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Reaching the unreachable - an engineering innovation revolutionised scaffolding half a century ago

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2024. 05. 03. 23:11
Big Ben in London, St Patrick's Cathedral in Dublin, the Basilicas of Eger and Esztergom, the Mol Campus - just a few of the thousands of buildings around the world that have been renovated and rebuilt using the Layher Allround modular scaffolding systems developed fifty years ago.

For nearly 80 years, the scaffolding manufacturer founded in 1945 in Güglingen-Eibensbach, Germany, has been serving those who strive for heights. Today, product development, manufacturing and logistics are still concentrated there. Founded in 1945 in Güglingen-Eibensbach, Germany – where product development, manufacturing and logistics are still concentrated today (ed.) – has initiated comprehensive changes in the industry from time to time with its innovative ideas and continuously expanding product range.

 

 

In 1957, for example, the company entered the market for wooden scaffolding and ladders with more durable and heavy-duty aluminium and steel products, and started a huge transformation process. In addition to the new use of materials, the first rolling scaffolds were developed. These evolved into the modular racking systems that are now used almost everywhere in the world and can be assembled without screws.
The philosophy behind the product development of Layher has remained the same since the company was founded: to make their tools simple, modern, efficient and safe. 

 

 

A revolution in diversity: fifty years since the development of the Allround racking system

1974 was a landmark year in the history of Layher and the industry as a whole. Fifty years ago, the company introduced to the construction industry its revolutionary innovation, the Allround stand.

The Layher has taken scaffolding to a new level. The steel and aluminium scaffolding system has been revolutionised by the company's engineering innovation of the wedge connection. The essence of the innovation is that the disc allows various scaffolding elements to be connected to the column at 8 points. This solution has made it possible to construct any spatial shape when erecting scaffolding. Half a century ago, the Allround became synonymous with modular scaffolding.

 

 

It has also been used to provide safe access to stone silos, tower blocks, church domes and irregularly shaped foundations during renovation and construction. A good example of the latter is the Tejfalusy House in the Veszprém castle district, a historicised house being renovated using Layher scaffolding.

 

 

The Allround's wedge-head technology and 8-point connection solution has quickly displaced the clamps and tubes used until then.

Allround: Security solution

Layher products are available in 160 countries around the world through the company's 44 subsidiaries. The company has been present in Hungary since 2003. The popularity of its modular racks has made the company a market leader.

 

 

Its products are widely used not only because of their practicality and efficiency, but also because the high quality of the scaffolding guarantees the safety of the workers during the construction works. 

 

Our heritage, built using Allround construction and industrial scaffolding, is being restored to priceless gems such as the 800-year-old St Patrick's Cathedral in Dublin. In Ireland's oldest church, the repair of the roof structure was carried out using Layher solutions to protect the church interior and the highly valuable organ from the elements.   

 

 

During the renovation of one of Hungary's largest churches, the basilica in Eger, the Layher Allround facade scaffolding ensured safe access to the building's towers and dome at a height of 45 metres.

 

 

In Esztergom, the restoration of the basilica also used sensational scaffolding solutions to gain access to both the extremely dissected interior spaces and the dome during the reconstruction.

 

 

The company was not satisfied with having revolutionised the industry fifty years ago. From time to time, it has evolved its production technology, scaffolding and accessories to keep pace with the development of the construction industry and the new needs of users of Layher systems. Since 2007, the range has been extended with the FW, Bridge, AGS, FlexBeam, TwixBeam and TG60.  

 

 

Layher systems are not only used at dizzying heights, but also in tunnels
 

In addition to heritage conservation projects at high altitudes, the versatility of the Allround is demonstrated by the fact that it is also frequently used by contractors in deep underground applications, such as tunnelling and industrial sites.

 

Good access to the curved shapes of one of the three structures under construction on the M85 motorway, the inner wall of the tunnel between Fertőrákos and the border, was ensured by the scaffolding of Layher. The work on the mobile scaffolding did not impede the free movement of construction traffic, trucks and concrete mixers.

 

The surface treatment allows the racking system to be used in aggressive environments

Thanks to its versatility and high quality and safety standards, Allround systems are also used in industrial installations.

 

The surface treatment of Allround systems is hot-dip galvanized, which makes them resistant to both mechanical and chemical stresses. This increases the lifetime of the scaffolding elements to almost 30 years and extends the range of applications (e.g. in mines or chemical plants).

 

The Layher scaffolding also provided stable, safe access for the implementation of the project aimed at strengthening the operational safety and protection system of the Paks Nuclear Power Plant. The Allround systems can be used to create any spatial configuration, which is ideal for the installation and servicing of industrial equipment of various sizes and shapes.

 

 

A three-storey, 7.5-metre-high and 26-metre-long suspended work platform was built above the river from the Dunakiliti Duzzasztómű upstream support system Layher Allround system, a three-level, 7.5-metre-high and 26-metre-long suspended work platform was built above the river, which made it possible to carry out the work.

Allround variations: for bridging high heights, supporting heavy loads

The popularity of the Layher modular scaffolding has been unbroken for fifty years, thanks to its adaptability to a wide range of construction situations.

The Allround FW system is designed for large span spans and to support heavy loads. It consists of just three basic elements, which can be assembled in a flash using pin connections.

 

 

This solution was also used in the construction of Budapest's tallest building, the 28-storey, 143-metre-high tower block MOL Campus.

The load capacity of the Allround, combined with the Bridge and some other components, makes it suitable for use as a long span footbridge or even as a support structure.
The Allround TG 60 is capable of carrying up to six tonnes per column, which is why the quick and easy to erect heavy-duty scaffolding is used as a formwork support scaffolding for bridge construction.

Scaffolding systems for sports and music events

Because of its versatility and ease of assembly, the Layher Allround is also a hit in the event technology market. The stand systems can also be found at major music festivals such as Sziget and Balaton Sound, while spectators at the Szeged Open Air Festival are seated on stands built from the company's products.
At sporting event venues, such as the 2017 World Aquatics Championships in Budapest, Allround's stairs and stair systems, the Bridge and the modular stair tower, were also used to access the venues.

   

 

The scaffolding heavyweight takes on the competition

As in 1974, the year 2013 saw a major change in scaffolding. This time, the launch of the fourth generation of the Allround, the Lightweight, brought a new dimension to the industry. The innovation of the Layher met a long-standing need, most notably cost-effectiveness.

 

Assembly, disassembly and transport account for a significant proportion of scaffolding service costs - nearly 80 percent. Layher has reduced this proportion with its Lightweight philosophy. The company has significantly reduced the weight of its scaffolding components while increasing their load capacity.

Engineering solutions to increase the competitiveness of the product group

The Layher engineers have developed a process in collaboration with steel manufacturers to use the highest grade of S460 steel for the system's components, which is twice the minimum strength required by the standard.

By using higher-quality steel, thinner wall thicknesses could be achieved, reducing the weight by 12 percent, which also reduced construction time and transportation costs.

With the Lightweight upgrade, the Layher has enabled companies to save money by providing a quick, easy bolt-free and securely assembled racking system. Elements can be attached at waist, blunt and acute angles using a single hammer. Thanks to the company's foresight, Lightweight products are compatible with previous devices.

 

 

Layher Allround systems have been serving the construction industry for fifty years. They have helped build and renovate iconic buildings in our country and around the world. 

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