BOSSCO ZONE:1 User manual

Instruction Manual
Mobile Fibreglass Tower
1450/850 Ladderspan
3T - Through the Trapdoor Method
EN 1004-2 en
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BoSS Zone:1 Instruction Manual
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Contents
1Safety First
1.1 Introduction 2
1.2 Tower Designation 3
1.3 Maintenance - Storage - Transport 3
2Building the Tower
2.1 Pre-Assembly Checks 4
2.2 Component Diagram 6
2.3 Quantity Schedule 8
2.4 Stabilisers 10
2.5 Assembly 11
2.5.1 Assembly General: Steps to 13
2.5.2 Assembly For 1450 Towers: Steps to 14
2.5.3 Assembly For 850 Towers: Steps to 16
2.6 Dismantling 18
3 Using the Tower
3.1 Safety Checklist 19
3.2 Pre-Use Checklist 19
3.3 Use 20
3.4 Movement of the Assembled Prefabricated Tower Scaffold 22
1 3
4 7
4 9
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2BoSS Zone:1 Instruction Manual
1 Safety First
1.1 Introduction
Please read this instruction manual carefully.
This instruction manual shall be available at the location of use of
this mobile access tower. Instruction manuals are also available to
download at www.bossaccesstowers.com.
This product shall only be used in accordance with this manual without any
modification.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY LEAD TO
DEATH OR SERIOUS INJURY.
Mobile access towers must always be used in accordance with the national
regulations. If any aspect of these instructions conflicts with local regulations, please
contact Werner UK Sales & Distribution Ltd. for advice.
Please note that diagrams are for illustrative purposes only.
User training courses are available but must not be used as a substitute for
familiarity with this manual.
A BoSS Zone:1 fibreglass mobile access tower is a safe and practical alternative
when other towers are not suitable for use, especially around electricity. They
provide indoor and outdoor access solutions where a stable and secure platform is
required. Ideal for maintenance and installation work or short-term access, the highly
versatile towers provide a strong working platform for a variety of heights.
Verification and assessment documentation is held by Werner UK Sales &
Distribution Ltd.
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1 Safety First
1.2 Tower Designation
3 8/12 XXXD H2
Load Class (2 = 153kg/m2UDL, 3 = 204kg/m2UDL*)
Max. Platform Height Outdoors (m)
Max. Platform Height Indoors (m)
Access Method
A = Stairway, B = Stair ladder, C = Inclined Ladder, D = Vertical Ladder
Clear Height Class (H1 = 1.85m, H2 = 1.90m)
*UDL = Uniformly distributed load
1.3 Maintenance - Storage – Transport
•The BoSS mobile tower system is robust and requires little maintenance.
•All components and their parts should be regularly inspected to identify
damage, particularly to joints.
•Refer to the BoSS Fibreglass Tower Inspection Guidance for detailed
inspection and maintenance advice, the guidance is available to download
at: www.bossaccesstowers.com.
•Threads, hinges, and brace latches may be lubricated with light oil. Ensure oil
does not contaminate climbing or walking surfaces.
•Safety labels should be kept legible. Replacement labels are available from
Werner UK Sales & Distribution Ltd.
•Surfaces should be kept reasonably free of dried paint, plaster etc.
•Use of solvents on wooden platform surfaces and plastic components should
be avoided.
•Components should be stored in clean, dry conditions with due care to prevent
damage.
•During transportation ensure components are not damaged by excessive
strapping forces.
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4BoSS Zone:1 Instruction Manual
2 Building the Tower
2.1 Pre-Assembly Checks
•Check overhead that the area into which the structure is to be erected contains
no obstructions, particularly electrical or radio radiation hazards.
•Ensure the ground on which the mobile access tower is to be erected is capable
of supporting the tower in use.
•Check the surface is level within the 315mm range of the adjustable legs.
•Only components specified in this manual shall be used with BoSS Zone:1
towers. Check all required components are onsite and in a suitable working
condition.
•Damaged components shall not be used and must be put beyond use and
disposed of according to local regulations.
•Adjustable legs should only be used for levelling purposes and never to gain
extra height.
•Ensure distance from the ground to first climbing rung is less than 400mm.
