Timber formwork beams

Transcription

1 /2014 en-gb The Formwork Experts. Timber formwork bems User Informtion Instructions for ssembly nd use (Method sttement)

2 Contents 3 Introduction 3 Elementry sfety wrnings 6 Dok services 8 Eurocodes t Dok 9 9 Product description 10 Instructions for ssembly nd use 13 Technicl condition 16 Trnsporting, stcking nd storing 18 Component overview /2014

3 Introduction Elementry sfety wrnings Introduction User trget groups This booklet is imed t ll persons who will be working with the Dok product or system tht it describes. It contins informtion on the stndrd design for setting up this system, nd on correct, complint utilistion of the system. All persons working with the product described herein must be fmilir with the contents of this booklet nd with ll the sfety instructions it contins. Persons who re incpble of reding nd understnding this booklet, or who cn do so only with difficulty, must be instructed nd trined by the customer. The customer is to ensure tht the informtion mterils provided by Dok (e.g. User Informtion booklets, Instructions for Assembly nd Use, Operting Instruction mnuls, plns etc.) re vilble to ll users, nd tht they hve been mde wre of them nd hve esy ccess to them t the usge loction. In the relevnt technicl documenttion nd formwork utilistion plns, Dok shows the workplce sfety precutions tht re necessry in order to use the Dok products sfely in the usge situtions shown. In ll cses, users re obliged to ensure complince with ntionl lws, Stndrds nd rules throughout the entire project nd to tke pproprite dditionl or lterntive workplce sfety precutions where necessry. Hzrd ssessment The customer is responsible for drwing up, documenting, implementing nd continully updting hzrd ssessment t every job-site. This booklet serves s the bsis for the site-specific hzrd ssessment, nd for the instructions given to users on how to prepre nd utilise the system. It does not substitute for these, however. Remrks on this booklet This booklet cn lso be used s generic method sttement or incorported with site-specific method sttement. Mny of the illustrtions in this booklet show the sitution during formwork ssembly nd re therefore not lwys complete from the sfety point of view. Any sfety ccessories not shown in these illustrtions must still be used by the customer, in ccordnce with the pplicble rules nd regultions. Further sfety instructions, especilly wrnings, will be found in the individul sections of this booklet! Plnning Provide sfe workplces for those using the formwork (e.g. for when it is being erected/dismntled, modified or repositioned etc). It must be possible to get to nd from these workplces vi sfe ccess routes! If you re considering ny devition from the detils nd instructions given in this booklet, or ny ppliction which goes beyond those described in the booklet, then revised sttic clcultions must be produced for checking, s well s supplementry ssembly instructions. Regultions; industril sfety All lws, Stndrds, industril sfety regultions nd other sfety rules pplying to the utilistion of our products in the country nd/or region in which you re operting must be observed t ll times. If person or object flls ginst, or into, the sidegurd component nd/or ny of its ccessories, the component ffected my only continue in use fter it hs been inspected nd pssed by n expert /2014 3

