PRODUCT DESIGN AND SELECTION GUIDE REVOLUTIONISING CONCRETE LIFTING

Transcription

1 REVOLUTIONISING CONCRETE LIFTING PRODUCT DESIGN AND SELECTION GUIDE PRECAST CONCRETE, TILT WALL CONSTRUCTION, CIVIL ENGINEERING & DEMOLITION LIFTING SYSTEMS

2 Contents Page Section Introduction Obelix Lifting Systems... 4 Section 2.0 -Tilt Wall Lifting Systems Installation Instructions... 5 Tilt Wall Lifting Clutches... 6 Tilt Wall Void Former Assemblies... 7 Tilt Wall Void Former Extension Chairs... 8 Plastic Finishing Caps... 9 Tilt Wall Lifting Accessories Tilt Wall Void Former Assembly Configurations Tilt Wall Void Former Installation Details Section 3.0 Precast Erection Systems Installation Instructions Precast Erection Lifting Clutches Precast Erection Void Formers Precast Erection Void Former Retainers Void Former Retainer Extraction Tool Plastic Finishing Caps Precast Lifting Accessories Precast Erection Installation Details 6.5T Edge Lift Precast Erection Installation Details 10.0T Edge Lift Component Reinforcement PRODUCT DESIGN AND SELECTION GUIDE I

3 Contents Page Section 4.0 Civil Construction Systems Installation Instructions Civil Construction Lifting Clutches Civil Construction Void Formers Civil Construction Void Former Retainers Void Former Retainer Extraction Tool Plastic Finishing Caps Civil Construction Lifting Accessories Civil Construction Void Former Installation Details Edge Lift Civil Construction Void Former Installation Systems Face Lift Component Reinforcement Section 5.0 Demolition Lifting Systems Installation Instructions Demolition Installation Details Demolition Lifting Clutches Demolition Under-Cutting Tools Plastic Finishing Caps Section 6.0 Technical Details Section 7.0 Notes

4 SECTION INTRODUCTION OBELIX Lifting System Obelix Lifting Systems Pty Limited is an Australian Owned and operated company which manufactures products specifically designed for concrete lifting applications both in precast construction and in the removal or demolition of existing concrete structures. Since 2011 the fully patented Obelix product systems have been successfully used by every major contracting company in Australia. The award winning Obelix Lifting System is safe, fast and cost effective. It provides a new approach to handling concrete in a broad range of Civil Engineering, Precast Construction and Demolition applications. The Obelix Lifting Clutches The key to the system is the patented Obelix Lifting Clutch which consists of mechanical fingers, a lifting eye, and a high tensile steel shaft. The re-useable Obelix Lifting Clutch is designed for use by insertion into an undercut concrete void. The mechanical fingers wedge against the concrete when the clutch is inits engaged position, enabling the load to be distributed over a wide area of concrete. The Obelix Clutch can only lift when the cone and lifting fingers are fully engaged by the hand operated latch mechanism, and once the clutch is engaged it cannot disengage whilst under load. It s all about safety. The Obelix Void Formers Lifting voids are formed into concrete elements by casting geometrically precise Obelix Void Formers at the prearranged lifting locations. The extensive Obelix product range includes application specific Void Formers each system being optimally engineered to provide unique, safe and cost effective solutions for a wide range of lifting needs. Such specific systems include general face lifting and edge lifting systems for the Precast and Civil Engineering industries and unique product solutions for face lifting applications in the Tilt Wall industry. Obelix Void former components are manufactured from inherently corrosion resistant engineered plastics. With the Obelix Systems no corrosion susceptible metal parts remain in the parent concrete element thus ensuring that corrosion is never an issue even over extended periods in the most severe environments. Conformance All Obelix Lifting product systems have been extensively and independently tested and certified in accordance with relevant international standards and performance criteria. Obelix Lifting Clutches have been fully mechanically tested certified by NATA (National Association of Testing Authorities) accredited testing laboratories in accordance with Australian and International Standards. 4 PRODUCT DESIGN AND SELECTION GUIDE I

5 SECTION TILT WALL SYSTEMS OBELIX Lifting System Tilt Wall The prime element of the Obelix Lifters Tilt Wall System is the unique, fully certified, patented and reusable Obelix Lifting Clutch 6.5T x 120mm. Installation of the Lifting Clutch requires the forming of a precise under-cut void that is cast in-situ using pre assembled Obelix Tilt Wall Void Former Assemblies and where required Void Former Extension Chairs. Fig 2.0 Installation Instructions Obelix Tilt Wall Lifting Systems. STEP 1 Select appropriate Obelix Void Former and insert Retainer. (Screw anticlockwise) STEP 5 Insert and engage the Obelix Lifting Clutch. STEP 2 Select appropriate Void Former Chair and attach. STEP 6 Attach lifting hooks. STEP 3 Locate assembly in panel, tie back to rebar and place concrete. STEP 7 Lift. STEP 4 After curing and prior to lifting, remove Retainer by unscrewing (Clockwise). STEP 8 On completion of lift disengage and remove Obelix Lifting Clutch then insert Plastic Finishing Cap. 5

6 SECTION TILT WALL SYSTEMS Obelix Lifting Clutch Tilt Wall Face Lift The Obelix Lifting Clutch is a unique, fully patented and reusable Lifting device that has been precision manufactured from high strength steel for the safe, efficient and economic lifting of concrete elements. Obelix Lifting Clutches are used in conjunction with cast in-situ lifting voids formed by casting a precisely engineered Obelix Void Former into the concrete element. Obelix Lifting Clutches are industry proven, independently tested and certified in accordance with the requirements of AS Each Obelix Lifting Clutch is permanently marked with a unique identification number and Working Load Limit (). Prior to delivery each Obelix Lifting Clutch is proof tested to 2 times, tagged and certified by the manufacturer Obelix Lifting Systems Pty Ltd. Obelix Lifting Clutch 6.5T x 120mm has been specifically designed for use in Tilt Wall Face Lifting applications. Remote Release Obelix Lifting Clutches are also available with ground release latches enabling safe release and removal from ground level. Obelix Tilt Wall Lifting Clutches The Obelix Lifting Clutches are engineered from high tensile steel alloy and is extensively tested and proof loaded to provide long and safe service. Tested and Certified to Australian Standard AS Individually proof tested and tagged. Simple, secure and safe operation. Available with Ground Release mechanism for remote release b l Table 2.1 LIFTING CLUTCHES FOR FACE LIFTING TILT WALL PANELS VIA OBELIX VOID FORMERS. Product Description Max Working Load Limit (WWL) (Tonnes) Nominal Length (I) Nominal Diameter (b) Material Pack Quantity Product Code 6.5T x 120mm Lifting Clutch (remote release) High Steel Alloy PRODUCT DESIGN AND SELECTION GUIDE I

7 SECTION TILT WALL SYSTEMS OBELIX Lifting System Tilt Wall b The Obelix Tilt Wall Panel Void Former assembly has been specifically developed for face lifting applications in Tilt Wall panels and thin precast elements. The system consists of a polypropylene void former assembled with a removable screw fit retainer complete with vertical antenna to assist location of the void former after wet concrete finishing operations. The base of the void formers also feature a quick connection mechanism to enable fast and secure attachment of preformed Void Former Extension Chairs for use in deeper elements. The combination of Tilt Wall Void Former Assemblies together with Void Former Extension Chairs provides the perfect vertical void former location in common panel thicknesses and secure depth control. Please note the Void Former Panel Chairs are not suitable for supporting reinforcing steel. Tilt Wall Panel Void Former l t Void Former Panel Chair Nominal Dimensions Tilt Wall Void Former Assembly The Obelix Plastic Void Former is a sacrificial face lifting assembly that when cast within the concrete element forms the geometrically precise void necessary for the subsequent engagement of the Obelix Lifting Clutch. With ridged base for secure attachment of extension chairs. Assembled complete with removable screw fit retainer. Complete with integral legs for perfect height control. Location antenna mounted on retainer cap for easy location. Inherently corrosion resistant (Polypropylene) Accepts clip on connection of Obelix Extension Chairs. Table 2.2 TILT UP PANEL - FACE LIFT VOID FORMER ASSEMBLIES - FULL LENGTH Void Former Assemblies with screw in Retainer, can also be used with chairs, suitable for face lifting in Tilt Up Wall Panel applications. Product Description Load Category (WWL) (Tonnes) Nominal Tilt Wall Panel Depth (t) Void Depth (I) Nominal Void Diameter (b) Material Pack Quantity Product Designation 6.5T x 120mm/125mm Tilt Panel Void Former Assembly Polypropylene/HDPE T x 120mm/150mm Tilt Panel Void Former Assembly Polypropylene/HDPE

