Youngman BoSS StairMAX 700 Mk2 User manual

INSTRUCTION 
BoSS StairMAX Mk2
(Cam-Lock Guardrail)
Aluminium Tower
700 Climbing Rung
3T - Through the Trap Door
700
BS1139-6:2014
EN1004:2004 - 3 - 5/12 - XXXD
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com

CONTENTS
Safety First
Component Diagram
Quantity Schedule
Build Method
Pre-use Safety Inspection Checklist
3 - 6
7
8
9 - 16
17
Instruction manual EN 1298 - IM - en
FILE: S140017 Drawn: 03/05/2016 Page: 2 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com

A
SAFETY FIRST
Introduction
Please read this guide carefully. Please note that diagrams are for illustrative purposes only.
User guides are also available to download from our website at www.bossaccesstowers.com
BoSS mobile aluminium towers are light-weight scaffold towers used throughout the building and construction industry
for both 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.
The law requires that personnel erecting, dismantling, altering or inspecting towers must be competent. Any person
erecting the product described in this user guide must have a copy of this guide. For further information on the use of
mobile access and working tower visit our website at www.bossaccesstowers.com or consult the PASMA website at
www.pasma.co.uk.
Verification and assessment documentation is held by Youngman Group Ltd.
If you need further information, design advice, additional guides or any other help with this product, please contact
Youngman on [phone] or email [email protected]
Safe Use
- 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.
- The tower has a single working level with a safe working load of 275kg. All platforms may be used for
working, but only one should be used at any one time.
- Before each use:
Check that each prefabricated tower scaffold is complete and correctly assembled. •
Check that the prefabricated tower scaffold is vertical and make any adjustments as required. •
Check that no environment changes will affect the safe use of the structure. •
- Adjustable legs should only be used for levelling.
- Do not use ladders, steps, boxes or similar, to gain additional working height.
- Only climb the tower from the inside using the access method provided.
- Tower scaffolds are not designed to be lifted or suspended.
- Beware of horizontal forces (e.g. power tools) which could generate instability.
Maximum horizontal force per working bay = 30kg
- 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.
- Safe working loads, normally expressed in kN/m², are expressed below in kg per defined working area.
* Persons are assumed to be 122kg (Reference to HSE - Revision
of body size criteria in standards Protecting people who work at
height - Research report 342 )
Access Classes
The Access Class provided for climbing this tower is: Access Class 'D' (Vertical Ladder).
DEFINED WORKING
AREA
MAX. SAFE
WORKING LOAD
(UNIFORMLY
DISTRIBUTED
INCLUDING
PERSONS)
LOAD CLASS
MAX NO. OF
PERSONS *
A
275kg
3 1
FILE: S140017 Drawn: 03/05/2016 Page: 3 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com

SAFETY FIRST
Lifting of Individual Tower Components
- Raising and lowering components, tools and/or materials by rope should be conducted within the tower base (i.e.
within the area bounded by the stabilisers). Ensure that the safe working load of the supporting decks and the tower
structure is not exceeded.
Movement of the assembled prefabricated tower scaffold
- The BoSS StairMAX 700 Mk2 tower system MUST NOT be moved once erected.
- Always dismantle it and rebuild at the new location.
- The pre-use checklist on the final page shall be used to determine tower integrity.
Maintenance - Storage - Transport
- All components and their parts should be regularly inspected to identify damage, particularly to joints. Lost or broken
parts should be replaced and any tubing with indentation greater than 5mm shall be replaced. Adjustable leg threads
should be cleaned and lightly lubricated to keep them free running.
- Brace claws, frame interlock clips, trap door latches, Cam-Locks and platform wind locks should be regularly
checked to ensure they lock correctly.
- Refer to the BoSS Inspection Manual for detailed inspection and maintenance advice:
www.bossaccesstowers.com
- Components should be stored in clean, dry conditions with due care to prevent damage.
- Ensure components are not damaged by excessive strapping forces when transported.
During Assembly, Use and Dismantling
- As part of the risk assessment, wind conditions must be taken into account and reviewed regularly, depending on
the duration the structure is on site.
- The structure has been assessed for wind loads equating to 27 mph (43 kph, 12 m/s).
- The effect of on-site wind conditions must be considered prior to the assembly of a tower. The tower must not be
used in wind speeds above this. If greater wind speeds are forecast, the tower must be dismantled while it is still safe
to do so.
- Sheets, tarpaulins, cladding or similar, must not be attached to the tower as these will significantly increase any side
loads from wind and will potentially make the tower unstable.
- Beware of wind turbulance and funnelling effects around buildings.
- Excessive side loads from working on the tower, i.e. through drilling or pulling, may also make a tower unstable.
The maximum allowable side load on a tower is 30kg.
- Do not abuse equipment. Damaged, incorrect or incompatible components should not be used.
- CAUTION: Always ensure the portal ladder is in closed position when descending the tower. If the portal ladder is in
open position, from the protected position of the trap door deck (i.e. seated), close the portal ladder ensuring the
locking claw has been fully engaged.
Ties
This structure is designed to be self-supporting under the loading condition requirements of BS 1139-6:2014 and does
not require tying in. Consideration should be given to potential wind conditions if the tower is left unattended - see
'During Assembly, Use and Dismantling' section above.
Designation  Safe Loading Plate
In accordance with BS1139-6:2014, the 'Designation & Safe Loading Plate' information shall be affixed to the base of
the prefabricated tower scaffold by means of the Scheme drawing and the Handover Certificate. They must be clearly
visible so that end users are aware of the conditions of safe use.
FILE: S140017 Drawn: 03/05/2016 Page: 4 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com

