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Cuplock Scaffolding Materials: Building Excellence with Quality and Durability

Cuplock scaffolding has become the go-to system for contractors who demand rapid, secure assembly without compromising on load capacity or versatility. At Avanza Steel, our Cuplock Scaffolding components are precision-manufactured to meet IS 1161 and BS EN 12811 standards, ensuring you get consistent performance—whether you’re erecting high-rise residential towers, industrial plants, or large-scale infrastructure projects.

What Is Cuplock Scaffolding?

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Cuplock is a modular scaffolding system that relies on vertical “standards” (also called uprights) with welded cups at half-meter intervals. Horizontal “ledgers” (blades) lock into these cups, enabling a tool-free, click-in assembly. No loose bolts or nuts are required. This design:

  • Speeds Up Erection & Dismantling—With each ledger simply slotted and pressed into the cup, a single worker can install or remove a connection in seconds per joint.

  • Delivers Superior Load Capacity—Each vertical upright supports up to 20 kN axially, and individual cup connections are tested to 10 kN minimum.

  • Enhances Site Safety—Weld-tested cups and laser-cut blade ends eliminate play, reducing wobble under live loads.
     

Why Cuplock? Rapid deck-level adjustments, minimum risk of human error, and the ability to build complex shapes (curved façades, odd-angle cantilevers) without custom fabrication.

1) Vertical Cuplock Standards (Uprights)

Technical Specifications

  • Material: 48.3 mm OD × 3.00 mm wall Mild Steel (IS 1239 Grade B), hot-dip galvanized (85 µm min) or painted (50 µm min).
     

  • Available Lengths (in meters): 0.50 (AV-05), 1.00 (AV-10), 1.50 (AV-15), 2.00 (AV-20), 2.50 (AV-25), 3.00 (AV-30).
     

  • Weight per Upright: 2.30 kg (0.50 m), 4.60 kg (1.00 m), 6.90 kg (1.50 m), 9.20 kg (2.00 m), 8.70 kg (2.50 m), 13.70 kg (3.00 m).
     

  • Cup Interval: 0.50 m vertical spacing between top and bottom cups (sliding top cup design).
     

  • Axial Load Rating: ≥ 20 kN per upright; each cup tested ≥ 1.25× design load.
     

  • Finish Options: Hot-dip galvanization (ASTM A123) or powder-coat paint.

2) Horizontal Ledgers

  • Material: 48.3 mm OD × 3.00 mm wall MS tube (IS 1239 Grade B), with forged cast-iron blade ends (tolerance ± 0.5 mm).
     

  • Available Lengths: 0.50 m (AL-05, 2.05 kg), 1.00 m (AL-10, 3.70 kg), 1.50 m (AL-15, 5.50 kg), 2.00 m (AL-20, 7.20 kg).
     

  • Blade-End Connection: MIG-welded blades ensure zero play when seated in cups.
     

  • Load-Bearing: Designed to carry 10 kN midspan with ≤ 5 mm deflection.
     

  • Finish Options: Hot-dip galvanization (85 µm min) or painted (50 µm min).

3) Accessories & Complementary Components

While Cuplock revolves around standards and ledgers, Avanza Steel offers the full ecosystem to build a complete system:
 

  • Adjustable Base Jack (ABJ): Threaded M30/M32 rod with 150 × 150 × 6 mm plate—extension range 150–200 mm—load rating 10 kN (hollow) to 15 kN (solid).
     

  • MS Working Platform (Jaali Walkway): Available in standard sizes like 2 m × 0.30 m and 3 m × 0.35 m, these perforated heavy-duty walkways have a load rating of 200 kg/m². Custom sizes can also be manufactured as per specific project requirements.
     

  • Adjustable U-Head Jack: Built with a threaded M30/M32 rod and a 250 × 100 × 6 mm U-shaped plate, this jack ensures stable support for slab and beam formwork. Load rated between 10–20 kN, depending on configuration (solid).
     

  • MS Plank (Anti-Skid): 230–300 mm width × 1–3 m length; 2.5–3.0 mm thickness; hot-dip galvanized; supports 300 kg/m².
     

  • Prop Sleeve & Joint Pins: Prop Sleeves are crafted from 50NB (60 mm) pipe, 300 mm in length, with threading for precise height adjustment. Joint Pins are manufactured from 38 mm OD pipe, 250 mm long — ideal for connecting standard scaffolding tubes securely.
     

