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Summary of Contents for Doka 150F
- Page 1 999775002 02/2020 en-GB The Formwork Experts. Climbing formwork 150F User Information Instructions for assembly and use (Method statement) © by Doka GmbH, A-3300 Amstetten 9775-236-01...
- Page 2 User Information Climbing formwork 150F 999775002 - 02/2020...
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Page 3: Table Of Contents
User Information Climbing formwork 150F Contents Introduction Elementary safety warnings Services System description Climbing formwork 150F System overview System dimensions Possible formwork systems Schematic workflow of climbing phases Structural design Loading data Structural design Anchoring on the structure Positioning point and suspension point... -
Page 4: Introduction
This booklet is aimed at all persons who will be work- This document can be used as general Instructions ing with the Doka product or system that it describes. for Assembly and Use (Method Statement) or be It contains information on the standard design for... - Page 5 ▪ It is strictly forbidden to weld Doka products – in par- ticular anchoring/tying components, suspension components, connector components and castings etc. – or otherwise subject them to heating.
- Page 6 The following symbols are used in this document: Observe all country-specific regulations applying to the handling of formwork and scaffolding. For system formwork the Doka slinging means stated in this DANGER booklet must be used – this is a mandatory require- This is a notifier drawing attention to an ment.
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Page 7: Services
Every single project is unique and calls for individual- ▪ Execution planning ised solutions. When it comes to the forming opera- ▪ Cycle planning tions, the Doka team can help you with its consulting, ▪ Structure modelling/3D-planning planning and ancillary services in the field, enabling ▪ Assembly drawings you to carry out your project effectively, safely and reli- ▪... -
Page 8: System Description
System description User Information Climbing formwork 150F System description Climbing formwork 150F Straightforward basic design, easy to Ingenious modular system with only a very few separate parts operate, proven thousands of times over ▪ permits easy adaptation to construction projects with vertical walls ▪... -
Page 9: System Overview
Permits up to 70 cm roll-back. Working platform ▪ Climbing bracket 150F (D) The Climbing bracket 150F is used for constructing the working platform, and carries the retractable formwork element or panel. Suspended platform ▪... -
Page 10: System Dimensions
System description User Information Climbing formwork 150F System dimensions System dimensions [mm] Formwork height 6000 Distance between top of poured concrete and anchoring point Distance between suspension point and pressure 1250 strut Width of bracket 1700 Height of railings on bracket... -
Page 11: Possible Formwork Systems
User Information Climbing formwork 150F System description Possible formwork systems Timber-beam formwork Framed formwork e.g. Large-area formwork Top 50 e.g. framed formwork Framax Xlife 9775-240-01 9775-239-01 For more information, see the 'Timber-beam For more information, see the 'Framed form- formwork Top 50' User Information booklet. -
Page 12: Schematic Workflow Of Climbing Phases
System description User Information Climbing formwork 150F Schematic workflow of climbing phases Start-up phases 9775-222-01 9775-241-01 9775-220-01 The 1st casting section is poured The 2nd casting section (and all further sec- The suspended platforms are mounted, and without a climbing scaffold. -
Page 13: Structural Design
User Information Climbing formwork 150F Structural design Structural design Loading data Anchoring on the structure Service loads Imposed loads 9775-256-01 V ... permitted vertical load: 35 kN H ... permitted horizontal load: 65 kN Dimensioning the suspension point The required cube compressive strength of the con- crete at the time of loading must be specified sepa- rately for each project by the structural designer. -
Page 14: Structural Design
Permissible wind speed = 147 km/h Follow the directions in the Calculation Guide Example "Wind loads to the Eurocodes" when determin- ing the wind pressure or ask your Doka techni- ▪ Basic data: cian! - Diagram (A) (wind pressure = 1.00 kN/m - formwork height: 4.00 m... - Page 15 ➤ When determining the influence width, add the differ- ence (b – 400 mm) to the actual formwork height. Influence width [m] C Without Wind bracing MF/150F/K 6.00m b ... min. 400 mm D With Wind bracing MF/150F/K 6.00m Example Example ▪...
