Marcegaglia Buildtech Realpont system 75 User manual

Instruction manual
Prefabricated frames

SUPPLY Various modes of
supply are available:
• sale
• sale with buyback agreement
• rent
• rent with redemption
All these modes of supply can be
combined with the following services:
• assembly
• disassembly
• service at the building site
MATERIAL ZC
hot dip galvanized steel
ZZ
Sendzimir galvanized steel
ZE
electro-galvanized steel
VR
painted steel
TR
tropicalized steel
LG
wood
AL
aluminium
REMARKS The weight refers to nominal
gage values
* Production
on request

Instruction manual • Prefabricated frames
1
Index
CERTIFICATIONS
Certifications
64
REALPONT SYSTEM DESCRIPTION
Prefabricated frames: Realpont system 75
Prefabricated frames: Realpont system 105
Realpont system components
04
05
06
INSTRUCTIONS FOR USE
Pre-erection
Erection
Use
Dismantling
Transport
30
31
33
34
34
ANCHORAGES
General characteristics
Tie anchorage
Ring anchorage
Screw-down anchorage
Bracing anchorage
Truss beam in tube-coupler anchorage
Anchorage with reinforced rod for reinforced concrete
Anchorage with steel structural plates
36
37
39
41
41
43
45
46
TEL DAL T5/UNIFORM SYSTEM DESCRIPTION
Prefabricated frames: Tel Dal T5/Uniform system
Tel Dal system T5 components
Uniform system components
14
15
20
ERECTION SEQUENCE
Connection elements
Realpont system erection sequence
48
49
TUBE-COUPLER SYSTEM DESCRIPTION
Tube-coupler system components 26

Instruction manual • Prefabricated frames
2

Instruction manual • Prefabricated frames
3
Prefabricated frames: Realpont system 75
Prefabricated frames: Realpont system 105
Realpont system components
04
05
06
Description
Realpont system

Instruction manual • Prefabricated frames
4
Sales, rent.
SUPPLY
-Hot dip galvanized: guaranteed min. coating thickness 55 micron (mean
value);
-Painting performed by immersion with resistance tested to ASTM D
2247-87 moist-room test;
- Color: red
PROTECTION
750 mm deep/wide frame • Painted or hot dipped galvanizing protection
Erection of 2500 mm and 3000 mm mixed bay structures • Bushing fit-
tings
-Steel grade S235JR
-Steel tubes: 48.3 mm outside diameter, 2.9 mm S235JRH nominal gage
UPRIGHTS MATERIAL
Prefabricated frames:
Realpont system 75
System with 75 cm frames with bushings
-Bushing fittings;
-Modular bushing fittings to obtain 1.8 m, 2.5 m and 3,0 m mixed bays;
-Safe erection;
-Licensed for uniform building loads of 300 daN/m2 (cl IV, EN12811)
CHARACTERISTICS
STANDARD DIMENSIONS
Width Span Module
750 mm 1800 mm
2500 mm
3000 mm
2000 mm
Fix height
TUBE CHARACTERISTICS ACCORDING TO EN10219
Outside diameter (mm) 48,30 40,00 38,00 38,00 26,90
Thickness (mm) 2,9 2 4 2,5 2
Section (cm2)4,14 2,38 4,27 2,78 1,56
Moment of inertia (cm4)10,7 4,32 6,26 4,41 1,22
Section modulus (cm3)4,43 2,16 3,29 2,32 0,907
Radius of gyration (cm) 1,61 1,34 1,21 1,25 0,88
Nominal weight (kg/m) 3,27 1,87 3,38 2,18 1,24
Ultimate stress (N/mm2)≥ 360 ≥ 360 ≥ 360 ≥ 360 ≥ 360
Elongation at rupture (%) ≥ 24 ≥ 24 ≥ 24 ≥ 24 ≥ 24
Thickness tolerance: ≤ 5%
Tolerance on the mass ± 5% on parts of at least 10 Ton
Other tolerances: as per ISO 65 recommendations
Manufacturing Standards
- Aut. Min. n.15/0009997/14.03.01.03 del 01/06/2005
- Est. 15/VI/3800/14.03.01.02 del 03/08/2006
- Decreto legislativo 9 Aprile 2008 n. 81
- D.M. 02/09/68
- D.M. 23/03/90 n. 115
- Circolari 44/90 e 156 AA.GG./STC.
- Disciplinare UNICMI sul marchio SQ

