Imperial Technical Instruction Manual

Transcription

1 Imperial Technical Instruction Manual

2 The Imperial wall form work is a cranedependent modular formwork system for use in industrial and civil engineering projects as well as ad ministration and residential building construction. A complete formwork set including acces sories weighs about 14 lbs/sq.ft. The admissible fresh concrete pressure is 2,025 psf when using 7/8 threadbars or 1 1/4 taper ties. All Imperial panels are available in 4 different heights (2, 4, 8, 12 ) and in 8 different widths (1, 1-6, 2, 2-6, 3, 3-6, 4, 8 ). In addition, there is a multi-purpose panel for each height available. The width of the multi-purpose panel is 4. All panels are entirely symmetric. Accessories are completing the program including aluminum fillers (1, 2, 3 ), corners (12 x12 ), push-pull props and safety parts. The panels have high grade 7/8 alkus plastic sheeting, which is riveted to the panel frames. I-2

3 Imperial Please note: This Technical Manual contains information, instructions and hints how to use the MEVA Imperial formwork on the construction site in a proper 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 Imperial formwork. Deviations require engineering calculation 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 oil or wax MEVA assembly locks! June 2010 Contents The Imperial panel...4 System description...5 Multi purpose panel...6 The alkus plastic sheet...7 Panel connection...8 Placing of ties...9 Height extension Rate of placing...13 Flatness of surface corner with standard panel corner with multi purpose panel Articulated corners Columns Length compensation Bulkheads...26 Wall offset...27 T wall connection...28 Connection to existing walls...29 Pilasters...30 Pilasters at corners...31 Pilaster panel Differences in height...34 Panels in horizontal position...35 Attachement of accessories...36 Tie off bar / Bump notch...37 Crane ganging Working plattform BKB Scaffolding bracket...41 Wall braces / Working scaffolds Stripping corner...44 Folding shaft formwork...45 Assembly and stripping (general) Assembly and stripping of gangs (exemplary) Crane slings Stapos Lifting hook 60 / Crane slings Crane hook...56 Climbing formwork / Single sided formwork...57 Service...58 Notes Product list I-3

4 The Imperial panel Fig. 4.1 The steel frames are manufactured of closed profiles which are welded in mitered joints. These profiles are provided with a groove and an integrated protection for the forming face. Fig. 4.2 Tie hole with conical anchor sleeve (see page 9). Fig. 4.3 Pioneering panel connection with MEVA assembly lock (see page 8). Fig. 4.4 The tie-off bar allows safe working on the formwork. Under no circumstances should panels be lifted or moved using these tie off bars. Fig. 4.5 The cross stiffeners are also made of closed profiles. Fig. 4.6 Fast and safe attachment of accessory parts at the multi function profile with Dywidagthreaded nuts (see page 36) Fig. 4.7 The bump notch is designed to facilitate shifting and lifting of panels (especially large size panels). Fig. 4.8 Transportation holes are used to attach the lifting hook 60, allowing stacked panels to be moved at ground or slab level (see page 54). 8 transportation holes all around the panel permit easy preassembly of gangs. Fig. 4.1 Fig. 4.2 Fig. 4.3 Fig. 4.4 Fig. 4.5 Fig. 4.6 Fig. 4.7 Fig. 4.8 I-4

5 Imperial System description Multi function profile Multi function profile at tie hole elevation Cross stiffener Frame Dywidag-threaded nuts Tie-off bar Tie hole Transportation hole Bump notch Multi-function profiles for fast and safe attachment of accessory items with Dywidag threaded nuts. The steel rails must be attached to the multifunction profile at tie hole elevation, the other multi function profiles are used for attaching accessory items. Cross stiffener stiffens the panel to provide rigidity. Transportation hole For further information about lifting panels and stacks see page 54. Panel height Standard panel heights are 2, 4, 8 and 12. The width varies in a 6 increment from 1 to 4, plus a width of 8. Fig. 5.1 Detail transportation hole Transportation hole Transportation hole Tie hole Fig. 5.2 I-5

6 Multi-purpose panel These panels are ideal for forming 90 corners, columns, pilasters, bridge abutments and connections to existing walls. The panels are provided with multiadjustment profiles where column clamps or ties are mounted (Fig. 6.1). The 12 panels have 3 multi adjustment profiles, the 8 panels have 2 and the 4 and 2 panels are provided with 1 multi adjustment profile. For further details see page 17. Multi function profile Multi adjustment profile Cross stiffener Frame Dywidag-threaded nuts Tie-off bar Standard tie hole Transportation hole Bump notch Fig. 6.1 Description Ref.-No. I-multi-purpose panels 12 x x x x I-6

7 Imperial The alkus plastic sheet Frame profile + plywood face Fig. 7.1: Negative impression in the concrete when using panels with a conventional plywood face Plastic layer Aluminum layer Frame profile + alkus plastic sheet Fig. 7.2: Smooth and even concrete surface as there is no projecting profile of the panel frame The new polypropylene and aluminum composite forming face has all the positive properties of plywood plus important advantages: longer life span, greater load bearing capacity, better nailholding 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. Foamed plastic core Aluminum layer Plastic layer Fig. 7.3: Composite alkus plastic sheet structure I-7

8 Panel connection The fast and efficient connection of the panels is accomplished with the MEVA assembly lock, no matter if the panels are assembled side by side or on top of each other. The lock can be attached on the frame at any position, and its 5 point contact does not only draw together the panels, it also aligns them. With only a few hammer blows a safe connection and a perfect alignment are achieved. Since the lock weighs only 6.6 lbs it can be easily attached with one hand. The 12 high panels require three assembly locks. Two locks are sufficient for the 8, 4 and 2 high panels. Fig. 8.1 = 5 point contact Description Ref.-No. M assembly lock Fig. 8.2 I-8

9 Imperial Fig. 9.1 Fig. 9.3 x x x Fig. 9.2 Detail Placing of ties The conical anchor sleeves, where the ties can be inserted, are located inside the panel frame. The conical shape allows one (Fig. 9.1) or both sides (Fig. 9.2) of the wall to be inclined. On sloping formwork the articu lated flange nuts 20/140 have to be used. In order to secure the fo rm work against uplift it has to be tied to the ground (see page 42 for details). 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 (used only with threadbars), the ties can be placed at the outside edge of the panels, for example when forming bulkheads, or directly above the panels when forming foundations. 1 7 / 16 Max. incline of 8' and 12' panels for single sided and two sided incline (Fig. 9.1 and 9.2) 8' height 12' height 1 9 / 16 x [inch] angle [α] x [inch] angle [α] Fig. 9.4 Taper tie 1" to 1 1/4" 5" 3 7 1/2" 3 Threadbar 7/8" 11 3/4" /2" 7 Description Ref.-No. Tie rod (threadbar) DW 20/ Articulated fl ange nut 20/ Plug D I-9