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Page 16: Anchoring On The Structure
Anchoring on the structure User Information Climbing formwork 150F Anchoring on the structure Positioning point and suspension point Cantilever positioning cone 15.0 5cm 9775-225-01 775 296-20 A Stop anchor 15.0 (expendable anchoring component) C Cantilever positioning cone 15.0 5cm B Depth mark D Sealing sleeve S 15.0 5cm (orange) - Page 17 User Information Climbing formwork 150F Anchoring on the structure Types of stop anchor c ... installation depth: 16.5 cm d ... Minimum wall thickness: 19 cm (where the concrete cover is 2 cm) d ... Minimum wall thickness: 20 cm (where the concrete cover is 3 cm) e ...
- Page 18 Anchoring on the structure User Information Climbing formwork 150F Opposite anchoring points Anchor points with no offset Anchor points with no offset are prepared using the Stop anchor double-ended 15.0 K. Note: If the wall thickness is less than twice the installation...
- Page 19 User Information Climbing formwork 150F Anchoring on the structure Preparing the positioning point Preparing the positioning point ➤ Push the sealing sleeve all the way onto the position- ing cone. WARNING Sensitive anchoring, suspension and connec- tor components! ➤ Never weld or heat these components.
- Page 20 If the positioning point is located too close to a more than once in the same position, as it can- Doka beam, a board can be nailed to this and not be fixed firmly and securely in the old nail- the adjoining beam to provide a support sur- holes.
- Page 21 User Information Climbing formwork 150F Anchoring on the structure Check of the positioning point Pouring ➤ Before pouring, check all positioning points and sus- pension points again. Mark the positions of the anchoring points at ▪ The sealing sleeve must be completely the top edge of the formwork to make them pushed onto the positioning cone.
- Page 22 , however. cones. Follow the directions in the Calculation Guide entitled "Load-bearing capacity of anchorages in concrete" or ask your Doka technician! Engaging the climbing bracket ➤ Unscrew the positioning cone, using a Reversible ratchet 1/2" and a Positioning-cone spanner 15.0 9775-229-01 ➤...
- Page 23 User Information Climbing formwork 150F Anchoring on the structure ➤ Dismounting the suspension point Tilt the fastening pin downward. ➤ Unscrew the climbing cone with a Reversible ratchet 1/2". 9775-230-02 C Fastening pin The climbing bracket is now secured against acci- 9775-22 -0 dental lift-out.
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Page 24: Other Possible Anchorages
Anchoring on the structure User Information Climbing formwork 150F Other possible anchorages Thin walls Wall thicknesses of 15 to 16 cm are prepared using the Wall anchor 15.0 15cm. Risk of confusion! ➤ NEVER use Stop anchors 15.0 for this appli- cation. -
Page 25: Retrofitting A Safe Suspension Point
User Information Climbing formwork 150F Anchoring on the structure Retrofitting a safe suspension point Dimensioning the suspension point NOTICE ➤ Weld a bead to the super plate to join the nut and the plate. Do this BEFORE screw- The required cube compressive strength of the con- ing the super plate onto the tie rod. - Page 26 Anchoring on the structure User Information Climbing formwork 150F 999775002 - 02/2020...
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Page 27: Operating The Formwork
User Information Climbing formwork 150F Operating the formwork Operating the formwork Closing the formwork ➤ After adjusting the formwork elements, tighten the This section only deals with how to operate the pressure wedges (A) . formwork. For details of how to tie the form-... -
Page 28: Opening The Formwork
Operating the formwork User Information Climbing formwork 150F Opening the formwork ➤ ➤ Undo and remove the form-ties of the formwork ele- Tighten the pressure wedges (A) . ment. ➤ Remove the connectors from the adjacent gang- forms. ➤ Detach the fixing-wedges (B) . -
Page 29: Plumbing & Aligning The Formwork
User Information Climbing formwork 150F Operating the formwork Plumbing & aligning the formwork Adjusting the formwork Vertical adjustment ➤ Turn both adjusting spindles. In order to permit exact adjustment of the formwork ele- ments in relation to one another and to the structure,... - Page 30 Operating the formwork User Information Climbing formwork 150F Side angle adjustment Ending the adjusting operation ➤ ➤ Only turn one adjusting spindle. Tighten the waling-to-bracket holders with a ham- mer. ➤ After adjusting the formwork panels, tighten the pres- sure wedges (A) .
