Layher Allround scaffold used for maintenance of two large distillation columns standing 55-metre and 37-metre height at Fitzroy Industrial Chimney, Taranaki, New Zealand.

Layher, that produces high-quality scaffolding systems in Germany, has worldwide presence with more than 40 sales subsidiaries. Layher products are being used by industries like construction, chemical plants, power plants, at shipyards and offshore. Nowadays for demanding and complex scaffolding applications i.e. wherever conventional scaffolding technology falls short of optimal thus cost effective use, Layher Allround Scaffolding convincingly comes in with a range of advantages: fast assembly, cost effective and an extensive range of series-produced accessories.

More Possibilities – Layher products and services
Layher’s present product characteristics and services help customers achieve long-term success and increase the profitability of their companies. Layher Allround scaffolding has been established as a synonym for modular scaffolds on the market. Allround scaffolding offers unsurpassed versatility to be used in construction sites, chemical industry, power plants, aircraft, shipyards, event sector, theatres and arenas.

Allround scaffolding uses a simple, unique and bolt free connection technology. Sliding the wedge head over the rosette and inserting the wedge into the opening immediately secures the component. There is still sufficient play to secure the other end of the ledger. A hammer blow to the wedge transforms the loose connection into a superbly strong structurally rigid one. The face of the wedge head is now precisely positioned against the standard. Connections in quick to assemble and spanner less scaffolding systems make a unique combination: providing structural strength immediately on assembly and subsequent ultimate force transmission while offering a choice of automatically right – angled or splayed connections with universal safety right from the start.

To transfer pulling force, every frame is secured by locking pins or bolts to each other. In this way the tower can be assembled on the ground and placed by crane.

Application of Layher Allround Scaffold for maintenance of chimney
The multiple structured with different sizes operated by refinery is currently being refurbished, and corrosion prevention experts have to treat the entire structure time to time. Safe access to all location of main building is assured with the use of a modular scaffolding system. By using Allround scaffold is only possibility to complete maintenance on time as per requirement.

The advantage lies in the speed with which not only the right angle can be automatically obtained with the system, but also variable angles can be achieved if required. This is done by fitting the ledgers in rosettes each with four holes at right angles, with four further larger holes (usually used for diagonal braces) being used to facilitate variable angles. This means that the erectors can also make connections at any angle as dictated by the conditions on site. A scaffolder can easily, thanks to the eight possible connections in every connector, make adoptions quickly and optimally for almost any application.

These advantages ensure the optimum conditions for effectively enclosing the circular and rectangular structure with safe and minimal time required to construct the scaffolding. Allround scaffolding was easily adapted to follow the contour shape of the structure without difficult to access. The erectors didn’t need to create complex tube structures, saw off tubes all the time, repeat measuring of connections or constantly align the upright elements. The wedge head provides an all in one simple yet stable connection, coupled with a logical assembly sequence and integral safety. Hot-dip galvanisation and certified quality assure Allround scaffolding top-quality products are extremely long-lived.

Layher Allround scaffold used for maintenance of two large distillation columns standing 55-metre and 37-metre height at Fitzroy Industrial Chimney, Taranaki, New Zealand.

Approximately 80 tonnes of scaffolding materials was used for this project. Layher Allround lightweight modular scaffold technology was the system chosen due to its fitting accuracy and speed of erection to gain access.

The major challenges for this project to erect scaffolding during operation mode of column the plant was live (working). The design needed to be free standing and to withstand significant wind loads.

Several work levels were required plus a lift going up 40 metres were required to be integrated into the scaffolding. The challenge set by this particular job was to follow as precisely as possible the double-curved surface of the tank. This was possible due to the extensive capability of parts Layher are able to offer.

The Layher aluminium platform stairs were also an excellent addition for allowing the maintenance team to safely move up and down the columns.

Conventional anchoring to the column was not possible. The scaffold erectors were only able to make connections to the all-round steel profile – the runner rail for the inspection ladders – at the tank’s ‘equator’ using scaffold couplers. Above and below this anchoring level, the scaffolding was secured by all-round steel cables. A Layher landing-type stairway tower allowed convenient access to the scaffold at various levels.

The top lift of the scaffold at the top of the structure called for Layher’s expertise. Following the increasingly safe scaffolding with proper Access at all locations, Layher’s Technical Bureau designed a series of connected lattice girders to the topmost Allround standards which made them converge in tension-resistant form. The scaffolders then placed the structure on the highest point of the building using Allround standards.

Application of lattice girder considered in design to construct cantilever projection on top to fulfil proper access. Construction of scaffolding to make approach for all required location was major challenge during the shutdown, but it is easy when will consider Allround scaffolding systems.

Layher new lightweight scaffolding is result of a major, multi-year R&D project with as clearly defined objective: to make scaffolding easier, safe and above all more cost effective for customer.

Authored by_
Mithilesh Kumar,
Director,
Layher Scaffolding Systems Pvt Ltd