•Only climb the tower from the inside using the access
method provided.
•This tower provides a work platform. It must not be
used to access other structures.
•Tower scaffolds are not designed to be lifted or suspended.
•Ensure the safe working load on the structure is not exceeded.
•Tools and materials should be lifted using a reliable lifting material (e.g. a strong
rope) employing a reliable knot (e.g. clove hitch) to ensure safe fastening and
always lift within the footprint of the prefabricated tower scaffold (i.e. within the
area bounded by the stabilisers).
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•Check this manual is available and its contents familiar to all those involved.
•If assembling outdoors; check the forecast windspeed.
○The assembled tower is certified to wind forces
equating to 27mph, but handling components under
those conditions would be hazardous.
○Also consider the wind funnelling effect of nearby
buildings.
•Towers greater than 8.2m platform height are for indoor use only.
•Consideration should be given to potential wind conditions if the tower is left
unattended.
2 Building the Tower
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6BoSS Zone:1 Instruction Manual
2.2 Component Diagram
2 Building the Tower
Instruction
Manual
Horizontal
Brace
Span
Frame
4 Rung
Platform
(Fixed and
Trapdoor
Platforms)
Ladder Frame
4 Rung
End Toe
Board
Stabiliser
Span
Frame
2 Rung
Ladder Frame
2 Rung
Adjustable Leg
Castor
Diagonal
Brace
Side
Toe
Board
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Component Weights
2 Building the Tower
Component
Code Name Weight (kgs)
32842300 Castor 150mm 3.3
32942300 Castor 125mm 3.0
33351300 Castor 200mm 4.0
35754300 Adjustable leg 1.1
31254300 Ladder Frame 850 2 Rung 9.1
30954300 Span Frame 850 2 Rung 3.5
31154300 Ladder Frame 850 3 Rung 10.4
30854300 Span Frame 850 3 Rung 5.0
31054300 Ladder Frame 850 4 Rung 11.7
30754300 Span Frame 850 4 Rung 6.6
30654300 Ladder Frame 1450 2 Rung 12.6
30354300 Span Frame 1450 2 Rung 6.7
30554300 Ladder Frame 1450 3 Rung 15.1
30254300 Span Frame 1450 3 Rung 9.5
30454300 Ladder Frame 1450 4 Rung 17.6
30154300 Span Frame 1450 4 Rung 12.2
32354300 Fixed Platform 1.8m 17.0
32254300 Fixed Platform 2.5m 23.0
32654300 Trapdoor Platform 1.8m 19.0
32554300 Trapdoor Platform 2.5m 25.0
34654300 Horizontal Brace 1.8m (red) 2.0
34554300 Horizontal Brace 2.5m (red) 2.5
34354300 Diagonal Brace 2.1m (blue) 2.3
34254300 Diagonal Brace 2.7m (blue) 2.6
33154300 Side Toe Board 1.8m 3.2
32254300 Side Toe Board 2.5m 4.4
33554300 End Toe Board 0.6m 1.0
33454300 End Toe Board 1.45m 2.1
35254300 Small Stabiliser 4.7
35354300 Large Stabiliser 5.5
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2.3 Quantity Schedule BoSS 1450 Zone:1 : Available in 2 lengths - 1.8m and 2.5m
Internal or External Use Internal Use
Component Working
Height (m) 3.2 3.7 4.2 4.7 5.2 5.7 6.2 6.7 7.2 7.7 8.2 8.7 9.2 9.7 10.2 10.7 11.2 11.7 12.2 12.7 13.2 13.7 14.2
Code Name Platform
Height (m) 1.2 1.7 2.2 2.7 3.2 3.7 4.2 4.7 5.2 5.7 6.2 6.7 7.2 7.7 8.2 8.7 9.2 9.7 10.2 10.7 11.2 11.7 12.2
33351300/ 32842300 / 32942300
Castor 125mm/150mm 200mm 44444444444444444444444
35754300 Adjustable Leg 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
30654300 Ladder Frame 1450 2 Rung - 1 1 - - 1 1 - - 1 1 - - 1 1 - - 1 1 - - 1 1
30354300 Span Frame 1450 2 Rung - 1 1 - - 1 1 - - 1 1 - - 1 1 - - 1 1 - - 1 1
30554300 Ladder Frame 1450 3 Rung - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 -