4.0m INTERVALS
4.0m INTERVALS
SAFETY FIRST
Stabilisers
Stabilisers shall always be fitted when specified.
Attach one stabiliser to each corner of the tower as shown.
Ensure stabilisers feet are equally spaced to form a square.
Telescopic stabilisers must always be fully extended.
Position the lower clamp so that the lower arm is as close to
horizontal as possible. Adjust the position of the upper clamp to
ensure the stabiliser foot is in contact with the ground. Ensure
clamps are secure.
Props
The BoSS StairMAX 700 Mk2 tower shall be adequately propped or tied to prevent lateral movement. They must be fitted
at regular 4.0m intervals. To improve stability, additional props or ties can also be fitted at lower levels.
The method shown below illustrates the use of BoSS Confined Space Stabilisers.
Attach one confined space stabiliser to each corner of the tower as shown (see page 16). Ensure stabiliser feet are
touching the lift shaft walls - adjust confined space stabilisers as necessary to achieve this.
If you require further advice, please contact Youngman on [phone].
FILE: S140017 Drawn: 03/05/2016 Page: 5 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com

SAFETY FIRST
Assembly Procedure
This tower structure must be assembled, and components oriented, in accordance with this documents.
Deviation from this instruction is not permitted.
A minimum of two persons are recommend for assembly and disassembly of this prefabricated tower structure. The
maximum number of persons for assembly is stated in the safe loading table.
Platforms must be installed with vertical distances between them not exceeding 2.1m when assembling and dismantling.
The maximum number of people on a working platform level permitted to simultaneously exert a horizontal load of 30kg is:
- 1 person per bay for bays less than 4m long and
- 2 persons per bay for bays greater than 4m in length
Check that all components, tools and safety equipment are on site (refer to quantity schedule), undamaged and that they
are functioning correctly, particularly the brace claw locking mechanism.
Full inspection guidance can be found at www.bossaccesstowers.com.
Damaged or incorrect components shall not be used.
Component weights can be found in the quantity schedule and on the corresponding BoSS Product Datasheets.
Check that the ground on which the tower structure is to be erected and moved is capable of supporting the tower and
within the levelling limits of the tower system.
Check overhead that the area into which the tower structure is to be built contains no obstructions, particularly electrical or
radio radiation hazards.
Never stand on an unguarded platform positioned above the first rung of a tower structure. If your risk assessment shows it
necessary, you may also need to guardrail platforms at this level.
Tower components 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 tower structure.
Ensure horizontal braces and guardrails
are fitted correctly.
Ensure interlock clips on frame
memebrs are in the 'locked' position.
Ensure wind locks are engaged before
moving onto the deck levels.
Information for the 'Designation & Safe Loading Plate' can be found in the safe loading table and this plate must be
attached to the base of the tower scaffold.
Ensure Cam-Locks are engaged.
FILE: S140017 Drawn: 03/05/2016 Page: 6 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com

