Tested to OSHA requirements

Anti impalement testing

The WISAblock anti impalement system has been fully tested to demonstrate its ability to reduce the risk of impalement as required by OSHA 1926.701b.

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Coda Plastics Ltd Test Report

Quality Test Report No. Wisablock 02/14

 

Subject: Wisablock Cap Impact Testing

By: Paul Stonebridge (Quality Systems Manager)

Date: 28/05/2014

Introduction

Date of Test: 22nd May 2014 Ambient Temperature: 17°C

Product Tested: Wisablock Conditions: Sunny

Coda Tool No: 1576

This report details the results of the testing conducted at Coda Plastics Ltd on the product WISAblock to observe and record its performance when under impact from a falling body.

The tests below were conducted using manufactured test fixtures that recreate the exact conditions the WISAblock is recommended to be used under at a construction site.

Test Report WISABlock V1Test Report WISABlock Internal showing rebar grips

The product has been designed to fit onto varied size rebars between 10mm to 32mm diameter as used in the construction industry and in conjunction with timber bracing reduce the risk of the bars penetrating a person’s body if an accident occurs and they fall onto them.

Limitations

This test does not, nor attempt to, quantify the potential for other types of injuries (other than rebar impalement injuries) which may result from falls onto wooden rebar guards held by WISAblock. This report also does not quantify similar or other types of rebar guards either.

Product Materials

WISAblock were manufactured in two different base materials for testing and both used the same yellow colouring (masterbatch).

A. High Density Polyethylene (HDPE) – grade HMA-014 and Masterbatch Yellow SCM 3028/2
B. Polypropylene (PP) – grade PHC27 and Masterbatch Yellow SCM 3028/2

Each test result below details the type of material used in the moulding of the caps.

Test Rig

The test rig consisted of two rows of 15 rebars (10 & 16mm Diameter) and 10 rebars at 32mm

Test Report - Diagram of test rig constructed

Diagram of test rig constructed

 

Test Report - 3 WISAblock per side Supporting timber - Two rows of 15 rebars set in concrete

Test Rig and Materials Used

5 x Concrete fixtures to hold rebars.

3 x Rebars sizes selected by WISAblock for test 10mm, 16mm & 32mm

6 x WISAblock in both HDPE and PP

2 x Length of timber (Drygraded ) 45mm x 95mm x 3500mm

1 x 114kg punch bag dropped from a 2m height.

Test Procedure

Each test of the different WISAblock on each rebar size was conducted by:

1) Positioning concrete fixtures 1.5m apart (except Test 9)
2) Clamping the rebar tightly in each fixture with two bolts fitted.
3) Pushing on WISAblock to each rebar to its maximum stop dictated by the design of cap.
4) Sliding in the length of timber into the tops of the WISAblock .
5) Raising the punch bag to a height of 2m (using forklift and cage) and rolling onto the test fixture. The bag impacted the test rig along the length of the timber central to fixture 2.
6) Observations recorded for each test.

Test Report - WISAblock position references

WISAblock position references

Test 1 Results

Rebar size: 10mm

Height of bag when dropped = 2m

WISAblock Material: PP (PHC 27)

Position 1 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 2 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 3 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 4 Pushed through cross but no penetration of cap
Position 5 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 6 Slight squash of internal cross. No penetration of rebar through cap or timber.

Timber penetration from free rebars (with no WISAblock ) = 5mm

Test 2 Results

Rebar size: 10mm

Height of bag when dropped = 2m

WISAblock Material: HDPE (HMA-14)

Observations:
Position 1 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 2 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 3 Internal cross collapsed, no penetration of cap
Position 4 Internal cross collapsed, no penetration of cap
Position 5 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 6 Slight squash of internal cross. No penetration of rebar through cap or timber.

Timber penetration from free rebars (with no WISAblock) = 5mm

Test 3 Results – Retest

Before testing commenced it was agreed with Coda that the 10mm diameter rebar was of the greatest concern for penetration of the cap and timber.

Rebar size: 10mm

Height of bag when dropped = 2m

WISAblock Material: PP (PHC 27)

Observations:
Position 1 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 2 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 3 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 4 Pushed through cross but no penetration of cap
Position 5 Slight squash of internal cross. No penetration of rebar through cap or timber.
Position 6 Slight squash of internal cross. No penetration of rebar through cap or timber.