8 SECTION TILT WALL SYSTEMS Tilt Wall Void Former Extension Chairs The Obelix Plastic Void Former Extension Chairs are engineered for simple clip attachment to the base of Tilt Up Void Former bases and where required provide an economical solution for height adjustment in thicker precast and Tilt Wall applications. Obelix Tilt Wall void Former Extension Chairs are used to extend 125mm and 150mm Void Former Assemblies for use in 175mm and 200mm Panel depths. Providing enhanced versatility. Cost effective solution Stable and secure Inherently corrosion resistant (Polypropylene) Tilt Wall Void Former Extension Chairs Table 2.3 TILT WALL - LIFTING CLUTCH ASSEMBLIES Lifting Clutches for Face Lifting Tilt Wall Panels via Obelix Void Formers. Product Description Nominal Tilt Wall Panel Depth (t) Nominal Chair Height (h) Nominal Void Diameter (b) Material Pack Quantity (Pcs) Product Code 6.5T x 55mm Tilt Panel Chair - Plastic Polypropylene T x 80mm Tilt Panel Chair - Plastic Polypropylene PRODUCT DESIGN AND SELECTION GUIDE I

9 SECTION TILT WALL SYSTEMS Obelix Plastic Finishing Cap The reusable Obelix Plastic Finishing Cap (Polypropylene) has been developed to neatly preserve the void for future reuse and provide an aesthetically acceptable capping of the lifting void in finished panels thus negating the need to undertake expensive patching or finishing works over completed lifting voids. The Plastic Finishing Cap is also conveniently marked with the lifting category to enable the correct selection of the appropriate Lifting Clutch in the event that future reuse of the Lifting Void is required. Obelix Plastic Finishing Cap Finishing Caps The Obelix Void Finishing Cap is manufactured from robust UV stable Polypropylene developed to seal and finish redundant voids. The pliable locking fins are engineered to ensure secure push fit location. Each Finishing Cap is clearly embossed with void former details including Category providing accurate records of Void Load Category in the event of future reuse. Provided a secure seal. Colour matched to provide neat finish. Embossed with Void Category. Simple and secure Push Fit application. Negates the need to grout and patch b Table 2.4 PLASTIC PUSH FIT FINISHING CAP Finishing Cap the sealing and finishing of lifting voids. Nominal Dimensions Product Description For Category Void () (Tonnes) Nominal Void Diameter (b) Material Pack Quantity (Pcs) Product Code 6.5T Void Former Finishing Cap Polypropylene T Void Former Finishing Cap Polypropylene

10 SECTION TILT WALL SYSTEMS TILT WALL SYSTEM ACESSORIES Remote Release Lanyards Obelix Remote Release Lanyard (Woven Polyester with Stainless Steel Connection Pin) is used to activate the Remote Release Latch on Obelix Tilt Wall Lifting Clutches. Prior to lifting the Remote Release Lanyard is attached to the Lifting Clutch Latch by engaging the Stainless Steel Connection Pin supplied, and the Lanyard is laid out along the Tilt Wall element. Once the panel has been positioned, secured and the Lifting Clutch is ready for removal the operator pulls lightly on the Remote Release Lanyard which disengages the Lifting Clutch from the lifting void. Enable the safe, remote release of the Lifting Clutch. Available in 10 and 5m Lengths. Table 2.5 REMOTE RELEASE LANYARDS For use with Lifting Clutch for the remote operation of the Ground Release Latch. Attaches to the Lifting Clutch via the included stainless steel Connecting Pin PRODUCT DESCRIPTION LENGTH (m) MATERIAL PACK QUANTITY PRODUCT CODE Remote Release Lanyard with Connecting Pin - 10m long 10 Polyester Reaming Tool The Obelix Reaming Tool consists of a steel cutting head mounted on an aluminium shaft that is mounted into the chuck of a power tool, and is used for clearing debris and blockages that have inadvertently entered the lifting void. Cleans fouled Lifting Voids Fast and efficient Table 2.6 REAMING TOOLS For the efficient removal of debris and blockages that have inadvertently fouled Lifting Voids. PRODUCT DESCRIPTION LENGTH (m) NOMINAL DIAMETER MATERIAL PACK QUANTITY PRODUCT CODE 6.5T x Reaming Tool - 280mm long Steel/Aluminium PRODUCT DESIGN AND SELECTION GUIDE I

11 SECTION TILT WALL SYSTEMS Tilt Wall Void Former Assembly Configurations Obelix Tilt Up Void Former Assemblies are available in full length units to suit 125mm and 150mm panel depths, both of which have been design for simple adaptation for both 175mm and 200mm panel depths by the simple attachment of robust Extension Chairs. Assembly configuration are conveniently displayed below: Figure 2.1 ELEMENT DEPTH VOID FORMER ASSEMBLY ASSEMBLY COMPONENTS 125MM Single Piece. 6.5Tx120mm (125) Void Former Assembly 150MM Single Piece. 6.5Tx120mm (150) Void Former Assembly 175MM Two Pieces. 6.5Tx120mm (125) Void Former Assembly with 55mm Chair Or 6.5Tx120mm (150) Void Former Assembly with 55mm Chair. 200MM Two Pieces. 6.5Tx120mm (125) Void Former Assembly with 75mm Chair. Or 6.5Tx120mm (150) Void Former Assembly with 75mm Chair 11

12 SECTION TILT WALL SYSTEMS INSTALLATION DETAILS Face Lifting Tilt Wall Panels 6.5T x 120mm Tilt Wall Assemblies and Extension Chairs For Face Lifting Applications the 6.5T Tilt Wall Void Former is available in assemblies to suit 125mm and 150mm panel depths and with the simple clip attachment of Void Former Extension Chairs 175mm and 200mm Panel depths are accurately accommodated. The appropriate assembly is placed in the required location and where necessary the mesh reinforcement is cut to permit accurate location. The Void Former Assembly is simply secured into location by tying back to the reinforcement mesh. If required supplementary support bars may be inserted and securely ties to the Mesh Reinforcement. Please note that whilst the Void Former Assemblies are of robust construction they are not intended for reinforcement support. Subsequent to concreting the Antennae assist location and the Void Former Retainer is simply removed by unscrewing. Lifting is achieved by use of the Obelix 6.5T x 120mm Lifting Clutch Void Former 2. Support Bar 3. Mesh 4. Tie 5. Soffit Side Elevation on Void Former Support Bar 2. Tie 3. Mesh Isometric View on Installation 12 PRODUCT DESIGN AND SELECTION GUIDE I

13 SECTION PRECAST ERECTION SYSTEMS OBELIX Lifting System - Precast The prime elements of the Obelix Lifters Precast System are the unique, fully certified, patented and reusable Obelix Lifting Clutches 6.5T x220mm and 10Tx350mm which have been developed for both edge lifting and face lifting applications common in Precast erection processes. Installation of the Lifting Clutch requires the forming of a precise under-cut void by the employment of an Obelix Plastic Void Former andretainer. Prior to concreting the Void Former assembly is securely attached to the formwork via the M8 threaded insert located on the face of the reusable Void Former Retainer. Subsequent to casting the Void Former Retainer is removed and the Lifting Clutch inserted and engaged ready for lifting. Fig 3.0 Installation Instructions Cast in Situ - Full Length Void Former System STEP 1 Select appropriate Obelix Void Former and insert Retainer. (Screw anticlockwise) STEP 5 Insert and engage the Obelix Lifting Clutch. STEP 2 Fix Void Former to formwork. (Fastened via the threaded insert in the centre of the Removable Cap) STEP 6 Attach lifting hooks. STEP 3 Install rebar (Fig 3.2 refers), cast concrete and cure. STEP 7 Lift. STEP 4 Using the Extractor Tool remove the Retainer (unscrew clockwise). STEP 8 On completion of lift disengage and remove Obelix Lifting Clutch then insert Plastic Finishing Cap. 13

14 SECTION PRECAST ERECTION SYSTEMS Obelix Lifting Clutch Precast The Obelix Lifting Clutch is a unique, fully patented and reusable Lifting Clutch that has been precision manufactured from high strength steel for the safe, efficient and economic lifting of concrete elements in conjunction with cast in-situ lifting voids formed by casting a precisely engineered Obelix Void Former into the concrete element. Obelix Lifting Clutches are industry proven, independently tested and certified in accordance with the requirements of AS Each Obelix Lifting Clutch is permanently marked with a unique identification number and Working Load Limit (). Each Obelix Lifting Clutch is annually inspected, proof tested, tagged and certified by the manufacturer Obelix Lifting Systems Pty Ltd. Obelix Lifting Clutches are equally suitable for both Face Lifting and Edge Lifting applications. Remote Release Obelix Lifting Clutches are also available with remote release enabling safe release and removal from ground level. Obelix Lifting Clutches - Precast The Obelix Lifting Clutches are engineered from high tensile steel alloy and is extensively tested and proof loaded to provide long and safe service. Tested and Certified to Australian Standard AS Individually proof tested and tagged. Simple, secure and safe operation. Available with Ground Release mechanism for remote release b l Table 3.1 PRECAST ERECTION LIFTING CLUTCH ASSEMBLIES Lifting Clutches for lifting Precast concrete elements via Obelix Void Formers in face lift or edge lift applications Product Description Maximum Working Load Limit () (Tonnes) Nominal Length (l) Nominal Diameter (b) Material Pack Quantity Product Code 6.5T x 120mm Lifting Clutch (Remote Release) T x 220mm Lifting Clutch (Remote Release) T x 220mm Lifting Clutch (Latch) T x 350mm Lifting Clutch (Latch) T x 350mm Lifting Clutch (Remote Release) High Steel Alloy High Steel Alloy High Steel Alloy High Steel Alloy High Steel Alloy PRODUCT DESIGN AND SELECTION GUIDE I