STABILISER
1.3m TRAP DOOR DECK
1.64m DIAGONAL BRACE
1.3m HORIZONTAL BRACE
ADJUSTABLE LEG & BASE PLATE
PORTAL LADDER FRAME Mk2
1.0m 4 RUNG
700 BoSS SOLO FRAME
ALUMINIUM FOLDING
TOE BOARD KIT
1.3m CAM-LOCK
GUARDRAIL FRAME
DOWNSTAIR END
UPSTAIR END
REAR
FRONT
CONFINED SPACE
STABILISER
INSTRUCTION MANUAL
COMPONENT DIAGRAM
FILE: S140017 Drawn: 03/05/2016 Page: 7 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com

QUANTITY SCHEDULE
Platform Heights Above 5.0m (INTERNAL USE ONLY)
When used internally, platform heights up to 11.0m can be achieved with the use of props. Please refer to page 5 for
guidance.
[ Working and Platform heights are measured from underside of lowest base plate. ]
Build Aid:
For every 2.0m lift required, add an additional four 4 rung frames, one trap door deck and three Cam-Lock guardrail
frames. Confined Space Stabilisers or props must be used at every 4.0m interval (see page 5 for advice).
FILE: S140017 Drawn: 03/05/2016 Page: 8 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com

BUILD METHOD
When building a BoSS tower:
- To comply with 'Work at Height Regulations' we show assembly procedures with platforms every 2 meters in height and
the locating of guardrails in advance of climbing onto a platform to increase safety and reduce the risk of a fall.
- Never stand on an unguarded platform positioned above the first rung of a tower. If your risk assessment shows it
necessary, you may also need to guardrail platforms at this level.
The procedure illustrated shows a 7.0m working height tower build.
Youngman recommend two persons are used to build BoSS Towers. Above 4.0m height, it is essential that at
least two persons are used. Only climb the tower from the inside.
1
Insert two Base Plates into Adjustable Legs and fit the leg and base plate assemblies into one of the two Portal Ladder
Frames. Repeat with the remaining legs and base plates. It is recommended, for ease of levelling, that a gap of 50mm is
left between the bottom of the leg and the adjustable nut.
Note: Adjustable Legs are for levelling only. They are not to be used to gain extra height at the working level.
FILE: S140017 Drawn: 03/05/2016 Page: 9 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com






BUILD METHOD

2
Fit one Horizontal Brace (red catch) onto the vertical
of end frame on the climbing side above 5th rung,
with the claw facing outwards.
Ensure the gate opens as shown.
Note: All locking claws must be opened before fitting.
3

Position a second Portal Ladder Frame higher on
stairs as shown and fit other end of Horizontal Brace
just above the bottom rung. Fit another Horizontal
Brace as shown. This will become the higher 'upstair'
end of the tower.
Ensure both gates open the same direction as shown.
FILE: S140017 Drawn: 03/05/2016 Page: 10 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com




BUILD METHOD
4

Fit two Diagonal Braces (blue catch) between bottom
rungs of both Portal Ladder Frames, one on each side of
the tower. Claws must face downwards.
The structure must be vertical to within 1cm per metre.
Ensure the frames are vertical and level by checking with
a spirit level and setting the adjustable legs as required.

5
Connect two 4 Rung Frames together and fit onto Portal
Ladder Frame as shown. Engage interlock clips. Fit one
Diagonal Brace in position shown.
Ensure interlock clips on frame
members are in the 'locked' position
FILE: S140017 Drawn: 03/05/2016 Page: 11 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
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©
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FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
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


1.5m (min)
1.2m (min)
outstand
BUILD METHOD

6
Fit one 4 Rung Frame onto the Portal Ladder
Frame at the higer level by standing on the
stairs. Engage interlock clips. Fit one more
Diagonal Brace as shown.
7

Fit Stabilisers.
SEE NOTES ON PAGE 5.
The upper clamp of Stabilisers must be at least 1.5m above
the bottom of the frame. Where possible, Stabilisers must
also have a minimum outstand of 1.2m.
FILE: S140017 Drawn: 03/05/2016 Page: 12 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com



BUILD METHOD

8
Fit one 1.3m Trap Door Deck onto the top rung of the
'upstair' Portal Ladder Frame as shown.
Ensure the trap door opens towards the rear of the tower.
9

From the protected position of the
trap door deck (i.e. seated), fit a
Cam-Lock Guardrail Frame on the
rear of the tower, with the upper
claws located on the 4th rungs above
the platform deck.
Repeat with a second Cam-Lock
Guardrail Frame on the front of the
tower.
As before, engage Cam-Locks to
lock guardrail units in position.
Do not climb onto the deck until it
is fully guardrailed.
Ensure the gate is fully engaged
before climbing.
Ensure all wind locks are engaged.
FILE: S140017 Drawn: 03/05/2016 Page: 13 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com





BUILD METHOD
11

Fit one 1.3m Trap Door deck onto the 8th
rung above the platform deck as shown.
Ensure wind locks are engaged.