Instruction manual • Prefabricated frames
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Sales, rent.
SUPPLY
-Hot dip galvanized: guaranteed min. coating thickness 55 micron (mean
value);
-Painting performed by immersion with resistance tested to ASTM D
2247-87 moist-room test;
- Color: red
PROTECTION
-Steel grade S235JR
-Steel tubes: 48.3 mm outside diameter, 2.9 mm S235JRH nominal gage
UPRIGHTS MATERIAL
-Bushing fittings;
-Modular bushing fittings to obtain 1.8 m, 2.5 m and 3,0 m mixed bays;
-Safe erection;
-Licensed for uniform building loads of 300 daN/m2 (cl IV, EN12811)
CHARACTERISTICS
TUBE CHARACTERISTICS ACCORDING TO EN10219
Outside diameter (mm) 48,30 40,00 38,00 38,00 26,90
Thickness (mm) 2,9 2 4 2,5 2
Section (cm2)4,14 2,38 4,27 2,78 1,56
Moment of inertia (cm4)10,7 4,32 6,26 4,41 1,22
Section modulus (cm3)4,43 2,16 3,29 2,32 0,907
Radius of gyration (cm) 1,61 1,34 1,21 1,25 0,88
Nominal weight (kg/m) 3,27 1,87 3,38 2,18 1,24
Ultimate stress (N/mm2)≥ 360 ≥ 360 ≥ 360 ≥ 360 ≥ 360
Elongation at rupture (%) ≥ 24 ≥ 24 ≥ 24 ≥ 24 ≥ 24
Thickness tolerance: ≤ 5%
Tolerance on the mass ± 5% on parts of at least 10 Ton
Other tolerances: as per ISO 65 recommendations
STANDARD DIMENSIONS
Width Span Module
1050 mm 1800 mm
2500 mm
3000 mm
2000 mm
Fix height
Prefabricated frames:
Realpont system 105
System with 105 cm frames with bushings
Installation of 1050 mm deep working bays • Protection or hot dipped
galvanizing protection • Erection of 2500 mm and 3000 mm mixed bay
structures • Bushing fittings.
Manufacturing Standards
- Aut. Min. Realpont 15/0006649/14.03.01.01 del 12/04/2005
- Est. 15/VI/3799/14.03.01.01 del 03/08/2006
- EU 92 15/0009998/14.03.01.03 del 01/06/2005
- Decreto legislativo 9 Aprile 2008 n. 81
- D.M. 02/09/68
- D.M. 23/03/90 n. 115
- Circolari 44/90 e 156 AA.GG./STC.
- Disciplinare UNICMI sul marchio SQ
- n. 15/VI/3974/14.03.01.02 del 3 agosto 2006
- n. 15/VI/7369/14.03.01.02 del 5 maggio 2008

Instruction manual • Prefabricated frames
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Realpont system - Components
Realpont half-frame
mm material cod daN
1050x1300 VR IT 3040105980 15,04
1050x1300 ZC IT 3040105981 15,08
1050x1300 ZC EN 3040105991 15,99
Realpont compensation-frame
mm material cod daN
750x1300 VR IT 3040106130 13,17
750x1300 ZC IT 3040106131 13,90
750x1300 ZC EN 3040105961 14,50
Spigot pin
mm material cod daN
100 TR IT/EN 3040701006 0,12
Guardrail with forged
connection devices
mm material cod daN
1800 VR IT 3040201010 2,76
1800 ZZ IT/EN 3040201015 2,88
2500 ZZ IT/EN 3040201175 5,80
3000 ZZ EN 3040201705 6,69
Base plate
mm material cod daN
48 TR IT/EN 3030100006 0,92
Adjustable base jack
mm material cod daN
355 ZE IT/EN 3040800902 2,49
700 ZE IT/EN 3060300141 3,30
1000 ZE IT/EN 3040501012 4,69
Realpont frame
mm material cod daN
750x2000 VR IT 3040106100 18,14
750x2000 ZC IT 3040106101 19,24
750x2000 ZC EN 3040106071 19,31
1050x2000 VR IT 3040106000 20,10
1050x2000 VR EN 3040107000 20,32
1050x2000 ZC IT 3040106001 21,13
1050x2000 ZC EN 3040107001 21,13