10 Height extension High degree of flexibility The formwork is extended in height using panels assembled vertically or horizontally, or in any combination on top of the bottom panels. No matter what configuration you opt for, the panel connection is always made with the MEVA assembly lock. The wide range of panel heights and widths ensures: Economical height extension in 6 incre ments through combined horizontal and vertical assembly Uniform joint grid. Functionality ensured by panel connection with assembly locks that can be positioned anywhere on the frame. Fig. 10.1: Formwork height from 4 to 8 in 6 increments Fig. 10.2: Formwork height 10 with 8 high and 2 high panels User-friendliness and profitability Vertical joints For a 2 and for a 4 standard panel you need just one 7/8 (20 mm) taper tie (or threadbar) and 2 assem bly locks. A 8 standard panel requires 2 of each and the 12 standard panel 3 of each. All tieing positions pre determined by the system have to be used. Fig. 10.3: Formwork height from 12 to 16 in 6 increments I-10

11 Imperial Height extension Horizontal joints The illustrations show generalized positions of the as sem bly locks and tie locations. Exact loca tions for specific job site conditions will be provided in the engi neer ing drawings by the technical depart ment. Fig. 11.1: Formwork height 8 with 8 high panels and 12 high panel in horizontal position Fig. 11.2: Formwork height from 10-6 to 12 in 6 increments In general, 2 assem bly locks per panel joint are required for 2, 4 and 8 high panels.12 high panels require 3 assembly locks. In some cases the number of ties can be reduced by using Imperial steel rails. At any rate, attention has to be paid not to exceed the permissible load of the ties and steel rails. For further details about Imperial steel rails see pages 25 and 72. This illustration does not take gang ing into consideration. (For crane ganging see page 38). I-11

12 Height extension In stacked panel condition with a height extension 1 it is not required to install ties in the tie holes of the extended panel (Fig. 12.1). For height extensions with panels > it is only required to install a tie in the top tie holes (Fig. 12.2). For height extensions 2 a tie should be installed in every tie location (Fig. 12.3). The dimensions refer to concrete height above lower panels. That means for instance, if you have to pour 10 above the lower panel and you only have a 2 panel available you do not need a tie (similar to Fig. 12.1). Or, if you have to pour 1 4 above the lower panel and you only have a 2 panel available you only need to install the top ties (similar to Fig. 12.2) etc. Fig Fig Fig I-12

13 Imperial Rate of placing ACI Coefficients to be used in pressure equations Unit weight coefficient, Cw Concrete weighing less than 140 pcf Cw = 0.5 (1+ w/145) but not less than 0.80 Concrete weighing 140 to 150 pcf Cw = 1.0 Concrete weighing more than 150 pcf Cw = w/145 Chemistry coefficient, Cc Types I, II and III cement without retarders* 1.0 Types I, II and III cement with a retarder* 1.2 Other types or blends containing less than 70% slag 1.2 or 40% fly ash without retarders* Other types or blends containing less than 70% slag 1.4 or 40% fly ash with a retarder* Blends containing more than 70% slag or % fly ash * Retarders include any admixture, such as a retarder, retarding water reducer, retarding midrange water-reducing admixture, or high-range water-reducing admixture (super-plasticizer), that delays setting of concrete. For concrete having a slump of 7 in. or less and placed with normal internal vibration to a depth of 4 ft or less, formwork can be designed for a lateral pressure as follows: For columns: P max = C w C c [ R/T] with a minimum of 600 C w lb/ft², but in no case greater than wh. For walls with a rate of placement of less than 7 ft/h and a placement height not exceeding 14 ft: P max = C w C c [ R/T] with a minimum of 600 C w lb/ft², but in no case greater than wh. For walls with a placement rate less than 7 ft/h where placement height excees 14 ft, and for all walls with a placement rate of 7 to 15 ft/h: The user and/or reader of this manual must check for available updates of the illustrated tables and values. Recommendations for concrete placement Concrete should be placed in layers, the thickness of which can vary from 18 to 4. Concrete must not be placed from great heights (exceeding 5 ) at free fall. When vibrating the concrete, which is done layer by layer, the vibrator must not penetrate more than 18 into the layer below. A final vibrating over the overall concrete height is not recommended. It does not provide any advantage, since concrete that has been vibrated once cannot be compacted further. This may result only in water bubbles (shrinkage cavities) on the concrete surface. Legend for equations: P max = max. lateral pressure (psf) DSI Taper tie, She-bolt: Technical data Taper tie 1 to 1-1/4 Safe working load [lbs] 32,500 She-bolt 7/8 Safe working load [lbs] 39,200 P max = C w C c [ ,400/T R/T] with a minimum of 600 C w lb/ft², but in no case greater than wh. DSI Thru-rod: Technical data Thru-rod 7/8 Safe working load [lbs] 39,200 R = rate of placement (ft/h) T = temperature of concrete ( F) C w = unit weight coefficient C C = chemistry coefficient I-13

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

15 Imperial 90 corner with standard panel Fig Fig Fig Fig IC OC Calculation of panel widths for 90º corner configurations Inside corner (side length 1 ) + wall thickness = panel 1 Fig The Imperial inside corner is provided with tie holes and consists of two parts. The steel face (protected with plastic coating) is replaceable. Only 2 assembly locks at each side are required to connect the inside corner to 2, 4 and 8 panels, whereas the 12 inside corner requires 3 assembly locks. The length of the sides is 1. For walls higher than 12 the amount and position of assembly locks must be directed by the technical department. Fig The Imperial outside corner and panels are connected with assembly locks. With extended formwork the amount and position of assem bly locks must be direct ed by the technical department. For 12 high outside corners 4 assembly locks on each side are required. 8 high out side corners require 3 assembly locks and for 2 and 4 high corners only 2 assembly locks on each side are sufficient. Description Ref.-No. Fig Fig IC OC panel 1 I-inside corners 12 x x x I-outside corners I-15

16 90 corner with standard panel The use of the 1, 2 and 3 fillers in conjunc tion with stand ard panels allows a wall width change in 1 increments. By using these fillers you can avoid the time consuming mounting of steel rails at the 90 corner. The connection in the filler area can be accomplished by the use of the Uni assembly lock 28, which spans up to 6 fillers. The locations of the locks will be indicated on the technical drawings. For panels with a height of 12 three Uni assembly locks 28 are required. 2, 4 and 8 high panels need two Uni assembly locks 28. Attention The diameter of the articulated flange nut has to span the width of the filler(s) for load transfer into standard panels (Fig ) OC Fig Fig filler 3 filler IC IC OC filler OC 1 filler IC IC 2 filler OC Fig Fig Description Ref.-No. Filler I fi ller 12 x x x x x x x x x x x x Uni assembly lock Detail Uni-assembly lock I-16