4 Introduction Rules pplying during ll phses of the ssignment The customer must ensure tht this product is erected nd dismntled, reset nd generlly used for its intended purpose in ccordnce with the pplicble lws, Stndrds nd rules, under the direction nd supervision of suitbly skilled persons. These persons' mentl nd physicl cpcity must not in ny wy be impired by lcohol, medicines or drugs. Dok products re technicl working pplinces which re intended for industril/commercil use only, lwys in ccordnce with the respective Dok User Informtion booklets or other technicl documenttion uthored by Dok. The stbility of ll components nd units must be ensured during ll phses of the construction work! The functionl/technicl instructions, sfety wrnings nd loding dt must ll be strictly observed nd complied with. Filure to do so cn cuse ccidents nd severe (even life-thretening) dmge to helth, s well s very gret mteril dmge. Fire-sources re not permitted nywhere ner the formwork. Heting pplinces re only llowed if properly nd expertly used, nd set up sfe distnce wy from the formwork. The work must tke ccount of the wether conditions (e.g. risk of slippge). In extreme wether, steps must be tken in good time to sfegurd the equipment, nd the immedite vicinity of the equipment, nd to protect employees. All connections must be checked regulrly to ensure tht they still fit properly nd re functioning correctly. It is very importnt to check ll screw-type connections nd wedge-clmped joins whenever the construction opertions require (prticulrly fter exceptionl events such s storms), nd to tighten them if necessry. It is strictly forbidden to weld Dok products in prticulr nchoring/tying components, suspension components, connector components nd cstings etc. or otherwise subject them to heting. Welding cuses serious chnge in the microstructure of the mterils from which these components re mde. This leds to drmtic drop in the filure lod, representing very gret risk to sfety. The only rticles which re llowed to be welded re those for which the Dok literture expressly points out tht welding is permitted. Assembly User Informtion Timber formwork bems The equipment/system must be inspected by the customer before use, to ensure tht it is in suitble condition. Steps must be tken to rule out the use of ny components tht re dmged, deformed, or wekened due to wer, corrosion or rot. Combining our formwork systems with those of other mnufcturers could be dngerous, risking dmge to both helth nd property. If you intend to combine different systems, plese contct Dok for dvice first. The equipment/system must be ssembled nd erected in ccordnce with the pplicble lws, Stndrds nd rules by suitbly skilled personnel of the customer's, hving regrd to ny nd ll required sfety inspections. It is not permitted to modify Dok products; ny such modifictions constitute sfety risk. Closing the formwork Dok products nd systems must be set up so tht ll lods cting upon them re sfely trnsferred! Pouring Do not exceed the permitted fresh-concrete pressures. Over-high pouring rtes overlod the formwork, cuse greter deflection nd risk brekge. Stripping out the formwork Do not strip out the formwork until the concrete hs reched sufficient strength nd the person in chrge hs given the order for the formwork to be stripped out! When stripping out the formwork, never use the crne to brek concrete cohesion. Use suitble tools such s timber wedges, specil pry-brs or system fetures such s Frmx stripping corners. When stripping out the formwork, do not endnger the stbility of ny prt of the structure, or of ny scffolding, pltforms or formwork tht is still in plce! /2014

5 Introduction Trnsporting, stcking nd storing Observe ll regultions pplying to the hndling of formwork nd scffolding. In ddition, the Dok slinging mens must be used - this is mndtory requirement. Remove ny loose prts or fix them in plce so tht they cnnot be dislodged or fll free! All components must be stored sfely, following ll the specil Dok instructions given in the relevnt sections of this booklet! Mintennce Only originl Dok components my be used s spre prts. Repirs my only be crried out by the mnufcturer or uthorised fcilities. Miscellneous We reserve the right to mke ltertions in the interests of technicl progress. Symbols used The following symbols re used in this booklet: Importnt note Filure to observe this my led to mlfunction or dmge. CAUTION / WARNING / DANGER Filure to observe this my led to mteril dmge, nd to injury to helth which my rnge up to the severe or even life-thretening. Instruction This symbol indictes tht ctions need to be tken by the user. Sight-check Indictes tht you need to do sight-check to mke sure tht necessry ctions hve been crried out. Tip Points out useful prcticl tips. Reference Refers to other documents nd mterils /2014 5

6 Introduction User Informtion Timber formwork bems Dok services Support in every stge of the project Dok offers brod spectrum of services, ll with single im: to help you succeed on the site. Every project is unique. Nevertheless, there is one thing tht ll construction projects hve in common nd tht is bsic structure with five stges. We t Dok know our clients' vrying requirements. With our consulting, plnning nd other services, we help you chieve effective implementtion of your formwork ssignment using our formwork products in every one of these stges Project Development Stge Bidding Stge Project Mngement Plnning Stge Tking well-founded decisions thnks to professionl dvice nd consulting Optimising the preliminry work with Dok s n experienced prtner Controlled, regulr forming opertions, for greter efficiency resulting from relisticlly clculted formwork concepts Find precisely the right formwork solutions, with the id of help with the bid invittion in-depth nlysis of the initil sitution objective evlution of the plnning, execution, nd time-risks Drw up potentilly winning bids, by bsing them on relisticlly clculted guideline prices mking the right formwork choices hving n optimum time-clcultion bsis Pln cost-effectively right from the outset, thnks to detiled offers determintion of the commissioning quntities co-ordintion of led-times nd hndover dedlines /2014

