Andrew Lipshut, Director at Pure Construction Solutions, give us an overview on their latest equipment – pureDECK
- Can you explain how the pureDECK self-loading system reduces reliance on tower cranes?
With its innovative self-lifting capabilities, pureDECK provides an alternate means of vertical material transportation. It has a two-tonne lifting capacity and can hoist materials up to fifty metres in height using either an electric or manual winch. As the lifting beam is integrated within the deck design, the system undertakes both the lifting and loading activities to reduce reliance on tower cranes or materials hoists.
Additionally, there are two common situations where the deck can provide increased productivity and economic savings. The first is when the deck is used as an accessory to an existing tower crane strategy to increase the total number of potential lifts per day. The second is when the deck allows early demobilisation of tower cranes during the latter stages of a project (i.e. during the finishes phase where smaller and lighter materials are generally shifted) which can lead to significant rental savings.
- How does the modular design of the system contribute to its versatility?
The unique modular design provides several key benefits. Firstly, as up to four disassembled pureDECKs fit within a standard 40-foot container, it can be shipped, transported, and stored using a fraction of the space (and cost) of traditional non-modular decks. Secondly, a single deck can be configured to either a static flush deck, a roller deck, or a self-lifting deck simply by adding or removing bolted elements. This “3-in-1” functionality provides a high level of versatility for the user.
Further versatility is provided when multiple decks are used at the same time. By placing the self-lifting deck on an upper floor and a number of rolling decks on floors below, multiple floors can be loaded at once. In addition, by providing a static deck on the floor below, materials can be shifted between floors without the use of a tower crane. This provides particular benefit to concrete frame subcontractors who can cycle formwork and shoring without as much reliance on tower cranes.
- Could you describe the differences between the static and rolling configurations of the “pureDECK” system?
The static configuration suspends the modular decking panels from underneath the primary cantilevered beams. This provides a “flush” deck level which is matching the slab surface and therefore eliminates the need for a ramp. This allows taller materials to be loaded (such as bathroom pods) and reduces the effort required to shift materials on and off the deck.
The roller configuration involves a dynamic deck which can be opened and closed to allow materials to pass through freely. A key benefit of this configuration is that multiple decks can be stacked directly above each other (to reduce the interruption to façade installation for example), with all decks able to be loaded at all times.
- How long did it take to design, develop, and test the “pureDECK” system?
We started developing the pureDECK system in 2021 by creating concept designs and sourcing bespoke proprietary items that were required to ensure the deck functioned as intended. Our philosophy was to conduct initial product development in a virtual space where 3D models, 4D simulations and clash-detection were used to validate the feasibility and practicality of the system.
We then moved to the physical mock-up stage where we fabricated a complete deck. We made regular inspections in the factory to identify possible issues and improvements. Once ready, we installed the deck on project in Dubai and completed a comprehensive load and functionality testing regime.
All in, it has taken approximately 18 months to develop this product to the point of being ready for commercial use.
- What were some of the most important considerations during the testing phase of the project?
There were two primary considerations during the on-site testing phase: structural load performance and functionality. The structural testing was necessary to ensure compliance with CE certification and local regulations and validated the design models that we had developed.
The on-site functionality testing was a vital part of the testing process and included everything from assembly, transportation, and installation through to operation of the deck when in-service. Of most importance was the performance of the unique aspects of the deck such as the ease of lifting materials with the electric winch and the practicality of manually retracting the deck.
There were a number of valuable findings from the testing process which we further developed and integrated into the final design of the pureDECK system that is available today.
- What are your plans for further development or improvement of the “pureDECK” system in the future?
There are a number of possible improvements to the system which we are currently studying including a mechanical means for retracting the deck and raising the lifting beam (using winch systems). We are also planning to develop additional modular elements to enable customers to order bespoke dimensions of the deck. Ultimately, we will continue to develop and improve the system to meet the ever-changing requirements of the construction equipment industry.