Instruction manual • Prefabricated frames
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Horizontal-diagonal brace
for pedestrian walk-thru frame
with forged connection device
mm material cod daN
1798x3000 ZZ EN 3040201745 7,68
Vertical-diagonal brace
mm material cod daN
1800 VR IT 3040201000 3,25
Vertical-diagonal
brace with forged
connection devices
mm material cod daN
1800 ZZ IT 3040201005 3,40
2500 ZZ IT 3040201185 6,40
2500 ZZ EN 3040201195 6,23
3000 ZZ EN 3040201715 7,05
Double fencing
structure
mm material cod daN
1800 VR IT 3040201900 9,10
1800 ZC IT 3040201901 10,09
1800 ZC EN 3040201791 8,85
2500 ZZ IT 3040201911 15,08
2500 ZC EN 3040201801 15,42
3000 ZC EN 3040201851 18,80
Horizontal-diagonal
brace
mm material cod daN
748x1800 VR IT 3040206160 2,86
748x1800 ZZ IT 3040206165 3,33
748x2500 ZZ IT 3040206175 5,94
748x3000 ZZ EN 3040201725 6,87
1048x1800 VR IT/EN 3040206010 3,12
1048x1800 ZZ IT/EN 3040206015 3,26
1048x2500 ZZ IT/EN 3040201195 6,23
1048x3000 ZZ EN 3040201715 7,05
Horizontal-diagonal brace
for tapered ends
with forged
connection devices
mm
material cod daN
348x1800 ZZ IT 3040202065 2,93
348x2500 ZZ IT 3040201165 5,85
648x1800 ZZ 3040201266 3,03
648x2500 ZZ IT 3040201155 5,88

Instruction manual • Prefabricated frames
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Steel denitive
guardrail frame
mm material cod daN
750 ZC EN 3040201691 14,08
1050 ZC EN 3040201681 15,10
1800 ZC EN 3040201661 16,98
2500 ZC EN 3040201671 18,74
3000 ZC EN 3040201751 21,96
Transom
mm material cod daN
750 VR IT 3040206180 1,16
750 ZZ IT 3040206185 1,66
1050 VR IT 3040206060 1,94
1050 ZZ IT 3040206065 2,02
Side fencing structure
with toeboard
mm material cod daN
750 VR IT 3040206040 8,25
750 ZC EN 3040206141 8,67
750 ZC IT 3040206041 9,37
1050 VR IT 3040206100 10,75
1050 ZC EN 3040206131 10,82
1050 ZC IT 3040206101 11,23
Securdeck scaffold
steel plank
mm material cod daN
1800x330x50 ZZ IT/EN 3070102041 10,80
2500x330x50 ZZ IT/EN 3070102051 14,38
3000x330x50 ZZ IT/EN 3070102161 16,75
3000x330x75 ZZ IT/EN 3070102071 19,90
1800x490x50 ZZ IT/EN 3070102011 15,16
2500x490x50 ZZ IT/EN 3070102021 21,30

Instruction manual • Prefabricated frames
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Steel plank
with trapdoor
mm material cod daN
1800x490x50 PZ 3070100011 28,68
1800x490x50 ZZ 3070100031 28,68
2500x490x50 ZZ 3070800031 38,41
1800x660x60 ZZ 3150200191 35,04
2500x660x60 ZZ 3150200201 45,38
Aluminium-plywood plank
with frontal opening trapdoor
mm material cod daN
1800x660 AL 3070101149 20,63
2500x660 AL 3070101139 26,35
3000x660 AL 3070101521 31,53
Aluminium-plywood plank
with frontal opening trapdoor and ladder
mm material cod daN
2500x660 AL IT/EN 3070101129 32,38
3000x660 AL EN 3070101069 38,06
Toeboard
mm material cod daN
1800 ZC 3070200001 5,02
2500 ZC 3070200051 7,35
3000 ZC 3070200071 7,321
Ladder
mm material cod daN
2000 VR 3070300130 6,05
2000 ZC 3070300131 7,35
Compensation frame ladder
mm material cod daN
1330 VR 3070300160 6,05
1330 ZC 3070300161 7,35