15 SECTION PRECAST ERECTION SYSTEMS Obelix Plastic Void Former - Precast The Obelix Plastic Void Former assembly is employed to form a geometrically precise void within the concrete element suitable for the subsequent engagement of the Obelix Lifting Clutch. The Void Former Assembly consists of 2 components, the inherently corrosion resistant, sacrificial Plastic Void Former (polypropylene) and the reusable Void Former Retainer. Prior to installation the Void Former Retainer is simply inserted into the body of the Void Former and locked into position by rotating (anti clockwise) and engaging the matching threads thus forming a secure connection. The Void Former Assembly is then secured to the formwork via the internally threaded (M8) insert located in the centre of the Void Formers Retainer cap. Subsequent to the pouring and curing of concrete the void former is unbolted from the formwork and prior to lifting the removable Retainer is simply removed (Clockwise rotation), using the Retainer Extraction Tool. Sealing of the void subsequent to lifting operations is neatly achieved by the insertion of the aesthetically acceptable, push fit Plastic Finishing Cap, thus mitigating the need for expensive patching and sealing. Full Length Void Former b l Void Former Retainer Nominal Dimensions Plastic Void Formers - Precast The Obelix Plastic Void Former is a sacrificial component that when cast within the concrete element forms the geometrically precise void necessary for the subsequent engagement of the Obelix Lifting Clutch. Used in conjunction with the Obelix Void Former Retainer. Simple Robust Economic Inherently corrosion resistant (Polypropylene) Table 3.2 PRECAST VOID FORMERS - PLASTIC For forming a full depth Lifting Void in concrete elements for face lifting and edge lifting applications. Product Description Load Category () (Tonnes) Void Depth (l) Nominal Void Diameter (b) Material Pack Quantity (Pcs) Product Code 6.5T x 220mm Void Former - Plastic Polypropylene T x 350mm Void Former- Plastic Polypropylene

16 SECTION PRECAST ERECTION SYSTEMS Plastic Void Former Retainer -Precast The Obelix Plastic Void Former Retainer is a reusable component that when assembled enables the Void Former to be securely attached to formwork panels or hangers, provides a secure seal and rigidity to the Void Former during the rigours of concrete placing. Used in conjunction with the Obelix Void Former. Durable and Reusable Secure 30mm long M8 Internally threaded steel insert Table 3.3 PRECAST REUSABLE VOID FORMER RETAINER - COMPLETE WITH M8 INSERT For use with Void Formers when casting lifting voids in concrete elements in face lifting and edge lifting applications. Product Description Load Category () (Tonnes) Void Depth (l) Nominal Void Diameter (b) Material Pack Quantity Product Code 6.5T x 220mm Void Former Retainer - Plastic Polypropylene T x 220mm Void Former Retainer - Steel Steel T x 350mm Void Former Retainer - Plastic Polypropylene T x 350mm Void Former Retainer - Steel Steel Retainer Extraction Tool The Obelix Retainer Extraction Tool enables the simple extraction of the Void Former Retainer from within the void former. The M8 thread of the extraction tool is inserted into the Threaded insert in the centre of the Void Former Retainer Cap and rotated (clockwise) to retrieve the reusable retainer. Used in conjunction with Obelix Void Former Assemblies. Durable and Reusable Robust (Steel construction) Simplifies Retainer extraction Table 3.4 VOID FORMER RETAINER EXTRACTION TOOL Extraction Tool for the removal of Void Former Retainers. Product Description Thread Size (d) Material Pack Quantity Product Code M8 Retainer Extraction Tool M8 Steel PRODUCT DESIGN AND SELECTION GUIDE I

17 SECTION PRECAST ERECTION SYSTEMS Obelix Plastic Finishing Cap The reusable Obelix Plastic Finishing Cap (Polypropylene) has been developed to neatly preserve the void for future reuse and provide an aesthetically acceptable capping of the lifting void in finished panels thus negating the need to undertake expensive patching or finishing works over completed lifting voids. The Plastic Finishing Cap is also conveniently marked with the lifting category to enable the correct selection of the appropriate Lifting Clutch in the event that future reuse of the Lifting Void is required. Obelix Plastic Finishing Cap Finishing Caps The Obelix Void Finishing Cap is manufactured from robust UV stable Polypropylene developed to seal and finish redundant voids. The pliable locking fins are engineered to ensure secure push fit location. Each Finishing Cap is clearly embossed with void former details including Category providing accurate records of Void Load Category in the event of future reuse. Provided a secure seal. Colour matched to provide neat finish. Embossed with Void Category. Simple and secure Push Fit application. Negates the need to grout and patch b Nominal Dimensions Table 3.5 PLASTIC PUSH FIT FINISHING CAP Finishing Cap the sealing and finishing of lifting voids. Product Description For Category Void () (Tonnes) Nominal Void Diameter (b) Material Pack Quantity (Pcs) Product Code 6.5T Void Former Finishing Cap Polypropylene T Void Former Finishing Cap Polypropylene

18 SECTION PRECAST ERECTION SYSTEMS PRECAST SYSTEM ACESSORIES Remote Release Lanyards Obelix Remote Release Lanyard (Woven Polyester with Stainless Steel Connection Pin) is used to activate the Remote Release Latch on Obelix Lifting Clutches equipped with Remote Release Latches. Prior to lifting the Remote Release Lanyard is attached to the Lifting Clutch Latch by engaging the Stainless Steel Connection Pin supplied, and the Lanyard is laid out along the precast element. Once the panel has been positioned, secured and the Lifting Clutch is ready for removal the operator pulls lightly on the Remote Release Lanyard which disengages the Lifting Clutch from the lifting void. Enable the safe, remote release of the Lifting Clutch. Available in 10 and 5m Lengths. Table 3.6 REMOTE RELEASE LANYARDS For use with Lifting Clutch for the remote operation of the Ground Release Latch. Attaches to the Lifting Clutch via the included stainless steel Connecting Pin PRODUCT DESCRIPTION LENGTH (m) MATERIAL PACK QUANTITY PRODUCT CODE Remote Release Lanyard with Connecting Pin - 10m long 10 Polyester Reaming Tool The Obelix Reaming Tool consists of a steel cutting head mounted on an aluminium shaft that is mounted into the chuck of a power tool, and is used for clearing debris and blockages that have inadvertently entered the lifting void. Cleans fouled Lifting Voids Fast and efficient Table 3.7 REAMING TOOLS For the efficient removal of debris and blockages that have inadvertently fouled Lifting Voids. PRODUCT DESCRIPTION LENGTH (m) NOMINAL DIAMETER MATERIAL PACK QUANTITY PRODUCT CODE 6.5T x Reaming Tool - 280mm long Steel/Aluminium T x Reaming Tool - 400mm long Steel/Aluminium PRODUCT DESIGN AND SELECTION GUIDE I

19 SECTION PRECAST ERECTION SYSTEMS INSTALLATION DETAILS Precast - Edge Lifting 6.5T x 220mm Void Former, with N16 W Bar Fig 3.1 PLAN ON VOID FORMER In Edge Lifting Applications the 6.5T x 220 Void Former is fastened to the formwork face using the M8 threaded insert in the centre of the Void former Retainer. Where necessary the mesh reinforcement is cut locally to permit location of the Void Former Formwork 2. N16 W Bar 3. N16 Perimeter Bar 4. Mesh Reinforcement Fig 3.2 SIDE ELEVATION ON VOID FORMER For vertical shear load conditions the N16 W Bar is installed over the top face of the Void former and securely tied back to the perimeter reinforcement and mesh with maximum 40mm cover. In applications where shear force is exerted in both directions a second N16 W Bar is installed on the bottom face Formwork 2. N16 Perimeter Bar 3. N16 W Bar 4. Mesh Reinforcement Fig 3.3 END ELEVATION VOID FORMER Prior to formwork stripping the M8 Bolt connection is released and after formwork removal and prior to lifting the Void Former Retainer is unscrewed and preserved for future reuse. Lifting is achieved by use of the Obelix 6.5T x 220mm Lifting Clutch Direction of Lift 2. N16 Perimeter Bar 3. Mesh Reinforcement 4. N16 W Bar 19