30254300 Span Frame 1450 3 Rung - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 -
30454300 Ladder Frame 1450 4 Rung 1 - 1 1 2 1 2 2 3 2 3 3 4 3 4 4 5 4 5 5 6 5 6
30154300 Span Frame 1450 4 Rung 1 - 1 1 2 1 2 2 3 2 3 3 4 3 4 4 5 4 5 5 6 5 6
32354300 / 32254300 Fixed Platform 1.8m and 2.5m 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 3 3 3 3 4 4 4 4
32654300 / 32554300
Trapdoor Platform 1.8m and 2.5m 11112222333344433333444
34654300/ 34554300
Horizontal Brace 1.8m and 2.5m (red) 6 6 6 6 10 10 10 10 14 14 14 14 18 18 18 18 22 22 22 22 26 26 26
34354300/ 34254300
Diagonal Brace 2.1m and 2.7m (blue) 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
33154300 / 33354300 Side Toe Board 1.8m and 2.5m 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
33454300 End Toe Board 1.45m 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
35254300 Small Stabiliser - - - 4 4 4 4 4 4 4 - - - - - - - - - - - - -
35354300 Large Stabiliser - - - - - - - - - - 4 4 4 4 4 4 4 4 4 4 4 4 4
Tower Total Self-weight 1.8m (kgs) 112 128 133 177 211 228 235 260 294 311 321 346 380 397 404 376 391 408 415 440 474 491 498
Tower Total Self-weight 2.5m (kgs) 130 146 152 201 244 261 269 300 342 359 370 401 444 460 468 428 446 463 471 501 544 561 569
2 Building the Tower
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BoSS 850 Zone:1 : Available in 2 lengths - 1.8m and 2.5m
Internal or External Use Internal Use
Component Working
Height (m) 3.2 3.7 4.2 4.7 5.2 5.7 6.2 6.7 7.2 7.7 8.2 8.7 9.2 9.7 10.2 10.7 11.2 11.7 12.2 12.7 13.2 13.7 14.2
Code Name Platform
Height (m) 1.2 1.7 2.2 2.7 3.2 3.7 4.2 4.7 5.2 5.7 6.2 6.7 7.2 7.7 8.2 8.7 9.2 9.7 10.2 10.7 11.2 11.7 12.2
33351300/ 32842300/
32942300
Castor 125mm/150mm 200mm 44444444444444444444444
35754300 Adjustable Leg 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
31254300 Ladder Frame 850 2 Rung - 1 1 - - 1 1 - - 1 1 - - 1 1 - - 1 1 - - 1 1
30954300 Span Frame 850 2 Rung - 1 1 - - 1 1 - - 1 1 - - 1 1 - - 1 1 - - 1 1
3115 4300 Ladder Frame 850 3 Rung - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 -
30854300 Span Frame 850 3 Rung - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 - 1 -
31054300 Ladder Frame 850 4 Rung 1 - 1 1 2 1 2 2 3 2 3 3 4 3 4 4 5 4 5 5 6 5 6
30754300 Span Frame 850 4 Rung 1 - 1 1 2 1 2 2 3 2 3 3 4 3 4 4 5 4 5 5 6 5 6
32354300/
32254300 Fixed Platform 1.8m and 2.5m - - - - - - - - - - - - - - - - - - - - - - -
32654300/
32554300
Trapdoor Platform 1.8m and 2.5m 11122223333444455556666
34654300/
34554300
Horizontal Brace 1.8m and 2.5m (red) 6 6 6 6 10 10 10 10 14 14 14 14 18 18 18 18 22 22 22 22 26 26 26
34354300/
34254300
Diagonal Brace 2.1m and 2.7m (blue) 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
33154300/
33354300 Side Toe Board 1.8m and 2.5m 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
33554300 End Toe Board 0.6m 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
35254300 Small Stabiliser - - 4 4 4 4 4 - - - - - - - - - - - - - - - -
35354300 Large Stabiliser - - - - - - - 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Tower Total Self-weight 1.8m (kgs) 80 92 113 138 151 163 168 195 208 220 226 250 263 275 280 304 317 329 335 359 372 384 389
Tower Total Self-weight 2.5m (kgs) 92 104 126 156 172 184 189 223 239 251 256 287 327 365 395 350 366 378 384 414 430 442 447
2 Building the Tower
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10 BoSS Zone:1 Instruction Manual
Assembly Variations
This section lists the permitted component variation from the Quantity Schedule.