17 Imperial 90 corner with multi-purpose panel Fig Fig. 17.2: Column clamp The multi purpose panel can be used to form pilasters, corners, columns, bridge abutments and connections to existing walls. The panels have multiadjust ment profiles (Fig ) for mounting column clamps or ties. The 12 panels have 3 multi adjustment profiles, so you will need 3 column clamps. The 8 panel has 2 pro files, and there fore requires 2 clamps. The 4 and 2 panels have only 1 multi adjustment profile each and require only 1 column clamp. To tighten the Imperial column clamp a flange nut 100 (15 mm / 5/8 thread) is required. 1 7/16 1 7/16 to 1 9/16 conical Description Ref.-No. Fig. 17.3: Multi-adjustment profile I-multi-purpose panels 12 x x x x I-column clamp Flange nut I-17

18 90 corner with multi-purpose panel To form a 90 corner you can use a multipurpose panel (MPP) and an Imperial panel connected by a column clamp (see page 17, Fig. 17.2). This gives a tight, rectangular and rigid connection. The MPP fits for wall thicknesses up to 2 2 in 2 increments (Fig. 18.1). The addition of a 1 filler allows wall thickness changes in 1 increments (Fig. 18.2). At the maximum wall thickness the indexing stud will be installed in the last tie hole of the multiadjustment profile (see detail). WT Fig. 18.1: For even wall thicknesses IC Column clamp Flange nut 100 WT WT Tie 1 filler IC WT Column clamp Flange nut 100 Tie Fig. 18.2: For odd wall thicknesses Indexing stud Last tie hole of multi-adjustment profile Description Ref.-No. I-multi-purpose panels 12 x x x x I-column clamp Flange nut Detail I-18

19 Imperial Articulated corners Fig Wooden blocking AIC AOC Acute and obtuse angled corners are formed using Imperial articulated inside and outside corners. Steel rails are attached to the multi function profile at the tie hole elevation of the outside corner assembly to provide alignment. (In case of MPP, steel rails are attached to multi adjustment profile using threadbars or taper ties). If wooden fillers are used, the panel profiles are connected using Uni assembly locks. Side length of outside corner: 5 Side length of inside corner: 1 Adjustment range: 70º to 220º (Fig ). AIC AOC Fig Fig Description Ref.-No. I-steel rails Fig AIC AOC Wooden blocking Wooden filler with Uni-assembly lock 28 Steel rail Bolted with flange screw 18 and flange nut 100 to provide rigidity I-articulated outside corners 12 x x x I-articulated inside corners 12 x x x Uni assembly lock I-19

20 Articulated corners If the inside angle is 100º, steel rails and wooden blockings have to be used on the inside (Fig. 20.1). To determine the dimension (y) between the Imperial articulated outside corner and the first panel where a tie can be used, see chart below. If measures marked in white, watch concrete pressure and pouring rate. In all cases rails must be calculated specifically for each application. Fig AOC AIC α 100º y WT Description Ref.-No. I-steel rails I-articulated outside corners 12 x x x I-articulated inside corners 12 x x x Uni assembly lock Wall thickness Angle WT = 8 inches WT = 9 inches WT = 10 inches WT = 11 inches WT = 12 inches WT = 13 inches WT = 14 inches WT = 15 inches inches inches inches inches inches inches inches inches A = 70 y = 18.4 y = 19.9 y = 21.3 y = 22.7 y = 24.1 y = 25.6 y = 27.0 y = 28.4 A = 75 y = 17.4 y = 18.7 y = 20.0 y = 21.3 y = 22.6 y = 23.9 y = 25.2 y = 26.5 A = 80 y = 16.5 y = 17.7 y = 18.9 y = 20.1 y = 21.3 y = 22.5 y = 23.7 y = 24.9 A = 85 y = 15.7 y = 16.8 y = 17.9 y = 19.0 y = 20.1 y = 21.2 y = 22.3 y = 23.4 A = 90 y = 15.0 y = 16.0 y = 17.0 y = 18.0 y = 19.0 y = 20.0 y = 21.0 y = 22.0 A = 95 y = 14.3 y = 15.2 y = 16.2 y = 17.1 y = 18.0 y = 18.9 y = 19.8 y = 20.7 A = 100 y = 13.7 y = 14.6 y = 15.4 y = 16.2 y = 17.1 y = 17.9 y = 18.7 y = 19.6 A = 105 y = 13.1 y = 13.9 y = 14.7 y = 15.4 y = 16.2 y = 17.0 y = 17.7 y = 18.5 A = 110 y = 12.6 y = 13.3 y = 14.0 y = 14.7 y = 15.4 y = 16.1 y = 16.8 y = 17.5 A = 115 y = 12.1 y = 12.7 y = 13.4 y = 14.0 y = 14.6 y = 15.3 y = 15.9 y = 16.6 A = 120 y = 11.6 y = 12.2 y = 12.8 y = 13.4 y = 13.9 y = 14.5 y = 15.1 y = 15.7 A = 125 y = 11.2 y = 11.7 y = 12.2 y = 12.7 y = 13.2 y = 13.8 y = 14.3 y = 14.8 A = 130 y = 10.7 y = 11.2 y = 11.7 y = 12.1 y = 12.6 y = 13.1 y = 13.5 y = 14.0 A = 135 y = 10.3 y = 10.7 y = 11.1 y = 11.6 y = 12.0 y = 12.4 y = 12.8 y = 13.2 A = 140 y = 9.9 y = 10.3 y = 10.6 y = 11.0 y = 11.4 y = 11.7 y = 12.1 y = 12.5 A = 145 y = 9.5 y = 9.8 y = 10.2 y = 10.5 y = 10.8 y = 11.1 y = 11.4 y = 11.7 A = 150 y = 9.1 y = 9.4 y = 9.7 y = 9.9 y = 10.2 y = 10.5 y = 10.8 y = 11.0 A = 155 y = 8.8 y = 9.0 y = 9.2 y = 9.4 y = 9.7 y = 9.9 y = 10.1 y = 10.3 A = 160 y = 8.4 y = 8.6 y = 8.8 y = 8.9 y = 9.1 y = 9.3 y = 9.5 y = 9.6 A = 165 y = 8.1 y = 8.2 y = 8.3 y = 8.4 y = 8.6 y = 8.7 y = 8.8 y = 9.0 A = 170 y = 7.7 y = 7.8 y = 7.9 y = 8.0 y = 8.0 y = 8.1 y = 8.2 y = 8.3 A = 175 y = 7.3 y = 7.4 y = 7.4 y = 7.5 y = 7.5 y = 7.6 y = 7.6 y = 7.7 A = 180 y = 7.0 y = 7.0 y = 7.0 y = 7.0 y = 7.0 y = 7.0 y = 7.0 y = 7.0 Chart: Residual measure (y) I-20

