Imperial Technical Instruction Manual

Size: px

Start display at page:

Download "Imperial Technical Instruction Manual"

William McGee
5 years ago
Views:

1 Technical Instruction Manual

The wall formwork is a cranedependent modular formwork system for use in industrial and civil engineering projects as well as administration and residential

Used formwork components can have a capacity lowered by up to 20%.

2 The wall formwork is a cranedependent modular formwork system for use in industrial and civil engineering projects as well as administration and residential building construction. A complete formwork set including accessories weighs about 14 lbs/sq.ft. The admissible fresh concrete pressure is 2,025 lbs/sq.ft. when using 7/8" threadbars or 11/4" taper ties. Used formwork components can have a capacity lowered by up to 20%. The high resistance to concrete pressure allows placement of up to 12' without consideration for rate of placement. The panels have highgrade 7/8" alkus plastic sheeting, which is riveted to the panel frames. 2

3 Please note: This Technical Manual contains information, instructions and hints how to use the MEVA formwork on the construction site in a proper and economic way. Most examples shown are standard assemblies, since they occur in practice most frequently. In case of problems or special cases not dealt with in this manual, please contact the MEVA experts for advice. When using our products the federal, state and local codes and regulations must be observed. What is shown on the following pages are assembly sketches for demonstration purposes. To display details more clearly, loading and safety factor aspects are not included. The pictures show site situations which do not always depict the final assembly of the formwork with regard to safety regulations. Please adhere to these technical instructions when applying the formwork. Deviations require engineering calculation and analysis for proper safety. Generally, only asnew material may be used. Damaged parts have to be sorted out. Please apply only original MEVA spare parts for replacement. Contents The panel / System description... 4/5 Multipurpose panel / The alkus plastic sheet... 6/7 Panel connection / Placing of ties... 8/9 Height extension... 10/11 Height extension / Rate of placing... 12/13 Flatness of surface / 90 corner with standard panel... 14/15 90 corner with standard panel / with multipurpose panel... 16/17 90 corner with multipurpose panel / Articulated corners... 18/19 Articulated corners... 20/21 Columns... 22/23 Length compensation... 24/25 Bulkheads / Wall offset... 26/27 Twall connection / Connection to existing walls... 28/29 Pilasters / Pilasters at corners... 30/31 Differences in height / Panels in horizontal position... 32/33 Attachment of accessories / Tie off bar / Bump notch... 34/35 Crane ganging... 36/37 Working platform BKB 125 / Scaffolding bracket... 38/39 Wall braces / Working scaffolds... 40/41 Stripping corner / Folding shaft formwork... 42/43 Assembly and stripping Crane slings Stapos /51 Lifting hook 60 / Crane slings /53 Crane hook / Singlesided formwork / Climbing formwork... 54/55 Service Product list

4 The panel Fig. 4.1 The steel frames are manufactured of closed profiles which are welded in mitered joints. These profiles are provided with a groove. Fig. 4.2 Tie hole with conical anchor sleeve (see page 9). Fig. 4.3 Pioneering panel connection with MEVA assembly lock (see page 8). Fig. 4.4 The tie off bar allows safe working on the formwork. Under no circumstances should panels be lifted or moved using these tie off bars. Fig. 4.5 The cross stiffeners are also made of closed profiles. Fig. 4.6 Fast attachment of accessory parts at the multifunction profile with Dywidagthreaded nuts (see page 34) Fig. 4.7 The bump notch is designed to facilitate shifting and lifting of panels (especially large size panels). Fig. 4.8 Transportation holes are used to attach the lifting hook 60, allowing stacked panels to be moved at ground or slab level (see page 52). 8 transportation holes all around the panel permit easy preassembly of gangs. Fig. 4.1 Fig. 4.2 Fig. 4.3 Fig. 4.4 Fig. 4.5 Fig. 4.6 Fig. 4.7 Fig

5 System description multifunction profile multifunction profile at tie hole elevation cross stiffener frame dywidagthreaded nuts tie off bar tie hole transportation hole Multifunction profiles for fast attachment of accessory items with Dywidag threaded nuts. The steel rails must be attached to the multifunction profile at tie hole elevation, the other multifunction profiles are used for attaching accessory items. Cross stiffener stiffens the panel to provide rigidity. Transportation hole For further information about lifting panels and stacks see page 52. Panel height Standard panel heights are 4', 8' and 12'. The width varies in a 6" increment from 1' to 4', plus a width of 8'. bump notch Detail transportation hole transportation hole transportation hole tie hole 5

6 Multipurpose panel These panels are ideal for forming 90 corners, columns, pilasters, bridge abutments and connections to existing walls. The panels are provided with multiadjustment profiles where column clamps or ties are mounted. The 12' panels have 3 multiadjustment profiles, the 8' panels have 2 and the 4' and 2' panels are provided with 1 multiadjustment profile. For further details see page 17. multifunction profile multiadjustment profile cross stiffener frame Dywidagthreaded nut tie off bar tie hole transportation hole bump notch Imultipurpose panels 12' x 4' ' x 4' ' x 4' ' x 4'