Note: These substitutions must be made before assembly.
Castors
Other Castor sizes and types
may be substituted:
2.4 Stabilisers
X
Y
90%
Double Width 1450 Tower Single Width 850 Tower
1.8m 2.5m 1.8m 2.5m
X Y X Y X Y X Y
Small Stabiliser 4330 3868 4918 3868 4330 3268 4918 3268
Large Stabiliser 4998 4536 5586 4536 4082 4629 4650 4650
Telescopic stabilisers must always be fully extended.
Position the lower clamp so that the arm is as close to horizontal as possible. Adjust
the position of the top clamp to ensure the stabiliser foot is in firm contact with the
ground. Ensure the clamps are secure.
2 Building the Tower
Component
Code Description Weight (kg)
31842300 Diameter 150mm (Tyred) 3.2
32942300 Diameter 200mm 3.9
31942300 Diameter 200mm (Tyred) 3.9
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2.5 Assembly
This tower structure must be assembled, and components oriented, in accordance
with this instruction manual. Deviation from this instruction manual is not permitted.
THIS TOWER MUST NOT BE USED AS AN ANCHOR POINT
FOR PERSONAL FALL PROTECTION EQUIPMENT.
•No tools are required for assembly.
•The assembly uses the 3T (Through the Trapdoor) method that provides
collective fall protection.
○From the sitting position in the trapdoor opening t all guardrails before
standing on the platform.
○Fit braces in the locations described and
ensure the claws are locked.
○DO NOT stand on an unprotected platform
•The tower may be assembled by a single person, but it is recommended that
two or more are used to pass up components on the taller assemblies.
•Components must be lifted within the footprint of the tower using a reliable
method such as a strong rope with a clove hitch knot.
•Castor brakes should be locked as soon as the tower base is in position.
•The tower base should be levelled to within 0.6° before continuing the assembly.
•The adjustable legs are for levelling the tower only and not to be used to gain
extra height.
•Ensure when the base is levelled the distance from the ground to the first
climbing rung is less than 400mm.
•Stabilisers of the size specified in the quantity schedule should be fitted at the
earliest opportunity.
2 Building the Tower
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2 Building the Tower
•Always start assembly with the smallest end frames at the base.
Platform Height (m) Frame at Base
1.7, 2.2, 3.7, 4.2, 5.7, 6.2, 7.7, 9.7, 10.2, 11.7,12.2 2 Rung
2.7, 4.7, 6.7, 8.7, 10.7 3 Rung
1.2, 3.2, 5.2, 7.2, 9.2, 11.2 4 Rung
•Where all three frames are specified, start with the 2 rung, 3 rung next and
4 rung on top. Refer to the quantity schedule for details.
Platform heights:
1.2m, 3.2m, 5.2m, 7.2m, 9.2m, 11.2m
Platform heights:
2.2m, 4.2m, 6.2m, 8.2m, 10.2m, 12.2m
Platform heights:
1.7m, 3.7m, 5.7m, 9.7m, 11.7m
Platform heights:
2.7m, 4.7m, 6.7m, 8.7m, 10.7m, 12.7m
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2 Building the Tower
2.5.1 Assembly General
Push castor into adjustable
leg. Push castor/adjustable leg
assemblies into a span frame. Lock
castors. Repeat procedure with a ladder
frame.
It is recommended that for ease of
levelling a gap of 50mm is left between
the bottom of the leg and the adjustable
nut.
Fit one horizontal brace (red) onto
the vertical of a span frame, just
above the bottom rung, with the claw
facing outwards. The frame will now be
self-supporting.
All locking claws must be opened
before fitting.