21 Imperial Articulated corners Fig AOC AIC α 100º y WT If the inside angle is 100º, steel rails and wooden blockings are not required on the inside (Fig. 21.1). To determine the dimension (y) between the Imperial articulated outside corner and the first panel where a tie can be used, see chart below. If measures marked in white, watch concrete pressure and pouring rate. In all cases rails must be calculated specifically for each application. Wall thickness Angle WT = 16 inches WT = 17 inches WT = 18 inches WT = 19 inches WT = 20 inches WT = 21 inches WT = 22 inches WT = 23 inches WT = 24 inches inches inches inches inches inches inches inches inches inches A = 70 y = 29.9 y = 31.3 y = 32.7 y = 34.1 y = 35.6 y = 37.0 y = 38.4 y = 39.8 y = 41.3 A = 75 y = 27.9 y = 29.2 y = 30.5 y = 31.8 y = 33.1 y = 34.4 y = 35.7 y = 37.0 y = 38.3 A = 80 y = 26.1 y = 27.3 y = 28.5 y = 29.6 y = 30.8 y = 32.0 y = 33.2 y = 34.4 y = 35.6 A = 85 y = 24.5 y = 25.6 y = 26.6 y = 27.7 y = 28.8 y = 29.9 y = 31.0 y = 32.1 y = 33.2 A = 90 y = 23.0 y = 24.0 y = 25.0 y = 26.0 y = 27.0 y = 28.0 y = 29.0 y = 30.0 y = 31.0 A = 95 y = 21.7 y = 22.6 y = 23.5 y = 24.4 y = 25.3 y = 26.2 y = 27.2 y = 28.1 y = 29.0 A = 100 y = 20.4 y = 21.3 y = 22.1 y = 22.9 y = 23.8 y = 24.6 y = 25.5 y = 26.3 y = 27.1 A = 105 y = 19.3 y = 20.0 y = 20.8 y = 21.6 y = 22.3 y = 23.1 y = 23.9 y = 24.6 y = 25.4 A = 110 y = 18.2 y = 18.9 y = 19.6 y = 20.3 y = 21.0 y = 21.7 y = 22.4 y = 23.1 y = 23.8 A = 115 y = 17.2 y = 17.8 y = 18.5 y = 19.1 y = 19.7 y = 20.4 y = 21.0 y = 21.7 y = 22.3 A = 120 y = 16.2 y = 16.8 y = 17.4 y = 18.0 y = 18.5 y = 19.1 y = 19.7 y = 20.3 y = 20.9 A = 125 y = 15.3 y = 15.8 y = 16.4 y = 16.9 y = 17.4 y = 17.9 y = 18.5 y = 19.0 y = 19.5 A = 130 y = 14.5 y = 14.9 y = 15.4 y = 15.9 y = 16.3 y = 16.8 y = 17.3 y = 17.7 y = 18.2 A = 135 y = 13.6 y = 14.0 y = 14.5 y = 14.9 y = 15.3 y = 15.7 y = 16.1 y = 16.5 y = 16.9 A = 140 y = 12.8 y = 13.2 y = 13.6 y = 13.9 y = 14.3 y = 14.6 y = 15.0 y = 15.4 y = 15.7 A = 145 y = 12.0 y = 12.4 y = 12.7 y = 13.0 y = 13.3 y = 13.6 y = 13.9 y = 14.3 y = 14.6 A = 150 y = 11.3 y = 11.6 y = 11.8 y = 12.1 y = 12.4 y = 12.6 y = 12.9 y = 13.2 y = 13.4 A = 155 y = 10.5 y = 10.8 y = 11.0 y = 11.2 y = 11.4 y = 11.7 y = 11.9 y = 12.1 y = 12.3 A = 160 y = 9.8 y = 10.0 y = 10.2 y = 10.4 y = 10.5 y = 10.7 y = 10.9 y = 11.1 y = 11.2 A = 165 y = 9.1 y = 9.2 y = 9.4 y = 9.5 y = 9.6 y = 9.8 y = 9.9 y = 10.0 y = 10.2 A = 170 y = 8.4 y = 8.5 y = 8.6 y = 8.7 y = 8.7 y = 8.8 y = 8.9 y = 9.0 y = 9.1 A = 175 y = 7.7 y = 7.7 y = 7.8 y = 7.8 y = 7.9 y = 7.9 y = 8.0 y = 8.0 y = 8.0 A = 180 y = 7.0 y = 7.0 y = 7.0 y = 7.0 y = 7.0 y = 7.0 y = 7.0 y = 7.0 y = 7.0 Chart: Residual measure (y) Description Ref.-No. I-steel rails I-articulated outside corners 12 x x x I-articulated inside corners 12 x x x Uni assembly lock I-21

22 Columns Columns with multipurpose panels The multi adjust ment profile allows to form columns (see Fig and 22.2) in increments of 2, in a size range from 2 to 3 2. To form columns with odd dimensions the column form should be furred out at the inside. At the maximum column size the indexing stud will be installed in the last tie hole of the multiadjustment profile (see detail). Columns with standard panels (Fig and 22.4) See page 23. Fig Column clamp Flange nut 100 Indexing stud Last tie hole of multiadjustment profile Fig Capacity The admissible fresh concrete pressure is of 2,025 psf for both types of columns. Detail OC OC Description Ref.-No. I-multi-purpose panel 12 x x x x I column clamp Flange nut OC OC Fig Fig I-22

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

24 Length compensation Filler Gaps up to 3 can be formed with 1, 2 and 3 fillers without additional steel rails (Fig. 24.1). Wooden filler An alternate method of forming gaps is with the use of wooden job built fillers. With job-built fillers a steel rail is required across the joint at the tie hole elevations (Fig. 24.2). The Uni assem bly lock will span a maximum gap of 6 (Fig and Fig. 24.4). Fig filler 3 filler Timber profile In penetration areas, an alkus plastic sheet or plywood is cut to size and nailed to the timber profiles connected to the adjacent panel by assembly locks. At all filler locations, substitute Uni assembly locks for the standard assembly lock (Figs and 24.6). Timber profiles are always delivered in pairs. Fig Fig Fig Fig Description Ref.-No. I-timber profiles* * delivered in pairs Uni assembly lock Fig. 24.5: Simplified drawing (steel rails not shown for clarity) I-24