20 SECTION PRECAST ERECTION SYSTEMS INSTALLATION DETAILS Precast - Edge Lifting 10.0T x 350mm Void Former, with N20 W Bar Fig 3.4 PLAN ON VOID FORMER In Edge Lifting Applications the 10.0T x 350 Void Former is fastened to the formwork face using the M8 threaded insert in the centre of the Void former Retainer. Where necessary the mesh reinforcement is cut locally to permit location of the Void Former. (See Section 5.0 for Bar details) Formwork 2. N20 W Bar 3. N20 Perimeter Bar 4. Mesh Reinforcement Fig 3.5 SIDE ELEVATION ON VOID FORMER For vertical shear load conditions the N20 W Bar is installed over the top face of the Void former and securely tied back to the perimeter reinforcement and mesh with a maximum of 40mm cover. In applications where shear force is exerted in both directions a second N20 W Bar is installed on the bottom face Formwork 2. N20 Perimeter Bar 3. M8 Bolt 4. N20 W Bar Fig 3.6 END ELEVATION VOID FORMER Prior to formwork stripping the M8 Bolt connection is released and after formwork removal and prior to lifting the Void Former Retainer is unscrewed and preserved for future reuse. Lifting is achieved by use of the Obelix 10.0T x 350mm Lifting Clutch Direction of Lift 2. N16 Perimeter Bar 3. Mesh Reinforcement 4. W Bar 20 PRODUCT DESIGN AND SELECTION GUIDE I

21 SECTION PRECAST ERECTION SYSTEMS Obelix Component Reinforcement W Bars / Bars Grade 500Mpa deformed bar to Class N in accordance with AS 4671 Table 3.8 COMPONENT REINFORCEMENT DIMENSIONS W Bar Designation Bar Diameter Slab Depth Overall Height (Hw) Overall Length (Lw) Length between Valleys (B) Internal Bend Diameter Half Bend Angle (deg) N16-125* N16-150* N N N N N N * reduced top cover, the use of Glavanised W Bars is recommended. Fig 3.7 Hw B Lw 21

22 SECTION PRECAST ERECTION SYSTEMS Obelix Component Reinforcement W Bars / Bars Grade 500Mpa deformed bar to Class N in accordance with AS 4671 Table 3.9 COMPONENT REINFORCEMENT GRADE N W TYPE SHEAR BARS For enhancing shear capacity in edge lifting applications DESCRIPTION PRODUCT CODE W Bar Designation Bar Diameter Slab Depth Plain Bar Galvanised Bar Pack Quantity N16-125* N16RW0125S025Z0 N16RW0125G025Z0 25 N16-150* N16RW0150S025Z0 N16RW0150G025Z0 25 N N16RW0175S025Z0 N16RW0175G025Z0 25 N N16RW0200S025Z0 N16RW0200G025Z0 25 N N16RW0300S025Z0 N16RW0300G025Z0 25 N N20RW0200S025Z0 N20RW0200G025Z0 25 N N20RW0250S025Z0 N20RW0250G025Z0 25 N N20RW0300S025Z0 N20RW0300G025Z0 25 * reduced top cover, the use of Glavanised W Bars is recommended. Obelix Component Reinforcement Installation Fig 3.8 Direction of lift Maximum cover 40mm SIDE ELEVATION ON SHEAR BAR END ELEVATION ON SHEAR BAR 22 PRODUCT DESIGN AND SELECTION GUIDE I

23 SECTION CIVIL CONSTRUCTION SYSTEMS OBELIX Lifting System Civil Construction The prime element of the Obelix Lifters Civil Construction System is the unique, fully certified, patented and reusable Obelix Lifting Clutch10.0Tx350mm which has been developed for both edge lifting and face lifting applications common in Civil Engineering processes. Installation of the Lifting Clutch requires the forming of a precise under-cut void by the employment of an Obelix Plastic Void Former andretainer. Prior to concreting the Void Former assembly is securely attached to the formwork via the M8 threaded insert located on the face of the reusable Void Former Retainer. Subsequent to casting the Void Former Retainer is removed and the Lifting Clutch inserted and engaged ready for lifting. Fig 4.0 Installation Instructions Cast in Situ - Full Length Void Former System STEP 1 Assemble appropriate Obelix Void Former and Retainer (Screw fit). STEP 5 Insert and engage the Obelix Lifting Clutch. STEP 2 Fix Void Former to formwork. (Fastened via the threaded insert in the centre of the Removable Cap) STEP 6 Attach lifting hooks. STEP 3 Cast concrete and cure. STEP 7 Lift. STEP 4 Using the Extractor Tool remove the Retainer Cap. STEP 8 On completion of lift disengage and remove Obelix Lifting Clutch then insert Plastic Finishing Cap. 23

24 SECTION CIVIL CONSTRUCTION SYSTEMS Obelix Lifting Clutch Civil Construction The Obelix Lifting Clutch is a unique, fully patented and reusable Lifting Clutch precision manufactured from high strength steel for the safe, efficient and economic lifting of concrete elements in conjunction with cast in-situ lifting voids formed by casting a precisely engineered Obelix Void Former into the concrete element. Obelix Lifting Clutches are industry proven, independently tested and certified in accordance with the requirements of AS Each Obelix Lifting Clutch is permanently marked with a unique identification number and Working Load Limit (). Each Obelix Lifting Clutch is annually inspected, proof tested, tagged and certified by the manufacturer Obelix Lifting Systems Pty Ltd. Obelix Lifting Clutches are equally suitable for both Face Lifting and Edge Lifting applications. Remote Release Obelix Lifting Clutches are also available with remote release enabling safe release and removal from ground level. Obelix Lifting Clutches Civil Construction The Obelix Lifting Clutches are engineered from high tensile steel alloy and is extensively tested and proof loaded to provide long and safe service. Tested and Certified to Australian Standard AS 3850 Individually proof tested and tagged. Simple, secure and safe operation. Available with Ground Release mechanism for remote release b l Table 4.1 CIVIL ENGINEERING CONSTRUCTION - LIFTING CLUTCH ASSEMBLIES Lifting Clutches for lifting concrete elements via Obelix Void Formers in face lift or edge lift applications. Product Description Maximum Working Load Limit () (Tonnes) Nominal Length (l) Nominal Diameter (b) Material Pack Quantity Product Code 6.5T x 220mm Lifting Clutch (Remote Release) T x 220mm Lifting Clutch (Latch) T x 350mm Lifting Clutch (Remote Release) T x 350mm Lifting Clutch (Latch) High Steel Alloy High Steel Alloy High Steel Alloy High Steel Alloy PRODUCT DESIGN AND SELECTION GUIDE I

25 SECTION CIVIL CONSTRUCTION SYSTEMS Obelix Plastic Void Former Civil Construction The Obelix Plastic Void Former assembly is employed to form a geometrically precise void within the concrete element suitable for the subsequent engagement of the Obelix Lifting Clutch. The Void Former Assembly consists of 2 components, the inherently corrosion resistant, sacrificial Plastic Void Former (polypropylene) and the reusable Void Former Retainer. Prior to installation the Void Former Retainer is simply inserted into the body of the Void Former and locked into position by rotating (anti clockwise) and engaging the matching threads thus forming a secure connection. The Void Former Assembly is then secured to the formwork via the internally threaded (M8) insert located in the centre of the Void Formers Retainer cap. Subsequent to the pouring and curing of concrete the void former is unbolted from the formwork and prior to lifting the removable Retainer is simply removed (Clockwise rotation), using the Retainer Extraction Tool. Sealing of the void subsequent to lifting operations is neatly achieved by the insertion of the aesthetically acceptable, push fit Plastic Finishing Cap, thus mitigating the need for expensive patching and sealing. b l Nominal Dimensions Plastic Void Formers - Civil Construction The Obelix Plastic Void Former is a sacrificial component that when cast within the concrete element forms the geometrically precise void necessary for the subsequent engagement of the Obelix Lifting Clutch. Used in conjunction with the Obelix Void Former Retainer. Simple Robust Economic Inherently corrosion resistant (Polypropylene) Table 4.2 CIVIL ENGINEERING VOID FORMERS - PLASTIC For forming a full depth Lifting Void in concrete elements for face lifting and edge lifting applications. Product Description Load Category () (Tonnes) Void Depth (l) Nominal Void Diameter (b) Material Pack Quantity (Pcs) Product Code 6.5T x 220mm Void Former - Plastic Polypropylene T x 350mm Void Former- Plastic Polypropylene