Position the ladder frame as
shown and fit the other end of the
horizontal brace on to the vertical (just
above the bottom rung).
Fit a second horizontal brace between
the bottom rungs on the other side of the
frames to square the tower.
1
2
Locked
Assembly for 1450 towers, see page 14 for following steps.
Assembly for 850 towers, see page 16 for following steps.
3
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14 BoSS Zone:1 Instruction Manual
2.5.2 Assembly For 1450 Towers
The procedure illustrated shows a 4.2m platform height tower starting with a 2 rung
end frame.
Fit two additional end frames,
ensuring the frame interlock
clips are engaged.
Fit two diagonal braces (blue) in
opposite directions between the 1st
and 3rd rungs.
Ensure the frames are vertical and
level by checking with a spirit level
and setting the adjustable legs as
required.
Fit stabilisers (see notes on page 10).
Only use the adjustment on the
legs to level the tower and not to
gain extra height.
Fit the next pair of diagonal braces
in opposite directions between the
3rd and 5th rungs. Fit a trapdoor platform
on the 4th rung (2.0m) with the trapdoor
next to the ladder. Ensure the trapdoor
is positioned with the hinges towards the
outside of the tower as shown. Fit a fixed
platform alongside it.
Climb the ladder from the protected
trapdoor position, fit the horizontal
braces on the 5th and 6th rungs (in that
order) on both sides of the platform.
When horizontal braces are fitted as
guardrails, they should be 0.5m and
1.0m (1 and 2 rungs) above the platform
level in all cases.
Do not climb onto the platform until
all guardrails are in place.
4
INTERLOCK CLIP
Spring
Clip
Spigot
5
2 Building the Tower
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2 Building the Tower
Continue the procedure until the
required height is reached, adding
additional pairs of end frames, diagonal
braces and fitting trapdoor and fixed
platforms, as shown on previous steps.
At every platform level, add horizontal
braces as guardrails from the protected
position within the trapdoor (as shown in
Step 5).
At the required platform height, fit the
fixed platform and a trapdoor platform
alongside it. Fit the final guardrails (as
shown in Step 5).
Fit toe boards.
End toe board
Side toe board
The tower is now complete.
6
7
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16 BoSS Zone:1 Instruction Manual
INTERLOCK CLIP
Spring
Clip
Spigot
2 Building the Tower
2.5.3 Assembly For 850 Towers
The procedure illustrated shows a 3.2m platform height tower starting with a 4 rung
end frame.
Fit a trapdoor platform on the 2nd
rung. Fit the horizontal braces on
both sides of the tower. When horizontal
braces are fitted as guardrails, they
should be 0.5m and 1.0m (1 and 2
rungs) above the platform level in all
case.
Fit two diagonal braces in
opposite directions between the
1st and 3rd rungs.
Ensure that the frames are vertical
and level by checking with a spirit level
and setting the adjustable legs, as
necessary.
Fit stabilisers (see notes on page 10).
Fit the next pair of end frames and
check the frame interlock clips are
engaged.
Only use the
adjustment on
the legs to level
the tower and
not to gain
extra height.
4
5
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2 Building the Tower
Fit two pairs of diagonal braces in
opposite directions between the 3rd
and 5th rungs and the 5th and 7th rungs.
Locate a trapdoor platform on the 6th
rung, with the trapdoor next to the ladder.
Climb up the inside of the tower
and from protected position of the
trapdoor, fit guardrails to the 7th and 8th
rungs (in that order) on both sides of the
tower.
Do not climb onto the platform until
all guardrail are in place.
6
7
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2 Building the Tower
Continue the procedure until the
required height is reached, adding
additional pairs of end frames, diagonal
braces and fitting trapdoor platforms,
as shown on previous steps. At every
platform level, add horizontal braces as
guardrails from the protected position
within the trapdoor (as shown in Step 7).
Fit toe boards.
End toe board
Side toe board
The tower is now complete.
2.6 Dismantling
To dismantle the tower, reverse the assembly procedure.
When removing the guardrails unlock the four claws furthest from the trapdoor and
return immediately to the protected position within the trapdoor. The other claws can
then be unlocked, and the guardrails removed from the tower.
8
9
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