  • 7. Layher | 7 AWARDS AND CERTIFICATES Innovation-Award Construmat 2011 Spanien Innovation-Award BATIMAT 2011 / Frankreich Certificate for Reduction of CO2 Emission, signed by German Minister for Environment Award for Innovation und Quality Baden-Württemberg
  • 8. Layher | 8  Swiss, Bern, Wankdorf City, facade scaffold
  • 9. Layher | 9 PRODUKTGRUPPE ALLROUND  Italien, Bologna, Basilika San Petronio
  • 10. Layher | 10  Swiss, Zurich, zoo, new house for elephants, dome shaped roof
  • 11. Layher | 11 PRODUKTGRUPPE ALLROUND  Finland, Oulu, water tower renovation
  • 12. Layher | 12 PRODUKTGRUPPE ALLROUND  England, power-lining
  • 13. Layher | 13 PRODUKTGRUPPE ALLROUND  Germany, Bremerhaven, Lloyd Wharf, ship repair
  • 14. Layher | 14 PRODUKTGRUPPE  Argentina, airplane maintenance dock
  • 15. Layher | 15  Deutschland, Mylau, Göltzschtal-bridge renovation
  • 16. Layher | 16  Italy, renovation of bridges
  • 17. Layher | 17 PRODUKTGRUPPE ALLROUND  Luxemburg, street crossing bridge
  • 18. Layher | 18 PRODUKTGRUPPE ALLROUND  Kasachstan, Astana, Abu Dhabi Tower
  • 19. Layher | 19 WHOLE RANGE OF PRODUCTS TO SURROUND SCAFFOLDING STRUCTURES Berlin “Gedächtniskirche”
  • 20. Layher | 20 PRODUKTGRUPPE ALLROUND  USA, Florida, Kennedy Space Center
  • 21. Layher | 21  Industrial facilities, power plants, refineries
  • 22. Layher | 22 PRODUKTGRUPPE ALLROUND  Finland, Kuopio, Tikkalansaari-bridge, shoring scaffold
  • 23. Layher | 23 PRODUKTGRUPPE ALLROUND  Germany, Dillingen, steel casting line, access and shoring scaffold
  • 24. Layher | 24  Sochi, Olympic winter games 2014
  • 25. Layher | 25  Australia, Gold coast, 3.200 seats stand
  • 26. Layher | 26 Precondition for a safe –and efficient- work during construction is a scaffold with high quality standard and proofed stability. What is the procedure to generate such a scaffold?
  • 27. Layher | 27 MAIN GERMAN NORMATIVE REQUIREMENTS ON SCAFFOLDS According to the European Act 305/2011 scaffolds are no building product → they belong to the non-harmonized area, scaffolds underlie national regulations. Therefore the European Codes DIN EN 12810 – façade scaffolds made by prefabricated parts and DIN EN 12811 - working scaffolds has been worked out on a “voluntary” basis and transferred into national law - partly with additional regulations. (Germany: working & protection scaffolds) In Germany each federal state (16) has an own “Landesbauordnung” (state building regulation) which state that scaffolds are “building structures”, the stability against collapse has to be approved by: a) A General Building Supervisory Approval (“Zulassung”) or a b) Static calculation for every single application (time consuming) The execution is checked by the Governmental Building Inspection
  • 28. Layher | 28 MAIN GERMAN NORMATIVE REQUIREMENTS ON SCAFFOLDS The German federal states transferred the responsibility for granting General Approvals to the „German Institute for Building Technology“ DIBt in Berlin. Besides statically requirements there are additional occupational challenges: Since scaffolds are also technical working equipment according to the “Industrial Safety Regulations” BetrSichV and the “Equipment and Product Safety Law” GPSG, they have to fulfill also the requirements of that bylaws. In addition, inspectors of the “Building Trade Association” check the compliance with this regulations.
