2/2011 Technical Manual MESA - ERTF. Modular Tunnel Form System

Transcription

1 2/2011 TechnicalManual MESA - ERTF Modular Tunnel Form System

2 Contents Introduction System Description 1 Comparisons 2 Scope of Applications 4 Simple Procedure 5 System Overview 11 Dimensions and Physical Properties 13 Technical Information Parts in Detail 16 Complementary Equipments 36 Types of Connection 37 Permanent Assemblies 38 Temporary Connections 45 Part List Panels 48 Supports 51 Jacks and Driving Units 54 Safety Componenets 55 Lifting & Transporting 57 Kicker Forms 58 Stopends 61 Intermediate Components 63 Tie-Rod Accessories 66 Tools 68

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. 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. Mesa Imalat reserves the right to make technical changes in the interests of progress. Information Important Note Sight-Check Warning 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 malat San.ve Tic. A.. 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. For Hydraulic Cylinders and Hydraulic Power Units, the limited warranty period is one (1) year. Service Life Steel Face Formworks and Slab Formworks, produced by Mesa MALAT San.ve Tic.A.., is good for 500 concrete castings unless The Operational Conditions described below are violated. 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. After 250 applications, maintenance should be done at site. This maintenance covers the flatning of active surface, repainting, welding and rust control. After 500 applications, maintenance should be done at work shop where the necessary equipments exist. 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. Maitenance procedure should be repeated for each 250 usages after first 500 usages are exceeded. For HCP-hydraulic system, the allowable working pressure must not be exceeded ( 250 bar ). All connections between hydraulic cylinders, hydraulic power units and hydraulic pipes and must be checked against leakage before each usage. 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 Tunnel form system contruction is a method that the wall and the slab are cast in a single operation. Half Tunnel System is composed of two half shells which are placed together to form a room or cell, while several cells making an apartment. Once reinforcement is placed, concrete for walls and slabs can be poured in a single operation. The Half tunnel design makes possible to remove one whole side of a tunnel, then to prop the slab near the joint before removing the other half, permitting a faster rotation of the equipment. By using a heating system during night ( only in countries where the air temperature is comperatively low ), the concrete has a sufficient strength to allow the early stripping of the forms in the next morning. Tunnel Formwork system which offers a complete solution is: Ergonomic to save time Professionally designed to solve every request Safe enough to offer fool-proof workplace safety When using tunnel form system the construction time is much shorter than that of conventional method. Many studies showed that almost 50% of the time is cut compared to traditional methods. A crew of 10 people can achieve a daily cycle of casting 1-2 apartments per day depending on the type of structure. Once you catch this daily cycle economy comes by itself. Installation of electrical conduits, water and gas pipes in the shell reduces the internal finishing work, internal finishing proceeds in accordance with the concrete shell construction resulting in reduced total building time. The dimensional accuracy of the concrete structure allows the placement of partition walls and fixing of all other finishing material such as joinery right after casting. Much of the finishing work like plastering is eliminated through a perfectly flat concrete surface. Paint, wall paper or any decoration can be applied directly to the surface. Advantages Half-Tunnel Formwork System provides ; Fast construction fits to tight construction schedules: In the high temperature zones and/or by thermal treatment, with the use of ordinary cement, the normal pace is one day per cycle. Reduction in total construction time: Installation of all utility conduits in the shell reduces the internal finishing work. Economy through reduced construction times: Not to get beaten by price increases. A perfect daily rhythm for other works at site. A monolithic structure with simultaneous casting of walls/cross-walls and slab A nice concrete surface that eliminates much of the finishing works: The obtained surface allow direct application of paint or wall paper after sanding off the fins at the joints connecting two forms and smoothing with paint filler. Dimensional accuracy Standardisation of finishing works such as joinery, partition walls, etc. Last three means quality Complete workplace safety The simultaneous casting of walls, slabs and cross walls results in a monolithic structure which meets the requirements of building codes of countries located in earthquake zones. 1

6 Introduction COMPARISONS Comparisons With Other Systems Generally, Half-Tunnel Formwork System gains ; Less Construction Items : Less masonry, no plastering, no formwork timber, no nails,less tie bars, etc. 15% less steel in weight and less Labor; By using ST IV instead of ST in. Higher Net Ffloor Area to Gross: 86-88% compared to 82-84% in conventional systems Advantageous over Industrial Timber Forms : After building of 140 housing units. Advantageous over Conventional System : After building of 90 housing units. Average Cost Advantage : 45% in projects of over 100 houses. Advantageous on Eartquake Zones : Area of load bearing walls to the total area is 2% more than compared to 0.5% in conventional systems. For low-rise buildings e.g. 5 storey, total weight of the building can be designed tons/m2 lighter than compared to 1,30 in conventional method. No buildings built by tunnel form system reported as demolished or damaged. Only minor cracks have been observed. 2