25 Imperial IC OC Fig. 25.1: Design by technical department Fig. 25.2: Tie location at the edge of the panel (panels up to 4 wide) Fig. 25.3: Tie location inside the panel (8 wide panels) Steel rail 4 Steel rail 4 Steel rail 6 Length compensation Compensation areas are reinforced with steel rails, which must always be attached to the multi function profile at tie hole elevation. The maximum filler width (L) for applications with standard panels up to 4 wide (Fig. 25.2) can be determined using the chart below, depending on the concrete pressure and the kind of steel rail used (the maximum pressure is 2,025 psf). Attention When 8 wide panels have a filler between them, the maxi mum filler width must not exceed 12 (Fig. 25.3). Please note When fillers are located near outside corners or bulkheads, the horizontal tensile force must always be considered. In this case, fasten the steel rail with flange screws on both sides of the filler (Fig and Fig. 25.3). Fig. 25.4: Standard application with smaller wooden filler I mperial steel rail Max. compensation width L [inches] (Steel rail attached to the multi function profile at hole elevation) Concrete pressure 2,025 psf Concrete pressure 1,400 psf 4 ' L = 30" L = 30" L = 30" 6 ' L = 30" L = 34" L = 37" 12' L = 49" L = 56" L = 61" Chart: Max. compensation width when using Imperial steel rails tie Concrete pressure 1,200 psf Description Ref.-No. I-steel rails Uni assembly lock I-25

26 Bulkheads Bulkheads can be formed using bulkhead brackets (Fig and Fig 26.2) or column clamps plus steel rails (Fig. 26.3). The column clamps and the rails are instal led at tie hole elevation. The tieing is achieved in placing Uni tie claws and thread bars or taper ties (Fig.26.6 and Fig. 26.7) below the tie loca tions. The bulkhead bracket can replace a tie and can take shear as well. Bulkhead bracket 60/23 for a wall thickness up to 30. Bulkhead bracket 40/60 for a wall thickness up to 16. Up to wall thickness of 30 Fig Bulkhead bracket Fig Wall thickness Chart 26.4 Amount of bulkhead brackets per 8 high form Attention Never use thread bars or taper ties for bulkheads if these ties are going to be subjected to shearing stress. Wall thickness Amount of bulkhead brackets per 12 high form Fig Chart 26.5 Flange nut 100 Description Ref.-No. Bulkhead bracket 60/ Bulkhead bracket 40/ I column clamp Flange screw Uni tie claw Uni-tie claw Column clamp Steel rail Fig Fig I-26

27 Imperial see Detail A Articulated flange nut Fig Wooden blocking IC see Detail B Articulated flange nut Wooden blocking Fig. 27.2: Clamped together with Uni-assembly locks 0 to 4 4 to 8 Wall offset One sided wall off sets of up to 4 are formed by moving back the corresponding panel (Fig. 27.1). For offsets exceeding 4, inside corners should be used (Fig. 27.2). The offset sections of the wall formwork are reinforced by steel rails. Wall offsets from 8 up to 36 can be formed with multipurpose panels (Fig. 27.3). Panels arranged offset from each other are connected by means of Uni assembly locks 28 (see details). IC IC Fig Detail A Uni-assembly lock Detail B Description Ref.-No. Corner bracket I-27

28 T-wall connection Connection is accom plished by using two inside corners. Different wall thicknesses are compensated for by means of the 1, 2, 3 or wooden fillers (Fig Fig. 28.4). For details about load bearing capacity of Imperial steel rails see page 25. Fig Standard panel Standard panel Filler IC IC IC IC Fig Fig Steel rail Wooden filler Description Ref.-No. I-filler 12 x x x x x x x x x x x x Uni assembly lock Fig IC IC I-28

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

30 Pilasters Pilasters are easily formed using inside corners, standard panels, and where necessary some wooden blocking (Fig. 30.1, Fig. 30.2). Bulkhead bracket Wooden blocking Attention For conditions simi lar to Figs and 30.4 the following quantities of assem bly locks at outside corners are required per joint: 4 high: 2 locks 8 high: 3 locks 12 high: 5 locks Above 12, one assembly lock per 1 6 in height. For heights exceeding 16 refer to page 23. Fig IC IC IC IC Multi-purpose panel Column clamp Fig OC OC IC IC Fig OC OC OC OC Stripping corner Fig I-30

31 Imperial Pilasters at corners IC Flange nut 100 Column clamp Pilasters at corners can also be formed using multi purpose panels (Fig. 31.1). To avoid interference with opposing ties, the multi purpose panels opposite each other need to be raised 2 using lumber soffits. By using fillers and blockouts a wide variety of pilasters can be formed (Fig. 31.2). IC OC Fig Blockout IC Flange nut 100 Column clamp Filler IC Description Ref.-No. OC Fig I-multi-purpose panel 12 x x x x I column clamp Flange nut I-31

32 Pilaster panel The pilaster panel (Fig and 32.2) is a combination of a hinged corner and a multi-purpose panel. It allows forming pilasters without having a tie going through the pilaster. Using a standard panel in combination with the column clamp as bulkhead allows forming pilasters with a depth from 4 to 1-8 in a 2 increment (Fig. 32.3). When using a standard panel and a bulkhead bracket, pilasters with a depth of 2-1 1/4 are possible (Fig. 32.4). Together with plywood, wood and a bulkhead bracket it allows forming pilasters with a depth up to 2-2 (Fig. 32.5). If a standard panel in combination with outside corners is used as bulkhead, it is possible to form pilasters with a depth of 2-6 (Fig. 32.6). Fig Fig Fig Fig Description Ref.-No. 2-6 I-pilaster panel I column clamp Bulkhead bracket 60/ Flange nut Fig Fig I-32

33 Imperial Pilaster panel Fig min. 4 max. 20 Wall offsets can also be formed with pilaster panels. The minimum offset is 4 (Fig. 33.1), the maximum offset is 20 (Fig. 33.2). Offsets at T-wall situations can be formed with pilaster panels as well. Combined with a 2 filler, offsets can be formed in 2 increments (Fig. 33.3). If 1 or 3 fillers are used, offsets can be formed in 1 increments (Fig. 33.4). Fig Fig filler Description Ref.-No. I-pilaster panel Fig filler I column clamp Bulkhead bracket 60/ Flange nut I-33

34 Differences in height The assembly lock can be attached at any position on the frame profile, so the formwork needs no connection grid and requires no additional accessories for assembly (Fig. 34.1). Vertical, horizontal and even inclined panels can all be safely connected by means of assembly locks, even with differences in height. Job built fillers are made with timber profiles and an alkus plastic sheet or plywood cut to size. When required, use a square timber for reinforcing. The timber profiles and panels are simply connected to each other with assembly locks. The wood filler areas need special attention (see page 24 and 25). The use of rails and/ or blocking may be required (Fig. 34.2). Fig Timber profile Timber profile Fig I-34

35 Imperial Panels in horizontal position A lot of forming problems can be easily solved by arranging panels horizontally (Fig. 35.1). These include basin walls in water treat ment plants, which often require a certain height, or when formwork height is restricted by an existing structure, or for single sided formwork. When the panels (width up to 4 ) are arranged horizon tally, replace the bottom tie by a foun dation spanner to geth er with a foun dation tape (Fig. 35.1). You can also use multi purpose panels to form foundations (Fig. 35.2). On top of the formwork use Uni tie claws for above tieing. Uni-tie claw Foundation spanner with foundation tape Fig. 35.1: Example of a typical foundation formwork Fig. 35.2: Example of a typical foundation formwork with multi-purpose panel Description Ref.-No. M foundation spanner Foundation tape I-35

