12/2014 Design Calculation. MESA Revola (HDWF) Modular Wallform System

Transcription

1 12/2014 Design Calculation MESA Revola (HDWF) Modular Wallform System

2 Contents Introduction System Description 1 System Overview 3 Technical Features Connection Variation 7 Loading Limits Concrete Pressure 12 Load Analysis 17 Tie-Rods 24 Formwork Connection 25 Push-Pull Props 26 Lifting Device 27 Platform Bracket 28 Test Results 29

3 General Remarks Remarks Symbols Used All products of MESA should be used according to the relevant safety regulations of the state or country in which they are operated. Information Schematic illustrations on this manual give only basic rules to be applied during assembly, therefore it does not complete from the safety point of view. MESA products could only be used according to the Instruction or User Manuals, any Technical Details given in Documents provided by MESA. Any MESA products could not be combined with the products of other manufacturers. Important Note Sight-Check Warning Mesa Imalat reserves the right to make technical changes in the interests of progress. Copyright by MESA Imalat San.ve Tic A.S.- Ankara-Turkey

4 Warranty Warranty Period Limited Warranty for two (2) years is promissed by Mesa İmalat San.ve Tic. A.Ş. for Steel Face Formworks and Slab Formworks unless the Operational Conditions described below are violated. This warranty covers defects of steel material, welding and painting. Operational Conditions Instruction or User s Manuals must be used while Formwork assemblies, accessory attachements and concrete casting. It is not allowed to use hummer, sedgehummer, cranka and vs that cause physical demage on Formworks, and also applications of extra welding, cutting and drilling without permission of authorities. It is not allowed to exceed the Max Concrete Pressure described in Technical or User s Manuals. Formwork should be used between + 50 C and 30 C. Formworks should be cleaned after each application to remove the concrete residues and active faces should be lubricated with suitable concrete/metal seperation oil. This maintenance covers the flatning of active surface, repainting, welding and rust control. During the storage period, all active surfaces should be lubricated with suitable oil to prevent rusting. Stock area should be closed area; if it is not possible, formworks and accessories should be stocked in open areas by covering them with water resistant materials. Electrical power supply and connections must be suitable as written in the ınstruction or User s Manuals given by MESA.

5 Introduction SYSTEM DESCRIPTION System Description Basic Introduction MESA-Revola Wall Formwork System is designed and manufactured for concreting of load bearing walls and columns. System ensures the higher concrete quality, perfect durability by setting new standards and cost efficiency due to its characteristics on easy cleaning, easy stocking with reduced quantities. MESA-Revola Wall Formwork System is cranedependent but admits very high concrete pressure up to 100 kn/m² when using suitable tie-rods System shortens the concreting time since high resistance to concrete pressure. Application Ranges Universal design of MESA-Revola Wall Formwork System gives wide range of application on construction sites. Both usage in industrial and civil engineering projects are easy. Although the modularity provides highly simplified application when adapting to any floorplan in large-area forming, it is easily adopted to shaft and column applications. Due to long lasting usage life without carrying out any maintenance or treatment, MESA-Revola Wall Formwork System is very suitable on core walls of towers. Specially designed frames are produced from high strength steel and they are manufactured of closed profiles welded in mitred joints. Surface Material Concrete facing materials differs according to demands of the costruction sites. 1 - Steel Plate having 4 mm thickness, 2-21mm thick Plywood 3-21mm thick Plywood covered Polyoplephine in both surfaces ; Three times longer lifetime than standart plywood life. When smooth and fluent concrete surface is on demand, St-44 thempered steel plates with 4 mm thickness is suitable. 21 mm plywood or Plywood covered Polyoplephine should be preferred if reconditioning process is wanted. All Panels are Hot-Deep Galvanised if the surface marerials are 21 mm plywood or Plywood covered Polyoplephine 1

6 Introduction System Overview Standart Lengths Standart Heights are 3,300 3,000-2, and 600 mm. Standart widths of panels are and 300 mm. Inner Corners having 300x300 mm widths are also produced with the heights of 3,300 3,000-2, and 600 mm. Adjustable fillers gives flexibility when special wall widths are to be reached. Universal Panel makes easy the special applications when non-standart tie-rods positions are needed and also they could be used on all outside corners and R.C. Standart Components Panel Clamp having 5 kn load bearing capacity gives versatility on application. Adjustable Clamps are used when wooden fillers between two Std.Panels are required. Std.Working Platform Bracket is suitable for both Std.Steel Platform and in-situ-wooden platforms. Panels are supported by Std.Prop sets. Connection of prop is easy with special prop connectors. Wall stopends are easily installed between universal panels with side connectors. column applications. Only difference between standard panels and universal panels is standart tie-rod holes in the level of intermediate open-c stiffners of panels. These holes are factory-drilled and have 5 mm increments between each others. 2

