Heavy Duty Cuplock System
Superior strength and versatility for quick assembly, high load-bearing capacity, and efficient support.
Allfit Modular Steel Formwork System
Allmarc’s Heavy Duty Cuplock Scaffolding System has established itself as a prominent choice for construction projects worldwide. Its adaptability and multipurpose design make it suitable for a variety of applications, even in tight or constrained spaces, simplifying the resolution of level differences during construction. The system's key features include quick and straightforward assembly, making it a preferred choice for both access and formwork support. It has a proven track record of performance and is equipped with safety accessories to meet statutory requirements. Our Cuplock's efficient joint fastening mechanism ensures a solid and rigid connection, saving time and labor during erection and dismantling. With versatile applications in construction, demolition, and maintenance projects, this system can accommodate a wide range of structure types, whether straight or curved. Remarkably lightweight yet capable of supporting heavy loads, Cuplock Scaffolding is a low-maintenance and cost-effective choice.
Basic Structure
Overview
The fundamental structure of a Cup Lock scaffolding system comprises four horizontal elements connected at specific points along the vertical element. These elements can be ingeniously employed to assemble stair towers due to the exceptional load-bearing capacity of this system. This system's vertical elements are equipped with locking kits that are welded at intervals of 500 mm or 1000 mm. This feature offers a cost-effective and practical solution for projects with ground or deck level variations.
Locking Kit
The locking kit, an integral part of this system, includes both bottom and top cups. The bottom cup is welded onto the vertical element, while the top cup is movable along its length. This adjustability is advantageous in situations where structural adaptability is required. It allows for accommodating varying ground or deck levels efficiently.
Security Measures
To prevent any inadvertent misplacement and potential structural complications, it's vital to ensure that the upper cup remains attached to the vertical element at all times. The structural integrity of the system relies on this safeguard.
Assembly Process
The horizontal elements have heads at both ends. To adjust the top cup's position, it can be rotated in a clockwise direction with the help of a hammer. This rotation results in firmly compressing the horizontal element's head between the upper and lower cups, ensuring the stability and safety of the entire Cup Lock scaffolding system.
Standard Sizes of Vertical
Standard Sizes of Ledger
Cuplock System Components
Cuplock Standard / Vertical
Cuplock Standards or Verticals are a crucial component of the Cuplock Scaffolding System. Manufactured by Allmarc Industries, these standards are made from 48 mm OD MS Round Pipes and are available in various sizes. Cup Joints are welded at 500 mm intervals, but customization is also offered based on client requirements. The top cups are crafted from durable malleable casting to withstand rugged on-site handling. Welded bottom cups are pressed from high-quality steel.
Cuplock Ledger / Horizontal
Allmarc’s Cuplock Ledger plays a pivotal role in creating a robust structural connection capable of withstanding uneven on-site conditions. Forged Ledger blades are welded at both ends, seamlessly fitting between the top cup and bottom cup of vertical components. These ledgers are crafted from 48.00 mm OD MS round pipes with a 3 mm thickness. The minimum projection of blades minimizes potential damage during handling, and uniform dimensions ensure the cup joints remain rigid. Customization options are available to meet specific client requirements.
U-Head Jack
The Adjustable Jack Stirrup Head is an essential element designed to provide additional height adjustment at the top of the Cuplock Standards or Verticals. This jack offers a maximum length adjustment of 300 – 600 mm and is primarily used to support MS Beams and channels on which formwork plates are placed during construction. Manufactured through a roll threading process, U-Jacks are not only safe but also boast an impressive load-bearing capacity of up to 4 tons.
Base Jack
Base Jacks are positioned at the bottom of the Cuplock Standards (Verticals). They serve the critical function of accommodating variations in ground levels, ensuring stability and load-bearing support. Each Base Jack has a safe working load of approximately 4 tons and consists of a hollow pipe with an OD of 38 mm and a solid rod with an OD of 32 mm. The jack nut is constructed from SG Iron Casting, and the base plate measures 150x150x6 mm.
Standard Sizes of Hollow Pipe Jack
Standard Sizes of MS Solid Jack
Scaffolding Accessories
Scaffold couplers are key components for connecting scaffold tubes, enabling versatile scaffolding structures.