7 Frame profile + plywood face Frame profile + alkus plastic sheet The new polypropylene and aluminum composite forming face has all the positive properties of plywood plus important advantages: longer life span, greater loadbearing capacity, better nailholding ability, fewer and easier repairs, 100 % recyclability. Besides the obvious advantages, such as considerably reduced Fig. 7.1: Negative impression in the concrete when using panels with a conventional plywood face Fig. 7.3: Composite alkus plastic sheet structure Fig. 7.2: Smooth and even concrete surface as there is no projecting profile of the panel frame plastic layer aluminum layer foamed plastic core aluminum layer plastic layer The alkus plastic sheet cleaning effort, minimum consumption of release agent and an excellent concrete finish, alkus offers substantial ecological benefits. Substituting plastic for wood saves valuable timber resources. Also, further releasing of highly toxic dioxin is avoided, which is released in the process of burning plywood (that is bonded with phenolic resin). Used or damaged alkus plastic sheets can be recycled into the same product. It is 100% recyclable, and the manufacturer guarantees reacceptance. 7

Panel connection The fast and efficient connection of the panels is accomplished with the MEVA assembly lock, no matter if the panels are assembled side by side or on top of each other.

8 Panel connection The fast and efficient connection of the panels is accomplished with the MEVA assembly lock, no matter if the panels are assembled side by side or on top of each other. The lock can be attached on the frame at any position, and its 5point contact does not only draw together the panels, it also aligns them. With only a few hammer blows a safe connection and a perfect alignment are achieved. Since the lock weighs only 6.6 lbs it can be easily attached with one hand. The 12' panels require three assembly locks. Two locks are sufficient for the 8' and 4' panels. = 5point contact Massembly lock

9 Placing of ties Fig. 9.3 x x x Fig. 9.1 Fig. 9.2 Detail The conical anchor sleeves, where the ties can be inserted, are located inside the panel frame. The conical shape allows one (Fig. 9.1) or both sides (Fig. 9.2) of the wall to be inclined. On sloping formwork the articulated flange nuts 20/ 140 have to be used. In order to secure the formwork against uplift it has to be tied to the ground (see page 40 for details). Please note If two panels of different width are assembled side by side, the ties should always be placed through the panel with the larger width (Fig. 9.3). When using Unitie claws (used only with threadbars), the ties can be placed at the outside edge of the panels, for example when forming bulkheads, or directly above the panels when forming foundations. Max. incline of 8' and 12' panels for singleand two sided incline (Fig. 9.1 and 9.2) 1 7 / 16 " 8 height 12 height x [inch] angle [α] x [inch] angle [α] 1 9 / 16 " taper tie /2 3 1" to 1 1/4" threadbar 11 3/ /2 7 7/8" Tie rod (threadbar) DW 20/ Articulated flange nut 20/ Plug D

10 Height extension High degree of flexibility The formwork is extended in height using panels assembled vertically or horizontally, or in any combination on top of the bottom panels. No matter what configuration you opt for, the panel connection is always made with the MEVA assembly lock. The wide range of panel heights and widths ensures: Economical height extension in 6" increments through combined horizontal and vertical assembly Uniform joint grid. Functionality ensured by panel connection with assembly locks that can be positioned anywhere on the frame. Fig. 10.1: Formwork height from 4' to 8' in 6" increments Fig. 10.3: Formwork height from 8' to 12' in 6" increments Userfriendliness and profitability Vertical joints For a 4' standard panel you need just one 7/8" (20 mm) threadbar (or taper tie) and 2 assembly locks. A 8' standard panel requires 2 of each and the 12' standard panel 3 of each. All tieing positions predetermined by the system have to be used. Fig. 10.4: Formwork height from 12' to 16' in 6" increments 10

11 Height extension Fig. 10.2: 12' high panel in horizontal position Horizontal joints The illustrations show generalized positions of the assembly locks and tie locations. Exact locations for specific job site conditions will be provided in the engineering drawings by the technical department. In general, 2 assembly locks per panel joint are required for 4' and 8' high panels.12' high panels require 3 assembly locks. In some cases the number of ties can be reduced by using steel rails. At any rate, attention has to be paid not to exceed the permissible load of the ties and steel rails. For further details about steel rails see pages 25 and 72. This illustration does not take ganging into consideration. (For crane ganging see page 36). 11

12 Height extension In stacked panel condition with a height extension 1' it is not required to install ties in tie holes of extended panel (Fig. 12.1). For height extensions with panels > 1' 1'6" it is only required to install a tie in the top tie holes (Fig. 12.2). For height extensions 2' a tie should be installed in every tie location (Fig. 12.3). 1' 1'6" Fig Fig ' Fig

