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.

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