  • Base Plates & Toeboards: 150 × 150 mm plate, 5–6 mm thick, MS finish; 3.5 to 4 inches toeboard height; MS or aluminum finish.

 Applications & Use Cases

  1. High-Rise & Commercial Buildings
     

    • Rapid erection of multi-story faades, atriums, and external maintenance platforms.

    • Ideal for “wrap” scaffolding where ledgers and guardrails must align seamlessly at each floor.
       

  2. Industrial Maintenance & Refineries
     

    • Curved or offset frames (reactor vessels, towers) demand the flexible angular connections that Cuplock provides via swivel clamps and ledgers.

    • Combined with adjustable U-Head Jacks and MS Planks for safe, elevated inspection decks.
       

  3. Bridges, Flyovers & Infrastructure
     

    • Coinciding with girder shuttering and pier cap formwork, Cuplock systems integrate easily with formwork accessories (haunch plates, girder shutters) for deck-level platforms.

    • Adjustable base jacks allow leveling on uneven riverbeds or embankments.
       

  4. Temporary Events & Industrial Shutdowns
     

    • Fast deployment of scaffolding towers (up to 20 m with proper bracing) for shutdown turnarounds.

    • Reusable MS Planks and Jaali Walkways minimize downtime and maintenance cost.

Why Choose Avanza Steel?

  • State-of-the-Art Manufacturing:
    Our Baidyabati, Hooghly facility integrates automated cut-to-length lines, robotic MIG welding for blade ends, and batch galvanization per ASTM A123.
     

  • Strict Quality Controls:
    Every Vertical Cuplock undergoes ultrasonic tube testing (per IS 1239), welding inspection to IS 4759, and load-test validation before dispatch.
     

  • Bulk Supply & Fast Dispatch:
    Production capacity of 5,000+ Cuplock uprights per month ensures large-scale projects stay on schedule—whether you’re in Kolkata, Delhi NCR, or the Middle East.

Installation & Best Practices

Vertical & Ledger Assembly
 

  1. Base Preparation
     

    • Place an MS Base Plate (150 × 150 mm, 5-6 mm thick) on a solid, level footing or wooden sole board.
       

    • Insert the adjustable base jack into position and fine-tune the height as needed using the threaded mechanism. Use a spirit level to ensure vertical alignment.
       

  2. Vertical Upright Setup
     

    • Slide the bottom cup flush to the base plate and tap the sliding top cup to its initial position (0.50 m above).
       

    • Confirm cup alignment—no lateral play—before loading.
       

  3. Ledger Insertion
     

    • Slot the Horizontal Ledger blade end into the bottom cup; press the top cup down to lock.
       

    • Verify a “click” resonance, indicating full engagement.
       

  4. Bracing & Planking
     

    • Install diagonal bracing at every third bay for lateral stability.
       

    • Place MS Planks / Jaali Walkways on ledger ledges; secure via anti-skid hooks at ≤ 1 m spacing.

 

Adjustments & Leveling
 

  1. Fine-Tune Height: Use the Adjustable U-Head Jack under formwork supports; ensure the unit is fully threaded within safety extension limits (≤ 70 % of total thread length).
     

  2. Vertical Alignment: After ledger insertion, use a laser plumb line to verify each upright is within ± 2 mm vertical deviation for multi-bay assemblies.


Inspection & Maintenance
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  • Daily Pre-Use Check: Inspect cups for cracks, proper welds, and corrosion. Verify blade ends show no deformation.
     

  • Monthly Load Testing: Randomly select 5 % of cuplock uprights to undergo a proof load test at 1.25× design capacity for continued compliance.
     

  • Corrosion Control: Touch-up zinc-rich paint on any bare steel spots before next use to avoid galvanic breakdown.
     

Safety Note: Never exceed specified load ratings of individual components. Do not deploy Cuplock scaffolding on frozen or excessively soft ground without proper pad and soleboard arrangements.

Frequently asked questions

Ready to accelerate your next project with Avanza Steel’s industry-leading Cuplock Scaffolding?
 

👉 Download the full Product Brochure for detailed part codes, dimensional drawings, and load charts.
 

👉 Contact our team at avanzasteel@gmail.com or +91 33 4000 7575 to request a site-specific quote, arrange a factory tour, or schedule an on-site technical consultation.

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