7 Introduction Comparisons With Classic Tunnel Form Systems ERTF Modular Half-Tunnel Formwork System has a lot of significant advantages according to the Classical Tunnel Formwork Systems. These are; 90% Less Labor Cost During Horizontal Alignments of Deck Panels : Foldable Inclined Props are adjusted at the beginning only. Locking Arm of the Prop will provide the required alignment of Deck Panel when it is locked. Separation of the Panels from the concrete will become unlaboured also. 75% Less Labor Cost During Setting Up and Striking Operations: Portable Rollers which enable to drive the Tunnels easily, reduce the setting up and striking times considerably. 65% Less Labor Cost During Plumbing Operation : Newly installed Jacks on Tunnel Wheels will make simple the plumbing of the Tunnel while reducing the labor cost. Higher Kicker means Easier Level Control : High kicker makes it easier to adjust tunnel heights which eliminate levelling mistakes of the foundation. Easy use with elevated level of lowest Tie-rod position: The Elevation of the lowest level of tie-rod position to 290mm eliminates the problem arisen with the concurrenge of kicker and tie-rod cones. Advantages on the Next Project : Since Vertical Panels have standart heights, it will be easy to adopt all vertical panels to new projects by changing the extension panels only. The same procedure is also valid for the Deck Panels. Modular Vertical Pannel with Extension : Vertical panels are produced in standard heights. It can be used for half-tunnels and also for end-walls which reduces different types of panels on site. Vertical panels are used with upper extension panels to reach different floor heights easily. In this way panels can easily be reused at new projects. ERTF Telescopic Push Pull Prop : Standard push-pull props can easily be used at any tunnel span by the help of its telescopic design. It eliminates the need for several different types of props. ERTF Push-Pull Props makes it very easy to adjust the height & level deck panels of tunnel form. Lifting up the the control arm will simply move the deck panel down. The arm is locked once the panel is adjusted properly. Modular Deck Pannel with Extension : Deck panels are produced in standard width and can be used at any span dimension with extension adapter panels. In this way panels can easily be reused at new projects. It eliminates the need for deck-panels with special dimensions. Provides better concrete finish at joints of extension panels. Roller for Stripping the Tunnels : Half-tunnels can easily be moved and stripped on platforms by the help of rollers which are used instead of wheels. It is placed under vertical panel of half-tunnels above the slab. It reduces vertical panel price by cancelling the wheels and also simplify storage of vertical panels. Formwork weight will not affect stripping platform as the tunnel forms are carried by the rollers during their movement. Allows to application on higher concrete pressure by means of powered lowest and highest Stiffeners: More strength and rigidity obtained by powered stiffeners located on the same level of the lowest and highest tie-rods allows the increased concrete pressure caused by higher rate of placing. Since the rate of placing of concrete increases, total concreting period will be decreases. 3

8 Introduction SCOPE of APPLICATION Scope of Application 4

9 Introduction SIMPLE PROCEDURE Simple Procedure On Layout Concrete Structure to be built will determine the quantity of Tunnel Formwork. Straight walls and slab ends must be preferred, because otherwise will increase the floor cycle time which is not the logic of Tunnel Formwork Operations. Lift & Stair Shafts Symmetric layout plans make easy the application of Tunnel Formwork if more than one concrete phase for one floor is to be planned. R.C.Wall to be cast Door Opening Slab End Platforms should be located all around the building. Full set of Platform of one floor give safer working area and easier application stage. For product, installation and operation details of Stripping Platforms, Landing Platforms and Gable End Frames to be used, refer to relevant booklets given by MESA. Stripping Platform Landing Platform Gable End Frame 5