Instruction manual • Prefabricated frames
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Ladder handrail
mm material cod daN
-ZC 3070300141 2,78
Simple reinforced terminal
mm material cod daN
-VR IT 3040404080 7,15
-ZC IT 3040404081 7,84
-ZC EN 3040303021 7,84
Top guardrail upright
mm material cod daN
2000 VR IT 3040404090 11,82
2000 ZC IT 3040404091 12,36
2000 ZC EN 3040404111 12,36
Walk-thru frame
mm material cod daN
1796x2516 ZC IT 3040104081 33,68
1796x2400 ZC EN 3040104051 34,14
Lower support
mm material cod daN
-VR IT 3040101030 18,21
-ZC IT 3040101031 19,66
Upper support
mm material cod daN
650x1050 VR IT 3040106020 25,93
650x1050 ZC IT 3040106021 27,10

Instruction manual • Prefabricated frames
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Bracket
for Realpont system 75
mm material cod daN
750 ZC IT 3040306031 6,54
750 VR IT 3040306030 6,82
750 ZC EN 3040307501 7,01
Bracket
for Realpont system 1050
mm material cod daN
1050 VR IT 3040306000 8,50
1050 ZC IT 3040306001 7,98
1050 ZC EN 3040307201 8,58
Bracket brace
mm material cod daN
750 ZC IT/EN 3040306041 8,30
1050 VR IT/EN 3040305010 8,44
1050 ZC IT/EN 3040305011 8,73
Street protection fan
mm material cod daN
-VR IT 3040301050 9,19
-ZC IT 3040301051 9,65
-ZC EN 3040800401 18,60
Bridging ledger
mm material cod daN
3600 VR IT 3040604020 41,84
3600 ZC IT/EN 3040604021 43,50
5000 ZC IT/EN 3040601031 52,82
5400 VR IT 3040604040 60,66
5400 ZC IT/EN 3040604041 63,06
Bridging ledger junction
mm
material cod daN
748 ZC EN 3040603021 10,78
748 ZC IT 3040606011 5,63
1048 VR IT/EN 3040605010 8,47
1048 ZC IT 3040605011 8,95
Bracket
for loading
platform
mm material cod daN
1048 VR IT 3040306900 13,01
1048 ZC IT/EN 3040306901 13,46

Instruction manual • Prefabricated frames
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Instruction manual • Prefabricated frames
13
Prefabricated frames: Tel Dal T5/Uniform system
Tel Dal system T5 - Components
Uniform System - Components
14
15
20
Description
Tel Dal T5/Uniform system

Instruction manual • Prefabricated frames
14
Sales, rent.
SUPPLY
- Painting performed by immersion with resistance tested to ASTM D
2247-87 moist-room test;
- Color: blue for Tel Dal T5, red for Uniform
PROTECTION
1050 mm deep/wide frame • Painted protection by immersion • Erection
of 1800 mm mixed bay structures • Pawl fittings
- Steel grade S235JR
- Steel tubes: 48.3 mm outside diameter, 2.9 mm nominal gage
UPRIGHTS MATERIAL
Prefabricated frames:
Tel Dal T5/Uniform system
System with 105 cm frames with pawl
-Pawl fittings;
-Span: 1,8 m;
-Safe erection;
-Licensed for uniform building loads of 300 daN/m2(cl. IV, EN 10811)
CHARACTERISTICS
DIMENSIONS
Width Span Module
1050 mm 1800 mm 2000 mm
Fix height
TUBE CHARACTERISTICS ACCORDING TO EN10219
Outside diameter (mm) 48,30 40,00 38,00 38,00 26,90
Thickness (mm) 2,9 2 4 2,5 2
Section (cm2)4,14 2,38 4,27 2,78 1,56
Moment of inertia (cm4)10,7 4,32 6,26 4,41 1,22
Section modulus (cm3)4,43 2,16 3,29 2,32 0,907
Radius of gyration (cm) 1,61 1,34 1,21 1,25 0,88
Nominal weight (kg/m) 3,27 1,87 3,38 2,18 1,24
Ultimate stress (N/mm2)≥ 360 ≥ 360 ≥ 360 ≥ 360 ≥ 360
Elongation at rupture (%) ≥ 24 ≥ 24 ≥ 24 ≥ 24 ≥ 24
Thickness tolerance: ≤ 5%
Tolerance on the mass ± 5% on parts of at least 10 Ton
Other tolerances: as per ISO 65 recommendations
Manufacturing Standards
- Aut. Min. n.19647/PR-7/B-9 del 10/03/1978
- Aut. Min. n.23455/OM-4 del 04/02/1998
- Decreto legislativo 9 Aprile 2008 n. 81
- D.M. 02/09/68
- D.M. 23/03/90 n. 115
- Circolari 44/90 e 156 AA.GG./STC.