10
Connect two 4 Rung Frames together to create two
subassemblies. Engage interlock clips. Whilst
standing on the protected platform deck, fit one
subassembly onto the 'downstair' end of the tower.
Again, engage interlock clips.
Repeat for the 'upstair' end of the tower.
Fit a Cam-Lock Guardrail Frame to the rear of the
tower, with the upper claws located on the 7th rung
above the platform deck.
Engage Cam-Locks to lock guardrail unit in position.
FILE: S140017 Drawn: 03/05/2016 Page: 14 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com



BUILD METHOD

12
From the protected position of the trap door deck
(i.e., seated), fit a Cam-Lock Guardrail Frame on
the rear of the tower, with the upper claws located
on the 4th rungs above the platform deck.
Repeat with a second Cam-Lock Guardrail Frame
on the front of the tower.
As before, engage Cam-Locks to lock guardrail
units in position.
Do not climb onto the deck until it is fully
guardrailed.
13

Unclip storage strap from Aluminium Folding Toe
Board set, unfold and fit into position on working
platform.
Ensure it sits squarely around deck and does not
impede the opening of the trap door in the deck.
THE TOWER IS NOW COMPLETE.
FILE: S140017 Drawn: 03/05/2016 Page: 15 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com





When building beyond 5.0m platform
height:
Continue to add two pairs of assembled 4 Rung Frames,
Cam-Lock Guardrail Frames, one Trap Door Deck and four
Confined Space Stabilisers as shown in previous steps. At
every platform level add guardrails between 2nd and 4th
rungs above the platform.
Fit these guardrail frames from the protected trap door
position. Do not climb onto the platform until it is fully
guardrailed.
Continue until the required height is reached.
At platform heights above 5.0m, Confined Space
Stabilisers must be fitted at 4.0m intervals as instructed
below and on page 5.
Fit a Confined Space Stabiliser to all four corners of the
tower as shown, with the upper clamp above the 24th
rungs as shown. Secure the lower clamp between the 23rd
and 24th rungs so that the stabiliser arm is horizontal.
Ensure the end of the stabiliser arm contacts the walls. If it does
not, adjust by unclipping and extracting the locking pin, sliding the
arm until correct length and hole alignment is achieved. Reinsert
the locking pin, ensuring clip is engaged. See images below.
Unclip & extract pin Extend/retract adjustable arm Reinsert pin and engage clip
BUILD METHOD
To dismantle a BoSS tower:
Simply follow the assembly steps in reverse, ensuring that the 3T method is followed.
FILE: S140017 Drawn: 03/05/2016 Page: 16 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com

Head Office and Customer Services
The Causeway, Maldon,
Essex. CM9 4LJ.
United Kingdom
t: [phone]
f: [phone]
e: [email protected]
w: www.bossaccesstowers.com
INSTRUCTION MANUAL PART NO. 108791
PRE-USE SAFETY INSPECTION CHECKLIST
Pre-use Safety Inspection Checklist
Tower structure upright & level •
Castors locked & legs correctly adjusted •
Diagonal braces fitted •
Stabilisers fitted as specified •
Platforms located & wind locks engaged •
Interlock clips engaged •
Toe boards located •
Guardrails fitted correctly & positively locked •
FILE: S140017 Drawn: 03/05/2016 Page: 17 OF 17 Issue: C
BoSS StairMAX 700 Mk2 (Cam-Lock Guardrail)
BoSS IS A REGISTERED TRADEMARK OF YOUNGMAN GROUP LTD
©
YOUNGMAN GROUP LTD - 03/05/2016
FOR UP TO DATE INFORMATION ON THIS PRODUCT CHECK
www.bossaccesstowers.com