36 Attachement of accessories All panels are provided with multifunction profiles. Dywidag threaded nuts are welded inside the profile (Fig. 36.6). The difference be tween these multi function profiles and the stiffeners is that the multi function profile allows for attachment of forming accessories. Fig Scaffolding brackets are provided with self locking pins (Fig. 36.2) and thus can be mounted on the multi function profile. The scaffolding bracket can be secured with a flange screw 18 (Fig. 36.3). Fig Steel rails must be attached to the multifunction profile at tie hole elevation to ensure proper load transfer (Fig. 36.5). Wall braces are attached to the panels by using the formwork prop connector and a flange screw 18. Formwork can be protected against uplift by using a small brace, attached to the panel with the formwork prop connector as shown in Figs and 36.4, or by the use of a shoe plate. Fig. 36.4: Formwork-prop connector Fig Fig Cross stiffener Multi-function profile at tie hole elevation Fig Multi-function profile I-36

37 Imperial Tie-off bar / Bump notch Tie-off bar Imperial panels come with welded tie-off bars allowing easy and safe access to the form (Fig and Fig.37.2). Fig. 37.2: Tie-off bar Bump notch Larger selected Imperial panels come with an in te grated bump notch. The bump notch along with a pry bar allows easy move ment of the panels on slab or ground elevation (Fig. 37.3). Attention When working with formwork observe all appli cable codes and re gulations. Fig Fig. 37.3: Bump notch I-37

38 Crane ganging In order to provide the necessary flexural rigidity when lifting and laying down gangs, steel rails are mounted by means of flange screws. For gangs with horizontally assembled panels on top, the crane hook must be attached above the horizontal profiles so that the crane hook cannot disengage. If the total weight of the gang exceeds 6,600 lbs, more than two crane hooks are needed. For further detail see page 56. Fig. 38.1: Standard application max. 60 max. 60 Vertical steel rails are required to avoid flexing between panels. The 6 and 12 steel rails must always be attached with 4 flange screws (Fig. 38.3, 39.1). The 4 steel rail can be mounted with 2 flange screws (Fig. 38.2, 38.4), in these particular applications. max. 60 Fig max. 60 Horizontal steel rails also avoid flexing between panels, and are used to keep gangs in line. For horizontal use the 4 steel rail is attached with 2 flange screws above a panel joint (Fig. 38.3, 39.1). For cases not addressed in this manual please consult the technical department. Fig Fig I-38

39 Imperial Crane ganging Fig Gang 12 x 8 = 96 sq.ft. Weight: 1,233 lbs. max. 60 Fig Gang 12 x16 = 192 sq.ft. with two 4 steel rails Weight: 2,596 lbs. Fig Gang 16 x18 6 = 296 sq.ft. with two 12 steel rails and one 4 steel rail Weight: 4,550 lbs. Fig Gang 8 x12 = 96 sq.ft. with one 4 steel rail Weight: 1,373 lbs. Fig Gang 16 x28 = 448 sq.ft. with four 6 steel rails and two 4 steel rails. Weight: 6,598 lbs. Fig The tie-off bar allows safe working on the formwork. Under no circumstances should panels be lifted or moved using these tie-off bars. I-39

40 Working plattform BKB 125 Folding access platform BKB 125 The ready made folding access platform BKB 125 unfolds quickly and provides a safe access and working scaffold. The 2 thick planks have a rough surface and a metal lining at the edges. The platform length of 7 8 1/2 makes the BKB 125/235 trucktransportable, as they fit crosswise on any truck. When stacked, the BKB 125 is only of 6 1/2 high (Fig Fig. 40.5). Permissible load: 42 psf. The side railing can be mounted at a 90 or 105 angle (Fig. 40.4). Two flange screws 18 are required to attach the side railing to the platform. 1-7 Suspension point 1-1 Fig The access platform is automatically secured against displacement by the integrated self-locking mechanism. Fig Attention Do not fly formwork units when the platform BKB 125 is attached to the formwork. When using our products the federal, state and local codes and regulations must be observed. Fig Fig Examples of application for corner configurations and length adjustment Side railing BKB 125 as side protection Residual measure Side railing BKB 125 as rear protection when using the BKB 125/140 for length adjustment Gap closed on site by compensation platform Description Ref.-No. Folding access platform BKB 125/ BKB 125/ BKB 125/ Side railing BKB Fig I-40

41 Imperial Scaffolding bracket Working platform Handrail (min. 2 x4 ) /4 18 3/4 Fig Midrail (min. 1 x6 ) Toe board (min. 1 x4 ) Platform min. 20 Scaffolding bracket (with self-locking pin) The scaffolding bracket is mounted to a multi function profile which is not at tie hole elevation. To insert the bracket turn it by 45, then turn it back to vertical position and secure it with a flange screw (Fig 41.2). After that, planks can be bolted to the brackets. For bracket spacings with an assumed load of 25 psf (including deck) see charts. Working groups specified by OSHA Working group Chart 1 Minimum platform width (inch) Fig Surface related loads (psf) Workers only, no material Side railing If the fall height is > 6 a side railing consisting of handrail, midrail and toe board is required (workers only, no material). Guard-railing post 100 is attached to the scaffolding bracket 125 or 90. For thickness and height of rails/boards see Fig Admissible bracket spacing (ft) for platforms made of wooden planks or boards Working group Plank or board width (inch) Plank or board thickness (inch) 1 1/4 1 1/2 1 3/4 2 Description Ref.-No. Chart 2 Workers only, no material Scaffolding bracket Scaffolding bracket Guard railing post Side railing 90/ Side railing 125/ I-41