13 Rate of placing Taper tie: Technical data Taper tie 1" to 11/4" Safe working load [lbs] 32,500 Tie rod: Technical data Tie rod 7/8" d 1 [inch] 13/16 d 2 [inch] 7/8 Safe working load [lbs] 30,900 R = rate of placing in feet per hour d 2 d 1 Recommendations for concrete 0lacement Concrete should be placed in layers, the thickness of which can vary from 18" to 4'. Concrete must not be placed from great heights at free fall ( 5'). When vibrating the concrete, which is done layer by layer, the vibrator must not penetrate more than 18" into the layer below. A final vibrating over the overall concrete height is not recommended. It does not provide any advantage, since concrete that has been vibrated once cannot be compacted further. This may result only in water bubbles (shrinkage cavities) on the concrete surface. Following the above recommen dations, you can pour concrete up to a height of 12' without worrying about the rate of placing. P = form working pressure in pounds per square foot For controlled pours of 150 lbs stone concrete in 18" layers, vibrated no more than 4'0" deep, no set retarders, plasticizers, or waterreducing agents. 12 ft/hr is considered the maximum rate of placing of controlled pours in wall forms. At higher rates or without rise control, use column formulae above 12'0" heights. For mix density other than 150 pcf, adjust calculated pressure proportionately. For set retarder or plasticizer additives, pressure increases about the same amount as reducing mix temperatures, as follows: dosage of 8 Oz/CY ~ 10 F; 12 Oz/CY ~ 15 F; and 16 Oz/CY ~ 20 F. Outside air temperature changes stripping and curing time, not form pressure. Urban concrete deliveries are commonly at 70 to 90 F at end of chute; heavy civil works or mass concrete pours are usually at or lower than 60 F. Ice in the mix for hot weather placing must be accounted for in form design pressure calculations. Attention The 5/8" shebolt can be used with the system. Do not exceed the rated tensile force of 21,800 lbs. or the admissible fresh concrete pressure of 1,362 lbs/sq.ft. 13

14 Flatness of surface As long as you follow the technical instructions you can obtain the deflections (see table) as recommended by the ACI. Deflection l/240 Definition Foundations, backfills Determining deflection For a standard wall thickness you can use the tieing positions as "fixed spots". Determine the deflection by positioning a guided lath at distance (a) to the stripped wall (Fig. 14.1). The admissible deflection is always determined by the measurement point interval (in this case the distance between tieing positions). l/360 l/480 Chart: Deflection Standard Exposed concrete a = constant t 1 and t 2 = reading off l 1 and l 2 = measurement point interval Deflection: f 1 = a t 1 f 2 = a t 2 Fig

90 corner with standard panel Fig. 15.1 Fig. 15.3 Fig. 15.5 Fig. 15.2 OC Calculation of panel widths for 90º corner configurations inside corner (side length 1') + wall thickness = panel 1 Fig. 15.115.

Only 2 assembly locks at each side are required to connect the inside corner to 4' and 8' panels, whereas the 12' inside corner requires 3 assembly locks. The length of the sides is 1'.

15 90 corner with standard panel Fig Fig Fig Fig OC Calculation of panel widths for 90º corner configurations inside corner (side length 1') + wall thickness = panel 1 Fig The inside corner is provided with tie holes and consists of two parts. The steel face is replaceable. Only 2 assembly locks at each side are required to connect the inside corner to 4' and 8' panels, whereas the 12' inside corner requires 3 assembly locks. The length of the sides is 1'. For walls higher than 12' the amount and position of assembly locks must be directed by the technical department. Fig The outside corner and panels are connected with assembly locks. With extended formwork the amount and position of assembly locks must be directed by the technical department. For 12' high outside corners 4 assembly locks on each side are required. 8' high outside corners require 3 assembly locks and for 4' high corners only 2 assembly locks on each side are sufficient. Fig Fig OC Iinside corner 12'x1' 'x1' 'x1' Ioutside corner 12' ' '

16 90 corner with standard panel The use of the 1", 2" and 3" fillers in conjunction with standard panels allows a wall width change in 1" increments. By using these fillers you can avoid the timeconsuming mounting of steel rails at the 90 corner. The connection in the filler area can be accomplished by the use of the Uniassembly lock 28, which spans up to 6" fillers. The locations of the locks will be indicated on the technical drawings. For panels with a height of 12' three Uniassembly locks 28 are required. 4' and 8' high panels need two Uniassembly locks 28. 2"filler 3"filler OC Fig Fig "filler OC 1"filler 2"filler Attention The diameter of the articulated flange nut has to span the width of the filler(s) for load transfer into standard panels. (Fig ) OC OC Fig Fig Ifiller 8'x3" 'x2" 'x1" 'x3" 'x2" 'x1" Uniassembly lock Detail filler Uniassembly lock 16

90 corner with multipurpose panel Fig. 17.2: Column clamp The multipurpose panel can be used to form pilasters, corners, columns, bridge abutments and connections to existing walls.

17 90 corner with multipurpose panel Fig. 17.2: Column clamp The multipurpose panel can be used to form pilasters, corners, columns, bridge abutments and connections to existing walls. The panels have multiadjustment profiles (Fig ) for mounting column clamps or ties. The 12 panels have 3 multiadjustment profiles, so you will need 3 column clamps. The 8' panel has 2 profiles, and therefore requires 2 clamps. The 4' and 2' panels have only 1 multiadjustment profile each and require only 1 column clamp. To tighten the column clamp a flange nut 100 (15 mm / 5/8 " thread) is required. Fig /16" 1 7/16" to 1 9/16" Fig. 17.3: Multi!djustment profile Imultipurpose panel 12'x4' 'x4' 'x4' 'x4' Icolumn clamp Flange nut

18 90 corner with multipurpose panel To form a 90 corner you can use a multipurpose panel (MPP) and an panel connected by a column clamp (see page 17 Fig. 17.2). This gives a thight, rectangular and rigid connection. The MPP fits for wall thicknesses up to 2'2" in 2" increments (Fig. 18.1). The addition of a 1" filler allows wall thickness changes in 1" increments (Fig. 18.2). At the maximum wall thickness the indexing stud will be installed in the last tie hole of the multiadjustment profile (see detail). WT Fig. 18.1: for even wall thicknesses column clamp flange nut 100 WT WT tie 1" filler WT column clamp flange nut 100 tie Fig. 18.2: for odd wall thicknesses indexing stud last tie hole of multiadjustment profile Imultipurpose panel 12'x4' 'x4' 'x4' 'x4' Icolumn clamp Flange nut Detail 18

Articulated corners Fig. 19.1 wooden blocking A AOC A AOC Fig. 19.4 Acute and obtuse angled corners are formed using articulated inside and outside corners.