7 Introduction Concrete Construction Stge 4 5 Project Close-out Stge The dvntges for you thnks to professionl dvice nd consulting Cost svings nd time gins When we dvise nd support you right from the word "go", we cn mke sure tht the right formwork systems re chosen nd then used s plnned. This lets you chieve optimum utilistion of the formwork equipment, nd effective forming opertions becuse your workflows will be correct. Optimum resource utilistion with ssistnce from the Dok Formwork Experts Workflow optimistion, thnks to thorough utilistion plnning interntionlly experienced project technicins pproprite trnsport logistics on-site support Seeing things through to positive conclusion with professionl support Dok Services re byword for trnsprency nd efficiency here, offering jointly hndled return of rented formwork professionl dismntling efficient clening nd reconditioning using specil equipment Mximised workplce sfety The dvice nd support we cn give you in how to use the equipment correctly, nd s plnned, leds to greter sfety on the job. Trnsprency Becuse our services nd costs re completely trnsprent, there is no need for improvistion during the project nd no unplesnt surprises t the end of it. Reduced close-out costs Our professionl dvice on the selection, qulity nd correct use of the equipment helps you void dmge, nd minimise wer-ndter /2014 7

8 Introduction User Informtion Timber formwork bems Eurocodes t Dok In Europe, uniform series of Stndrds known s Eurocodes (EC) ws developed for the construction field by the end of These re intended to provide uniform bsis, vlid throughout Europe, for product specifictions, tenders nd mthemticl verifiction. The EC re the world's most highly developed Stndrds in the construction field. In the Dok Group, the EC re to be used s stndrd from the end of They will thus supersede the DIN norms s the "Dok stndrd" for product design. The widely used "Permissible stress design" (compring the ctul stresses with the permissible stresses) hs been superseded by new sfety concept in the EC. The EC contrst the ctions (lods) with the resistnce (cpcity). The previous sfety fctor in the permissible stresses is now divided into severl prtil fctors. The sfety level remins the sme! E d R d E d F d F k F Design vlue of effect of ctions (E... effect; d... design) Internl forces from ction F d (V Ed, N Ed, M Ed ) Design vlue of n ction R d Design vlue of the resistnce (R... resistnce; d... design) Design cpcity of cross-section (V Rd, N Rd, M Rd ) Steel: R d = R k Timber: R d = k mod Rk F d = F F k M M (F... force) Chrcteristic vlue of n ction R k Chrcteristic vlue of the resistnce "ctul lod", service lod e.g. moment resistnce to yield stress (k... chrcteristic) e.g. ded weight, live lod, concrete pressure, wind Prtil fctor for ctions (in terms of lod; F... force) e.g. for ded weight, live lod, concrete pressure, wind Vlues from EN M k mod Prtil fctor for mteril property (in terms of mteril; M...mteril) e.g. for steel or timber Vlues from EN Modifiction fctor (only for timber to tke ccount of the moisture nd the durtion of lod ction) e.g. for Dok bem H20 Vlues s given in EN nd EN Comprison of the sfety concepts (exmple) Permissible stress design EC/DIN concept [kn] 60<70 [kn] 60 [kn] F yield ~ 1.65 F permissible F A ctul R [kn] k R 90<105 [kn] d M =1.1 A E 90 [kn] d F = The "permissible vlues" communicted in Dok documents (e.g.: Q permissible = 70 kn) do not correspond to the design vlues (e.g.: V Rd = 105 kn)! Avoid ny confusion between the two! Our documents will continue to stte the permissible vlues. Allownce hs been mde for the following prtil fctors: F = 1.5 M, timber = 1.3 M, steel = 1.1 k mod = 0.9 In this wy, ll the design vlues needed in n EC design clcultion cn be scertined from the permissible vlues. F ctul F permissible A Utilistion fctor E d R d /2014