26 SECTION CIVIL CONSTRUCTION SYSTEMS Plastic Void Former Retainer - Civil Construction The Obelix Plastic Void Former Retainer is a reusable component that when assembled enables the Void Former to be securely attached to formwork panels or hangers, provides a secure seal and rigidity to the Void Former during the rigours of concrete placing. Used in conjunction with the Obelix Void Former. Durable and Reusable Robust Secure 30mm long M8 Internally threaded steel insert Table 4.3 CIVIL ENGINEERING REUSABLE VOID FORMER RETAINER - COMPLETE WITH M8 INSERT For use with Void Formers when casting lifting voids in concrete elements in face lifting and edge lifting applications. Product Description Load Category () (Tonnes) Void Depth (l) Nominal Void Diameter (b) Material Pack Quantity Product Code 6.5T x 220mm Void Former Retainer - Plastic Polypropylene T x 220mm Void former Retainer - Steel Steel T x 350mm Void Former Retainer - Plastic Polypropylene T x 350mm Void Former Retainer - Steel Steel Void Former Retainer Extraction Tool The Obelix Retainer Extraction Tool enables the simple extraction of the Void Former Retainer from within the void former. The M8 thread of the extraction tool is inserted into the Threaded insert in the centre of the Void Former Retainer Cap and rotated (clockwise) to retrieve the reusable retainer. Used in conjunction with Obelix Void Former Assemblies. Durable and Reusable Robust (Steel construction) Simplifies Retainer extraction Table 4.4 VOID FORMER RETAINER EXTRACTION TOOL Extraction Tool for the removal of Void Former Retainers. Product Description Thread Size (d) Material Pack Quantity Product Code M8 Retainer Extraction Tool M8 Steel PRODUCT DESIGN AND SELECTION GUIDE I

27 SECTION CIVIL CONSTRUCTION SYSTEMS Obelix Plastic Finishing Cap The reusable Obelix Plastic Finishing Cap (Polypropylene) has been developed to neatly preserve the void for future reuse and provide an aesthetically acceptable capping of the lifting void in finished panels thus negating the need to undertake expensive patching or finishing works over completed lifting voids. The Plastic Finishing Cap is also conveniently marked with the lifting category to enable the correct selection of the appropriate Lifting Clutch in the event that future reuse of the Lifting Void is required. Obelix Plastic Finishing Cap Finishing Caps The Obelix Void Finishing Cap is manufactured from robust UV stable Polypropylene developed to seal and finish redundant voids. The pliable locking fins are engineered to ensure secure push fit location. Each Finishing Cap is clearly embossed with void former details including Category providing accurate records of Void Load Category in the event of future reuse. Provided a secure seal. Colour matched to provide neat finish. Embossed with Void Category. Simple and secure Push Fit application. Negates the need to grout and patch b Nominal Dimensions Table 4.5 PLASTIC PUSH FIT FINISHING CAP Finishing Cap the sealing and finishing of lifting voids. Product Description For Category Void () (Tonnes) Nominal Void Diameter (b) Material Pack Quantity (Pcs) Product Code 6.5T Void Former Finishing Cap Polypropylene T Void Former Finishing Cap Polypropylene

28 SECTION CIVIL CONSTRUCTION SYSTEMS PRECAST SYSTEM ACESSORIES Remote Release Lanyards Obelix Remote Release Lanyard (Woven Polyester with Stainless Steel Connection Pin) is used to activate the Remote Release Latch on Obelix Lifting Clutches equipped with Remote Release Latches. Prior to lifting the Remote Release Lanyard is attached to the Lifting Clutch Latch by engaging the Stainless Steel Connection Pin supplied, and the Lanyard is laid out along the precast element. Once the panel has been positioned, secured and the Lifting Clutch is ready for removal the operator pulls lightly on the Remote Release Lanyard which disengages the Lifting Clutch from the lifting void. Enable the safe, remote release of the Lifting Clutch. Available in 10 and 5m Lengths. Table 4.6 REMOTE RELEASE LANYARDS - CIVIL CONSTRUCTION For use with Lifting Clutch for the remote operation of the Ground Release Latch. Attaches to the Lifting Clutch via the included stainless steel Connecting Pin PRODUCT DESCRIPTION LENGTH (m) MATERIAL PACK QUANTITY PRODUCT CODE Remote Release Lanyard with Connecting Pin - 10m long 10 Polyester Reaming Tool The Obelix Reaming Tool consists of a steel cutting head mounted on an aluminium shaft that is mounted into the chuck of a power tool, and is used for clearing debris and blockages that have inadvertently entered the lifting void. Cleans fouled Lifting Voids Fast and efficient Table 4.7 REAMING TOOLS For the efficient removal of debris and blockages that have inadvertently fouled Lifting Voids. PRODUCT DESCRIPTION LENGTH (m) NOMINAL DIAMETER MATERIAL PACK QUANTITY PRODUCT CODE 6.5T x Reaming Tool - 280mm long Steel/Aluminium T x Reaming Tool - 400mm long Steel/Aluminium PRODUCT DESIGN AND SELECTION GUIDE I

29 SECTION CIVIL CONSTRUCTION SYSTEMS INSTALLATION DETAILS Edge Lifting 6.5T x 220mm & 10.0T x 350mm Void Formers Fig 4.1 SECTION ON VOID FORMER In Edge Lifting Applications the 6.5T x 220 or 10.0T x 350 Void Former is fastened to a formwork hanger using the M8 threaded insert in the centre of the Void former Retainer. Additional reinforcement around Void Former should be considered to control splitting Hanger To support Void Former 2. Reinforcement Increased or reduced spacing local to Void Former to control splitting 3. Formwork INSTALLATION DETAILS Edge Lifting 6.5T x 220mm & 10.0T x 350mm Void Formers and Retainers Fig 3.2 SECTION ON VOID FORMER Formwork 2. M8 Bolt 3. Reinforcement Fig 3.3 FRONT ELEVATION ON REINFORCEMENT 1 FACE LIFTING Bolt the Void Former to the inside face of the formwork via the M8 insert located in the centre of the Void Former Retainer. Additional Void Former support may be required in deep pours Vertical Reinforcement 2. Horizontal Reinforcement 29

30 SECTION CIVIL CONSTRUCTION SYSTEMS Obelix Component Reinforcement W Bars / Bars Grade 500Mpa deformed bar to Class N in accordance with AS 4671 Table 4.8 COMPONENT REINFORCEMENT DIMENSIONS W Bar Designation Bar Diameter Slab Depth Overall Height (Hw) Overall Length (Lw) Length between Valleys (B) Internal Bend Diameter Half Bend Angle (deg) N16-125* N16-150* N N N N N N * reduced top cover, the use of Glavanised W Bars is recommended. Fig 4.4 Hw B Lw 30 PRODUCT DESIGN AND SELECTION GUIDE I

31 SECTION CIVIL CONSTRUCTION SYSTEMS Obelix Component Reinforcement W Bars / Bars Grade 500Mpa deformed bar to Class N in accordance with AS 4671 Table 4.9 COMPONENT REINFORCEMENT GRADE N W TYPE SHEAR BARS For enhancing shear capacity in edge lifting applications DESCRIPTION PRODUCT CODE W Bar Designation Bar Diameter Slab Depth Plain Bar Galvanised Bar Pack Quantity N16-125* N16RW0125S025Z0 N16RW0125G025Z0 25 N16-150* N16RW0150S025Z0 N16RW0150G025Z0 25 N N16RW0175S025Z0 N16RW0175G025Z0 25 N N16RW0200S025Z0 N16RW0200G025Z0 25 N N16RW0300S025Z0 N16RW0300G025Z0 25 N N20RW0200S025Z0 N20RW0200G025Z0 25 N N20RW0250S025Z0 N20RW0250G025Z0 25 N N20RW0300S025Z0 N20RW0300G025Z0 25 * reduced top cover, the use of Glavanised W Bars is recommended. Obelix Component Reinforcement Installation Fig 4.5 Direction of lift Maximum cover 40mm SIDE ELEVATION ON SHEAR BAR END ELEVATION ON SHEAR BAR 31

32 SECTION DEMOLITION LIFTING SYSTEM Obelix Post-Installed Lifting System In situations where existing concrete elements have no available lifting mechanisms installed or where cast-in systems have failed, the Obelix Lifters Post-Installed Systemenables the safe, efficient and highly cost effective alternative to expensive remedial works or in situ demolition. In such cases installing under-cut voids into hardened concrete is simply achieved by using standard diamond coring equipment to core a hole into the existing hardened concrete and then forming an under-cut profile to the base of the cored hole using the unique, patented and reusable Obelix Under- Cutting Tool. Subsequent lifting of the concrete element is then reliably achieved by inserting and engaging the removable Obelix Lifting Clutch system. Fig 5.0 Installation Instructions - Post - Installed Method - Lifting cured concrete elements STEP 1 Diamond Core void into cured concrete to prescribed diameter and depth. (Table 5.1 refers) Extract cut core. STEP 5 Visually inspect the Lifting Clutch for damage. Insert the prescribed Obelix Lifting Clutch. STEP 2 Attach Obelix Under-Cutting Tool into core rig and insert into the cored void to the prescribed depth. STEP 6 Engage the prescribed Obelix Lifting Clutch. STEP 3 Engage core rig motor to rotate Under-Cutting Tool and form under-cut. STEP 7 Attach Lifting hooks and lift. STEP 4 Remove the Obelix Under -Cutting tool from the under-cut void and evacuate debris. STEP 8 On completion of lift disengage and remove Obelix Lifting Clutch and insert Plastic Finishing Cap. 32 PRODUCT DESIGN AND SELECTION GUIDE I