Timber penetration from free rebars (with no Wisablock caps) = 10mm

Test 4 Results – Retest

Rebar size: 10mm

Height of bag when dropped = 2m

WISAblock Material: HDPE (HMA -14)

Observations:
Position 1 Internal cross squashed. No penetration of rebar through cap or timber.
Position 2 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 3 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 4 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 5 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 6 Slight squash of internal cross. No penetration of rebar through cap or timber

Timber penetration from free rebars (with no WISAblock ) = 10mm

Test 5 Results

Rebar size: 10mm

Height of bag when dropped = 3m

WISAblock Material: PP (PHC 27)

Observations:
Position 1 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 2 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 3 Internal cross squashed. No penetration of rebar through cap or timber.
Position 4 Pushed through cross but no penetration of cap
Position 5 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 6 Slight squash of internal cross. No penetration of rebar through cap or timber

Timber penetration from free rebars (with no Wisablock caps) = 20mm

Test 6 Results

Rebar size: 10mm

Height of bag when dropped = 3m

WISAblock Material: HDPE (HMA-14)

Observations:
Position 1 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 2 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 3 Internal cross squashed. No penetration of rebar through cap or timber.
Position 4 Pushed through cross but no penetration of cap.
Position 5 No internal damage to cap.
Position 6 Pushed through cross but no penetration of cap.

Timber penetration from free rebars (with no WISAblock ) = 19mm

Test 7 Results

Rebar size: 16mm

Height of bag when dropped = 3m

WISAblock Cap Material: PP (PHC 27)

Observations:
Position 1 No damage to the cross or penetration into cap
Position 2 No damage to the cross or penetration into cap
Position 3 No damage to the cross or penetration into cap
Position 4 Cap split but no penetration of the rebar through plastic into timber.
Position 5 No damage to the cross or penetration into cap
Position 6 Slight squash of internal cross. No penetration of rebar through cap or timber

Test Report - Cap Position 4

Timber penetration from free rebars (with no WISAblock ) = 4mm

Test 8 Results

Rebar size: 16mm

Height of bag when dropped = 3m

WISAblock Material: HDPE (HMA-14)

Observations:
Position 1 No damage to the cross or penetration into cap
Position 2 No damage to the cross or penetration into cap
Position 3 No damage to the cross or penetration into cap
Position 4 Cross collapse, no penetration of cap or timber
Position 5 Slight squash of internal cross. No penetration of rebar through cap or timber
Position 6 Slight squash of internal cross. No penetration of rebar through cap or timber

Timber penetration from free rebars (with no WISAblock caps) = 10mm

Test 9 Results

Rebar size: 32mm

Height of bag when dropped = 3m

WISAblock Material: PP (PHC 27)

Observations:
Position 1 No damage to the cross or penetration into cap
Position 2 No damage to the cross or penetration into cap
Position 3 No damage to the cross or penetration into cap. All compression taken by internal rebar grips
Position 4 No damage to the cross or penetration into cap. All compression taken by internal rebar grips
Position 5 No damage to the cross or penetration into cap
Position 6 No damage to the cross or penetration into cap

Test 10 Results

Rebar size: 32mm

Height of bag when dropped = 3m

WISAblock Material: HDPE (HMA-14)

Position 1 No damage to the cross or penetration into cap
Position 2 No damage to the cross or penetration into cap
Position 3 No damage to the cross or penetration into cap. All compression taken by internal rebar grips
Position 4 No damage to the cross or penetration into cap. All compression taken by internal rebar grips
Position 5 No damage to the cross or penetration into cap
Position 6 No damage to the cross or penetration into cap

Summary

  • 10mm Rebars – High Density Polyethylene (HDPE, HMA-14)
    Testing at 2m and 3m heights resulted in no penetration of the rebar through the cap or timber.
    The free rebars (no WISAblock fitted) only penetrated into the timber to a depth of 5mm when load dropped at 2m and 19mm when dropped at 3m.

 

  • 10mm Rebars – Polypropylene (PP, PHC 27)
    Testing at 2m and 3m heights resulted in no penetration of the rebar through the cap or timber.
    The free rebars (no WISAblock fitted) only penetrated into the timber to a depth of 5mm and 10mm when load dropped at 2m and 20mm when dropped at 3m.

 

  • 16mm Rebars – High Density Polyethylene (HDPE, HMA-14)
    Testing at 3m height resulted in no penetration of the rebar through the cap or timber.
    The free rebars (no WISAblock fitted) only penetrated into the timber to a depth of 10mm.

 

  • 16mm Rebars – Polypropylene (PP, PHC 27)
    Testing at 3m height resulted in no penetration of the rebar through the cap or timber. The WISAblock taking all the impact did split due to the cap being forced onto the rebar but there was no penetration of the cap or the timber.
    The free rebars (no WISAblock fitted) only penetrated into the timber to a depth of 4mm.

 

  • 32mm Rebars – High Density Polyethylene (HDPE)
    Testing at 3m height resulted in no penetration of the rebar through the cap or timber.
    The free rebars (no WISAblock caps fitted) made only minor impressions in the timber.

 

  • 32mm Rebars – Polypropylene (PP)
    Testing at 3m height resulted in no penetration of the rebar through the cap or timber.
    The free rebars (no WISAblock fitted) made only minor impressions in the timber.

Conclusion

The testing at Coda on the WISAblock was conducted using test fixtures which recreate the recommended conditions for this product.

All testing at heights of 2m and 3m did not result in penetration of the cap or timber brace by the rebar.

The free rebars (no cap) also did not pierce through the timber.

 

 

Watch the video demonstration of WISAblock application here