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Page 31: Repositioning Lifting By Crane
User Information Climbing formwork 150F Repositioning Repositioning Lifting by crane Instructions for safe repositioning of the complete unit NOTICE ▪ Before repositioning: Remove any loose items from the formwork and platforms, or secure them firmly. ▪ 'Passenger transportation' is forbidden! ▪... - Page 32 Repositioning User Information Climbing formwork 150F NOTICE Initial situation ▪ When a climbing unit is repositioned, this opens up exposed fall-hazard locations on the remaining sections. These exposed locations must be made safe by putting up an access prohibition barrier.
- Page 33 User Information Climbing formwork 150F Repositioning ➤ Repositioning the entire unit Lift the entire unit by crane and hang it into place in the suspension point. ➤ Prepare the suspension points. ➤ Dismount the 'Wind bracing'. ➤ Manoeuvre the formwork into the centre-of-gravity position.
- Page 34 Repositioning User Information Climbing formwork 150F 999775002 - 02/2020...
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Page 35: Operating The Climbing Formwork
User Information Climbing formwork 150F Operating the climbing formwork Operating the climbing formwork Starting up The modular design of the Climbing formwork 150F system means that many different combinations are possible. Depending on the project, the actual design may differ significantly from that described here. -
Page 36: 1St Casting Section
Operating the climbing formwork User Information Climbing formwork 150F 1st casting section ➤ Apply concrete release agent and set up one side of the formwork. ➤ Mount the positioning points. ➤ If necessary, mount positioning-points for a "Wind bracing". ➤... -
Page 37: 2Nd Casting Section
➤ Hanging the working platform into place on the Fasten the tensioning unit of the Wind bracing suspension points: MF/150F/K 6.00m to the structure, i.e. to the posi- tioning point prepared with a climbing cone. ➤ Prepare the suspension points. - Page 38 Operating the climbing formwork User Information Climbing formwork 150F ➤ Fix the pre-assembled formwork to the vertical wal- Add provisions to safeguard improper lifting and ings with waling-to-bracket holders. repositioning of the unit as one piece. WARNING Waling-to-bracket holder 9-...
- Page 39 User Information Climbing formwork 150F Operating the climbing formwork Formwork set-up and pouring ➤ Apply concrete release agent and set up one side of the formwork. ➤ Mount the positioning points. ➤ Place the reinforcement. ➤ Close the formwork and tie it.
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Page 40: 3Rd Casting Section
Operating the climbing formwork User Information Climbing formwork 150F 3rd casting section ➤ ➤ Prepare the suspension points. Mount the suspended platform, working from a ➤ mobile scaffold tower. Dismount the 'Wind bracing'. ➤ Attach the lifting chain to the lifting-brackets of the Vertical waling. - Page 41 User Information Climbing formwork 150F Operating the climbing formwork ➤ Formwork set-up and pouring Bolt on the outside suspension tube with an M 16x140 hexagon bolt. ➤ Apply concrete release agent and set up one side of the formwork. ➤...
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Page 42: Assembly
Pre-drill the platform beams. Hole diameter 10 mm 9775-214-01 a ... centre-to-centre distance b ... 120 mm ➤ Bolt the Doka beams H20 to the climbing brackets. 9775-215-01 a ... centre-to-centre distance A Climbing bracket 150F Nail on stop-blocks to ensure constant centre- to-centre distances. - Page 43 160 mm. Lay deck-boards flush to either side of each Climb- ing bracket. ➤ Fasten deck-boards to the Doka beams with Torx TG 6x90 A2 universal countersunk screws. Every deck-board must be fixed with 4 screws! Do a sight-check to make sure that the deck-...