  • 29. Layher | 29 SCAFFOLDING APPROVALS IN GERMANY (IN ACCORDANCE WITH EN 12810 AND 12811) According to the German Law for Building and Construction System Scaffolds need an official Approval Procedure: German Institute for Structural Technology (DIBt, Berlin) This is the only body in Germany that officially grants Approvals General Building Supervisory Approval E & D Manual is a mandatory part of the approval! Scaffold Manufacturer Has to provide comprehensive documents: ( Static calculations, test reports, expert opinions )
  • 30. Layher | 30 30  By Conformity Check Testing of the scaffold components: • a first extensive component test, carried out by an independent external supervision • self-controlled production of components • regular external supervision (carried out by an independent institute) Production The compliance of scaffold components with the approval specifications has to be proven (for each production site separately) Conformity certificate HOW? If everything is fulfilled FORMAL PROCEDURE AFTER GETTING THE APPROVAL
  • 31. Layher | 31 31 Approval (document) The approval requires: Inspection certificates for all semi- finished products (tubes, sheets,…) Inspection certificates according to EN 10204 are required. Inspection certificates confirm material specifications; e. g. higher yield stress of 320 N/mm2. Layher asks suppliers for material certificates for each charge. ContEeXntA oMf PthLeE aSp pOroFv AalP PROVAL REGULATIONS I
  • 32. Layher | 32 32 Inspection Certificate: Round Tube 48.3 x 3.2 with increased yield stress fy,k = 320 N/mm2 Additionally internal tests for each material delivery are worked out ADDITIONAL INTERNAL MATERIAL TESTS
  • 33. Layher | 33 33 Approval (document) The approval specifies marking of each scaffolding part with: Identifier of material supplier, producer (Layher), month or day of production, approval number, Ü – sign for “conformity” ContEeXntA oMf PthLeE aSp pOroFv AalP PROVAL REGULATIONS II
  • 34. Layher | 34 34 The track from the approval to the scaffold component Ü 64 (shortcut) is the mark of the approval Z-8.22-64 for Layher Allround scaffold Allround Rosette Allround wedge Allround ledger wedge head EXAMPLES FOR MARKING OF SCAFFOLDING PARTS
  • 35. Layher | 35 35 Quality assurance in production Steel deck Day Year Machine number Automated date embossing on machines: • Welding of end profiles • Welding of ledgers • Welding of standards • Crimping of spigots • Lattice girder/standard • Diagonals machine • Welding of base collars EXAMPLES FOR MARKING OF SCAFFOLDING PARTS
  • 36. Layher | 36 36 Further requirements set in the approval FURTHER REQUIREMENTS FOR PRODUCING STEEL PARTS Certificates for welding according to DIN 18800-7 (Factory Requirement) The factory and the workers must be proven acc. to the standard to be allowed to produce welded constructions in steel and aluminium. This includes: - regular tests and certificates for welders - nomination of a responsible (and skilled) supervisor for welding
  • 37. Layher | 37 CONTINUOUS TESTING DURING PRODUCTION
  • 38. Layher | 38 38 All approved decks must have passed the drop test acc. to EN 12810-2: A 100 kg- sphere drops down to the deck from 2.5m height  The deck must be able to hold the sphere ! Two drop positions must be tested: middle of the deck and at the end support. IMPACT TESTS FOR DECKS
  • 39. Layher | 39 What are the Requirements on a “safe” Scaffold? What does that mean? High quality of each single scaffolding component (exact measurement, no risk of injury during handling and use) “Self-explanatory” erection sequences – easy to train (even unskilled workers cannot do things wrong) Versatile and adaptable to given building geometries (no uncovered holes, no fall traps) Sturdy design + hot dip galvanizing = long life time (> 30 years!) Low maintenance (robust in use, no losable parts) The scaffolding system must supply a maximum on safety to workers during erection, use and dismantling SUMMARY
  • 40. Thank you very much for your attention! Safety and efficiency are not a contradiction More efficiency – through safety