9 Product description Dok formwork bems Dok formwork bems re solid-webbed bems mde of wood or wood-bsed mteril to EN nd in ccordnce with the pprovls issued by the Germn Institute for Construction Engineering, Berlin (Z-9.1- ***), exclusively for use in wll nd floor formwork. Other fetures include: Bem-flnge mrkings in 50 cm grid for the Dokflex nd Dokflex 30 tec systems Option of dding "customer nme" to wording (indicted by the suffix "BS" in the rticle designtion.). Wood for flnges is grded by utomtic grding mchines for mximised dependbility Menings of the code letters used in the rticle designtion Code letter P Web mde of specil flt-pressed sheet N Web mde of three-ply Innovtive polyurethne end reinforcement for highly top effective protection of the formwork bem Tried-nd-tested end reinforcement in the form of eco bevelled ends with plstic rivet in the bem flnge Types of bem H16 N H16 P H20 N H20 P Approvl Number Z Z Z Z or EN Dok bems with no EN mrk (i.e. those produced on or before 3rd Nov. 2008) re covered by the bove-mentioned DIB ( Germn Institute of Building Technology) Approvl. Dok bems with n EN mrk (i.e. those produced from 4th Nov onwrd) re covered by EN Overll height tolernce ±1.0 mm, ssuming 12% timber moisture content. H24 N H30 H D C B A Approvl Number Z Z Z Overll height tolernce ±1.0 mm, ssuming 12% timber moisture content. 5.4 F E A Web (yellow) B Flnge (yellow) C Bem-flnge mrkings for the Dokflex system D System holes E End reinforcement (blue plstic cp for Dok bem H20 top, rivet for Dok bem H20 eco) F Notch for chlking line The innovtive end reinforcement of the Dok bem H20 top significntly reduces dmge to the bem ends /2014 9

10 Instructions for ssembly nd use Dok bems nd Dok formwork bems cn be used only s formwork bems for floor nd wll formwork nd only when subjected to the lods occurring in situtions of direct support for floor or wll formwork in structurl concreting, but not for higher individul lods (e.g. sfety bems). Prcticl exmple In order to mximise durbility, it is importnt to hndle the components with due cre; this pplies prticulrly when stripping out floor-slb formwork. You will lso find informtion on correct usge in the in user informtion for the individul products, for exmple: Lrge-re formwork Top 50 Dokflex Dok Xtr To prevent ny stining of the concrete from direct contct with new formwork bems, we recommend covering the formwork bems with non-woven fbric. Permissible vlues from EN 13377, Schedule E H20 H16 P H16 N H24 H30* H36* N nd P perm. Q [kn] perm. M [knm] E J [knm 2 ] perm. spn [m] These vlues llow for γ F = 1.5, k mod of 0.9 nd γ M = 1.3. Bsed on residul moisture content of 20 % or less. The vlues must be djusted ccordingly if conditions of use differ. *According to pprovl issued by the Institute for Construction Engineering, Berlin /2014

11 Deflection digrms Dok formwork bems H24 Dok formwork bems H20 N nd P Deflection [mm] p [kn/m] L Support centres L [m] M... permitted bending moment Q... permitted sher force p... ctul lod (service lod) 10 Q 7.5 M L/ kn/m Deflection [mm] p [kn/m] Support centres L [m] M... permitted bending moment Q... permitted sher force p... ctul lod (service lod) Dok formwork bems H30 L Q M L/ kn/m 6.0 Dok formwork bems H16 N nd P Deflection [mm] p [kn/m] L Support centres L [m] M... permitted bending moment Q... permitted sher force p... ctul lod (service lod) 7.5 Q M L/ kn/m Deflection [mm] p [kn/m] Support centres L [m] M... permitted bending moment Q... permitted sher force p... ctul lod (service lod) Q Dok formwork bems H36 L M L/ kn/m Deflection [mm] p [kn/m] L Support centres L [m] M... permitted bending moment Q... permitted sher force p... ctul lod (service lod) M Q L/ kn/m /