- Page 44 Assembly User Information Climbing formwork 150F Fitting a manhole Mounting the railing ➤ ➤ Screw planks to the underside of the deck-boards to Bolt handrail-post uprights onto the Climbing bracket distribute the loads. with M16 nuts & bolts. Every deck-board must be fixed with a...
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Page 45: Mounting The Vertical Waling And Scissor-Action Spindle
User Information Climbing formwork 150F Assembly Mounting the Vertical waling and scissor-action spindle ➤ Setting the adjusting spindle Pin the spindle tube onto the Vertical waling 3.00m with the handle-bolt. Tools needed: ▪ Reversible ratchet 1/2" ▪ Box nut 24 and ▪... - Page 46 Assembly User Information Climbing formwork 150F ➤ Lower the pre-assembled unit onto the Climbing Knock the fixing-wedge into place. bracket by crane. This fixes the Vertical waling to the Climbing bracket. 9775-211-04 ➤ Detach the lifting chain from the Vertical waling.
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Page 47: Mounting The Formwork
User Information Climbing formwork 150F Assembly Mounting the formwork Timber-beam formwork NOTICE It is not permitted to locate Multi-purpose wal- e.g. Large-area formwork Top 50 ings anywhere in the range of travel of the scissor-action spindle. Follow the directions in the 'Large-area form-... - Page 48 Assembly User Information Climbing formwork 150F Framed formwork Mounting the pouring platform ➤ Secure the Framax brackets and install the deck- e.g. framed formwork Framax Xlife boards. Follow the directions in the "Framed formwork ➤ Also install Handrail posts 1.00m and guardrail Framax Xlife"...
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Page 49: Assembling The Suspended Platform
Always bend the anti-twisting plate over the flat side of the hexagon nut. Use each anti-twisting plate once only. 9715-260-02 ➤ Mount Doka beams H20 to the platform profiles with e.g. Brace stirrups 8. 9775-253-01 A Platform profile B Brace stirrup 8... - Page 50 Assembly User Information Climbing formwork 150F Mounting the suspension tubes Mounting the guard-rail boards ➤ ➤ Mount the suspension tubes to the platform profiles Attach a toeboard (min. 15x3 cm) to the Handrail- with two M16x90 hexagon bolts for each tube.
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Page 51: Sideguards On Exposed Platform-Ends
User Information Climbing formwork 150F Assembly Sideguards on exposed platform-ends Edge protection system XP Platform railings which do not extend all the way around the platform must be closed by attaching side railings, e.g. at ▪ corner transitions ▪ exposed fall-hazard locations which result from a... - Page 52 Assembly User Information Climbing formwork 150F 999775002 - 02/2020...
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Page 53: Dismantling
User Information Climbing formwork 150F Dismantling Dismantling ➤ Remove the waling-to-bracket holders and lift the NOTICE formwork element or panel off the climbing unit. ▪ A hard, flat, firm surface is needed! ▪ Provide a sufficiently large dismantling space. ▪... - Page 54 Dismantling User Information Climbing formwork 150F ➤ Lifting the climbing unit off the All other dismantling steps are carried out on the ground, in the opposite order of steps from those in structure which the equipment was assembled. ➤ Attach the lifting chain to the lifting-brackets of the Vertical waling.
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Page 55: General Ladder System
User Information Climbing formwork 150F General General Ladder system For safe up-and-down access between platforms. 9775-255-02 a ... min. 1 m b ... height of casting section Note: The Ladder system XS must be implemented in such a way that all national regulations are complied with. - Page 56 General User Information Climbing formwork 150F Attaching the ladders Lengthening the ladder Manhole B 70/60cm Telescoping ladder extension (for adjusting to ➤ ground level) Fix the System ladder XS 4.40m to the manhole with ➤ a ladder stirrup. To telescope the ladders past one another, lift the ➤...
