The NUDURA Alignment and Tall Wall Scaffold Adaptor Systems- A “HowTo” Installation Guide. NUDURA Alignment System Each NUDURA Alignment System comes in complete sets of twenty (20). A set includes a Channel (8 or 10 foot), , a Turnbuckle, a Catwalk Bracket, and a Guardrail Post. The connection hardware is also included. The Turnbuckle has four length settings and each end is threaded so that smaller adjustments can be made simply by rotating the shaft.. Using the NUDURA Alignment System. Assembling the Turnbuckle. First, use the 3” bolt to fasten the foot pad to the end of the thicker shaft piece of the turnbuckle. Next, slide the smaller shaft piece into the thicker shaft piece and insert a cotter-pin bolt through one set of aligning holes. Attaching the Guardrail Post to the Catwalk Bracket. The Guardrail Posts slide onto the top of the Catwalk brackets and are by a cotter-pin bolt though the aligning holes. The Guardrail Post may face either towards the wall or away from the wall. Component Assembly 1. Place Bracing Channel against wall. If installing as an 8 foot or 10 foot high installation mark out locations at 6’-0” (2.1 m) o/c 2. Screw the bracing channel in place with # 10 x 1 ½” (38mm) 5/16” hex head drive coarse thread self-tapping sheet metal screws – 1 screw per slot – keeping all but the bottom screw at top of slot to allow for movement Component Assembly 3. Bolt top of turnbuckle in place at required height to suit ground or slab condition through hole set provided in bracing channel to suit required scaffold placement height in using gravity pin insert provided. 4. Anchor Turnbuckle Base plate firmly into ground, slab or floor with either steel drift pins, Tapcons, or Wood Screws. Component Assembly 4. NOTE: Anchorage of the base plate must be in conformance with local Codes and Safety Standards and with adequate strength to support the required loads of workers and material along with accounting for prevailing winds. (The contractor is responsible for making this determination). Component Asssembly 4. Finally, hook the catwalk bracket/handrail post assembly in place over the gravity pin bolt to complete the installation. Component Assembly to Wall System for Tall Wall Installations NOTE: When assembling standard NUDURA Alignment System for tall wall assembly, the component installation will be similar – EXCEPT for 2 items: (a) Instead of spacing at 6’-0” (1.83 m) the bracing channels will be typically positioned at 7’-0” (2.13m) o/c (b) The channels will be anchored with 14” tall wall connection wires as shown (left) and described in the following section. NUDURA Tall Wall Adapter System Each Tall Wall Adapter Kit (set of 20) contains: -20 Scaffold to Turnbuckle Adapters -20 Channel to Scaffold Adapters -10 Scaffold to Scaffold Adapters NUDURA Tall Wall Connection Wires (14” (356 mm) Self-Threading Washer Tall Wall Connection Wires are sold in boxes containing 100 pieces and come in a 14” (356 mm) length to accommodate all form sizes. Using the NUDURA Tall Wall Adapter System. IMPORTANT NOTICE: TO ALL BIDDING DISTRIBUTORS AND CONTRACTORS Whenever considering utilizing the NUDURA Alignment System and Tall Wall Adapter Components in conjunction with standard frame scaffolding, be sure to allow for Engineering Costs associated with design of the scaffold required to sustain the required loads for the site (wind and safety) These typically can add anywhere between $ .25 to $1.00 /SF ($2.70 to $11.00 /m2) of wall area depending on site conditions and building design. Consult with your local scaffold supplier to find an experienced designer who can competently execute this work with a minimum of cost overrun. Measure Width of Scaffolding. The NUDURA Tall Wall Adapter Kit can be used with any conventional scaffolding. Measure the width of the scaffolding being used and transfer this dimension to mark out locations on the wall system (typically this dimension will be 7’-0” (2.13 m) o/c. Position First Set of Connection Wires. During each course placement of the wall assembly, at each projected bracing channel position, cut two slits in the form with a hand saw – 4” (102 mm) apart. Place cuts on the form score lines; either on each side of the web or at center of the cavity between webs. Insert a 12” (305 mm) piece of rebar through the web as indicated. Hook the pairs of connection wires on the rebar and slide down into cuts as shown above. Position Second Set of Connection Wires. Measure for the width of the scaffolding and place the second set of connection wires at the score lines on either side of the center of the web cavity. With 7’-0” (2.13 m) spacing, every other brace will end up halfway between webs (as shown above) Secure connection wires on each course to the height of the first pour. Attaching Channels and/or Scaffolding Using Connection Wires. After third course, place bracing channel in position on first pour level as shown left. Place cross tie connection clips in placeover wires as shown below. Securing Cross Tie Connection Clips In Place & 1st Pour. Once cross ties clips are in place, apply 3.8” (10 mm) dia. self threading washer/nuts over each wie and handtighten clip against bracing channel. Cut off excess wire. Finally, use 3/8” deep socket to cinch nuts and clip tightly against bracing channel. Complete erection and concrete placement as would normally be completed for 1st pour. Channels Removal and Scaffolding Placement. Following completion and initial cure of first pour, remove and retain self threading washers and cross tie connection clips for re-use. Remove and stow NUDURA Alignment Components (catwalk bracket, turnbuckle and bracing channel) for reuse. Begin scaffold set-up, aligning scaffold uprights locations where wires were previously anchoring the NUDURA Bracing Channels in place. Scaffold Installation Continued… These photos represent suggested applications. NUDURA recommends that cross braces be applied to the channels and at least the top and bottom cross brace for the scaffolding. Follow installation precisely in accordance with engineers specifications for cross bracing placement, diagonal brace poles as well as required staging bays for additional wind resistance. (Staging bays are periodic double or triple tiered frames of scaffolding used to stiffen the scaffold assembly to provide the required performance for support of the NUDURA Wall) Examples of Use of Scaffold to Scaffold Adapters. Installation of Tall Wall Adaptor Components Once the scaffold is erected, the NUDURA Tall Wall Adapter Components can be installed to enable adaptation of the NUDURA Alignment System to the top of the scaffold platform. Channel to Scaffold Adapters Installation Insert the Channel to Scaffold Adapter into the end of the scaffold frame and secure using a pin or nut and bolt. Slide the channel down onto the adapter. Secure the channel to the adapter by inserting a 4” bolt through the aligning holes and tighten nut. Using the Scaffold to Turnbuckle Adapters. Insert the Scaffold to Turnbuckle Adapters into the free end of the scaffold frame. Use the spring pin to secure the bottom of the frame and insert a pin or bolt through the aligning holes of the frame. Using the Scaffold to Turnbuckle Adapters. Once in place, install the guardrail posts and turnbuckle components of the NUDURA Alignment System can be installed The pad of the turnbuckle attached to the channel slides into the Adapter and is secured by a pin and clip. The Result. Other Installation Photos. Post Installation After concrete placement and initial curing is completed with roof framing in place, the alignment and scaffold system can be removed. The nuts can either be backed of and tie clips removed and retained for future use or the nuts can simply be cut off using a bolt cutter tool behind the cross tip connector clip and the components discarded. The tie wires should then be clipped back as close as possible with the bolt cutters to leave the foam surface clear for finish application. For questions on working with the NUDURA Alignment System and Tall Wall Adaptor Components, please contact your local NUDURA distributor. We will assist them in answering any query you may have.