12 Possible incorrect usges WARNING Use Dok formwork bems only in the "upright" position. The only exceptions to this rule re use cses explicitly permitted in Dok documents. (e. g. in formwork for csting drop bems with the Bem forming support 20, etc.) Correct "upright" positioning Incorrect positioning "turned on (lod direction is prllel to web side" (lod direction t right plne). ngles to web plne). Wll formwork WARNING The uses illustrted below re prohibited, s re other, similr uses! Do not use s scffold flooring Do not use s trffic-route flooring. Floor formwork Supported length of the bem 15 cm permitted. Supported length of the bem < 15 cm not permitted. No butt joins permitted (e.g. on screw-jck U-heds) /2014

13 Technicl condition The following qulity criteri define the extent of dmge permissible in terms of lod-bering strength. Use is prohibited if dmge is beyond these limits. Flnge Splintering t side permissible up to depth = 10 mm nd length b = 500 mm on one side. Angled crcks (cross the grin) Not permissible. b Stright crcks (prllel to the flnge) prllel to flnge, permissible up to width = 2 mm. If the flnge cn be prted t the crck the bem is not in usble condition Angled splintering cross the edge permissible up to = 30 mm cross the digonl nd up length b = 500 mm b /

14 Sw cuts Superficil sw cuts up to depth = 2 mm re permissible. Drilled holes Not permissible, with the exception of system holes: Wling ttchment with bem screw b b mm b mm Drilled-hole dimeter mx. 10 mm Attchment of tble hed with bem screw c Flnge end mm c mm Drilled-hole dimeter mx. 10 mm - Attchment of profiled timber formers Splintering up to length = 60 mm is permissible. d d mm Drilled-hole dimeter mx. 12 mm - System holes in the plstic cp of the Dok bem top Drilled-hole dimeter mx. 10 mm Dmge to the plstic cp hs no effect on lodbering strength, but bems dmged evincing dmge of this kind do not necessrily meet the qulity criteri for Dok rentl formwork /2014

15 Web Dmge to web permissible only if slight nd t one side of the bem Drilled holes in web Permissible drilled holes: Stndrd holes - Ech stndrd bem hs 2 drilled holes, di mm Additionl system holes for: - Flnge clw - Fstening plte - Connection splice plte - Tble hed 30 - Lifting brcket - Portl hed One drilled hole of mximum dimeter 20 mm per running metre in ddition to the system holes is permissible. If the incidence of drilled holes is frequent the overll condition of the bem is definitive Dmge to web end permissible up to mx. = 20 mm Detchment of flnge from web not permissible /

16 Trnsporting, stcking nd storing Protect Trnsport stcked bems from extreme climtic influences such s exposure to sunshine or moisture by covering them (with brethble trpulins). This reduces crcking. Only cover them never envelope them completely. Alwys use strp slings to lift stcked bems - do not use chins. User Informtion Timber formwork bems Alwys sort bems for stcking, in other words do not stck bems N nd P together in mixed stck. N P P N N P N N N P Alwys use edge protectors when strpping bems together. Edge protectors cn be pdding mde of plstic, wood or crdbord. P N N When moving bems not securely strpped together, tke cre tht loose bems cnnot slip. Stcked bems mx kg per stck b Bem lengths 5.90m < 5.90m up to < 6.50m 6.50m to 12.00m Mx. number of bems per stck Minimum number of wooden bttens (min. 8 x 8 x 100 cm) Size 108 cm 108 cm 108 cm Size b for Dok bem H20 P 105 cm 64 cm 44 cm Size b for Dok bem H20 N 113 cm 69 cm 47 cm Mx. number of stcks on top of one nother Ground conditions for stcking Mximum ngle of inclintion of ground 3%. The ground on which the stck is to be plced must be dequtely firm nd level. Best-cse conditions re concreted or pved storge res. Storge on sphlt: Depending on the prts stored, plce wooden bttens, strips of formwork sheeting or metl sheet between the prts nd the sphlt surfce to ensure tht the weight is dequtely spred. Storge on other surfces (snd, grvel...): Adopt suitble mesures for storge (e.g. plce thick plywood sheets underneth the lods) /2014

17 Reprocessing scrp mteril Dok formwork bems contin no wood preservtives nd, consequently, they cn be deposited for reprocessing. Reprocessing by incinertion in suitble incinertion plnts is recommended. It is dvisble not to ttempt to burn scrp mteril in open fires or domestic woodburners. Alwys comply with the pplicble locl or ntionl regultions /