19 Articulated corners Fig wooden blocking A AOC A AOC Fig Acute and obtuse angled corners are formed using articulated inside and outside corners. Steel rails are attached to the multifunction profile at the tie hole elevation of the outside corner assembly to provide alignment. (In case of MPP, steel rails are attached to multiadjustment profile using threadbars or taper ties). If wooden fillers are used, the steel members are connected using Uniassembly locks. Side length of outside corner: 5" Side length of inside corner: 1' Adjustment range: 70º to 220º (Fig ). Fig Fig A AOC wooden blocking wooden filler with Uniassembly look 28 steel rail bolted with flange screw 18 and flange nut 100 to provide rigidity Isteel rail 12' ' ' Iarticulated outside corner 12'x5" 'x5" 'x5" Iarticulated inside corner 12'x1' 'x1' 'x1' Uni assembly lock

20 Articulated corners If the inside angle is 100º, steel rails and wooden blockings have to be used on the inside (Fig. 20.1). To determine the dimension (y) between the articulated outside corner and the first panel where a tie can be used, see chart below. If measures marked in white, watch concrete pressure and pouring rate. In all cases rails must be calculated specificially for each application. AOC A α 100º y WT Fig Isteel rail 12' ' ' Iarticulated outside corner 12'x5" 'x5" 'x5" Iarticulated inside corner 12'x1' 'x1' 'x1' Uni assembly lock wall thick ness WT = 8 WT = 9 WT = 10 WT = 11 WT = 12 WT = 13 WT = 14 WT = 15 angle inches inches inches inches inches inches inches inches A = 70 y = 18.4" y = 19.9" y = 21.3" y = 22.7" y = 24.1" y = 25.6" y = 27.0" y = 28.4" A = 75 y = 17.4" y = 18.7" y = 20.0" y = 21.3" y = 22.6" y = 23.9" y = 25.2" y = 26.5" A = 80 y = 16.5" y = 17.7" y = 18.9" y = 20.1" y = 21.3" y = 22.5" y = 23.7" y = 24.9" A = 85 y = 15.7" y = 16.8" y = 17.9" y = 19.0" y = 20.1" y = 21.2" y = 22.3" y = 23.4" A = 90 y = 15.0" y = 16.0" y = 17.0" y = 18.0" y = 19.0" y = 20.0" y = 21.0" y = 22.0" A = 95 y = 14.3" y = 15.2" y = 16.2" y = 17.1" y = 18.0" y = 18.9" y = 19.8" y = 20.7" A = 100 y = 13.7" y = 14.6" y = 15.4" y = 16.2" y = 17.1" y = 17.9" y = 18.7" y = 19.6" A = 105 y = 13.1" y = 13.9" y = 14.7" y = 15.4" y = 16.2" y = 17.0" y = 17.7" y = 18.5" A = 110 y = 12.6" y = 13.3" y = 14.0" y = 14.7" y = 15.4" y = 16.1" y = 16.8" y = 17.5" A = 115 y = 12.1" y = 12.7" y = 13.4" y = 14.0" y = 14.6" y = 15.3" y = 15.9" y = 16.6" A = 120 y = 11.6" y = 12.2" y = 12.8" y = 13.4" y = 13.9" y = 14.5" y = 15.1" y = 15.7" A = 125 y = 11.2" y = 11.7" y = 12.2" y = 12.7" y = 13.2" y = 13.8" y = 14.3" y = 14.8" A = 130 y = 10.7" y = 11.2" y = 11.7" y = 12.1" y = 12.6" y = 13.1" y = 13.5" y = 14.0" A = 135 y = 10.3" y = 10.7" y = 11.1" y = 11.6" y = 12.0" y = 12.4" y = 12.8" y = 13.2" A = 140 y = 9.9" y = 10.3" y = 10.6" y = 11.0" y = 11.4" y = 11.7" y = 12.1" y = 12.5" A = 145 y = 9.5" y = 9.8" y = 10.2" y = 10.5" y = 10.8" y = 11.1" y = 11.4" y = 11.7" A = 150 y = 9.1" y = 9.4" y = 9.7" y = 9.9" y = 10.2" y = 10.5" y = 10.8" y = 11.0" A = 155 y = 8.8" y = 9.0" y = 9.2" y = 9.4" y = 9.7" y = 9.9" y = 10.1" y = 10.3" A = 160 y = 8.4" y = 8.6" y = 8.8" y = 8.9" y = 9.1" y = 9.3" y = 9.5" y = 9.6" A = 165 y = 8.1" y = 8.2" y = 8.3" y = 8.4" y = 8.6" y = 8.7" y = 8.8" y = 9.0" A = 170 y = 7.7" y = 7.8" y = 7.9" y = 8.0" y = 8.0" y = 8.1" y = 8.2" y = 8.3" A = 175 y = 7.3" y = 7.4" y = 7.4" y = 7.5" y = 7.5" y = 7.6" y = 7.6" y = 7.7" A = 180 y = 7.0" y = 7.0" y = 7.0" y = 7.0" y = 7.0" y = 7.0" y = 7.0" y = 7.0" Chart: residual measure (y) 20

