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Meva AluStar Instruction Manual

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GSV-tested
AluStar tested by a neutral test institute.
Güteschützverband Betonschalungen (Quality Pro-
tection Association for Concrete Formwork)
StarTec / AluStar
Technical Instruction Manual

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Summary of Contents for Meva AluStar

  • Page 1 GSV-tested AluStar tested by a neutral test institute. Güteschützverband Betonschalungen (Quality Pro- tection Association for Concrete Formwork) StarTec / AluStar Technical Instruction Manual...

  • Page 2: Product Features

    The StarTec/AluStar wall formwork is a frame formwork system made Abbreviations, measurements, figures and tables, etc. of robust steel (StarTec) and crane-independent aluminium panels The abbreviation ST is used for the StarTec series and the abbreviation (AluStar). AS for the AluStar series. DIN means Deutsche Industrie-Norm (German Industrial Standard).

  • Page 3: Table Of Contents

    Fall protection – Tilting bracket 40/60 ..........25 This Technical Instruction Manual contains information, instructions Crane hook ..................26 and tips that describe how to use the MEVA equipment on the Inside corner 90° ................27 construction site in a proper, quick and economic way. Most examples Outside corner 90°...

  • Page 4: Formwork Assembly And Stripping

    Wall formwork StarTec / AluStar Formwork assembly and stripping Important! Ground When assembling and stripping The ground on which the Step 1 – Place and brace the formwork, strictly observe the formwork is going to be placed outside formwork local accident prevention rules.
  • Page 5 Wall formwork StarTec / AluStar Formwork assembly and stripping Step 1 with two or three assembly locks. Place and brace the outside For outside corner configurations formwork refer to pages ST/ AS-28 to The following description is -30. based on an straight wall. Before...
  • Page 6 Wall formwork StarTec / AluStar Formwork assembly and stripping Working scaffold The plug-in walkway bracket (the figures show the BKB) is used to support the working scaffold. The maximum bracket spacing for a load of 150 kg/ m² (platform group 2) is 250 cm as defined in DIN 4420.
  • Page 7 Wall formwork StarTec / AluStar Formwork assembly and stripping Stripping Note Do not start stripping before the The release agent must not be concrete has set to the point stored in galvanized containers. where it can no longer deform. It is best to start stripping at the Please note stop ends or at a short corner.

  • Page 8: The Startec Panel

    Fig. 8.6 Note For a list of the all available panels including their designations and reference numbers refer to the product list. Fig. 8.7 Fig. 8.1 StarTec 330/135 ST/AS-8 Technical Instruction Manual / SV / Status August 2024...
  • Page 9 (ST/ AS-8.7). Observe the transport guidelines (see page ST/ AS-76). Description Ref. No. Fig. 9.3 StarTec AL 20 330/ 270 ..21-217-01 StarTec AL 20 270/ 240 ..21-200-03 Technical Instruction Manual / SV / Status August 2024 ST/AS-9...

  • Page 10: The Alustar Panel

    Wall formwork StarTec / AluStar The AluStar panel Fig. 10.2 Tie hole with conical anchor sleeve (see page ST/ AS-13) Fig. 10.3 Panel connection with the AS assembly lock (see page ST/ AS-12). Fig. 10.2 Fig. 10.4 Cross stiffener made of closed, robust and easy-to-handle aluminium profile.

  • Page 11: The Alkus All-Plastic Facing

    The release agent MevaTrenn is to be sprayed onto MEVA wall and slab formwork before each Plastic layer use. One litre of release agent is sufficient for 50 to 90 m²...

  • Page 12: Panel Connection

    Wall formwork StarTec / AluStar Panel connection Fast and efficient connection of the panels is accomplished with the AS assembly lock (Fig. 12.1) whether the panels are assembled side by side or on top of each other (height- extended). The assembly lock can...

  • Page 13: Placing Of Ties

    Wall formwork StarTec / AluStar Placing of ties The conical anchor sleeve for tie rods DW 15 is welded to the panel frame (Figures 13.1 and 13.2). The ST/ AS formwork can be inclined up to 4 cm/m. Inclined formwork requires articulated flange nuts and must be secured against uplift.

  • Page 14: Rules For Concrete Pouring And Rate Of Placing

    Wall formwork StarTec / AluStar Rules for concrete pouring and rate of placing The maximum permissible fresh- concrete pressure for StarTec/ Maximum rate of placing v (depending on the concrete's consistency and end AluStar is 60 kN/m². of setting t...

  • Page 15: Flatness Of Surface

    Wall formwork StarTec / AluStar Flatness of surface The permissible deflection of DIN 18202, Table 3 formwork parts is defined in DIN Column 18202 (flatness tolerances),Table Distances as limiting values in mm 3, lines 5 to 7 (Table 15.1). for distances between measuring...

  • Page 16: Attachment Of Accessories

    Wall formwork StarTec / AluStar Attachment of accessories All panels are provided with multi-function profiles with welded-in Dywidag-threaded nuts (Figures 16.1 and 16.6). The difference between the multi-function profiles and the cross stiffeners is that the multi-function profiles allow accessories to be attached.

  • Page 17: Wall Braces

    Wall formwork StarTec / AluStar Wall braces A push-pull prop or the brace Formwork height h (m) frame 250 with formwork-prop Wall braces 2.25 2.40 2.70 3.15 3.30 3.60 3.75 connector is attached to the R250+ R250+ R250+ R250+ R250+...
  • Page 18 (see Table ST/ AS-17.1) connector The shoe plate 40 can be used to 60° secure the StarTec/AluStar panel to the ground (Fig. 18.4). It can be secured using a bolt anchor or concrete anchor bolt with d = Double-jointed foot plate 16 mm, e.g.

  • Page 19: Workspaces

    Wall formwork StarTec / AluStar Workspaces The fall height at workspaces must Working scaffold according to DIN 12811-1 not exceed 2.00 m in accordance with DIN 12811-1. Handrail (min. 15 x 3) According to DIN 12811-1 the or scaffold tube 48 mm design of the working scaffold Midrail (min.

  • Page 20: Workspaces - Folding Access Platform Bkb 125

    Wall formwork StarTec / AluStar Workspaces – Folding access platform BKB 125 Folding access platform BKB Suspension point The ready-made folding access platform BKB 125 with folding guardrailing provides safe access and a 125 cm wide working platform (Fig 20.2). It enables quick and safe installation of working scaffolds.
  • Page 21 Workspaces – Folding access platform BKB 125 When using the BKB folding access platform with 330 cm high StarTec panels, tying at the top needs to be done above the panels using Uni-tie claws rather than tying through the top tie holes (Figures 21.1 and 21.2).

  • Page 22: Workspaces - Walkway Bracket

    Wall formwork StarTec / AluStar Workspaces – Walkway bracket The pluggable walkway bracket The guardrailing post 48/120 UK 90 (Fig. 22.1) is mounted to a can be used to allow scaffold multi-function profile. To insert tubes to be installed as a the bracket, turn it by 45°, fall protection measure.

  • Page 23: Workspaces - Aluminium Platform

    Wall formwork StarTec / AluStar Workspaces – Aluminium platform The aluminium platform In order to install the telescopic (Figures 23.1 and 23.2) enables ladder on the aluminium the formwork panel to be accessed platform, first of all remove the quickly and safety. It is equipped telescopic ladder’s integrated...
  • Page 24 Wall formwork StarTec / AluStar Workspaces – Aluminium platform The aluminium platform can be extended using the extension 450 (Fig. 24.1). It is inserted into the hollow profile on the long side of the aluminium platform and can be secured in 2.5 cm increments using the bolts and cotter pins Fig.

  • Page 25: Fall Protection - Tilting Bracket 40/60

    The tilting bracket 40/60 (Fig. 25.1) is designed for the MEVA wall formwork systems Mammut XT, Mammut 350, Mammut, StarTec XT and StarTec/AluStar and is used to attach MEVA guardrailing posts to create a fall protection system. Fig. 25.1 It is attached to the panel’s frame profile with the integrated wedge (Fig. 25.2).

  • Page 26: Crane Hook

    Wall formwork StarTec / AluStar Crane hook The permissible load of an AS When to replace the crane crane hook (Fig. 26.1) is 15 kN hook (1.5 t). If the reference dimension exceeds 41 mm, the crane hook Important must be replaced immediately. The load-bearing capacity of 15 This also applies if only one kN (1.5 tons) may be reduced...

  • Page 27: Inside Corner 90

    Wall formwork StarTec / AluStar Inside corner 90° The StarTec inside corner is galvanised and has an alkus all- plastic facing. The AluStar inside corner is made of aluminium with a high-quality cured powder coating. Both inside corners have tie...

  • Page 28: Outside Corner 90

    Outside corner 90° The aluminium AS/ST outside corner with its high-quality cured powder coating (Figures 28.1 to 28.3) together with the StarTec or AluStar panels and the AS assembly lock results in a solid 90° outside corner solution. For the number of AS assembly...

  • Page 29: 90° Outside Corner With Side Lengths 10 Cm And 5 Cm

    10 cm and 5 cm side lengths on both sides as well as an integrated triangular fillet (Fig. 29.1) together with the StarTec or AluStar panels and the AS assembly lock result in a solid 90° outside corner solution. For the number of AS assembly...

  • Page 30: Height-Extended 90° Outside Corner

    Wall formwork StarTec / AluStar Height-extended 90° outside corner Pouring heights of 4.05 m or higher (Fig. 30.1) require the number of assembly locks and alignment rails shown in Table 30.3. The alignment rails must be attached to the panels with two flange screws 18. Always start...

  • Page 31: 90° Corner With Filler

    Wall formwork StarTec / AluStar 90° corner with filler The filler is attached per panel height with two Uni-assembly locks up to a height of 270 cm or with three RS or Uni-assembly locks for panel height 330 cm. Wide filler area: Æ...

  • Page 32: 90° Corner - Combinations

    Wall formwork StarTec / AluStar 90° corner – Combinations A 90° corner can be made in increments of 5 cm with just a few panel widths. AS/ST outside corner AS/ST standard panel The AS/ST aluminium filler 5 can be used for a 5 cm gap (Fig. 32.3).

  • Page 33: Hinged Corners

    (see page ST/ AS-66). ≥ 60° Fig. 33.2 Description Ref. No. StarTec HIC 330/30 ....21-270-20 AluStar HIC 270/30 ....21-270-00 AluStar HIC 135/30 ....21-270-10 StarTec HOC 330/7.5 ..... 21-280-20 AluStar HOC 270/7.5 ..... 21-280-00 AluStar HOC 135/7.5 ....21-280-10...
  • Page 34 Wall formwork StarTec / AluStar Hinged corners α If the inside angle is less than 100°, alignment rails and a wooden blocking are not required on the inside (Fig. 34.1). Table 34.2 shows the different Bolt M17x150 y = panel width E1 + required wooden blocking...

  • Page 35: Stripping Corner

    Description Ref. No. ST stripping corner StarTec SC 330/25....21-262-05 StarTec SC 270/25....21-262-10 StarTec SC 135/25....21-262-30 Adhesive tape ....41-912-10 Fig. 35.4 A Fig. 35.5 B...
  • Page 36 Height 330 cm requires three assembly locks (Fig. 36.1). 111 109 Fig. 36.1 ST stripping corner 330/25 No assembly locks possible in grey shaded areas! Description Ref. No. StarTec SC 330/25....21-262-05 ST/AS-36 Technical Instruction Manual / SV / Status August 2024...
  • Page 37 Fig. 37.1 ST stripping corner 270/25 Fig. 37.2 ST stripping corner 135/25 No assembly locks possible in grey shaded areas! Description Ref. No. Stripping corner StarTec SC 270/25....21-262-10 StarTec SC 135/25....21-262-30 Technical Instruction Manual / SV / Status August 2024 ST/AS-37...
  • Page 38 Description Ref. No. Fig. 38.1 Detail C StarTec SC 330/25....21-262-05 Detail C – Pouring position StarTec SC 270/25....21-262-10 StarTec SC 135/25....21-262-30 ST/AS-38 Technical Instruction Manual / SV / Status August 2024...
  • Page 39 Wall formwork StarTec / AluStar Stripping corner Stripping support The stripping support (Fig. 39.1) Spanner size Spanner size 36 is used to easily activate the stripping corner from above with a power screwdriver, a ratchet spanner or a spanner. Tools with width across flats of 27, 30 or 36 mm are to be used.
  • Page 40 Wall formwork StarTec / AluStar Stripping corner Working principle of the Power screwdriver stripping support / stripping corner tool The stripping support has three hexagonal nuts that are operated Hexagonal nut with tools with width across flats of 27, 30 and 36 mm.
  • Page 41 Wall formwork StarTec / AluStar Stripping corner The ST stripping corner can also be used as a stripping aid. In this case, the stripping corner is used to reduce the tension between the panels so that they can easily be removed from the poured wall between the corners.

  • Page 42: Length Compensation

    Wall formwork StarTec / AluStar Length compensation Gaps up to 14 cm can be formed on site using a corresponding timber filler (Figures 42.1 and 42.2) or an ST/ AS aluminium filler (Fig. 42.3) and Uni-assembly locks 22 (for gaps up to 20 cm Uni-assembly locks 28 are used).
  • Page 43 Wall formwork StarTec / AluStar Length compensation Timber profile Gap up to 36 cm without square timber Length compensation greater than 14 cm (Figures 43.1 and 43.2) can be achieved with a Timber profile timber profile and a facing cut to the right size. Reinforcement...

  • Page 44: T Wall Connection

    Wall formwork StarTec / AluStar T wall connection A T wall connection is made using two inside corners (Figures 44.1 to 44.5). Different wall widths can be compensated for using timber profiles (Fig. 44.4) or timber fillers (Fig. 44.5). For the use of alignment rails refer to the table on page ST/ AS-52.

  • Page 45: Connection To Existing Walls

    Wall formwork StarTec / AluStar Connection to existing walls Figures 45.1 to 45.7 show various options for connecting formwork to an existing Alignment rail attached through wall. Depending on the wall Hexagonal nut with washer plate existing tie holes layout and conditions on the...

  • Page 46: Stop Ends

    Wall formwork StarTec / AluStar Stop ends Outside corners and standard panels Stop ends can also be formed using outside corners and standard panels (Figures 46.1 to 46.3). Outside corners Panels that are 50 cm wide or wider require additional bracing with alignment rails above a Fig.
  • Page 47 Wall formwork StarTec / AluStar Stop ends Stop end bracket Stop ends can also be formed using the stop end bracket 23/40 for a wall thickness up to 30 cm or the stop end bracket 40/60 for a wall thickness up to 40 cm (Fig 47.2).

  • Page 48: Wall Offset

    Wall formwork StarTec / AluStar Wall offset One-sided wall offsets of up to 10 cm are formed by moving back the corresponding standard panel (Figures 48.1 and 48.4). For offsets greater than 13 cm Detail A inside corners should be used Wooden blocking (Figures 48.2 and 48.5).

  • Page 49: Pilasters

    Wall formwork StarTec / AluStar Pilasters Standard pilasters are easily formed with inside corners, standard panels and, where necessary, wooden blockings. Alignment rails must be attached Pilasters: for reinforcement (Figures 49.1 Up to 50 cm (AS) Up to 85 cm (ST) to 49.3).

  • Page 50: Differences In Height

    Wall formwork StarTec / AluStar Differences in height The assembly lock can be attached at any position on the frame profile. The formwork’s grid-free design does not require additional accessories for panel connection. Vertical, horizontal and inclined panels can all be...

  • Page 51: Horizontal Panels

    These include basin walls in water treatment plants, foundations and strip footings which often require a certain height. The central tie hole makes the 135 cm wide StarTec and AluStar panels ideal Tensioner for Max. distance for foundations. (Table 51.6) foundation tape...

  • Page 52: Substitution Of Ties

    In certain cases alignment rails can reduce the number of tie rods required. When extending a horizontal StarTec panel 270/240 with a horizontal panel 270/90 and by placing three alignment rails on the multi-function profile, the alignment rails substitute one row of ties (Fig. 52.1).

  • Page 53: Height Extension

    Wall formwork StarTec / AluStar Height extension Note the following for horizontal height extension Æ Tie rods must be used for all tie holes for a height extension with a panel that is wider than 50 cm (Fig. 53.1). Æ Only the top ties need to...
  • Page 54 Foundation All panels can be height- extended vertically or horizontally. The standard panels are 330, 270, 135 and 90 cm (StarTec) high. This results in maximum height increments of Fig. 54.1 45 cm. Using horizontal panels, almost any formwork height can be achieved.
  • Page 55 Wall formwork StarTec / AluStar Height extension Free combination of vertical Max. 60° and horizontal panels All panels can be height- extended vertically or horizontally. The panels must always be connected with AS assembly locks (see page ST/ AS-12). M alignment rail 180 Æ...

  • Page 56: Crane Ganging

    AS crane hook refer to page Steel ST/ AS-26. Aluminium Steel The StarTec panels 270/90 and 270/75 produced until 2006 are equipped with aluminium and steel cross stiffeners (Fig. 56.1), Aluminium whereas StarTec panels produced since 2006 have only steel cross stiffeners (Fig. 56.2).

  • Page 57: Crane Ganging - Method 1

    Wall formwork StarTec / AluStar Crane ganging – Method 1 Use this method for single vertical AluStar and StarTec panels or vertical panel gangs irrespective of the year of manufacture (Fig. 57.1). The crane hook’s load capacity is 15 kN (1.5 tons). Max. 60°...

  • Page 58: Crane Ganging - Method 2

    StarTec / AluStar Crane ganging – Method 2 Use this method for single horizontal panels or for units height-extended with horizontal panels when using StarTec panels manufactured in 2006 or later (Fig. 58.1). The crane hook’s load capacity is 15 kN (1.5 tons).

  • Page 59: Crane Ganging - Method 3

    (Figures 59.1 to 59.3 and page ST/ AS-56). Fig. 59.1 Fig. 59.2 StarTec panel 270/90 StarTec panel 270/75 Max. 60° Fig. 59.3 Height extension with horizontal StarTec panels 270/90 or 270/75 Technical Instruction Manual / SV / Status August 2024 ST/AS-59...

  • Page 60: Crane Ganging - Method 4

    9 kN (0.9 tons). Max. 60° Max. 60° Fig. 60.2 StarTec panel 270/75 Fig. 60.1 StarTec panel 270/90 Max. 60° Fig. 60.3 Height extension with horizontal StarTec panels 270/90 or 270/75 ST/AS-60 Technical Instruction Manual / SV / Status August 2024...

  • Page 61: Crane Ganging - Method 5

    (Fig. 61.2). The load capacity of each crane hook is 11 kN (1.1 tons). Max. 60° Fig. 61.1 AluStar panel 270/90 Fig. 61.2 AluStar or StarTec unit, height-extended with horizontal AluStar panel 270/90 Technical Instruction Manual / SV / Status August 2024 ST/AS-61...

  • Page 62: Crane Ganging

    Size: 2.70 x 0,90 m = 2.43 m² Weight: AluStar = 65.0 kg StarTec = 103.4 kg Fig. 62.3 StarTec panel unit with alkus all- plastic facing. Size: 5.40 x 4.65 m = 25.11 m². Weight including four alignment rails 180 = 1605 kg. Fig. 62.3...
  • Page 63 StarTec panel unit with alkus all-plastic facing. Size: 5.40 x 3.30 m = 17.82 m² Weight: 1065 kg. Max. 60° Fig. 63.2 StarTec panel unit with alkus all- plastic facing. Size: 5.40 x 6.60 m = 35.64 m². Weight including four alignment rails 250 = 2250 kg. Fig. 63.1 Max.

  • Page 64: Startec Column Formwork

    A chamfer strip 270 can be used to create columns with h = 600 chamfered edges. It grips the frame profile of the StarTec or Fig. 64.2 Fig. 64.3 AluStar panel (Fig. 64.2). Cut out the chamfer strip on the frame...