Forged Double Coupler / Fix Coupler
- Joins two scaffold tubes at right angles (48.3mm OD). - Robust design, drop-forged steel, hot-dip galvanized for enhanced durability. - Typical working load limit of 6.25kN with a torque of 54 Nm.
Ladder Clamp
- Joins Aluminum/Steel Straight Ladders to 48 O.D. scaffold tubes. - Offers quick and precise fitting within scaffolding structures.
Putlog Coupler - Wrapover
- Joins 48 O.D. scaffold tubes at right angles. - Used for positioning Putlog tubes on ledger tubes. - Typically secures guardrails and mid-rails, not for connecting ledger tubes.
Expanding Joint Pin
- Joins 48 O.D. scaffold tube standards end-to-end internally. - Expands to fit the tube's internal diameter when bolt tightened.
Forged Swivel Coupler
- Joins two scaffold tubes (48.3mm OD) at any angle. - Swivel pin connects halves. - Ideal for bracing members or tension splicing of scaffold tubes.
Beam / Girder Clamp
- Joins 48 O.D. scaffold tubes to Tapered or Parallel Flange steel beams at 90°. - Suitable for 50/75/100mm beams/girders. - Working load limit of 6.25 kN, resists slipping along the tube or beam flange.
External Sleeve Coupler
- Joins two scaffold tubes (48.3mm OD) at any angle. - Swivel pin connects halves. - Ideal for bracing members or tension splicing of scaffold tubes.
Board Retaining Clamp (BRC Coupler)
Retains scaffold planks to 48 O.D. scaffold tubes. Suitable for plank thicknesses of 35 to 38mm. Made from pressed steel with a drop-forged steel cap.
General Safety Guidelines
Scaffolds may only be erected, moved, dismantled, or altered under the supervision of qualified individuals. A qualified person is someone capable of identifying existing or predictable hazards in the surroundings or working conditions, and authorized to take prompt corrective actions to eliminate them. Note that these guidelines are based on generally accepted safety standards. Compliance with these recommendations does not guarantee conformity with building codes or federal, state, or local safety regulations. It is the responsibility of property owners to inform tenants or occupants of any existing safety hazards.
Safety of Scaffolding Frames
- Scaffold frames must support the maximum intended load. - When using a horizontal frame separation of 7 feet, the maximum plank extension over the end support should not exceed 12 inches unless guardrails are used to block access. - On a scaffold that is 10 feet wide, the overlap for each plank should be 12 inches. - For a scaffold that's 5 feet wide, 35 feet in length, and 30 feet high with 7-foot frame spacing, there should be horizontal bracing every 20 feet and vertical cross-bracing every 20 feet. - A three-section-high frame scaffold with a cantilevered outrigger platform should utilize ties, guys, braces, outriggers, scaffold manufacturer's stabilizer legs, or equivalent support.
Safety Rails for Scaffolding
- Guardrails are mandatory for welded frame scaffolds that are 10 feet high or taller. - The top rail should be at least 36 inches high but no more than 45 inches. - The top rail must withstand a force of at least 200 pounds for welded frame scaffolds. - The mid rail on a welded frame scaffold must handle at least 150 pounds. - Scaffold legs should rest on base plates that are firmly grounded or on mud sills.
Safety of Scaffolding Planks
- Gaps between scaffold planks must not exceed 25 mm. - The maximum permissible distance between a plank and a frame upright is 225 mm. - An uncleated scaffold plank must extend over the end support by a minimum of 150 mm.
Additional Specification
- Scaffold platforms that are more than one section high should have safe access. - When using hook-on-ladders, provide a rest platform every 35 feet. - Maintain a distance of at least three feet between the scaffold and an insulated 220-volt line. - Work should not proceed during high winds, defined by the National Weather Service as gusts of 50 kph or higher. The final decision rests with the qualified individual.
Customisations Feasible
Our team of experienced engineers excels in fabricating bespoke solutions tailored to your specific requirements. From intricate details to large-scale projects, we ensure precision and excellence in every customization. Your vision, our expertise – let's build success together.
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