7 Introduction SYSTEM OVERVIEW System Overview Wall Formwork Parts Platform Bracket Working Platform Main Panel Extension Panel Lifting Device Steel Waler Fixing Tie and Flange Nut Adjustable Filler Tension Device Inside Corner Panel Lock Tie Rod and Flange Nut Corner Tie and Flange Nut Revola Wall Formwork System -HDWF 3

8 Introduction System Overview Parts Adjustable Lock Corner Tie and Flange Nut Universal Panel Easy Filler Upper Prop Prop Connector Lower Prop Prop. Base Tie-Rod and Flange Nut Main Panel Working Platform Guardrail Post Ladder Connector Access Ladder Outside Corner Access Platform Revola Wall Formwork System -HDWF DESIGN CALCULATION 12/2014 4

9 Introduction System Overview Column Formwork Parts Ladder Connector Ladder Access Platform Flange Tie Universal Main Panel Platform Bracket Prop Connector Lower Prop Upper Prop Prop Base Working Platform Panel Lock Universal Extension Panel Guardrail Post Lifting Device 5

10 Technical Features CONNECTION VARIATION Connection Variation MESA Revola Wall Formworks are designed so that vertically placed two sets of Tie-rods will be satisfied up to the concrete height of 2,700 mm. Maximum horizontal distance between two adjacent tie-rods is 1,200 mm. Tie-rod holes on each panel frames are positioned so that the arranging all the panels to different height combinations will be possible, With 300 mm increments, concrete height could be arranged up to 4,500 mm. Each Width Set of Panels ( and 300mm) have two different heights for vertical adjustment ; 600 and 1,200mm Main Panels could also be superposed to achieve bigger heights. While using Main Panels having 3000mm and 3300mm, setting up of the panels as upside down is recommended. 7

11 Technical Features Connection Variation Panel Combinations for Walls Up to Concrete Height of 270 cm Up to Concrete Height of 300 cm Up to Concrete Height of 330 cm 8

12 Technical Features Connection Variation Up to Concrete Height of 360 cm Up to Concrete Height of 390 cm Up to Concrete Height of 420 cm 9

13 Technical Features Connection Variation Up to Concrete Height of 450 cm 10

14 Technical Features Connection Variation Adjustment on Column Formwork Wmax MESA Revola Column Formworks are made up of Revola Universal Panels with three different widths of 1, mm. Each edge of the columns are sized by adjusting the connection points with the holes on the panels. Wmax Wmax Adjusting Holes allow to adjust the size of the column with 50mm incrementation (d). Wmax W distance (mm) for Different Widths of Column formworks Detail A Hole No.s Panel Widths ,050 (Wmax) 750 (Wmax) 450 (Wmax) 2 1, (Wmin) (Wmin) (Wmin) Detail A Wmin Wmin Wmin W Wmin If the size of the column is greater than 1,050 mm then it is possible to use two or more Universal Panels which are connected to each other side by side. Column Tie d Embedded Nut Hole No. For the column sizes greater than 1,100 mm; Extra Tie-Rod should connect the reciprocal panels. 11

15 CONCRETE PRESSURE LoadAnalysis Concrete Pressure Deflection According to Standard DIN 18202, table 3, line 5 to 7; Admissible deformation values for the concrete are listed by means of the relation to the distance between the measuring points. mm Flatness Tolerances for Walls and Slabs Under-Faces (line values according to DIN 18202, table 3) tolerances distance betweenmeasuring points m 12

16 LoadAnalysis Pressure of Fresh Concrete on Vertical Formwork (DIN 18218: ) 13

17 LoadAnalysis 14

18 LoadAnalysis 15

19 LoadAnalysis 16

20 LoadAnalysis LOAD ANALYSIS Calculation Method Finite Element Analysis Program ANSYS R15.0 This type of analysis depends on the Matrix displacement method. On the analysis, the principle of linear static elastic analysis was taken into consideration. Basic Formwork Design Dimensions : 1,200mm x 4,000mm Materials : Primary Sections on Frames : S315MC (δall= 315kg/mm2) Secondary Sections ; St-37 (δall= 235 kg/mm2) Concrete Facing ; Plywood Cover Polyoplephine (21mm thickness)) 17

21 LoadAnalysis Loads Acting on the System Fresh Concrete Pressure ; 10,000 kg/m²max.(as hydrostatic pressure) (H = 4000 mm) Density of Fresh Concrete ; 2,500 kg/m3 100 KN/m²