  • Page 65: Alustar Column Formwork

    Wall formwork StarTec / AluStar AluStar column formwork Columns with a maximum side AluStar column formwork length of 50 cm and a maximum pouring height of 405 cm can Formwork height h [cm] Number of alignment rails Number of (from bottom to top)

  • Page 66: Multi-Purpose Panel

    Fig. 66.3 Description Ref. No. Tie rod DW 15 Multi-purpose panel StarTec AL MPP 270/75..21-212-26 StarTec AL MPP 135/75..21-212-46 Stop end fixture 23/40 yellow 29-402-85 Flange screw 18..... 29-900-20 Articulated flange nut 15/ 120 .29-900-10 Tie rod DW 15/90 ....29-900-80...
  • Page 67 42.5 x 42.5 cm 16.5 x 16.5 cm 48 x 48 cm 54 x 54 cm Table 67.4 Description Ref. No. Multi-purpose panel StarTec AL MPP 270/75..21-212-26 StarTec AL MPP 135/75..21-212-46 Technical Instruction Manual / SV / Status August 2024 ST/AS-67...

  • Page 68: Corner Solutions With Multi-Purpose Panels

    13 (standard tie hole)! Fig. 68.2 5 8.5 5.5 6 10 11 Square nut Fig. 68.3 Description Ref. No. Multi-purpose panel StarTec AL MPP 270/75..21-212-26 StarTec AL MPP 135/75..21-212-46 ST/AS-68 Technical Instruction Manual / SV / Status August 2024...
  • Page 69 Fig. 69.2 Fig. 69.3 Description Ref. No. Multi-purpose panel StarTec AL MPP 270/75..21-212-26 StarTec AL MPP 135/75..21-212-46 Fig. 69.4 Stop end fixture 23/40 yellow 29-402-85 Flange nut 100 ...... 29-900-20 Technical Instruction Manual / SV / Status August 2024...

  • Page 70: Panel With Filling Nozzle / Concreting Window

    Wall formwork StarTec / AluStar Panel with filling nozzle / concreting window The ST panel AL 17 270/45 with a filling nozzle (Fig. 70.1) is used when concrete cannot be poured from above, e.g. in the case of tunnel formwork. The manual gate valve SK (Fig. 70.2) prevents the concrete...

  • Page 71: Circular Formwork

    Wall formwork StarTec / AluStar Circular formwork Circular buildings can be formed polygonally with standard panels, radius panels and tensioning bows (Figures 71.1 and 71.2). The ties are inserted through the radius panels. The load is transferred through the tensioning bows. The minimum radius is 1.75 m.
  • Page 72 Wall formwork StarTec / AluStar Circular formwork When planning formwork for a full circle, ensure there Height of arch (h) in cm for different radii and panel widths are sufficient Uni-assembly locks 22 and timber fillers for compensation. When forming arches, make sure...

  • Page 73: Further Applications

    Wall formwork StarTec / AluStar Further applications STB support frame for single- sided formwork The StarTec and AluStar formwork together with STB support frames can also be used when concrete has to be poured against earth, rock, an existing wall or the like, i.e.

  • Page 74: Transport

    The lifting hook (Figures 74.1 and 74.3) can be used with any 4-rope crane sling on the construction site to transport StarTec panel stacks. Always use four hooks at once (Fig. 74.2). To calculate the permissible load- bearing capacity, assume that only two hooks are used.
  • Page 75 1. Insert a stacking angle (Fig. 75.1) made of galvanized 60/40/23 at each corner of the steel, two to five wall formwork StarTec/AluStar panel so that panels of the same size with the panel lies on the supporting frame profile widths of 60 mm, surface with the facing side 40 mm or 23 mm can be stacked...
  • Page 76 MEVA secures the StarTec panels 270/240 with the grey ST 270/240 safety bolt and all other AluStar and StarTec panels with the black AS/ST safety bolt (Fig. 76.2). The safety bolts are inserted into Safety bolt Long side of the frame Fig.

  • Page 77: Services

    MEVA formwork so they can our engineers. see its benefits for themselves in actual use. RentalPlus For a flat-rate fee MEVA's "fully comprehensive insurance" for rental formwork and equipment covers all secondary costs that occur after return (excludes losses and write-offs). For the...
  • Page 78 Notes ................

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