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Page 57: Transporting, Stacking And Storing
Max. load-bearing capacity: 700 kg (1540 lbs) Permitted imposed load: 3150 kg (6950 lbs) To make the Doka skeleton transport box easier to load and unload, one of its sidewalls can be opened. 999775002 - 02/2020... - Page 58 Max. n° of units on top of one another Outdoors (on the site) Indoors Different items in the Doka multi-trip transport box can Floor gradients up to 3% Floor gradients up to 1% be kept separate with the Multi-trip transport box par-...
- Page 59 Spread angle β max. 30°! Max. carrying capacity: 1100 kg (2420 lbs) Permitted imposed load: 5900 kg (12980 lbs) Using Doka stacking pallets as storage units Max. n° of units on top of one another Outdoors (on the site) Indoors...
- Page 60 General User Information Climbing formwork 150F Doka accessory box Repositioning by forklift truck or pallet stacking truck Storage and transport device for small items The forks can be inserted under either the broadside or the narrowside of the containers. Bolt-on castor set B The Bolt-on caster set B turns the stacking pallet into a fast and manoeuvrable transport device.
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Page 61: Fall-Arrest Systems On The Structure
User Information Climbing formwork 150F General Fall-arrest systems on the structure Handrail post XP 1.20m Handrail clamp T ▪ ▪ Attached with Screw-on shoe XP, railing clamp, Fixed in embedded anchoring components or Handrail-post shoe or Step bracket XP reinforcement hoops ▪... -
Page 62: Doka Shaft Platform
User Information Climbing formwork 150F Doka shaft platform The climbing formwork for inside- shafts Doka shaft platforms permit quick and easy reposition- ing in just one crane cycle. This makes them a cost- saving system for forming inside-shafts. Ingenious modular system ▪... -
Page 63: Component Overview
User Information Climbing formwork 150F Component overview [kg] Article N° [kg] Article N° Component overview [kg] Article N° Climbing bracket 150 F 97.0 580401000 Wind bracing MF 6.00m 4.3 580677000 Kletterkonsole 150 F Windabspannung MF 6,00m Galvanised Galvanised Width: 173 cm Height: 255 cm Suspended platform 120 3.30m... - Page 64 Component overview User Information Climbing formwork 150F [kg] Article N° [kg] Article N° Framax bracket 90 12.5 588167000 Universal railing shackle 3.0 580478000 Framax-Konsole 90 Universal-Geländerbügel Galvanised Galvanised Length: 103 cm Height: 20 cm Height: 185 cm Delivery condition: railing included Scaffold tube 48.3mm 0.50m...
- Page 65 User Information Climbing formwork 150F Component overview [kg] Article N° [kg] Article N° Universal tool box 15.0 9.1 580392000 Ladder extension XS 2.30m 19.1 588641000 Universal-Werkzeugbox 15,0 Leiternverlängerung XS 2,30m included in scope of supply: Galvanised (A) Reversible ratchet 1/2"...
- Page 66 Component overview User Information Climbing formwork 150F [kg] Article N° [kg] Article N° Tie rod system 15.0 Pigtail anchor 15.0 0.92 581984000 Wellenanker 15,0 Non-treated Climbing cone 15.0 5cm 0.97 581980000 Length: 67 cm Kletterkonus 15,0 5cm Galvanised Length: 17 cm...
- Page 67 User Information Climbing formwork 150F Component overview [kg] Article N° [kg] Article N° Tie-rod wrench 15.0/20.0 1.9 580594000 Doka stacking pallet 1.20x0.80m 38.0 583016000 Ankerstabschlüssel 15,0/20,0 Doka-Stapelpalette 1,20x0,80m Galvanised Galvanised Length: 37 cm Height: 77 cm Diameter: 8 cm Multi-trip packaging Doka skeleton transport box 1.70x0.80m...
- Page 68 70 countries, the Doka Group has a highly efficient dis- than 6000. tribution network which ensures that equipment and Doka GmbH | Josef Umdasch Platz 1 | 3300 Amstetten | Austria | T +43 7472 605-0 | F +43 7472 66430 | info@doka.com | www.doka.com 999775002 - 02/2020...
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