33 SECTION DEMOLITION LIFTING SYSTEM Obelix Lifting System Post- Installed Method The prime element of the Obelix Lifting System is the unique, fully certified, patented and reusable Obelix Lifting Clutch. Application of the Lifting Clutch requires prior cutting of a precise undercut lifting void into the fully cured base material. For Post-Installed applications into existing concrete the lifting void is simply formed by standard diamond coring techniques and the undercut profile subsequently formed by employment of the Obelix Under-Cutting Tool. Obelix Demolition and Rehabilitation System l The Obelix Demolition and Rehabilitation System provides a safe and efficient alternative to costly repairs of existing lifting systems and a unique alternative to the removal of large concrete elements without the need to undertake expensive in-situ demolition. Tested and Certified Lifting Clutch. b L D Effective method for the replacement of failed cast in lifting points. Economic method for lifting large concrete elements in demolition. Reusable system components. Table 5.1 INSTALLATION DETAILS LOAD CATEGORY CORING DETAILS LIFTING CLUTCH DETAILS PRODUCT CODES Maximum Working Load Limit () (Tonnes) Optimal Diamond Core Bit Diameter (D) Diamond Core Bit Diameter Tolerance (D) Nominal Depth of Cored Hole (L) Nominal Lifting Clutch Diameter (b) Lifting Clutch Length (l) LIFTING CLUTCH (Reusable) Product Code UNDER CUTTING TOOL (Reusable) Product Code (-1 to +3) (-1 to +3) or (-1 to +3) or The Nominal Depth of Cored Hole displayed in the above table includes 20mm over drill to accommodate possible irregularities in the depth of the cored hole due to uneven breakout of the core. NB. In all cases lift planning, engineering assessment and supervision must be undertaken by suitably qualified and competent persons. 33

34 SECTION DEMOLITION LIFTING SYSTEM Obelix Lifting Clutch Demolition The Obelix Lifting Clutch is a unique, fully patented and reusable Lifting Clutch that has been precision manufactured from high strength steel for the safe, efficient and economic lifting of concrete elements in conjunction with lifting voids formed by coring and forming an under-cut at the base of the cored lifting void with the Obelix Under-Cutting Tool. Obelix Lifting Clutches are industry proven, independently tested and certified in accordance with the requirements of AS Each Obelix Lifting Clutch is permanently marked with a unique identification number and Working Load Limit (). Prior to delivery each Obelix Lifting Clutch is inspected, proof tested, tagged and certified by the manufacturer Obelix Lifting Systems Pty Ltd. Obelix Lifting Clutches Demolition The Obelix Lifting Clutches are engineered from high tensile steel alloy and is extensively tested and proof loaded to provide long and safe service. Tested and Certified to Australian Standard AS 3850 Individually proof tested and tagged. Simple, secure and safe operation. Available with Ground Release mechanism for remote release b l Table 5.2 DEMOLITION & REHABILITATION - LIFTING CLUTCHES Lifting Clutches for lifting concrete elements via diamond cored lifting voids. Product Description Maximum Working Load Limit () (Tonnes) Nominal Length (l) Nominal Diameter (b) Material Pack Quantity Product Code 6.5T x 120mm Lifting Clutch (Remote Release) T x 220mm Lifting Clutch (Remote Release) T x 220mm Lifting Clutch (Latch) T x 350mm Lifting Clutch (Latch) T x 350mm Lifting Clutch (Remote Release) High Steel Alloy High Steel Alloy High Steel Alloy High Steel Alloy High Steel Alloy PRODUCT DESIGN AND SELECTION GUIDE I

35 SECTION DEMOLITION LIFTING SYSTEM Obelix Under-Cutting Tool The Obelix Under-Cutting Tool is a unique, patented and reusable tool employed to form a precisely matched undercut profile to the base of diamond cored holes suitable for the subsequent lifting operations using the Obelix Lifting Clutch. A single Obelix Under-Cutting Tool is capable of producing precision under-cut profiles for all lengths of Obelix Lifting Clutches within a given Category, each marked with convenient void depth indicators engraved on the shank of each cutting tool. Under -cutting is achieved by the activation of multiple diamond faced cutting fingers which are automatically engaged when driven by standard diamond coring rigs. Standard Connection 1.1/4 7 UNC Demolition Under-Cutting Tools The reusable Obelix Demolition Tools are manufactured from abrasion resistant steel alloy with high grade industrial diamond cutting segments to provide long and safe service. Manufactured from high grade diamond for extended service life. Universal drive mechanism suitable for connection to most drilling rigs. Fast and efficient cutting even in heavily reinforced concrete. Table 5.3 DEMOLITION & REHABILITATION - LIFTING CLUTCHES Lifting Clutches for lifting concrete elements via diamond cored lifting voids. Product Description Maximum Working Load Limit () (Tonnes) Nominal Diameter (b) Maximum Working Length (l) Cutting Material Pack Quantity Product Code 6.5T Diamond Under Cutting Tool - (suitable for all lengths) Diamond T Diamond Under Cutting Tool - (suitable for all lengths) Diamond Fig TYP 46mm l l 1 l /4-7 UNC - 2B ENSURE HOLE IS CENTRED IN HEX BAR Drive Connection Nominal Dimensions 35

36 SECTION DEMOLITION LIFTING SYSTEM Obelix Finishing Cap The reusable Obelix Plastic Sealing Cap (Polypropylene) has been developed to provide a seal and an aesthetically acceptable capping of cored lifting voids. The Plastic Sealing Cap provides an effective barrier to the ingress of dust and debris, thus preserving the function of the Lifting Voids, also negates the need to patch or finish over voids and neatly preserves voids for future reuse. The Plastic Sealing Cap is conveniently marked with the lifting category to enable the correct selection of the appropriate Lifting Clutch on future reuse. Obelix Plastic Finishing Cap Finishing Caps The Obelix Void Finishing Cap is manufactured from robust UV stable Polypropylene developed to seal and finish redundant voids. The pliable locking fins are engineered to ensure secure push fit location. Each Finishing Cap is clearly embossed with void former details including Category providing accurate records of Void Load Category in the event of future reuse. Provided a secure seal. Colour matched to provide neat finish. Embossed with Void Category. Simple and secure Push Fit application. Negates the need to grout and patch Prevents entry of debris into the Void b Nominal Dimensions Table 5.4 PLASTIC PUSH FIT FINISHING CAP Finishing Cap the sealing and finishing of lifting voids. Product Description For Category Void () (Tonnes) Nominal Void Diameter (b) Material Pack Quantity (Pcs) Product Code 6.5T Void Former Finishing Cap Polypropylene T Void Former Finishing Cap Polypropylene PRODUCT DESIGN AND SELECTION GUIDE I

37 SECTION TECHNICAL DATA Contents Page Introduction Obelix Lifting Clutches Conformance AS Working Load Limits () AS : 2.2a Proof Testing AS : 2.6c Markings AS : 2.6c Concrete Capacity Concrete capacity modes of failure Combined tension and shear loads Face Lifting Face Tension Uncracked Concrete Face Tension Cracked Concrete Face Uncracked Concrete Face Cracked Concrete Face Tension - One reduced edge distance Uncracked Concrete Face Tension - One reduced edge distance Cracked Concrete Face - One reduced edge distance Uncracked Concrete Face - One reduced edge distance Cracked Concrete Edge Lifting Edge Tension - Two reduced edge distances Uncracked Concrete Edge Tension - Two reduced edge distances Cracked Concrete Edge - Two reduced edge distances Uncracked Concrete Edge - Two reduced edge distances Cracked Concrete SECTION 7.0 Notes

38 SECTION TECHNICAL DATA Introduction The Obelix Lifting System is an innovative system consisting of a Void Former assembly and a Lifting Clutch that transfers load directly to the concrete base material by mechanical interlock without the need for metal lifting inserts. Accordingly there are 2 possible primary failure modes associated with the Obelix Lifting System namely, failure of the lifting clutch and failure of the concrete base material, whereas traditional methods that rely upon metal inserts to transfer load to the concrete have 3 possible primary failure modes, lifting clutch failure, Insert Failure and concrete failure. Since there are no corrosion susceptible metal inserts left within the parent concrete the Obelix Lifting System also presents significant long term benefits in respect of durability and sustainability. Table 6.1 TRADITIONAL LIFTING SYSTEMS OBELIX LIFTING SYSTEM Component Features Component Features Benefits Lifting Clutch (Reusable) Forged / Cast Steel Lifting Clutch (Reusable) High Strength Steel Alloy Durability Ductility Precision machined High Strength Reduced risk of deformation Lifting Insert Galvanised Steel Lifting Insert Not Required Reduced risk of failure. No risk of corrosion. No need for tension bars. Reduced installation errors. No effect on concrete cover No risk of embrittlement No risk of mechanical damage. No breach of thermal break. Reduced Cost. Void Former Plastic Void Former Plastic Pre-Lift inspection possible. Preserves lifting point for future use. Concrete Base Material Concrete Base Material Positive mechanical engagement. Reduced edge distances Reduced Spacing. Finishing Grout and Patch Finishing Plastic Finishing Cap Efficient Neat Permits reuse of lifting point. Size identified. Low Cost. 38 PRODUCT DESIGN AND SELECTION GUIDE I

