A scaffold is a temporary structure or working platform on the outside of a building. Typically made of a series of metal poles and wooden/metal planks, it is used by construction professionals when building, repairing, cleaning, or painting a structure. It is an essential piece of construction equipment for accessing upper stories of tall buildings and other hard-to-reach areas. 

With that said, scaffolds can be quite dangerous when not properly constructed. OSHA reported 2,835 scaffold violations in FY 2023, with many breaches directly linked to inadequate planking. To ensure the safety of all workers and guarantee compliance with all OSHA codes, it is critical to understand scaffold plank load capacity and select the appropriate scaffolding planks or walkboards. 

Scaffold Plank Load Capacity

To determine a scaffold’s maximum intended load, OSHA declares that a scaffold and its components must be able to accommodate its own weight and a minimum of four times its intended load, which consists of all workers, equipment, and materials. To help streamline this calculation, OSHA has three distinct categories for quantifying load-bearing capacities of scaffolding planks:

  • Light-Duty – these planks can accommodate 25 pounds per square foot (psf) when applying weight uniformly. This type of plank is used primarily for inspections and short-term jobs that will not require extensive materials or equipment.
  • Medium-Duty – these planks can accommodate 50 psf. This is one of the most common plank capacity grades as it can generally support more than one worker and most types of equipment safely.
  • Heavy-Duty – these planks can accommodate 75 psf or more. As their name implies, these are the most robust scaffolding planks and guarantee safety when working with heavy materials and equipment. 

To determine the total load capacity of a scaffolding surface, simply take this base rating and multiply it by the total working area on the scaffold. If the working surface uses heavy-duty planks (75 psf) and has a 5X10 platform (50 square feet), then the total weight capacity of the surface would be 3,750 pounds (75 X 50). This would mean that the platform could safely accommodate no more than 3,750 pounds of workers, materials, and equipment. 

Deflection Testing for Load Capacity

Deflection is the bend in a scaffolding plank when introduced to a load. As longer planks will deflect slightly more than shorter planks, OSHA has set guidelines for deflection testing as another means of determining scaffold plank load rating. The guidelines state that deflection may not exceed more than 1/60th of the span between supports. Therefore, if a plank spans 10 feet (120 inches) between supports, its deflection may not exceed 2 inches (120/60). Likewise, a plank that spans 5 feet (60 inches) between supports may not have deflection greater than 1 inch (60/60).

It is important to consider deflection in conjunction with the base rating of the scaffolding planks. Damaged planks or those that have received heavy use may begin to deteriorate over time, causing them to deflect more than they should. When testing plank deflection as part of a scaffolding inspection, use a straight edge that spans the length of the plank supports. Load the planks and measure the distance between the straight edge and plank surface to determine if the deflection falls within the OSHA-allowed parameters. 

Scaffolding Planks (Walkboards) Built for High-Load Capacity

When it comes to innovative scaffolding planks that exceed OSHA standards for safety, Bil-Jax is the most trusted name in the industry. With a wide selection of medium- and heavy-duty walkboards, Bil-Jax offers scaffolding for construction professionals that have the load capacity to handle any kind of project. 

TUF-N-LITE Walkboard

The Bil-Jax TUF-N-LITE Walkboard is the most widely used industrial-grade scaffolding plank on the market. Fabricated from ½-inch finished plywood decking and heavy-duty aluminum I-beam side rails, the TUF-N-LITE Walkboard comes in various lengths and widths that offer load capacities of up to 75 psf. With offset hooks for continuous decking, this is the go-to walkboard for construction professionals who need to safely cover a large amount of platform area. 

X-TRU-LITE Walkboard

The Bil-Jax X-TRU-LITE Walkboard uses a 3-hook, deck interlock design for continuous decking. In addition, its grooved aluminum surface offers no-slip features for enhanced safety. Available in various lengths and widths that offer load capacities up to 75 psf, this is a perfect walkboard for wet conditions, as the no-slip surface and non-corrosive aluminum fabrication guarantee the ongoing safety and performance of the decking surface. 

X-PANDED Steel Walkboard

The Bil-Jax X-PANDED Steel Walkboard employs an expanded galvanized steel mesh design that does not allow liquid, dirt, mortar, or any other type of debris to accumulate on the platform surface. It also uses offset hooks for continuous decking. All lengths and widths for this walkboard come with a load capacity of 75 psf, making it an extremely durable choice for tackling messy scaffolding jobs. 

Steel Walkboard

The Bil-Jax Steel Walkboard offers the highest quality and durability standards on the market. Coming in lengths of 7, 8, and 10 feet with a narrow width of 9 inches for each span, this premium-duty walkboard offers an astounding 140 psf for its 7-foot option. It is the preferred choice for hosting hefty equipment and bulky masonry on scaffolding surfaces. 

Checking Scaffold Planks for Safety

Even when adhering to the strictest OSHA parameters for load capacity and deflection, regular inspections are critical to ensuring the ongoing health and safety of scaffold planks. Some common issues identified during inspections include:

  • Weathered or Damaged Plywood: Older boards often have weathered plywood, especially when stored flat. Rainwater and moisture can collect on the boards, leading to rot and degradation over time.
  • Foreign Substances: Plywood, aluminum, or steel boards covered in paint, mortar, or other substances can obscure damage and compromise the board’s structural integrity.
  • Damaged Aluminum Side Rails: Inspect side rails for bends, cracks, or other signs of damage that may affect the plank’s load capacity and safety.
  • Damaged Hooks: Hooks that are bent, cracked, or otherwise compromised may fail to securely attach the plank to the scaffold, increasing the risk of accidents.
  • Missing Wind Latches: Wind latches prevent walkboards from being uplifted by strong winds. Inspections show that over 50% of walkboards are missing these critical components, making replacement or installation of wind latches essential.

Best Practices for Scaffold Plank Inspections

  1. Check for Deflection: Planks holding a visible bend when not loaded should be replaced, as this indicates compromised structural integrity.
  2. Inspect for Splits, Checks, and Notches: Planks with splits should be immediately retired, while checks and notches deeper than ¼ inch are unsafe and require replacement.
  3. Examine for Splinters and Rough Edges: Address any sharp edges or splinters that may cause tripping or injury to workers.

Taking proactive measures to address these common issues and conducting daily inspections ensures the long-term safety and performance of scaffold planks.

For additional safety information, check out our article “12 Important Scaffolding Safety Tips”.

Contact Bil-Jax for the Highest Load Rated Scaffolding Walkboards

Many of the most common scaffolding injuries and OSHA violations can be avoided by choosing the correct planks that offer adequate load-bearing capacity. For help on choosing the best walkboard solutions for your scaffolding project, contact Bil-Jax today for a consultation.