The OrbiPlate™ system tackles the age-old problem of misaligned holes in bolted connections, which has often been a source of frustration, time loss and potential structural inadequacies.

OrbiPlate™ is a revolutionary approach to managing tolerances and improving flexibility in steel-to-steel and steel-to-concrete connections. By providing orbital connection tolerances of up to 20mm around the centre of the connection, the solution significantly reduces the stress associated with hole alignment.

How OrbiPlate™ works

OrbiPlate™ comprises a main washer with a unique orbital shape that allows for adjustments in multiple directions. The steel member has a pre-formed 70mm hole, which can be either punched or cut at the centre of the connection location. The installation process is simple: rotate, slide, torque:

• Place the main washer over the pre-formed hole
• Rotate the washer to align its slot with the ferrule
• Secure the connection using a Class 8.8 bolt through a smaller washer.

This effective method ensures that even if the holes are not perfectly aligned, the connection can still be made securely and efficiently.

The installation guide can be downloaded here.
 

Benefits for construction projects

Time and cost savings

By eliminating the need for time-consuming traditional methods of dealing with misaligned holes, OrbiPlate™ significantly reduces labour costs and crane time. The quick and easy installation process means connections can be made rapidly, keeping projects on schedule.

Improved safety

The time worked at height is reduced and the need for hot works is negated.

Enhanced structural integrity

Unlike some solutions, OrbiPlate™ maintains the structural integrity of the connection. This is crucial for ensuring the long-term stability and safety of buildings, particularly in diverse climate conditions. OrbiPlate™ is hot-dipped galvanised for corrosion resistance, maximising its design life.

Positioning precision

The system not only accommodates misalignments, but also allows for fine-tuning the position of steel members. This level of precision within millimetres is invaluable in projects where exact placement and time is critical.

Versatility

OrbiPlate™ can be used in various applications, including steel-to-steel and steel-to-concrete connections. This versatility makes it an ideal solution for a wide range of construction projects, from residential buildings to large-scale commercial structures.
 

Technical specifications

OrbiPlate™ is part of Ramset™’s comprehensive suite of construction solutions. It has been thoroughly laboratory-tested simulating as-built conditions, and the technical data is presented in a user-friendly, easy to understand format.
 

OrbiPlate™ in action

The effectiveness of OrbiPlate™ has been demonstrated in projects such as the Catalina Bay Apartments in Auckland, New Zealand. The project’s coastal location meant it was exposed to strong winds and harsh weather conditions, requiring reliable structural connections.

This project showcased the system’s ability to deliver 360-degree connection tolerances of up to 20mm in structural connections. As they are made of high tensile steel, the 20mm OrbiPlate™ connector solution was recommended for all steel-to-steel connections on the apartment’s precast concrete balconies.

In total, 900 OrbiPlate™ connectors were used throughout the project, demonstrating the system’s scalability and reliability in large construction projects. Project manager Blake Honeyfield said the OrbiPlate™ saved time, reduced costs and increased safety on site – all critical factors in modern construction projects.

The alternative method of fixing the steel to the concrete would have required reworking with welding, which would be more time consuming and difficult on the exposed site.

In Australia, the OrbiPlate™ solution was also used on a car park architectural screen in Bendigo, Victoria. Early on in this project it was identified that the key construction challenge would be fixing the steel architectural screens to the exterior with little to no margin for misalignment.

The importance of speed and efficiency in connection was keeping the crane time to a minimum and limiting the disruption to traffic flow in Bendigo’s CBD.

A spokesman for the project said the solution cut project time down by around 40 per cent.

The OrbiPlate™ system is a significant improvement in managing connection tolerances and alignment in concrete and steel construction. When seeking to enhance project efficiency, structural integrity, and overall build quality, the OrbiPlate™ system aligns with the industry’s push towards more innovative and reliable construction methods.

Learn more about the OrbiPlate™ solution for New Zealand.