42 Wall braces / Working scaffolds Wall braces are attached to the multifunction profiles by formwork prop connectors and flange screws. For adjustment range, weight, adm. pressure and tensile forces of wall braces please see table Detail: Shoe plate Guard-railing post Scaffolding adapter Scaffolding bracket Detail: Scaffolding adapter Brace frame 250 consists of push pull prop R 250, brace SRL 120 and doublejointed foot plate. Anchoring 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. Working scaffolds To provide a safe and roomy working platform you can either use two scaffolding brackets (Fig. 42.1) or a combination of a scaffolding bracket and the scaffolding adapter (Fig. 42.2). Description Ref.-No. Push-pull prop R R R R Braces SRL SRL Articulated foot plate Formworkprop connector Scaffolding adapter Shoe plate Shoe plate anchored to the ground Shoe plate Fig. 42.1: Guard-rail system 1 (controlled access zone) Description Ref.-No Adjustment range ft (m) Braces SRL SRL to 4-11 (0.90m 1.50m) SRL to 7-3 (1.20m 2.20m) Braces RSK RSK to 4-11 (0.90m 1.50m) RSK to 7-3 Push-pull props R (1.20m 2.20m) R to 6-6 (1.35m 2.00m) R to 10-5 (1.90m 3.20m) R to 17 (3.40m 5.20m) R to Tab (5.10m 7.60m) Push-pull prop Adm. pressure lbf(kn) 4,495 lbf (20.0kN) 5,620 lbf (25.0kN) 11,240 lbf (40.0kN) 11,240 lbf 4,495 lbf (40.0kN 20.0kN) 5,620 lbf (25.0kN) 5,620 lbf (25.0kN) 4,495 lbf (20.0kN) 2,100 lbf (9.5kN) Fig. 42.2: Guard-rail system 2 (controlled access zone) Adm. tensile force lbf(kn) 6,745 lbf (30.0kN) 11,240 lbf (40.0kN) 11,240 lbf (40.0kN) 11,240 lbf (40.0kN) 5,620 lbf (25.0kN) 6,745 lbf (30.0kN) 6,745 lbf (30.0kN) 5,620 lbf (25.0kN) Weight lbs(kg) 13.2 lbs (8.3kg) 23.2 lbs (10.5kg) 24.3 lbs (11.0kg) 26.5 lbs (12.0kg) 24.3 lbs (11.0kg) 40.8 lbs (18.5kg) 78.9 lbs (35.8kg) lbs (68.0kg) Recommended area of application Horizontal and vertical alignment; can be used in combination with push-pull props Horizontal and vertical alignment; can be used in combination with push-pull props Horizontal and vertical alignment; can be used in combination with push-pull props Horizontal and vertical alignment; can be used in combination with push-pull props Horizontal and vertical alignment; for wall heights up to 8 Horizontal and vertical alignment; for wall heights up to 14 Horizontal and vertical alignment; for wall heights up to 20 Horizontal and vertical alignment; for wall heights up to 30 I-42

43 Imperial Free fall height < 6 Fig. 43.1: Guard-rail system 3 (fall arrest system) Fig. 43.2: Guard-rail system 4 (fall restraint system) Free fall height < 6 Wall braces / Working scaffolds The scaffolding adapter without guard rail offers the possibility to attach lifelines and lanyards (Fig and Fig. 43.2). Braces for high walls For forms exceeding 30 in height we re com mend using Triplex (reinforced braces specially designed for heavyduty use). Attention When using our products the federal, state and local codes and regulations must be observed. Lifeline Lanyard Scaffolding adapter Detail: Lifeline with lanyard Distances between wall braces For formwork alignment 12' For transfer of wind loads 8' Description Ref.-No. Push-pull prop R R R R Braces SRL SRL Articulated foot plate Formworkprop connector Scaffolding adapter Shoe plate I-43

44 Stripping corner The stripping corner allows gangs for elevator shafts and core walls to be set and stripped without disassembling the gangs (Fig and 44.2). The stripping corner is designed with three pieces to permit inward movement when a turnbuckle connection is retracted. Minimal crane time is required because the stripping corners turn all sides of the gang into one moveable unit. After resetting the gang for the next pour, the turnbuckles return the gang form to the rectangular shape. Stripping corners allow easy stripping of gangs adjacent to corners or pilasters (Fig. 44.3). Fig Fig Fig Description Ref.-No. I-stripping corner 8 x x Detail: expanded Detail: retracted I-44

45 Imperial Folding shaft formwork Fig ➂ ➄ ➃ ➁ ➀ ➅ ➀ ➁ ➂ ➃ ➄ ➅ Outside corner Articulated outside corner Inner reinforcement with steel rails or squared timbers attached to the multi-function profile Articulated inside corner Braces SRL or sqared timbers and tensioning chains Imperial panel The various shaft dimensions are formed with standard panels; if necessary length com pen sations are performed according to the examples shown on pages 24 and 25. Minimum shaft dimensions: 5 1 x 5 1 (without reinforcing rails being taken into consideration). Inner formwork Articulated inside corners are used to form the angles, whereas the hinged outside corners are inserted between the panels in the straight section (Fig. 45.1). This kind of assembly allows a star shaped contraction of the complete inner formwork. 7 1/2 Fig. 45.2: Combi-connector (reversible) or Fig universal joint connector and Combi-lock with coupling Brace Adjustment range Inner shaft dimensions* SRL to to /4 SRL to /4 to 9 2 1/4 * taking reinforcing rails into consideration Dismantling After removing the ties and steel rails, the inner formwork is contracted by means of SRL braces. The crane can now lift the complete inner core and move it to the next place of application (Fig. 45.3). Universal joint connector The universal joint connector (Fig. 45.2) provides the lateral displacement of Combilock and brace while contracting the inner formwork. Description Ref.-No. Combi lock Universal joint connector Combi connector (reversible) I-45

46 Assembly and stripping (general) Planning stage Reasonable planning and preparation are the keys to a successful application 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 dismantling, 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 these aspects have been considered, the quantities of formwork items can be specified. Assembly area The area where the formwork is set should be clean, even and capable of taking the expected load. Formwork 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. 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 preassembly. Don t forget to spray the alkus face with release agent. Panel connection In general the 4 and 8 high panels are connected at the vertical joint using 2 assembly locks, while 12 high panels are connected with 3 assembly locks. Exception: outside corners are connected to the adjacent panels as follows: outside corner 4 high: 2 assembly locks, outside corner 8 high: 3 assembly locks, outside corner 12 high: 5 assembly locks. Fig Fig Filler for easy stripping I-46

47 Imperial Assembly and stripping (general) Formwork height = 8 Fig Scaffolding bracket 90 or 125 Push-pull prop with formwork-prop connector; attachment to the multi-function profile by flange screw Safe attachment of the scaffolding bracket by means of a flange screw 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. (Fig. 47.1) The spacing of braces is described on page 43. Working scaffold Scaffolding brackets are attached quickly with their integrated self locking pins. The brackets are the basic item for the working scaffold. The walkboards can be bolted to the scaffolding brackets. The walkboards must not be placed on the scaffolding brackets before: 1. the braces are attached to the formwork, and 2. all ties are placed, connecting the two sides of the formwork. For planning and installation of the brackets see details on page 41. Closing the formwork After setting and bracing the outside formwork: mark the pouring height install blockouts and reinforcement when using threadbars install a tie in all tie locations install PVC sleeves over the ties set the inside formwork tighten the formwork, using either standard or articulated flange nuts on both sides of the tie. Stripping When short wall sections ( 20 ) are involved, be sure to install a filler, or if possible use stripping corners while assemb ling the formwork (Fig and 46.2). 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 scaffold and braces prior to dismantling the panels. If the formwork is handled by crane, working scaffold 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). Safety regulations When using our products the federal, state and local codes and regulations must be observed. I-47