Instruction manual • Prefabricated frames
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Tel Dal system T5 - Components
Base plate
mm material cod. daN
48 TR 3030100006 0,92
Adjustable base jack
mm material cod. daN
330 ZE 3040501062 2,42
1000 ZE 3040501012 4,69
Frame Tel Dal T5
mm material cod. daN
2000x1050 VR 3040104000 18,83
2000x1050 ZC 3040104001 19,00
Half-frame Tel Dal T5
mm material cod. daN
1330x1050 VR 3040104010 14,26
1330x1050 ZC 3040104011 14,30
Spigot pin
mm material cod. daN
10 TR 3040701006 0,12
Double guardrail P22
mm material cod. daN
-VR 3040204030 7,42
-ZC 3040204031 8,00

Instruction manual • Prefabricated frames
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Ledger P11
mm material cod. daN
-VR 3040204020 2,42
-ZC 3040204021 2,76
Vertical-diagonal brace
mm material cod. daN
-VR 3040204000 2,99
-ZC 3040204001 3,06
Horizontal-diagonal brace
mm material cod. daN
-VR 3040204050 2,68
-ZC 3040204051 2,60
Aluminium temporary
guardrail frame
mm material cod. daN
1048 AL 3040201919 12,33
1800 AL 3040201879 12,85
Side fencing structure
with toeboard T5
mm material cod. daN
-VR 3040206120 12,05
-ZC 3040206121 12,39
Steel plank
with trapdoor
mm material cod. daN
1800x500x50 ZZ 3070100011 28,68
Toeboard
mm material cod. daN
1800x500 ZZ 3070100001 18,29

Instruction manual • Prefabricated frames
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Ladder
mm material cod. daN
2000 VR 3070300130 6,05
2000 ZC 3070300131 7,35
Compensation frame ladder
mm material cod. daN
1330 VR 3070300160 3,96
1330 ZC 3070300161 4,15
Ladder handrail
mm material cod. daN
-ZC 3070300141 2,78
Top guardrail
upright Tel Dal
mm material cod. daN
-VR 3040404000 7,84
-ZC 3040404001 7,29
Upright TD4
mm material cod. daN
-VR 3040404020 7,07
-ZC 3040404021 7,42
Reinforcement upright RP12
mm material cod. daN
2000 VR 3040406030 8,26
2000 ZC 3040406031 8,58
Walk-thru frame
mm material cod. daN
-VR 3040104060 32,16
-ZC 3040104061 33,68

Instruction manual • Prefabricated frames
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Guardrail ledger
for walkthrough passage
with forged
connection device
mm material cod. daN
-ZZ 3040204105 4,26
Horizontal-diagonal brace
for walkthrough passage
with forged
connection device
mm material cod. daN
-ZZ 3040204125 5,84
Horizontal-diagonal brace
for walkthrough passage
with cold-pressed
connection device
mm material cod. daN
-VR 3040204120 5,44
Vertical-diagonal brace
for walkthrough passage
with forged
connection device
mm material cod. daN
-ZZ 3040204115 5,03
Lower support Tel Dal
mm material cod. daN
-VR 3040104040 17,70
-ZC 3040104041 18,90