39 SECTION TECHNICAL DATA Obelix Lifting Clutches The Obelix Lifting Clutch is an innovative, fully patented and reusable device used to connect the crane rigging (Shackle) to the concrete element by mechanical engagement with an under-cut Obelix Void former that has been cast into the concrete element at the prescribed lifting location. The mechanical fingers of the Lifting clutch wedge against the concrete when the clutch is in its engaged position, enabling the load to be distributed over a wide area of concrete. For added safety the Obelix Lifting Clutch can only lift when the Cone and lifting fingers are fully engaged by the hand operated latch mechanism, and once the clutch is engaged it cannot disengage whilst under load. Conformance Obelix Lifting clutches have been independently tested by NATA (National Association of Testing Authorities) accredited laboratories in accordance with the procedures specified in Australian Standard AS Prefabricated concrete elements - Section 2.2a) and are individually proof tested in accordance with AS Section 2.6. A Certificate of conformance is supplied with each Obelix Lifting Clutch. Table 6.2 LIFTING CLUTCH WORKING LOAD LIMITS () IN TENSION & SHEAR Lifting Clutch Designation 6.5T Lifting Clutch Details Length l Nominal Diameter b AS Test Results Mean Ultimate Test Values Recommended Working Load Limit Stress Area Tension Tension As (mm²) x (kn) x (Tonnes) x (kn) x (Tonnes) () (Tonnes) T Critical characteristic loads R u were obtained by testing in accordance with AS Appendix A8 Test Reports MT-14/ t and MT-14/826-A-10t refer. Note: Recommended Working Load Limits () of Lifting Clutches have been limited by the tensile capacity of the Lifting Shackles () (Tonnes) Working Load Limit () Calculation in accordance with AS (Section 2.2a) 6.5 Tonne Obelix Lifting Clutches 10.0 Tonne Obelix Lifting Clutches R u = = FoS R u FoS Tension Tension = = 12.6 Tonnes = 4 4 = 18.3 Tonnes = = 5.6 Tonnes = 4 4 = 13.7 Tonnes Where R u = Critical characteristic strength of the lifting clutch, derived from testing in accordance with AS : A4 with a 5% fractile at 90% confidence level using a normal distribution and average values. FoS = Working Load Limit () Factor according to AS Section 2.2, Table

40 SECTION TECHNICAL DATA Obelix Lifting Clutches Conformance Proof Testing Each Obelix Lifting Clutch is marked with a unique serial number, category and size, prior to delivery all Obelix Lifting Clutches are Proof Tested and individually Certified by the manufacturer. Proof Testing to 2.0 times is undertaken in accordance with Australian Standard AS ( c). (AS Prefabricated concrete elements Part 1: General requirements) Proof Testing Certification Each Obelix Lifting Clutch is supplied complete with a printed Proof Test Certificate and a durable Proof Load Test Tag is attached to each Lifting Clutch displaying; Working Load Limit () Test Number Lifting Clutch Size Lifting Clutch Serial Number Retest due date. Annual Proof Testing AS Section 2.6 ( c ) requires that proof testing using a load equal to 1.2 times shall be conducted and recorded at least at twelve monthly intervals. Please note: Annual Proof Testing and certification of Obelix Lifting clutches shall only be undertaken at Obelix approved and accredited testing facilities. For details please contact Obelix Lifting Systems Pty Ltd. Inspection before use. In accordance with AS ( c ) users are required to inspect all Lifting Clutches for wear and deformation. 6.5T O120L10125 Identification Marking In accordance with AS Section 2.6 ( c ) each Obelix Lifting Clutch is permanently marked with a unique Serial Number and Product Sizes as follows; Working Load Limit Clutch Length Locking mechanism type. Unique Serial Number. Example: Working Load Limit: ( 6.5T) 6.5 Tonnes Product size: (120) - 120mm Locking Mechanism: (L) - Latch Type Serial Number: (10125) PRODUCT DESIGN AND SELECTION GUIDE I

41 SECTION TECHNICAL DATA Concrete Capacity Performance data displayed in the following tables has been derived from in concrete testing of the complete Obelix Lifting system including Lifting Clutch, Void Former and concrete base material. The arrangement for the application of test loads being made to simulate the field use of the complete system. System testing was undertaken by independent NATA (National Association of Testing Authorities) accredited laboratories and witnessed by suitably qualified persons. All system testing was conducted in accordance with the principles of Australian Standard AS Prefabricated concrete elements Part 1: General requirements Capacity Tables The Characteristic data displayed in the following Capacity Tables were derived by competent persons from the ultimate loads determined by the above comprehensive testing regime. The general design principles employed in the production of the published data is based on the concrete capacity method published in CEN/TS :2009, the principles of ACI 318 and in accordance with AS 3850 Appendix B, modified for the intended application with consideration for: Tension Capacity including, a) breakout cone, b) pull out, c) blow out and d) splitting modes of failure AS : B3.2 refers Capacity for concrete edge failure mode AS : B3.4 refers Combined Tension and AS : B3.4 refers, (see Fig 6.2) a) Breakout Cone b) Pull Out Performance Variations Capacity tables are also provided for variations in performance due to the condition of the concrete and application variations, including: Application in Cracked Concrete Application in Un Cracked Concrete Effects of Edge Distance Effects of Member Thickness Effects of Loading Direction. Influence of Concrete Compressive Strength at the time of loading. c) Blow Out State of the concrete Performance tables for both cracked and un cracked concrete have been provided in this publication developed in accordance with AS : B Where Un Cracked concrete may be assumed if under service load conditions the lifting device is situated in un cracked concrete over it`s entire embedment depth, including consideration of shrinkage and thermal effects. d) Splitting 41

42 SECTION TECHNICAL DATA Fig 6.2 Combined tension and shear loading Where a cast-in insert is subjected to combined tension and shear, the insert shall conform to the interaction relationship given in the following equation (AS : B3.4 refers) : N s F + V s F 1.0 R u,n R u,v Where: R u,n = characteristic ultimate tensile strength of cast-in insert R u,v = characteristic ultimate shear strength of cast-in insert N s = tension component of the applied load N v = shear component of the applied load N s 1.0 Trilinear interaction approach N V N s R u,n N V Ru,V Combined tension and shear loading and tensile load interaction Concrete splitting In cases where the spacing between lifting points is less than 8 times the embedment depth of the lifting void then additional reinforcement should be provided to resist splitting. In such cases provide reinforcement sufficient to resist the working lifting load at stress of 0.3fy. AS : B3.2.4 refers 42 PRODUCT DESIGN AND SELECTION GUIDE I

43 SECTION TECHNICAL DATA FACE LIFTING FACE TENSION WORKING LOAD LIMIT IN TENSION FOR OBELIX LIFTING SYSTEMS c 1 2 x c 1 c 1 Table 6.3a UNCRACKED CONCRETE h ef PRODUCT DETAILS Standard Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Tension Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Minimum Edge Distance or Half Spacing (C1) Minimum Edge Distance or Half Spacing in Normal Direction (C2=1.5x hef) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) 6.5Tx Tx Tx Loading Conditions: Single Lifter, No reduction due to edge proximity, Lift angle 0, FOS Lifter = 5.0, FOS Concrete Failure = 2.5,Uncracked at service loads, Formed void c 1 2 x c 1 c 1 WORKING LOAD LIMIT IN TENSION FOR OBELIX LIFTING SYSTEMS Table 6.3b CRACKED CONCRETE h ef PRODUCT DETAILS Standard Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Tension Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Minimum Edge Distance or Half Spacing (C1) Minimum Edge Distance or Half Spacing in Normal Direction (C2=1.5x hef) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) 6.5Tx Tx Tx Loading Conditions: Single Lifter, No reduction due to edge proximity, Lift angle 0, FOS Lifter = 5.0, FOS Concrete Failure = 2.5,Cracked at service loads, Formed void Note: In some cases the value given for C1 is less than that for the full breakout cone width (1.5 * depth of anchor). In these cases the failure is controlled by pull out or anchor capacity and so increasing the edge distance gives no increase in anchor. 43