48 Assembly and stripping of gangs (exemplary) I. Unloading and assembly 1. For unloading panels from a truck, a stack at a time, use the crane slings 60. The stacks usually come with panels face up (Fig. 48.1). 2. Lift one panel at a time and lay it down (face up) on square timber. 3. Remove the crane slings 60 and attach crane hooks. 4. Lift and turn the panel by 180 and put it down again on the square timber face down. 5. Arrange all the panels you need for the gang in that manner and attach the assembly locks and steel rails. 6. Mount the scaffolding brackets and braces. Fig Fig I-48

49 Imperial Assembly and stripping of gangs (exemplary) II. Lifting and setting 1. For lifting the gang use at least 2 crane hooks plus standard crane slings (supplied by contrac tor (Fig. 48.2)). 2. Lift the gang to upright position and spray the alkus face with release agent (Fig. 49.1). 3. Move the gang into place and immediately anchor the braces to the ground. 4. Remove the crane hook. 5. Proceed with the other gangs in the same way (Fig. 49.2). Fig Fig I-49

50 Assembly and stripping of gangs (exemplary) III. Closing the formwork The opposite formwork is assembled the same way as described before. For this formwork, however, you may not necessarily need braces. Attention: Do not remove crane hooks until both sides of the formwork are sufficiently secured with ties. I-50 Fig Fig a) Closing with DWthreadbars 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 constant wall thickness (Fig and 50.2). b) Closing with taper ties 1. Lift and move second formwork into place. 2. Insert the taper ties and adjust them to the required wall thickness. Secure the ties on both sides with flange nuts. c) Closing with shebolts or steel cones Please consult technical department for details.

51 Imperial Assembly and stripping of gangs (exemplary) IV. Pouring See pages 41 ff. for safety advice for work e rs on platforms (Fig. 51.1). Observe all federal, state and local codes and regulations for pouring concrete. Attention: The admissible fresh concrete pressure of 2,025 psf must not be exceeded. Fig V. Stripping and dismantling Do not start stripping until the concrete has set to the point where it cannot deform anymore. Always start with the second side of the formwork (the one without braces). 1. Mount the crane hooks to the gangs, attach the standard crane slings and pull them tight. 2. Remove the ties and assembly locks. 3. Pull the gang up vertically (Fig. 51.2). 4. Move the gang to the next pour or a temporary storage, or dismantle it (as required). 5. If heavily soiled you might need to clean the panels and spray them with release agent before the next use. Fig Attention: All personnel must be OFF the formwork when moving gangs by crane. Make sure to remove all loose objects (such as concrete remnants, tools, etc.). I-51

52 Crane slings Stapos 60 Crane slings made of polyester tape with double sided textile coating. The load bearing capacity is stamped on the coating. The sling is provided with a galvanized selflocking fastening device. 4 crane slings 60 are needed to move and transport panel stacks. They loop securely to the four corners (Fig. 52.1). Fig Fig Handling Place the panel stack on square timbers (Fig. 52.2). First, push the suspension device under the stack with your foot (Fig. 52.3). Then yank the sling up (Fig. 52.5). The elastic fastening pin will engage completely in the profile groove and secure the stack against accidental uplift (Fig. 52.4). Fig Fig Description Ref.-No. Crane slings Stapos Fig I-52

53 Imperial Crane slings Stapos 60 While transporting the stack by crane the load bearing capacity is uniformly distributed to all slings. Just one person is required for attachment and removal of the slings. Fig Attention The Stapos crane slings may be used only in conjunction with double rope crane devices in compliance with applicable safety regulations. If panel width exceeding 6 6 a four rope crane device is imperative (Fig. 53.1). To calculate the admissible loadbearing capacity assume only 2 slings. Technical data Description Crane slings Stapos 60 Ref. No Weight Color Adm. load bearing capacity Adm. stack weight 7.1 lbs blue per sling 2,200 lbs 4,400 lbs For frame profile width 2 3/8 Max. stack height Max. stack height for large size panels 10 panels Imperial 8 x8 = 5 panels Imperial 12 x8 = 3 panels I-53

54 Lifting hook 60 / Crane slings 60 Transport device consisting of crane slings 60 and lifting hook 60 The transport device (Fig and 54.3) helps to quickly load and unload trucks and move the stacks near the ground. The lifting hooks are inserted into the welded sleeves of the bottom panel frame. Lifting hook The lifting hook can be used with any four rope crane device available on the construction site to transport stacks of panels (always use 4 hooks at a time). To calculate the admissible loadbearing capacity assume only 2 hooks. Attention After tightening the device check to make sure the hooks are safely locked (Fig. 54.2). Fig Fig Description Ref.-No. Crane slings Lifting hook Fig I-54

55 Imperial Lifting hook 60 / Crane slings 60 Technical data Crane slings 60 for Imperial stack height: 5 panels of 8 width or 10 panels of less than 4 width Weight: 48.5 lbs Max. load bearing capacity: 4,400 lbs Ref. No Lifting hook 60 Weight: 3.8 lbs Max. load bearing capacity: 2,200 lbs Ref. No Transport When transporting several panels at a time, the stack must be secured against dis place ment using a tensioning belt or two Dywidag rods with flange nuts. Fig Maintenance The eccentric part of the lifting hook must rotate under its own dead weight. If necessary, clean and grease the lifting hook. A drilled hole is provided for this; or it can be greased with a nipple. Inspection The lifting hook/ crane slings must be regularly checked (at least once a year) by an expert. In addition, the user must check it during use for obvious damage. Fig Description Ref.-No. Crane slings Lifting hook I-55

56 Crane hook The admissible load of a crane hook (Fig. 56.1) is 3,300 lbs (Safety factor: 5:1 against failure) The handling is very simple: Open the safety lever as far as possible (Fig. 56.2). 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. 56.3). When moving gangs (Fig. 56.4), 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. For more illustrations see pages 38 and 39. Attention If the reference dimension exceeds 2 13/32 the crane hook must be replaced immediately. (Fig. 56.5) Replace it even if only one side of the hook exceeds this dimension. Safety regulations When using our products the federal, state and local codes and regulations must be observed. Fig Fig Fig Safety tips Always check the crane hook before use. Do not over load the crane hook. Overloading causes damage. Fig Reference dimension Description Ref.-No. M-crane hook Fig I-56

57 Imperial Single-sided formwork Support frame STB The Imperial formwork together with support frames can also be applied when concrete has to be poured against an existing wall or the like, i.e. when a single sided formwork is required. Support frames 300 are good for wall heights up to 12. Support frames 450 with height extensions allow for wall heights over 30. Technical data sheets are available on request. Climbing formwork Climbing scaffold KLK 230 When forming high walls, facades, pillars, staircases or elevator shafts, Imperial formwork is set and secured on climbing scaffolds KLK 230. Technical data sheets are available on request. Attention The use of support frame and climbing scaffold requires a detailed formwork planning! I-57

58 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. 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. 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 I-58