21 Articulated corners AOC A α 100º y WT If the inside angle is 100º, steel rails and wooden blockings are not required on the inside (Fig. 21.1). To determine the dimension (y) between the articulated outside corner and the first panel where a tie can be used, see chart below. If measures marked in white, watch concrete pressure and pouring rate. In all cases rails have to calculated specificially for each application. Fig wall thick ness WT = 16 WT = 17 WT = 18 WT = 19 WT = 20 WT = 21 WT = 22 WT = 23 WT = 24 angle inches inches inches inches inches inches inches inches inches A = 70 y = 29.9" y = 31.3" y = 32.7" y = 34.1" y = 35.6" y = 37.0" y = 38.4" y = 39.8" y = 41.3" A = 75 y = 27.9" y = 29.2" y = 30.5" y = 31.8" y = 33.1" y = 34.4" y = 35.7" y = 37.0" y = 38.3" A = 80 y = 26.1" y = 27.3" y = 28.5" y = 29.6" y = 30.8" y = 32.0" y = 33.2" y = 34.4" y = 35.6" A = 85 y = 24.5" y = 25.6" y = 26.6" y = 27.7" y = 28.8" y = 29.9" y = 31.0" y = 32.1" y = 33.2" A = 90 y = 23.0" y = 24.0" y = 25.0" y = 26.0" y = 27.0" y = 28.0" y = 29.0" y = 30.0" y = 31.0" A = 95 y = 21.7" y = 22.6" y = 23.5" y = 24.4" y = 25.3" y = 26.2" y = 27.2" y = 28.1" y = 29.0" A = 100 y = 20.4" y = 21.3" y = 22.1" y = 22.9" y = 23.8" y = 24.6" y = 25.5" y = 26.3" y = 27.1" A = 105 y = 19.3" y = 20.0" y = 20.8" y = 21.6" y = 22.3" y = 23.1" y = 23.9" y = 24.6" y = 25.4" A = 110 y = 18.2" y = 18.9" y = 19.6" y = 20.3" y = 21.0" y = 21.7" y = 22.4" y = 23.1" y = 23.8" A = 115 y = 17.2" y = 17.8" y = 18.5" y = 19.1" y = 19.7" y = 20.4" y = 21.0" y = 21.7" y = 22.3" A = 120 y = 16.2" y = 16.8" y = 17.4" y = 18.0" y = 18.5" y = 19.1" y = 19.7" y = 20.3" y = 20.9" A = 125 y = 15.3" y = 15.8" y = 16.4" y = 16.9" y = 17.4" y = 17.9" y = 18.5" y = 19.0" y = 19.5" A = 130 y = 14.5" y = 14.9" y = 15.4" y = 15.9" y = 16.3" y = 16.8" y = 17.3" y = 17.7" y = 18.2" A = 135 y = 13.6" y = 14.0" y = 14.5" y = 14.9" y = 15.3" y = 15.7" y = 16.1" y = 16.5" y = 16.9" A = 140 y = 12.8" y = 13.2" y = 13.6" y = 13.9" y = 14.3" y = 14.6" y = 15.0" y = 15.4" y = 15.7" A = 145 y = 12.0" y = 12.4" y = 12.7" y = 13.0" y = 13.3" y = 13.6" y = 13.9" y = 14.3" y = 14.6" A = 150 y = 11.3" y = 11.6" y = 11.8" y = 12.1" y = 12.4" y = 12.6" y = 12.9" y = 13.2" y = 13.4" A = 155 y = 10.5" y = 10.8" y = 11.0" y = 11.2" y = 11.4" y = 11.7" y = 11.9" y = 12.1" y = 12.3" A = 160 y = 9.8" y = 10.0" y = 10.2" y = 10.4" y = 10.5" y = 10.7" y = 10.9" y = 11.1" y = 11.2" A = 165 y = 9.1" y = 9.2" y = 9.4" y = 9.5" y = 9.6" y = 9.8" y = 9.9" y = 10.0" y = 10.2" A = 170 y = 8.4" y = 8.5" y = 8.6" y = 8.7" y = 8.7" y = 8.8" y = 8.9" y = 9.0" y = 9.1" A = 175 y = 7.7" y = 7.7" y = 7.8" y = 7.8" y = 7.9" y = 7.9" y = 8.0" y = 8.0" y = 8.0" A = 180 y = 7.0" y = 7.0" y = 7.0" y = 7.0" y = 7.0" y = 7.0" y = 7.0" y = 7.0" y = 7.0" Chart: residual measure (y) Isteel rail 12' ' ' Iarticulated outside corner 12'x5" 'x5" 'x5" Iarticulated inside corner 12'x1' 'x1' 'x1' Uni assembly lock

At the maximum column size the indexing stud will be installed in the last tie hole of the multi adjustment stiffener Fig. 22.

22 Columns Columns with mul tipurpose panels The multiadjustment profile lets you form columns (see Fig. 22.1, Fig. 22.2) in increments of 2", in a size range from 2" to 3'2". To form columns with odd dimensions the column form should be furred out at the inside. At the maximum column size the indexing stud will be installed in the last tie hole of the multi adjustment stiffener Fig column clamp flange nut 100 indexing stud last tie hole of multiadjustment profile Fig (see detail). Columns with standard panels (Fig. 22.3, Fig. 22.4) See page 23. Detail Capacity The admissible fresh concrete pressure is of 2,025 lbs/sq.ft. for both types of columns. OC OC Imultipurpose panel 12'x4' 'x4' 'x4' 'x4' Icolumn clamp Flange nut OC Fig OC Fig

23 Columns height of column amount of strengthening collars (from bottom to top at tie hole elevation) 1' 1.5' 2' 2.5' 3' 3.5' 4' 8' 10' 12' 14' 16' ' ' ' ' ' ' ' ' Chart: Column forms with use of steel rail collars at tie hole elevation 2,600 lbs/sq.ft. 2,025 lbs/sq.ft. Columns up to a height of 12' and a width of 4' can be formed without the addition of steel rails as strengthening collar. Columns higher than 12' will require steel rails at tie hole elevation. Columns not shown will require directing of technical department. Fig Shows 12' high column without collar (7 assembly locks per joint). Fig Shows 18' high column with one collar at tie hole elevation (12' panel 7 locks per joint, 4' panel 2 locks per joint, 2' panel (horizontal) 2 locks per joint). If you would use a 8' panel instead of 4' and 2' panels you would need 5 locks per joint. Fig Shows 24' high column with two collars at tie hole elevation (14 assembly locks per joint). Number of assembly locks required for each panel height per joint: 12' = 7 locks 8' = 5 locks 4' = 2 locks. Capacity The admissible fresh concrete pressure for columns is 2,600 lbs/sq.ft. 1'3' 2,025 lbs/sq.ft. 3,5'4'. Fig Fig Fig

24 Length compensation Filler Gaps up to 3" can be formed with 1", 2" and 3" fillers without additional steel rails (Fig. 24.1). Wooden filler An alternate method of forming gaps is with the use of wooden jobbuilt fillers. With job builtfillers a steel rail is required across the joint at the tie hole elevations (Fig. 24.2). The Uniassembly lock will span a maximum gap of 6" (Fig and Fig. 24.4). Fig " filler 3" filler Timber profile In penetration areas, an alkus plastic sheet or plywood is cut to size and nailed to the timber profiles connected to the adjacent panel by assembly locks. At all filler locations, substitute Uniassembly locks for the standard assembly lock (Figs and 24.6). Timber profiles are always delivered in pairs. Fig Fig Fig Fig Itimber profile* 12 ft ft ft * delivered in pairs Fig. 24.5: Simplyfied drawing (steel rails not shown for clarity) Uniassembly lock

25 Length compensation OC Fig. 25.1: Design by technical department Fig 25.2: Tie location at the edge of the panel (panels up to 4' wide) Compensation areas are reinforced with steel rails, which must always be attached to the multifunction profile at tie hole elevation. The maximum filler width (L) for applications with standard panels up to 4' wide (Fig. 25.2) can be determined using the chart below, depending on the concrete pressure and the kind of steel rail used (the maximum pressure is 2,025 psf.). Attention When 8' wide panels have a filler between them, the maximum filler width must not exceed 12" (Fig. 25.3). Fig 25.3: Tie location inside the panel (8' wide panels) Fig 25.4: Standard application with smaller wooden filler Please note When compensating length differences near outside corners or bulkheads, the horizontal tensile force must always be considered. In this case fasten the steel rail with flange screws on both sides of the compensation area (Fig and Fig. 25.4). I mperial steel rail max. compensation width L [inches] (Steel rail attached to the multifunction profile at tie hole elevation) concrete pressure 2025 lbs/sq.ft. concrete pressure 1400 lbs/sq.ft. concrete pressure 1200 lbs/sq.ft. 4 ' L = 30" L = 30" L = 30" 6 ' L = 30" L = 34" L = 37" 12' L = 49" L = 56" L = 61" Chart: Max. compensation width when using steel rails Isteel rail 4 ft ft ft Uniassembly lock

Bulkheads Bulkheads can be formed using bulkhead brackets (Fig. 26.1 and Fig 26.2), or column clamps plus steel rails (Fig. 26.5). The column clamps and the rails are installed at tie hole elevation.

26 Bulkheads Bulkheads can be formed using bulkhead brackets (Fig and Fig 26.2), or column clamps plus steel rails (Fig. 26.5). The column clamps and the rails are installed at tie hole elevation. The tieing is achieved in placing Unitie claws and threadbars or taper ties (Fig and Fig. 26.4) at the tie locations. The bulkhead bracket can replace a tie and can take shear as well. Bulkhead bracket 2.5' for a wall thickness up to 30". Bulkhead bracket 40/60 for a wall thickness up to 16". up to wall thickness of 30" Fig bulkhead bracket Fig Wall thickness 16" 2 24" 3 30" 4 amount of bulkhead bracket per 8' high form Attention Never use threadbars or taper ties for bulkheads if these ties are going to be subjected to shearing stress. Fig flange nut 100 column clamp steel rail Bulkhead bracket 2,5' Bulkhead bracket 40/ Icolumn clamp Flange screw Unitie claw unitie claw Fig Fig

27 Wall all offset fset Fig wooden blocking wooden blocking Fig. 27.2: Clamped together with Uniassembly locks see detail articulated flange nut articulated flange nut Onesided wall offsets of up to 4" are formed by moving back the corresponding panel (Fig. 27.1). For offsets exceeding 4", inside corners should be used (Fig. 27.2). The offset sections of the wall formwork are reinforced by steel rails. Wall offsets from 6" up to 36" can be formed with multipurpose panels (Fig. 27.3). Panels arranged offset from each other are connected by means of Uniassembly locks 28 (see detail). Fig Detail wooden blockings corner bracket

28 Twall connection Connection is accomplished by using two inside corners. Different wall thicknesses are compensated for by means of the 1", 2", 3" or wooden fillers (Fig Fig. 28.4). For details about loadbearing capacity of steel rails see page 25. Fig standard panel standard panel filler Fig Fig steel rail wooden filler Ifiller 8'x3" 'x2" 'x1" 'x3" 'x2" 'x1" Isteel rail 12' ' ' Uniassembly lock Fig

29 Connection to existing walls Fig Fig Fig wooden blocking steel rail multipurpose panel existing tie hole Fig These sketches show some options for connecting formwork to an existing wall (Fig Fig. 29.6). According to the conditions on the construction site the most suitable solution may be chosen. Make sure the formwork is securely attached to the existing wall in order to avoid a leakage of the fresh concrete and a patchy concrete surface. The largesize panels 8'x8' and 12'x8' allow for a length adjustment up to 1'6" (Fig. 29.1). The rails must be calculated for each specific application. steel rail connection through existing tie holes steel rail Fig Fig

30 Pilasters Pilasters are easily formed using inside corners, standard panels, and where necessary some wooden blocking (Fig. 30.1, Fig. 30.2). bulkhead bracket wooden blocking Attention For conditions similar to Figs and 30.4 the following quantities of assembly locks at outside corners are required per joint: 4' high: 2 locks 8' high: 3 locks 12' high: 5 locks Above 12' high one assembly lock per 1'6" in height. For heights exceeding 16' refer to page 23. Fig Fig multipurpose panel column clamp OC OC Fig OC OC OC OC stripping corner Fig

31 flange nut 100 column clamp Pilasters at corners Pilasters at corners can also be formed using multipurpose panels (Fig. 31.1). To avoid interference with opposing ties, the multipurpose panels opposite each other need to be raised 2 using lumber soffits. By using fillers and blockouts a wide variety of pilasters can be formed (Fig. 31.2). OC Fig blockout flange nut 100 column clamp filler OC Fig IMultipurpose panel 12'x4' 'x4' 'x4' 'x4' Icolumn clamp Flange nut

32 Differences in height The assembly lock (Fig. 32.1) can be attached at any position on the frame profile, so the formwork needs no connection grid and requires no additional accessories for assembly. Vertical, horizontal and even inclined panels can all be safely connected by means of assembly locks, even with differences in height. Job built fillers are made with timber profiles and an alkus plastic sheet or plywood cut to size. When required, use a square timber for reinforcing. The timber profiles and panels are simply connected to each other with assembly locks. The wood filler areas need special attention (see page 24 and 25). The use of rails and / or blocking may be required (Fig. 32.2). Fig timber profile timber profile Fig

33 Panels in horizontal position A lot of forming problems can be easily solved by arranging panels horizontally (Fig. 33.2). These include basin walls in water treatment plants, which often require a certain height, or when formwork height is restricted by an existing structure, or for singlesided formwork. When the panels (width up to 4') are arranged horizontally replace the bottom tie with a foundation spanner together with a foundation tape (Fig. 33.1). You can also use multipurpose panels to form foundations (Fig. 33.2). On top of the formwork use Unitie claws for above tieing. Unitie claw foundation spanner with foundation tape Fig. 33.1: Example of a typical foundation formwork Fig. 33.2: Example of a typical foundation formwork with MultiPurpose Panel Mfoundation spanner Foundation tape

Attachment of accessories All panels are provided with multifunction profiles.

The difference between these multifunction profiles and the stiffeners is that the multifunction

Scaffolding brackets are provided with selflocking pins (Fig. 34.

The scaffolding bracket can be secured with a flange screw 18 (Fig. 34.3).

34 Attachment of accessories All panels are provided with multifunction profiles. Dywidag threaded nuts are welded inside the profile (Fig. 34.6). The difference between these multifunction profiles and the stiffeners is that the multifunction profile allows for attachment of forming accessories. Scaffolding brackets are provided with selflocking pins (Fig. 34.2) and thus can be mounted on the multifunction profile. The scaffolding bracket can be secured with a flange screw 18 (Fig. 34.3). Steel rails must be attached to the multifunction profile at tie hole elevation to ensure proper load transfer (Fig. 34.5). Formwork can be protected against uplift by using a small brace, attached to the panel with the formworkpropconnector as shown in Figs and 34.4, or by the use of a shoe plate. Fig Fig Fig Fig. 34.4: Formwork prop connector Fig cross stiffener multifunction profile at tie hole elevation multifunction profile Fig

Tie off bar / Bump notch Tie off bar panels come with welded tie off bars

2: Tie off bar Bump notch Larger selected panels come with an integrated

35 Tie off bar / Bump notch Tie off bar panels come with welded tie off bars allowing easy and safe access to the form (Figs ). Fig. 35.2: Tie off bar Bump notch Larger selected panels come with an integrated bump notch. The bump notch along with a pry bar allows easy movement of the panels on slab or ground elevation (Fig. 35.3). Attention When working with formwork observe all applicable codes and regulations. Fig Fig. 35.3: Bump notch 35

36 Crane ganging In order to provide the necessary flexural rigidity when lifting and laying down gangs, steel rails are mounted by means of flange screws. For gangs with horizontally assembled panels on top, the crane hook must be attached above the horizontal profiles so that the crane hook cannot disengage. If the total weight of the gang exceeds 6,600 lbs, more than two crane hooks are needed. For further detail see page 54. Vertical steel rails are required to avoid flexing between panels. The 6' and 12' steel rails must always be attached with 4 flange screws (Fig. 36.4, 37.2). The 4' steel rail can be mounted with 2 flange screws (Fig. 36.2, 36.3). Horizontal steel rails also avoid flexing between panels, and are used to keep gangs in line. For horizontal use the 4' steel rail is attached with 2 flange screws above a panel joint (Fig. 36.4, 37.2). For cases not addressed here consult specifications from the technical department. Fig. 36.1: Standard application Fig Fig Fig

37 Crane ganging selflocking pin bottom part part of bracket touching ground Fig Fig Gang 12' x 8' = 96 sq. ft. Weight: 1,175 lbs. Fig Gang 8'x12' = 96 sq. ft. with one 4' steel rail Weight: 1,310 lbs. Fig Gang 12'x16' = 192 sq. ft. with two 4' steel rails Weight: 2,480 lbs. Fig Gang 16'x18'6"= 296 sq. ft. with two 12' steel rails and one 4' steel rail Weight: 4,356 lbs. Fig In case the gangs (laid down on the ground facing up) have scaffolding brackets, the brackets must be secured to the panel with an additional flange screw 18 (at bottom part). Make sure that the scaffolding bracket touches the ground only with the part indicated. Fig Gang 16'x28' = 448 sq. ft. with four 6' steel rails and two 4' steel rails. Weight: 6,354 lbs. Fig

Working platform BKB 125 Folding access platform BKB 125 The readymade folding access platform BKB 125 unfolds quickly and provides a safe access and working scaffold.

When stacked the BKB 125 is only of 6 1/2" high (Fig. 38.1 Fig. 38.5). Permissible load: 42 lbs/sq.ft. The side railing can be mounted at a 90 or 105 angle (Fig. 38.4).

38 Working platform BKB 125 Folding access platform BKB 125 The readymade folding access platform BKB 125 unfolds quickly and provides a safe access and working scaffold. The 2" thick planks have a rough surface and a metal lining at the edges. The platform length of 7'8 1/2" makes the BKB 125/235 trucktransportable, as they fit crosswise on any truck. When stacked the BKB 125 is only of 6 1/2" high (Fig Fig. 38.5). Permissible load: 42 lbs/sq.ft. The side railing can be mounted at a 90 or 105 angle (Fig. 38.4). 1'7" suspension point 1'1" 4'1" Fig Fig The access platform is automatically secured against displacement by its selflocking mechanism. Attention The platform BKB 125 must not be moved when attached to the formwork. When using our products the federal, state and local codes and regulations must be observed. Fig Fig Examples of application for corner configurations and length adjustment side railing BKB 125 as side protection residual measure side railing BKB 125 as rear protection when using the BKB 125/140 for length adjustment gap closed on site by compensation platform Folding access platform BKB 125/ BKB 125/ BKB 125/ Fig

Scaffolding bracket Working platform 42" 18 3/4" 18 3/4" Fig. 39.1 handrail (min. 2"x4") midrail (min. 1"x6") toe board (min. 1"x4") platform min.

39 Scaffolding bracket Working platform 42" 18 3/4" 18 3/4" Fig handrail (min. 2"x4") midrail (min. 1"x6") toe board (min. 1"x4") platform min. 20" Chart 1 Working groups specified by OSHA w orking group workers only, no material minimu m platform width ( (inch inch) Fig s surfacerelated loads ( (psf psf) 20" 25 Scaffolding bracket (with selflocking pin) The scaffolding bracket is mounted to a multifunction profile which is not at tie hole elevation. To insert the bracket turn it by 45, then turn it back to vertical position and secure it with a flange screw. After that planks can be bolted to the brackets. For bracket spacings with an assumed load of 25 psf (including deck) see chart (Fig Fig. 39.2). Side railing If the fall height is > 8' a side railing consisting of handrail, midrail and toe board is required (workers only, no material). Guardrailing post 42" is attached to the scaffolding bracket 125. If scaffolding brackets are attached to gangs see page 37 for crane ganging instructions. Chart 2 Admissible bracket spacing (ft) for platforms made of wooden planks or boards workin orking grou roup plank or board width ( (inch inch) plank or board thickness s ( (inch inch) 1 1/4" 1 1/2" 1 3/4" 2" workers only, no material 1 0" 4 ' 6 ' 7 ' 8' Side railing BKB Scaffolding bracket Guardrailing post 42" Side railing 125/

User Guide MEGAFORM 02FAR14

User Guide MEGAFORM 02FAR14 IMPORTANT: Any safety provisions as directed by the appropriate governing agencies must be observed when using our products. The pictures in this brochure are snapshots of situations