22 LoadAnalysis Result of Analysis Maximum von Misses Stress Maximum Principal Stress 19

23 LoadAnalysis Factor of Safety 315 / = > =>OK! 20

24 LoadAnalysis Maximum Deflection 1560 mm, between two support 2.55 mm is under the range of Table 3, line 7 on DIN 18218: Conclusion For Revola wall formwork system Max. Permissible fresh concrete pressure is 100KN/m² 21

25 LoadAnalysis Maximum Tension Force Acted on Tie-Rods 1 st Tie-Rods 2 nd Lowest Tie-Rods 22

26 LoadAnalysis 3 rd Lowest Tie-Rods 4 th Lowest Tie-Rods 23

27 Tie-Rods TIE-RODS Tension Forces of tie-rods 7,918 kg = kN<160 kn 5,590 kg (for 1st Tie-Rods) 5,513 kg (for 2 nd Tie-Rods) 7,918 kg (for 3 rd Tie-Rods) 7,843 kg (for 4 th Tie-Rods) (working load of Ø20mm Tie-rod SAS 900/1100- Type FA Optimum Rate of Concrete Placing With20FA Tie-Rod and 20Fx55 Flange Nut Permissible Rate of Concrete placing will be ; Temperature Kind of Concrete Air / Concrete HOZ / L NW PZ 35F PZ 45F / PZ 55 ºC m/h m/h m/h

28 Formwork Connection FORMWORK CONNECTION Tb : Buckling Moment on the Frame Me :Moment from each 2 nd Stiffeners Ta :Buckling Moment between 2 tie-rods Fc :Total Tension Force on Panel Locks Fc Fc Fb :Tension Force between 2 tie-rods c b :Total Number of Panel Locks :Number of Panel Locks between 2 tie-rods ForVerticalConnections of Panels, at least 2 number of Panel Locksmust be used. Tie-Rods Panel Lock Frame 2 nd Stiffener Working Load of a Panel Lock= Buckling Load / 1.7 = 64,72kN / 1.7 = 38.07kN = 4,700 kg. Min.Number of Panel Locks Required for different Panel Heights to be connected Hmax Height (m) Tb Me Ta Fc Fb c b kgm kgm kgm kg kg pcs pcs ,378 3, ,222 5, , ,600 9, , ,444 9, , ,289 9,

29 Push-PullProps PUSH-PULL PROPS q = 1.43 kn/m2 K2d Wmax H2d Hmax Ka K1d X Kv emax Kh L2d 60 < X < 70 Connections of Push- PullPropsshould be closetoverticalprofiles of Panel F Maximum Axial Loads for different Panel Areas supported by Two sets of Push Pull Prop Hmax Height (m) e Push Pull Prop interval (m) Wmax = 2 x emax e K1d K2d Ka Kh Kv L2d : Push Pull Prop Interval : Axial Load : Axial Load : Support Reaction : Support Reaction : Support Reaction : 1.5 m (max.) WindSpeed w = 151 km/h WindPressure q = 1.43 kn/m2 Up to 100 m above ground (Cf= 1.3 DIN 1055) Axial Working Load of Mesa-Push Pull Prop Kall = kn / 1.7 = kn See Section Test Results of this Manual. 26

30 Lifting Device LIFTING DEVICE α Panel Width 6 m. Permissible Working Load = 1,450 kg Panel Height 6 m. α 60 Permissible Working Load = 1,190 kg Panel Height (m) Maximum Panel Area to be lifted (m2) Panel Widths (m) Maximum weight of Panels to be lifted together ; 1,500 kg x 2 Lifting Device = 3,000 kg Average Weight of RevolaPanels = 90 kg/m2 Maximum Panel Area to be lifted together = 3,000 kg / 90 kg/m2 = 33 m2 27

31 Lifting Device PLATFORM BRACKET Permissible Platform Load; = 150 kg/m2 Total Load acting on a 600x2400mm Platform; 0.6m x 2.4m x 150kg/m2 = 216kg q Uniform Distributed Load on Platform Bracket; = 216 kg/ 2 / 0.6m = 180 kg/m Platform Bracket Platform Lengths Max.Total Load (kg) Bracket Load (kg/m) 600 mm mm ,200 mm ,500 mm ,400 mm L/4 L L/2 L/4 W Maximum Loadacting on Mesa Platforms in abovetableshould not be exceeded. Use Standard Mesa Working Platforms or 5mm thick timber. 28

32 Test Results TEST RESULTS Test Results of Mesa Push-Pull Props 29

33 Notes Revola Wall Formwork System - HDWF