44 SECTION TECHNICAL DATA c 1 c 1 FACE LIFTING FACE SHEAR WORKING LOAD LIMIT IN SHEAR FOR OBELIX LIFTING SYSTEMS Table 6.4a UNCRACKED CONCRETE h ef Lifting Clutch Designation PRODUCT DETAILS Standard Setting Details Concrete Compressive Strength (at Lift) Maximum Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Minimum Edge Distance in direction of (C1) Minimum Edge Distance or Half Spacing in Normal direction (C2=1.5xC1) Minimum Edge Distance opposite to direction of shear Minimum Depth Loading Conditions: Single Lifter, Lifting angle 90, No reduction due to edge proximity, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Uncracked at service loads (C3) (H=1.5xC1) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) 6.5Tx Tx Tx c 1 c 1 FACE LIFTING FACE SHEAR WORKING LOAD LIMIT IN SHEAR FOR OBELIX LIFTING SYSTEMS Table 6.4b CRACKED CONCRETE h ef Lifting Clutch Designation PRODUCT DETAILS Standard Setting Details Concrete Compressive Strength (at Lift) Maximum Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Minimum Edge Distance in direction of (C1) Minimum Edge Distance or Half Spacing in Normal direction (C2=1.5xC1) Minimum Edge Distance opposite to direction of shear Minimum Depth Loading Conditions: Single Lifter, Lifting angle 90, No reduction due to edge proximity, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Cracked at service loads (C3) (H=1.5xC1) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) 6.5Tx Tx Tx PRODUCT DESIGN AND SELECTION GUIDE I

45 SECTION TECHNICAL DATA FACE LIFTING FACE TENSION WORKING LOAD LIMIT IN TENSION FOR OBELIX LIFTING SYSTEMS WITH ONE REDUCED EDGE DISTANCE c 3 c 1 Table 6.5a UNCRACKED CONCRETE PRODUCT DETAILS Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Tension Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Minimum Edge Distance or Half Spacing in Normal Direction (C2=1.5x Hef) Minimum Distance to Parallel Edge or Half Spacing (C3) Distance to Closest Edge (C1) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) Tx Tx Tx Loading Conditions: Single Lifter, Lift angle 0, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Uncracked at service loads, Formed Void 45

46 SECTION TECHNICAL DATA FACE LIFTING FACE TENSION WORKING LOAD LIMIT IN TENSION FOR OBELIX LIFTING SYSTEMS WITH ONE REDUCED EDGE DISTANCE c 3 c 1 Table 6.5b CRACKED CONCRETE PRODUCT DETAILS Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Tension Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Minimum Edge Distance or Half Spacing in Normal Direction (C2=1.5x Hef) Minimum Distance to Parallel Edge or Half Spacing (C3) Distance to Closest Edge (C1) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) Tx Tx Tx Loading Conditions: Single Lifter, Lift angle 0, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Cracked at service loads, Formed Void 46 PRODUCT DESIGN AND SELECTION GUIDE I

47 SECTION TECHNICAL DATA c 1 c 1 FACE LIFTING FACE SHEAR WORKING LOAD LIMIT IN SHEAR FOR OBELIX LIFTING SYSTEMS WITH ONE REDUCED EDGE DISTANCE h ef Table 6.6a UNCRACKED CONCRETE Minimum slab depth (H) = 1.5C1) PRODUCT DETAILS Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Edge Distance in Direction of (C1) Min Edge Distance or Half Spacing in Normal Direction (C2=1.5xC1) Min Edge Distance opposite to direction of shear (C3) Minimum Depth (H=1.5xC1) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) Tx Tx Tx Loading Conditions: Single Lifter, Lift angle 0, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Cracked at service loads, Formed Void 47

48 SECTION TECHNICAL DATA c 1 c 1 FACE LIFTING FACE SHEAR WORKING LOAD LIMIT IN SHEAR FOR OBELIX LIFTING SYSTEMS WITH ONE REDUCED EDGE DISTANCE h ef Table 6.6b CRACKED CONCRETE Minimum slab depth (H) = 1.5C1) PRODUCT DETAILS Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Edge Distance in Direction of (C1) Min Edge Distance or Half Spacing in Normal Direction (C2=1.5xC1) Min Edge Distance opposite to direction of shear (C3) Minimum Depth (H=1.5xC1) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) Tx Tx Tx Loading Conditions: Single Lifter, Lifting angle 90, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Cracked at service loads 48 PRODUCT DESIGN AND SELECTION GUIDE I

49 SECTION TECHNICAL DATA EDGE LIFTING EDGE TENSION WORKING LOAD LIMIT IN TENSION FOR OBELIX LIFTING SYSTEMS WITH TWO REDUCED EDGE DISTANCES t/2 t/2 Table 6.7a UNCRACKED CONCRETE t PRODUCT DETAILS Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Tension Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Minimum Edge Distace or Half Spacing in Normal Direction (C2=1.5 Hef) Element Thickness (t) Actual Distance to each Free Edge (C1=t/2) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) Tx Tx Tx Loading Conditions: Single Lifter, Lift angle 0, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Uncracked at Service Loads, Formed void 49

50 SECTION TECHNICAL DATA EDGE LIFTING EDGE TENSION WORKING LOAD LIMIT IN TENSION FOR OBELIX LIFTING SYSTEMS WITH TWO REDUCED EDGE DISTANCES t/2 t/2 Table 6.7b CRACKED CONCRETE t PRODUCT DETAILS Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Tension Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) Minimum Edge Distace or Half Spacing in Normal Direction (C2=1.5 Hef) Element Thickness (t) Actual Distance to each Free Edge (C1=t/2) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) Tx Tx Tx Loading Conditions: Single Lifter, Lift angle 0, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Cracked at Service Loads, Formed void 50 PRODUCT DESIGN AND SELECTION GUIDE I

51 SECTION TECHNICAL DATA EDGE LIFTING EDGE SHEAR WORKING LOAD LIMIT IN SHEAR FOR OBELIX LIFTING SYSTEMS WITH TWO REDUCED EDGE DISTANCES AND SPECIAL REINFORCING t/2 t/2 Table 6.8a UNCRACKED CONCRETE PRODUCT DETAILS Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) W Bar Size Panel Thickness (t) Actual Distance to each Free Edge (t/2) Min Edge Distance or Half Spacing in Normal Direction (C2) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) 6.5Tx120 Not Recommended N N N Tx N N N N N N N N Tx N N N N N Loading Conditions: Single Lifter, Lifting angle 90⁰, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Uncracked at service loads 51

52 SECTION TECHNICAL DATA EDGE LIFTING EDGE SHEAR WORKING LOAD LIMIT IN SHEAR FOR OBELIX LIFTING SYSTEMS WITH TWO REDUCED EDGE DISTANCES AND SPECIAL REINFORCING t/2 t/2 Table 6.8b CRACKED CONCRETE PRODUCT DETAILS Setting Details Concrete Compressive Strength (at Lift) Lifting Clutch Designation Maximum Working Load Limit (WWL) (T) Void Depth (l) Nominal Void Diameter (b) W Bar Size Panel Thickness (t) Actual Distance to each Free Edge (t/2) Min Edge Distance or Half Spacing in Normal Direction (C2) 15 MPa 20 MPa 25 MPa 32 MPa 40 MPa 50 MPa 65 MPa (T) (T) (T) (T) (T) (T) (T) 6.5Tx120 Not Recommended N N N Tx N N N N N N N N Tx N N N N N Loading Conditions: Single Lifter, Lifting angle 90⁰, FOS Lifter = 5.0, FOS Concrete Failure = 2.5, Uncracked at service loads 52 PRODUCT DESIGN AND SELECTION GUIDE I

53 SECTION NOTES This publication is a product selection guide to be used in conjunction with concrete engineering principles. The design data included in the enclosed technical tables relates to diverse applications for Obelix Lifting Systems relating to Obelix 6.5T and 10.0T Lifting Clutches and accessories. This information is provided for the assistance of appropriately qualified professionals in the preparation of lifting design specifications for concrete panels and concrete precast elements. The appropriate personal protective equipment, PPE, (safety eyewear, gloves, hard hats, hi-visibility vests and safety footwear) is to be worn during all stages of production, transportation and installation of concrete. VALIDITY This publication was issued in March 2016 and supersedes all previous Obelix Lifting Systems Pty Ltd publications of the same title. Due to on going research and development, changes may occur to specifications and features without notice. It is recommended that the user consults with Obelix Lifting Systems Pty Ltd, or downloads the most current version of this publication from DISCLAIMER These instructions are intended for use by suitably qualified professional building, construction and erection specialists. Obelix Lifting Systems Pty Ltd expressly excludes all liability for injury, damage, cost, expense or claim whatsoever suffered by any person resulting either directly or indirectly as a consequence of failure to install Obelix Lifting Systems Pty Ltd Products in accordance with these installation instructions or applicable industry codes and standards. 53

54 SECTION NOTES 54 PRODUCT DESIGN AND SELECTION GUIDE I

55 SECTION NOTES 55

56 Parchem Construction Supplies Pty Ltd 7 Lucca Road, Wyong NSW 2259 Phone: