AluFix Technical Instruction Manual

Transcription

1 AluFix Technical Instruction Manual

2 General Notes AluFix is a versatile and flexible modular formwork system for all applications in structural and civil engineering. It is used in residential construction, reconstruction measures, civil engineering as well as in all cases where a crane is not available or out of reach. Single panels can be set by hand. For a fast and safe panel connection only one part is sufficient: the EA-, and/or E-assembly lock. It can be set with one hand, steplessly at any position of the frame. With only a few hammer blows a safe connection and a perfect alignment are achieved which results in a flush panel joint. The modular wall formwork system AluFix consists of an aluminium frame with an annealed, impact and scratch resistant plastic coating. The closed profiles are easy to clean and torsion proof. That increases the lifespan and reduces the cleaning effort. The MEVA multi-function profile with welded-in Dywidag threaded nuts allows for easy attachment : Braces and alignment rails are easily attached to the panels by using flange screws. Scaffolding brackets can be mounted extremely fast by using the self-securing, integrated pin. Problem areas can be solved by using tie rods with different lengths. The advantages are easy dispatching, small size inventory and no time consuming, unproductive search for parts. State: June 2008 AF-2

3 AluFix AF Please note: Contents This technical manual contains information, instructions and hints describing how to use the AluFix system on the construction site in a proper, quick and economic way. Most examples shown are standard applications, that will occur in practice most often. For more complicated or special applications not covered 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. Many of the details shown do not illustrate the wall formwork system in the ready to pour condition as to the fore mentioned safety regulations. Please adhere to these technical instructions when applying the AluFix wall formwork. Deviations require engineering calculations and analysis to guarantee safety. Generally, only well maintained material may be used. Damaged parts must be replaced. Apply only original MEVA spare parts for replacement. Attention: Do not wax or oil assembly locks! AluFix-panel...4/5 alkus plastic sheet...6 Panel connection...7/8 Placing of ties...9 Rate of placing...10 Flatness of surface...11 Attachment of accessories...12 Wall braces...13 Working scaffolds...14 Crane hook...15 Inside corner Outside corner Articulated corners...18/19 Length compensation...20 T-wall connection...21 Connection to existing walls...22 Stop ends...23 Wall offset...24 Pilasters...25 Differences in height...26 Panels in horizontal position...27 Substitution of ties...28 Height extension...29/30 Crane ganging...31 Foundations / Columns...32 Assembly and stripping (step by step) Assembly and stripping (general) Transport Service...41 Product list...43 AF-3

4 AluFix-panel Fig. 4.1 The AluFix-panel with double groove. Fig. 4.2 The aluminium frames are mitre welded and consist of a three chamber profile equipped with a double groove and an edge protection. Fig. 4.2 Fig. 4.3 Pioneering panel connection with EA-assembly lock or E-assembly lock (see page AF-7 and AF-8). Fig. 4.4 Fast, friction-type attachment of accessory parts at the multi-function profile (see page AF-12). Fig. 4.3 Fig. 4.5 The cross stiffeners are made of closed, easy to grab and robust aluminium profiles. Fig. 4.4 Fig. 4.6 Tie holes for an easy installation of tie rods (see page AF-9). Fig. 4.5 Fig. 4.1 Fig. 4.6 AF-4

5 AluFix AluFix-panel Fig. 5.1 The AluFix-panel with single groove. Fig. 5.2 Fig. 5.2 The aluminium frames are mitre welded and consist of a two chamber profile equipped with a groove and an edge protection. AF Fig. 5.3 Pioneering panel connection with E-assembly lock (see page AF-7 and AF-8). Fig. 5.3 Fig. 5.4 Fast, friction-type attachment of accessory parts at the multi-function profile (see page AF-12). Fig. 5.5 The cross stiffeners are made of closed, easy to grab and robust aluminium profiles. Fig. 5.4 Fig. 5.6 Tie holes for an easy installation of tie rods (see page AF-9). Fig. 5.5 Fig. 5.1 Fig. 5.6 AF-5

6 alkus plastic sheet The new poly-propylene and aluminium composite forming face has all the positive properties of plywood plus important advantages: longer lifespan, greater loadbearing capacity, better nail-holding ability, fewer and easier repairs, 100 % recyclability. Besides the obvious advantages, such as considerably reduced 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 pro cess 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. The structure of the alkus sheet is illustrated in Fig Fig. 6.1 Frame profile with plywood face negative impression in the concrete when using panels with a conventional plywood face. Plastic layer Metal or fibres Fig. 6.2 Frame profile with alkus plastic sheet smooth and even concrete surface as there is no projecting profile of the panel frame. Foamed plastic core Metal or fibres Plastic layer Fig. 6.3 AF-6

7 AluFix Panel connection Fig. 7.1 Depending on whether the AluFix-panel with double groove (see page AF-4) or single groove (see page AF-5) is used, the EA- or the E-assembly lock has to be used. Both allow for a fast and efficient connection of the panels, 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 5-point contact (EA-assembly lock; Fig. 7.2), or 3-point contact (E-assembly lock; Fig. 7.3) does not only draw together the panels, it also aligns them (Fig. 7.1). Since the lock weighs only 1.5 kg or 0.8 kg it can be easily attached with one hand. Three assembly locks per panel joint are sufficient for the 3.00 m high panels. Two assembly locks per panel joint are sufficient for the 2.64 m and 1.32 m high panels. For outside corners and columns other configurations are valid (see page AF-17 and AF-32). AF 5-point contact 3-point contact Fig. 7.2 EA-assembly lock Fig. 7.3 E-assembly lock Description Ref.-No. EA-assembly lock E-assembly lock AF-7

8 Panel connection Connection of panels with double groove by using the EA-assembly lock (Fig. 8.1). Connection of panels with double groove and single groove by using the E-assembly lock (Fig. 8.2). Connection of panels with single groove by using the E-assembly lock (Fig. 8.3). We recommend, if possible, the use of the EA-assembly lock. The panel connection with the E-assembly lock is always possible (Fig. 8.2 to 8.4). Fig. 8.1 Fig. 8.2 Fig. 8.3 Fig. 8.4 AF-8

9 AluFix Placing of ties Fig mm The tie hole sleeves (Fig. 9.1), where the ties DW 15 can be inserted, are welded to the frame. The size of the tie holes (Fig. 9.1) allows one or both sides of the wall to be inclined. On sloping formwork the articulated flange nuts 15/120 have to be used. These flange nuts can be easily installed by using a hammer (Fig. 9.2) or a spanner SW 27. In order to secure the formwork against uplift it has to be tied to the ground. Please note: If two panels of different width are assem bled side by side, the ties should always be placed through the panel with the larger width (Fig. 9.3). When using Uni-tie claws, the ties can be placed at the outside edge of the panels, for example when forming stop ends, or directly above the panels when forming foundations. AF Fig. 9.2 right wrong Fig. 9.3 Description Ref.-No. Tie rod (thru-rod) DW 15/ Flange nut Articulated flange nut 15/ Plug D Spanner SW AF-9

10 Rate of placing Recommendations for concrete placement (Tab and 10.2) Concrete should be placed in layers, the thickness of which can vary from 0.50 to 1.00 m (acc. to DIN 4235). Concrete must not be placed from great heights at free fall (1.50 m and higher). When vibrating the concrete, which is done layer by layer, the vibrator must not penetrate more than 0.50 m 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. Basis of calculation for table 10.2 is concrete without additives (e. g. retarder, plasticizer). Technical data of tie rods DW 15 Tie rod DW 15 d1 (mm) 15 d2 (mm) 17 Nominal cross section (mm²) 177 adm. working load acc. DIN (kn) 90 Elongation of tie rods at working load (mm/m) 2.5 Tab Maximum rate of placing depending on fresh concrete pressure 1. Wall height up to 2.64 m without consideration of pouring rate 2. Wall height exceeding 2.64 m (see table below) 2.1 Use of tie rod DW 15 with articulated flange nut 15/120 recommended and acc. to E DIN 18218: and acc. to the adm. load capacity determined rate of placing Maximum rate of placing v b (depending on fresh concrete pressure)* in m/h AluFix t E =5h t E =7h t E =10h t E =15h Consistency F F F F SVB Tab * acc. to draft E DIN 18218: Concrete pressure on plumb-vertical formwork t E = end of setting of concrete (to be asked at the concrete supplier or knead-bag test acc. to DIN 18218) v b = maximum rate of placing AF-10

11 AluFix DIN 18202, Table 3 Column Tab Distances as critical value in mm Distances between measuring points in m Line Reference 0.1 1* 4* 10* 15* 5 Not exposed walls and undersides of slabs Exposed walls and undersides of slabs, e.g. plastered walls, paneling, suspended ceiling Like line 6, but with increased requirements Flatness of surface The permissible deformation of a structural member is defined in DIN 18202, Table 3, line 5 to 7 (Tab. 11.1). The admissible deflection is determined by the measurement point interval. Adm. concrete pressure acc. to DIN 18202, Table 3, line 6, for AluFix = 55 kn/m², considering entire surface; Concrete pressure full liquid head = 65 kn/ m² AF Not stacked: AluFix 2.64 m and 3.00 m Concrete pressure full liquid head, 65 kn/m², deflection f = 3.6 mm Stacked panels: AluFix 2.64 m and 3.00 m Concrete pressure across entire surface, 55 kn/m², deflection f = 4.3 mm Tolerances of deflection of walls and undersides of slabs (According to DIN 18202, Table 3) Tolerances Fig line 5 line 6 line 7 Distance of measuring points * Interim values can be found in Fig Tolerances of deflection. Round up found values to full mm. The lath is placed on the highest protruding points of the surface and the deflection is measured at the deepest point inbetween. The distance between measuring points means the distance between the highest protruding points. AF-11

12 Attachment of accessories All panels are provided with multi-function profiles. Dywidag threaded nuts are welded inside the profile (Fig. 12.1). The difference be tween these multi-function profiles and the stiffeners is that the multi-function profile allows for attach ment of forming accessories. Scaffolding brackets are provided with self-locking pins (Fig and 12.4) and thus can be mounted on the multifunction profile. The scaffolding bracket can be secured with a flange screw 18 (Fig. 12.4). Steel rails must be attached to the multifunction profile at tie hole elevation to ensure proper load transfer (Fig. 12.2). Formwork can be set plumb by using a push-pull prop, attached to the panel with the form work-propconnector as shown in Figs and Fig Fig Fig Fig Fig Fig AF-12

13 AluFix Wall braces Distances (x) between wall braces / push-pull props For formwork max m alignment For transfer of max m wind loads Tab x Push-pull prop, Braceframe Wall braces are attached to the multi-function profiles by formwork-prop connectors and flange screws 18 (Fig. 13.1). If braces are used to align wall formwork, we recommend a maximum distance between braces of 4.00 m. For transfer of wind loads a maximum distance of 2.50 m is recommended (Tab. 13.2). For further applications please contact our technical department. Height of formwork and length of braces should be equal. The angle between support structure and top wall brace should not exceed 60 (Fig and Tab. 13.3). AF Tab Fig Description Braces SRL Ref- No. Adjustment range [m] Adm. pressure [kn] max. 60 Adm. tensile force [kn] Weight [kg] Recommended area of application Brace SRL Horizontal alignment of bottom of wall formwork; Brace frame 250, Climbing formwork Brace SRL Folding shaft formwork Push-pull props R Push-pull prop R 160 Push-pull prop R 250 Push-pull prop R 460 Push-pull prop R Horizontal and vertical alignment Top brace of brace frame 250; for wall heights up to 4.05 m for wall heights up to 6.00 m for wall heights up to 9.00 m Wall braces and push-pull props must be anchored to the ground by using foot plates and dowels. Before anchoring the formwork to the ground, the properties of the ground and the rating of the dowels or nails must be verified according to the federal, state and local codes and regulations. Description Ref.-No. Push-pull prop R Push-pull prop R Push-pull prop R Push-pull prop R Brace SRL Brace SRL Brace frame 250 with formwork prop connector AF-13

14 Working scaffolds Scaffolding bracket The scaffolding bracket is mounted to a multifunction profile. To insert the bracket turn it by 45, then turn it back to vertical position and secure it with a flange screw. Afterwards planks can be bolted to the brackets (Fig. 14.1). Guard-railing post Side railing Scaffolding bracket Attention According to DIN 4420, with an adm. load of 150 kg/m² (scaffold group 2) the max. distance between two brackets must not exceed 1.50 m (Min. plank thickness = 3.5 cm). If the fall height is exceeding 2.00 m a side railing consisting of handrail, midrail and toe board is required (Fig. 14.2). Fig Note When ganging units we recommend to bolt the planks to the brackets. Make sure that the side railing is also attached properly. Working platform acc. to DIN 4420 part 1 and bulletin 8 10/01 Bauberufsgenossenschaft (Professional Construction Association) Handrail (min. 15 x 3 cm) Description Ref.-No. Scaffolding bracket Guard-railing post UK Side railing 90/ / Swivel joint coupler 48/ Scaffold tube 48/ / / ± 5 cm Fig Midrail (min. 15 x 3 cm) Toe board (min. 10 x 3 cm) Planking 30 Dimensions in cm AF-14

15 AluFix Crane hook Fig mm Reference dimension The admissible load of the EA/ML crane hook (Fig. 15.1) is 600 kg. The handling is very simple: Open the safety lever as far as possible. Then push the crane hook over the panel profile until the claw engages completely in the groove. Move the safety lever back to the starting position to lock the crane hook (Fig. 15.3). When using AluFix panels with single groove the AF crane hook is needed (adm. load 600 kg). Note If the reference dimension exceeds mm the crane hook must be replaced immediately (Fig. 15.2). Replace it even if only one side of the hook exceeds this dimension. Safety regula tions When using our products the federal, state and local codes and regulations must be observed. AF Fig Fig max. 60 Fig max. 60 Safety tips Always check the crane hook before use. Do not over load the crane hook. Overloading causes damage. A damaged crane hook is not capable of full load! Attention When moving gangs (Fig. 15.6), make sure that each crane hook is attached at a panel joint or above a stiffener (when horizontally stacked). This avoids displace ment of the crane hook. Also make sure to use always two crane hooks even if you move only a single panel (Fig and 15.5). Please observe Instruction Manual Crane hook EA/ML, which is attached on each crane hook when delivered. max Fig Fig Description Ref.-No. EA/ML-crane hook AF-crane hook AF-15

16 Inside corner 90 Only 3 assembly locks at each side are required to connect the inside corner to 3.00 m high panels (Fig.16.1); 2 assembly locks are needed for 2.64 m and 1.32 m high panels. The length of the sides is 20.0 cm (Fig. 16.3). Corner plus wooden filler (Fig. 16.2): The connection can be accomplished by the use of Uni-assembly locks (3 for 3.00 m high panels and 2 for 2.64 m and 1.32 m high panels (per panel joint). When using AF panels with single groove, E-Uni-assembly locks have to be used. To cover the joints between panels and filler and to provide rigidity an AS-alignment rail is required on each multi-function profile. Wood fillers are generally placed at the outside of the corner when using the AluFix system. Fig Description Ref.-No. AF-inside corners 300/ / / Uni-assembly lock E-Uni-assembly lock Fig Fig AF-16

17 AluFix Outside corner 90 Fig Panel width = WT + 20 cm (WT = Wall thickness) Fig WT Panel width The AF-outside corner (Fig. 17.1) made of aluminium with annealed plastic paint provides a rigid outside corner assembly for 90 -corners (Fig and 17.3) in combination with AluFix-panels and the EA-assembly lock (double groove), or E-assembly lock (single groove). For 3.00 m and 2.64 m high outside corners 4 assembly locks on each side are required. The panel joint adjacent to the corner joint needs 3 assembly locks, for all other joints 2 assembly locks are sufficient (Fig. 17.3). For 1.32 m high outside corners 2 assembly locks are required. AF Fig Description Ref.-No. AF-outside corners 300 Alu Alu Alu AF-17

18 Articulated corners Corners with an angle between Acute and obtuse angled corners are formed by using AF-articulated inside and outside corners (Fig. 18.1). Alignment rails are required at the outside corners. The rails are attached to the multi-function profiles of the panels by using flange screws. If the inside angle is wider than 100, alignment rails and wooden blockings have to be used on the inside (Fig. 18.1). Fillers are attached to the panels by using Uni-assembly locks (double groove), or E-Uni-assembly locks (single groove). Side length of inside corner: 20.0 cm Wood filler with Uni-assembly lock Wooden blocking AF-articulated inside corner Fig WS Equation to determine the dimension y (cm): WT y = + 20 cm α tan 2 y = Panel width E1 + filler y Angle Pin M 18 x 100 AS-alignment rail 125 AF-articulated outside corner Adjustment range: Articulated inside corner Articulated outside corner That gives an adjustment range from 80 to 120. To determine the dimension (y) between the articulated outside corner and the first panel where a tie can be used, see chart Description Ref.-No. AF-articulated inside corner 132/ / AF-articulated outside corner Wall thickness (WT) in cm Tab Inside angle α in Y in cm Panel width E 1 in cm Filler width in cm AF-18

19 AluFix Articulated corners Wood filler with Uni-assembly lock Wooden blocking AF-articulated inside corner WS Fig Equation to determine the dimension y (cm): y = panel width E1 + filler Wall thickness (WT) in cm Tab Inside angle α in Angle WT y = + 0 cm α tan 2 Y in cm y Panel width E 1 in cm Pin M 18 x 100 AS-alignment rail 125 AF-articulated inside corner Filler width in cm Corners with an angle between Acute and obtuse angled corners can also be formed by using 2 AF-articulated inside corners. We recommend to attach the alignment rails with flange screws before installing the tie rods (Fig. 19.1). Adjustment range: To determine the dimension (y) between the articulated outside corner and the first panel where a tie can be used, see chart With standard wall thicknesses usually the filler width is smaller than a standard panel width. Adjustment range: Articulated inside corner, used as inside corner Articulated inside corner, used as outside corner That gives an adjustment range from 95 to 180. Description Ref.-No. AF- articulated inside corner 132/ / AF AF-19

20 Length compensation Wood filler Gaps up to 17.0 cm can be formed by using wood fillers and Uni-assembly locks (double groove) or E-Uni-assembly locks (single groove). Compensation areas are reinforced with alignment rails, which must be always attached to the multi-function profile at tie hole elevation. (Figs. 20.1, 20.4 and 20.5). Gaps up to 5.0 cm can be formed with a wood filler plus a flange nut 100 (Fig. 20.3). For details about alignment rails please see page AF-28. Fig Fig up to 5 cm Fig Fig Fig AF-20

21 AluFix T-wall connection The connection at a T-wall application is accomplished by using two inside corners (Fig to 21.4). Different wall thicknesses are compensated for by means of wooden fillers and Uni-assembly locks (double groove) or E-Uni-assembly locks (single groove) up to a width of 17.0 cm (Fig. 21.4). AF Fig Max. dimension depending on alignment rail (max. 1/2 length of alignment rail) Standard panel Wood filler Fig Fig Alignment rails see page AF-28 up to 17 cm Wood filler plus Uni-assembly lock Fig AF-21

22 Connection to existing walls These sketches show some options for connecting formwork to an existing wall (Fig to 22.5). According to the conditions on the construction site the most suitable solution may be chosen. Make sure that the formwork is securely attached to the existing wall in order to avoid a leakage of the fresh concrete and a patchy concrete surface. Wooden blocking Existing tie hole Fig Fig Different panel widths Fig Drive nut 60 Pressing on of alignment rail through existing tie holes Fig Fig AF-22

23 AluFix Stop ends Stop ends can be formed by using stop end brackets (Fig and 23.6) or outside corners and panels (as long as the wall thickness matches a panel width (Fig Fig. 23.3). AF Fig cm Attention Never use thru-rods or threadbars for stop ends if these ties are going to be subjected to shearing stress. The board has to be nailed to the facing of the panel - shear stress is on the nails (Fig 23.5) Fig If the distance between last tie and stop end panel is more than 50 cm, steel rails are required to install a tie behind the stop end panel. Fig Fig Fig Fig Description Ref.-No. Stop endbracket 60/ AF-23

24 Wall offset One-sided wall off-sets of up to 8 cm are formed by moving back the correspond ing panel (Fig. 24.1). For offsets exceeding 8 cm, inside corners should be used (Fig and 24.4). The offset sections of the wall formwork are reinforced by steel rails. For wall offsets between 8 and 18 cm alignment rails are required in general. They are attached by using tie rods and flange nuts. They can be easily screwed into the Dywidag threaded nuts of the multi-function profiles, which results in a rigid and force-fit connection. Panels arranged offset from each other are connected by means of Uni-assembly locks 22 (Fig. 24.2). Fig Detail A Fig Detail A Tie rod with articulated flange nut 15/120 Wooden blocking Alignment rail (AS 125 or AS 200) Uni-assembly lock up to 8 cm Detail B 8 to 18 cm Fig Tie rod with articulated flange nut 15/120 Wooden blocking Alignment rail (AS 125 or AS 200) Detail B Description Ref.-No. Inside corner 300/ / / Fig Uni-assembly lock AF-24

25 AluFix Pilasters Flange screw 18 Tie rod with articulated flange nut 15/120 Wooden blocking Pilasters are easily formed by using inside corners, standard panels, and where necessary, some wooden blocking (Fig ). AF Fig Flange screw 18 Tie rod with articulated flange nut 15/120 Fig Flange screw 18 Tie rod with articulated flange nut 15/120 Wooden blocking Fig AF-25

26 Differences in height The assembly lock can be attached at any position on the frame profile (Fig. 26.1), 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 (EA-assembly lock for double groove panels, E-assembly lock for single groove panels). Job built fillers are made with square timbers and an alkus plastic sheet or plywood cut to size. When required, use a square timber for reinforcing. Square timbers and panels are simply connected to each other with assembly locks (EA-assembly lock for double groove panels, E-assembly lock for single groove panels). The wood filler areas need special attention (see page 20). The use of rails and/ or blockings may be required (Fig and 26.2). Fig Job built fillers Fig Filler AF-26

27 AluFix Panels in horizontal position Fig Fig Fig Fig e Tie rod DW 15 Drive nut 60 Tie rod DW 15 Foundation tape Foundation spanner EA Tie claw 23 Flange nut 100 Foundation spanner EA Foundation tape Detail A Fig Fig Detail B Push-pull strut Fig A lot of forming problems can be easily solved by arranging panels horizontally (Fig and 27.2). These include basin walls in water treat ment plants, foundations and strip footings, which often require a certain height. Or, when the formwork height is restricted by an existing structure. Instead of using a bottom tie in combination with a drive nut (Fig ), a foundation tape together with the foundation spanner can be used (Fig ). The foundation spanner is attached to the formwork panel by using a wedge. On top of the formwork you can also use a tie claw 23, a regular tie (Fig. 27.1, 27.2, 27.4 and 27.5) or the push-pull strut (Fig. 27.6) for above tieing. The push-pull strut allows a max. wall thickness of 64 cm. Max. distance e at pour-height 75 cm e = 185 cm. Max. distance e at pour-height 100 cm e = 120 cm. Max. distance e at pour-height 135 cm e = 70 cm. AF Fig Detail A AluFix panel Drive nut 60 Tie rod DW 15 Fig Detail B AluFix panel Foundation spanner EA Foundation tape Description Ref.-No. Foundation tape Foundationspanner EA Trolley for foundation tape Tie claw AF-27

28 Substitution of ties In stacked panel condition (four 300/75 vertical, one 300/75 horizontal, Fig. 28.1) it is possible to save ties if you substitute them with alignment rails. In Fig four (4) alignment rails are required to substitute one row of ties. Fig Fig Compensation areas are reinforced with alignment rails, which must always be attached to the multi-function profile at tie hole elevation (Fig. 28.3). The maximum filler width for applications with standard panels can be determined using the chart below (the maximum pressure is 55 kn/m²) (Tab. 28.4). With a fresh concrete pressure of P b max = 55 kn/m 2 and when following line 5 and 6 of the DIN Tolerances in building construction, the following filler widths can be accomplished: Alignment rail AS-RS 50 AS-RS 125 AS-RS 200 Tab Width up to 0.35 m up to 0.70 m up to 0.80 m Please note When compensating length differences near outside corners or stop ends, the horizontal force must always be considered. In this case, fasten the alignment rail with flange screws on both sides of the compensa tion area. Description Ref.-No. AS-alignment rail 50, galv AS-alignment rail 125, galv AS-alignment rail 200, galv Fig Fig /4 Filler 1/4 width AF-28

29 AluFix Height extension When stacking vertical panels an alignment rail AS 200 or longer is required on every second panel to provide flexural rigidity and to avoid flexing between panels when lifting and laying down gangs (Fig. 29.1). Every rail is attached to the panel by using two (2) flange screws 18. AF Fig AF-29

30 Height extension Particularities of height extensions with horizontal panels: For height extensions > 30 cm a tie should be installed in every tie location (Fig and 30.2). > 30 cm Fig Fig For height extensions < 30 cm it is not required to install ties in the tie holes of the extended panels, as long as the scaffolding bracket is attached to the panel below (Fig. 30.3). For height extensions with panels < 30 cm and the scaffolding bracket attached to this panel it is only required to install a tie in the top tie holes (Fig. 30.4). The tie claw 23 in combination with a tie rod and flange nuts 100 can also be used to tie this configuration. < 30 cm Fig Tie claw 23 < 30 cm Fig AF-30

31 AluFix Crane ganging Crane ganging unit incl. accessories (Fig. 31.3) Amount Description kg/piece kg total 6 AluFix-panels 300/ EA-assembly lock AS-alignment rail Scaffolding bracket 90 + guardrailing post 2 Crane hook Flange screw Push-pull prop R Push-pull prop R Formwork-prop connector Double-jointed foot plate Platform planking m² incl. safety accessories Weight kg Tab max. 60 When moving gangs the crane hook must be attached at the panel joints (Fig and 31.3). For gangs with horizontally assembled panels on top, the crane hook must be attached above horizontal profiles so that the crane hook cannot disengage or slide. In order to provide the necessary flexural rigidity when lifting and laying down gangs, alignment rails are mounted by means of flange screws. The figures do not show scaffolding brackets, guard-railing posts and brace frames. For more information about that please see page AF-13 and AF-14. AF max. 60 Attention Always use two (2) crane hooks when moving gangs. The capacity of the EA/ML-, or AF-crane hook is 600 kg. The total weight of the gang must not exceed 1200 kg (2 crane hooks x 600 kg = 1200 kg). Fig.31.2 Fig AF-31

32 Foundations / Columns Foundations with a width of 0.75 m and a height of 1.32 m (Fig. 32.2) can be formed with 3 assembly locks per joint (Fig. 32.1). Foundations Columns with a width of up to 0.50 m (Fig. 32.5) and a height of 2.64 m can be formed with 6 assembly locks per joint (Fig. 32.4). Columns with a height of 3.00 m and a width of 0.50 m require 8 assembly locks per panel joint (Fig 32.3). Wider or taller columns need additional alignment rails or strengthening collars because of the high concrete pressure. Fig h= 1.32 m Columns Fig max m max m max m max m Fig Description Ref.-No. AF-outside corners 300 Alu Alu Alu Fig h = 3.00 m Fig h = 2.64 m AF-32

33 AluFix Assembly and stripping (step-by-step) In the following we take a straight wall as an example to illustrate the sequence of operations. Transport: When unloading the truck and moving piles of panels on the construction site take care to use appro priate crane slings or the like. AF Fig.33.1 Assembly: Erect the first panel and immediately attach a push-pull prop or brace (Fig. 33.1). Anchor the brace to the ground in order to prevent the panel from tilting over. Erect further panels and connect them to each other with assembly locks (see pages AF 7 and AF 8). Spray the forming face with release agent MevaTrenn FT 8. Attach the scaffolding brackets and side railing (Fig. 33.2). Fig AF-33

34 Assembly and stripping (step-by-step) Closing of formwork After the reinforcement is installed you can start to close the formwork. After the ties have been installed the opposite side of the formwork is secured against tilting over (Fig. 34.1). However, for this side you may not necessarily need braces. 1. Insert the ties through the first formwork equal to the required wall thickness. 2. Install spacer cones and PVC sleeves over the ties. 3. Lift and move the second formwork into place. 4. Push the ties through the second formwork and secure them on both sides with flange nuts. 5. When using systems without spacers apply Z-bars to ensure a constant wall thickness. Fig Finally complete the working scaffold and mount side railings (Fig. 34.2). Pouring Watch rate of pouring and observe DIN 4235 part 2 when pouring (see also page AF-10). Observe all federal, state and local codes and regulations for pouring concrete. Fig AF-34

35 AluFix Assembly and stripping (step-by-step) Stripping: Do not start stripping until the concrete has set to the point where it cannot deform anymore. AF Always start stripping the formwork on the second side (the one without braces) (Fig and 35.2). 1. Remove planking of working scaffold. 2. Remove scaffolding brackets. 3. Remove ties. 4. Remove panels. If heavily soiled, you might need to clean the panels and spray them with release agent (MevaTrenn FT 8) before the next use. Fig If stripping is done by crane, move units away from the wall and place them on the ground. The working scaffold is disassembled at the ground. Fig AF-35

36 Assembly and stripping (step-by-step) The panels can be removed by hand or by using a crane hook one by one after the wall braces and the respective assembly locks have been removed (Fig and 36.2). When using a crane, larger panel units can be lifted as one, also after the wall braces and the respective assembly locks have been removed. Fig Fig AF-36

37 AluFix Assembly and stripping (general) Fig Filler for easy stripping Planning stage: Reasonable plan ning and pre pa ration are the keys to a successful appli cation of any modern formwork system. First of all, determine the amount of formwork material that will be needed. In this regard, several factors of influence should be taken into account: Weight of the formwork to be handled Time allowed for assembly and strip ping Transportation of the formwork from one pour to the next either panel by panel, or in gangs (which considerably reduces forming time) Capacity of the lifting equipment Size of pours (taking into account the number of corners etc.) Once all the aspects have been considered, the quan tities of formwork items can be specified. If you choose to pre-assemble large-size gangs on the ground, attach braces and working scaffold before lifting the whole unit. You should have a flat surface for the pre-assembly. Do not forget to spray the alkus face with release agent. Panel connection: In general, the 1.32 m and 2.64 m panels are connected at the vertical joints using two assembly locks. The 3.00 m panels require 3 assembly locks per joint. Exception: Outside corners are connected to the adjacent panels as follows: 2.64 m and 3.00 m outside corner: 4 locks The next following panel would require 3 locks at the joint. (Fig and 37.2) For more details see page AF-17. AF Fig Assembly area: The area where the formwork is set should be clean, even and capable of taking the expected load. Form work assembly: In most cases it is recommended to set the outside formwork first. Always start at a convenient location and immediately attach a brace to the panels set in place. Bracing the formwork: After erecting the panels, braces must be attached immediately in order to prevent the panels from tilting over. Anchor the foot plates of the braces to the ground. If anchoring in soil, use ground nails; if anchoring to a concrete slab, use heavy-duty dowels. The spacing of braces is described on page AF-13. AF-37

38 Assembly and stripping (general) Working scaffold: Scaffolding brackets are quickly attached with their integrated self-locking pins. The brackets are the basic item for the working scaffold. The walk boards can be bolted to the scaffolding brackets. They must not be placed on the scaffolding brackets before: 1. the braces are attached to the formwork 2. all ties are placed connecting the two sides of the formwork. (Fig. 38.2) For planning and installation of the brackets see details on page AF-14. Closing the formwork: After setting and bracing the outside formwork: mark the pouring height install blockouts and reinforcement install a tie in all tie locations install PVC-sleeves over the ties set the inside formwork tighten the form work, using either standard or articulated flange nuts on both sides of the tie. Stripping: When short wall sections (< 6.0 m) are involved, make sure to install a filler (Fig. 37.2), or, if possible, use stripping corners while assembling the formwork. This allows easy stripping. In all other cases start stripping at one end or at a corner. Flange nuts and ties are removed section by section. The side of the formwork without braces must be stripped immediately or otherwise secured in order to prevent the panels from tilting over. The panel units are stripped by removing the assembly locks from the panel joints. If the formwork is handled manually, remove working scaffolds and braces prior to dismantling the panels. If the formwork is handled by crane, working scaffolds and braces can remain on large-size gangs. The dismantled units are cleaned in upright position and release agent is applied before moving them to the next pour. When there is no further use for the large-size gangs they should be placed face down to remove scaffolding and braces. The panels are cleaned on the ground and stacked for transport (for example with transport angles, see page AF-39). Transport of panel stacks When moving panel stacks on site make sure that panels are secured. MEVA secures panels by using the safety plug for panel stacks. These plugs should also be used by the job-site when returning material. Safety regulations: When using our products the federal, state and local codes and regulations must be observed. Fig Fig AF-38

39 AluFix Transport Transport angle By using the trans port angles (Fig. 39.1), panel stacks can be stored without the need of squared timber to support the stack and thus save space. With the transport angles 5-12 AluFix panels can be stacked and transported. AF Max. load capacity = 10 kn (1 t) per angle. For safety reasons consider 20 kn (2 t) as maximum capacity for the whole stack. It is recommended to use two (2) foldable angles and two (2) of the rigid type for each stack. Fig Description Ref.-No. Transport angle 10, foldable Transport angle 10, rigid type AF-39

40 Transport Make sure that all material is secured properly. Recommendation: Use one load/cargo strap per 1 meter of cargo (Fig 40.1). That means for a fully loaded truck with a trailer length of m 14 load/ cargo straps would be required. When moving panel stacks make sure that panels are secured. MEVA secures panels by using the safety plug for panel stacks (Fig. 40.2). These plugs should also be used by the job-site when returning material. Fig Safety regulations: When using our products the federal, state and local codes and regulations must be observed. Fig Description Ref.-No. Safety plug for panel stacks AS/ST black AF-40

41 AluFix Service Rentals We offer our customers the option of renting supplementary material during peak times. We also give prospective customers the chance to test MEVA formwork so they can see its benefits for themselves in actual use. RentalPlus Since MEVA started the flat rate for cleaning and repair of rented formwork systems in early 2000 more and more contractors experience the outstanding advantages. Ask our representatives about the details! Formwork drawings Of course, all offices in our technical department have CAD facilities. You get expert, clearly represented plans and work cycle drawings. MBS - MEVA Basic Support MBS is an addition to AutoCAD, developed by MEVA Formwork Systems in MBS is based on standard programs (AutoCAD and Excel) and can be used on any PC that has these two programs installed. It includes pull down menues for AutoCAD and applications to ease forming. It also includes the possibility to create take-offs. Special solutions We can help with special parts, custom designed for your project, as a supplement to our formwork systems. Static calculations Generally, this is only necessary for applications like single-sided formwork where the anchor parts are embedded in the foundation or the base slab. If requested, we can perform static calculations for such applications at an additional charge. Formwork seminars To make sure that all our products are used properly and efficiently, we offer formwork seminars. They provide our customers a good opportunity to keep themselves up-to-date and to benefit from the know how of our engineers. AF AF-41

42 Notizen AF-42