Scaffolding is an essential piece of construction equipment for building, cleaning, painting, and maintaining the exterior of tall buildings. However, without adequate scaffold construction and safety standards, these towering structures can become quite hazardous. 

Of the hundreds of scaffolding accidents that occur each year, many are the direct result of inadequate planking. As planking is arguably the most essential feature of a successful scaffold, the importance of selecting, inspecting, and replacing planks cannot be understated. 

To help contractors meet the mark for safe scaffold construction, OSHA scaffold plank requirements draw out a specific set of parameters for adequate planking. 

Lumber Quality

OSHA scaffold wood plank requirements distinguish scaffold-grade lumber from construction-grade lumber. Construction-grade lumber is one-third weaker than scaffold-grade and should never be used as a scaffolding platform. Not only is using construction-grade lumber an OSHA violation, but it creates an immediate safety risk for workers.

Scaffold-grade lumber quality is determined by:

  • Rings per inch: Indicates density and strength.
  • Slope of the grain: Reflects structural integrity.
  • Defects: Checks, notches, and knots that compromise performance.

Solid-sawn wood used for scaffold planks must meet the criteria of a lumber grading association or independent grading agency. However, even scaffold-grade lumber with a visible stamp can degrade over time due to heavy loads or exposure to weather.

Plank Condition

As mentioned, even scaffold-grade lumber will degrade over time. UV exposure, moisture absorption, and heavy usage are just a few of the forces that can cause scaffolding planks to break down. Three imperfections to scaffold planking to constantly monitor are splits, checks, and notches.

Splits are cracks in the scaffolding plank that go all the way through the board. Any plank bearing a split should immediately be retired. Checks are cracks on the surface of the plank that do not go all the way through. While it is permissible to use planking lumber that contains checks, they must be closely monitored to ensure that they do not expand into splits. Checks larger than ¼ inch are generally considered unsafe. Notches are checks on the ends of planks. Like checks, notches themselves do not preclude a plank from use, but they are at heightened risk of expanding into splits. 

Any plank that contains accumulated layers of paint, plaster, mortar, or any other concealing substance is not permissible for use, as it makes it impossible to assess the condition of the plank. Expanded steel walkboards are a great option for these types of scaffolding projects, as they do not allow the accumulation of surface debris. In addition, wood planks used on mudsill projects are not permitted for re-use, as they are at heightened risk of moisture absorption that can compromise the quality of the plank. 

Maximum Spans

The span of a scaffolding plank is the distance it covers between supports. Longer span will result in greater deflection (bend), reducing the plank’s load-bearing capacity. As such, the greater the intended load of the platform, the shorter the span of the scaffolding plank. This will limit deflection and keep workers and materials safe.

For fabricated planks that do not consist of basic sawed lumber, the maximum span will be determined based on manufacturer recommendations. There will be three base ratings for fabricated scaffold planks: light-duty (25 psf), medium-duty (50 psf), and heavy-duty (75 psf or more). Each manufacturer will provide a safe allowable span for their planks to adhere to its given base rating. 

Deflection Standards

Deflection is the bend in a scaffolding plank when introduced to a load. OSHA stipulates that deflection may not be more than 1/60th the span between supports. For a quick illustration, a 10 foot (120 inch) plank may not have deflection greater than 2 inches. Likewise, a 5 foot (60 inch) plank may not have deflection greater than 1 inch. Too much deflection is an indication of overloading. 

Any time the deflection level appears suspect, the platform should be cleared and the condition of the planking assessed. 

Requirements for Fully Planked Scaffolding

Continuous planking is the goal for the highest-quality scaffolding platforms. As such, OSHA plank overlap requirements are quite stringent. OSHA mandates that the distance between planks or the distance between a plank and an upright can never exceed one inch. 

The only exception is when the employer deems it necessary for additional space, such as when fitting around uprights and side brackets to extend the width of the platform. This exception is in place to prevent cutting or notch-slanting planks to achieve compliance with the one-inch rule, as such alterations can increase the risk of tipping when introduced to eccentric loading. 

However, even when this exception is applicable, the distance between planks or planks and uprights should never exceed 9 and ¼ inch, under any circumstance. 

OSHA Compliant Continuous Planking Solutions From Bil-Jax

To ensure compliance with all OSHA requirements, it’s essential to use high-quality planking solutions that prioritize safety and durability. While “scaffold-grade lumber” is common in the industry, Bil-Jax takes this a step further by offering advanced materials that outperform traditional options.

Innovative Materials: Exterior Grade, 5-Layer Plywood

Bil-Jax walkboards are fabricated using Exterior Grade, 5-layer plywood, specifically designed for enhanced durability and moisture resistance. Unlike scaffold-grade lumber, this material features:

  • High-Density Composition: Resists warping and splitting even under heavy loads.
  • Moisture Resistance: Stamped to meet exterior grade standards, ensuring long-term performance in challenging conditions.
  • Enhanced Safety: The 5-layer construction provides consistent strength across spans, reducing the risk of plank failure.

By utilizing Exterior Grade plywood with innovative engineering, Bil-Jax planks offer superior reliability for a variety of scaffolding needs.

TUF-N-LITE Walkboard

The Bil-Jax TUF-N-LITE Walkboard is the most widely used industrial grade scaffolding plank on the market. It is fabricated of ½-inch finished plywood decking and aluminum I-beam side rails. It features offset hooks for continuous decking and a 75 psf for multiple walkboard spans, making it the ideal walkboard for safely covering large platform areas. 

X-TRU-LITE Walkboard

The Bil-Jax X-TRU-LITE Walkboard uses a 3-hook, deck interlock design for continuous decking. Its grooved aluminum surface provides a no-slip platform. The non-corrosive, moisture resistant aluminum fabrication makes it an ideal solution for wet conditions where more absorptive wood planks are not adequate. Multiple walkboard spans offer 75 psf, providing heavy-duty load-bearing capacity. 

X-PANDED Steel Walkboard

The Bil-Jax X-PANDED Steel Walkboard uses a galvanized expanded steel mesh design that does not allow paint, mortar, dirt, or any other type of debris to accumulate on the walkboard surface, making it the ideal solution for messy scaffolding projects. With offset hooks for continuous decking and a 75 psf for all walkboard spans, this is an extremely durable walkboard designed to tackle diverse scaffolding needs. 

Steel Walkboard

The Bil-Jax Steel Walkboard is the epitome of quality and durability. With up to a 140 psf, it is the go-to choice for masonry projects or those that require the use of heavy equipment. The galvanized steel surface is impervious to moisture and UV damage, guaranteeing ongoing viability for ongoing scaffolding application. 

Contact Bil-Jax for OSHA Compliant Plank Solutions

In order to guarantee the safety and success of a scaffolding construction project, it is important to source scaffold-grade, heavy-duty walkboards. As the industry leader on all aspects of scaffolding infrastructure, contact Bil-Jax today for help identifying the ideal walkboard for any scaffolding project.