18 Component overview User Informtion Timber formwork bems [kg] Article n [kg] Article n Component [kg] Article n overview Dok bem H20 top N 1.80m Dok bem H20 top N 2.45m Dok bem H20 top N 2.65m Dok bem H20 top N 2.90m Dok bem H20 top N 3.30m Dok bem H20 top N 3.60m Dok bem H20 top N 3.90m Dok bem H20 top N 4.50m Dok bem H20 top N 4.90m Dok bem H20 top N 5.90m Dok bem H20 top N...m Dok bem H20 top N...m BS Dok-Träger H20 top N Vrnished yellow Dok bem H20 eco N 1.25m Dok bem H20 eco N 12.00m Dok-Träger H20 eco N Vrnished yellow Dok bem H20 top P 1.80m Dok bem H20 top P 2.45m Dok bem H20 top P 2.65m Dok bem H20 top P 2.90m Dok bem H20 top P 3.30m Dok bem H20 top P 3.60m Dok bem H20 top P 3.90m Dok bem H20 top P 4.50m Dok bem H20 top P 4.90m Dok bem H20 top P 5.90m Dok bem H20 top P...m Dok bem H20 top P...m BS Dok-Träger H20 top P Vrnished yellow Dok bem H20 eco P 1.80m Dok bem H20 eco P 2.45m Dok bem H20 eco P 2.65m Dok bem H20 eco P 2.90m Dok bem H20 eco P 3.30m Dok bem H20 eco P 3.60m Dok bem H20 eco P 3.90m Dok bem H20 eco P 4.50m Dok bem H20 eco P 4.90m Dok bem H20 eco P 5.90m Dok bem H20 eco P 9.00m Dok bem H20 eco P...m Dok bem H20 eco P...m BS Dok-Träger H20 eco P Vrnished yellow Dok bem H20 eco P 1.25m Dok bem H20 eco P 12.00m Dok-Träger H20 eco P Vrnished yellow Dok bem H20 eco N 1.80m Dok bem H20 eco N 2.45m Dok bem H20 eco N 2.65m Dok bem H20 eco N 2.90m Dok bem H20 eco N 3.30m Dok bem H20 eco N 3.60m Dok bem H20 eco N 3.90m Dok bem H20 eco N 4.50m Dok bem H20 eco N 4.90m Dok bem H20 eco N 5.90m Dok bem H20 eco N...m Dok bem H20 eco N...m BS Dok-Träger H20 eco N Vrnished yellow Dok bem H16 N 1.80m Dok bem H16 N 2.45m Dok bem H16 N 2.90m Dok bem H16 N 3.30m Dok bem H16 N 3.90m Dok bem H16 N 4.90m Dok bem H16 N 9.00m Dok bem H16 N...m Dok-Träger H16 N Vrnished yellow /2014

19 Component overview Dok bem H16 P 1.80m Dok bem H16 P 2.45m Dok bem H16 P 2.90m Dok bem H16 P 3.30m Dok bem H16 P 3.90m Dok bem H16 P 4.90m Dok bem H16 P 9.00m Dok bem H16 P...m Dok-Träger H16 P Vrnished yellow [kg] Article n [kg] Article n Dok formwork bem H24 N 4.90m Dok formwork bem H24 N 7.40m Dok-Schlungsträger H24 N Vrnished yellow Dok formwork bem H30 N...m Dok-Schlungsträger H30 N...m Vrnished yellow Dok formwork bem H36 N...m Dok-Schlungsträger H36 N...m Vrnished yellow Timber vrnish yellow 5l Holzlsur gelb 5l /

20 Ner to you, worldwide Dok is one of the world leders in developing, mnufcturing nd distributing formwork technology for use in ll fields of the construction sector. With more thn 160 sles nd logistics fcilities in over 70 countries, the Dok Group hs highly efficient distribution network which ensures tht equipment nd technicl support re provided swiftly nd professionlly. An enterprise forming prt of the Umdsch Group, the Dok Group employs worldwide workforce of more thn Dok GmbH Josef Umdsch Pltz Amstetten Austri T F info@dok.com /2014