10 Introduction Simple Procedure Since transferring of both Tunnel Formworks and Platforms have to be evaluated; generally, full set of Tunnel Formwork of one full floor should be avoided. Because, before transferring of all Tunnel Formworks to the next phase, one should transfer the Platforms also. In order to transfer a full set of tunnels of a floor, one must transfer them to the ground first, then transfer the platforms to the next floor and then transfer the tunnels on the ground onto the platforms. This procedure will repeated in each floor. Back Panel Outside Wallform Length of a Half Tunnel Set Deck Panel Extension Length of a Half Tunnel Approximately, 300 m2 Formwork Area on Layout Plan is suitable for everyday concreting cycle. This area gives approximately 1000 m2 total formwork area (total area of all Vertical and Horizontal Panels) Figure shows the first day application: erecting the Formwork, Concreting and Stripping the Formwork for the next phase. Stripping Direction Tunnel Number The lengths of Half Tunnel Sets should be determined so that, the weight of the one which has the maximum weight should not exceed maximum allowable load of the Tower Crane. Second day is started with the transferring and erecting of Tunnel Formworks and Outside Wallforms to their next locations and continue with concreting. Slab casted in 1st. Phase of Concreting Half Tunnel Sets kept in previous positions Half Tunnel Sets transferred to location of 2.nd Phase of Concreting At the same time, Platforms left behind the First Concreting Phase is transferred to the next locations (generally to the next floor) Cycle has to be completed and next day will be started with the transferring and erecting of Tunnel Formworks to the First Concreting Phase of the next floor. R.C.Wall casted in 1st. Phase of Concreting Slab casted in half in 1st. Phase of Concreting Outside Wallforms transferred to location of 2.nd Phase of Concreting 6

11 Introduction Simple Procedure Once the Tunnel Formworks and Outside Wallforms are erected to the locations on the First Concreting Phase, the Platforms left behind the Second Concreting Phase will be transferred to the next locations (generally to the next floor) Slab cast in 1st. Phase of Concreting Slab completed in 2nd. Phase of Concreting Slab cast in 2nd. Phase of Concreting R.C.Wall cast in 1st. Phase of Concreting R.C.Wall cast in 2nd. Phase of Concreting 7

12 Introduction Simple Procedure On Site Foundation is completed as per construction drawings. Before the first casting with Tunnel Form, kicker should be cast in order to position the load bearing concrete walls. Reinforcement wire mesh and bars of the concrete walls are installed. First Half-Tunnel set is taken to place by crane in accordance to the formwork layout. Bottom of Tunnel Form is set levelled with the line on the kickers by the help of the jacks mounted on the Vertical Panels. Block-outs for door/window openings are assembled on vertical surface. Electrical Conduits are installed. Cones and tie-rods are placed. Second Half Tunnel Unit is taken to place. Blockouts are assembled. The verticalities of Half Tunnel Units are set using the Wheeled Supports. After providing adverse deflection of deck panels, two Half-Tunnel Units are locked by the roof locks on the Deck Panels. Cones and tie-rods are placed. 8

13 Introduction Simple Procedure All Tunnel Form Units for the first casting phase are located in a same manner. Outside Wall Formworks for endwalls are positioned. After adjusting the verticalities of all Tunnel Forms, tie-rods are fastened and Horizontal surfaces are oiled. Electrical Conduits are installed. Block-outs for openings on slab are installed. Wall and Slab stopends are set in place. Reinforcement wire mesh and bars on slab are installed and the Kicker forms for next level are fixed on the Tunnels. Final checks are performed before concreting and Insulation curtains are placed for night-time heating at cold weathers. Concreting procedure is started from the inside walls towards the end walls firstly. Then the slab concrete is cast. Each tunnel room is heated by simple heaters throughout the night for curing purpose at cold weather. Next morning is started with dismantling of tierods. Half Tunnel Sets are dismantled to each other. Block-outs are also dismantled from Half Tunnel Units. Half Tunnels are moved on the rollers and pulledout by crane to the next place of concreting by the help of lifting triangle. Reinforcement wire mesh and bars are installed for the next level. 9

14 Introduction Simple Procedure Surfaces of Vertical panels are cleaned and oiled while stripping the Half Tunnel Sets. At every span, the slab is back propped after the first Half Tunnel Unit is stripped. Second Half Tunnel Unit is removed after back propping. Stripping-Platforms and Gable-end-Platforms are introduced to the building on the ground level where the Half Tunnels are in the first level. These platforms are all around the perimeter of the building. Tunnel Form Sets are stripped out on Stripping- Platforms. 10

15 Introduction SYSTEM OVERVIEW System Overview Main Parts C J B E G A B C D E F G H I J K L M N P Half Tunnel Back Panel Outside Wallform Lifting Beam Lifting Device Roller Kicker Form Slab Stopend Wall Stopend Slab Boxout Door Boxout Window Boxout Stripping Platform Gable End Frame Tie-rod & Cone Set N D M H F A For product, installation and operation details of Stripping Platforms, Landing Platforms and Gable End Frames to be used, refer to relevant booklets given by MESA. 11

16 Introduction System Overview I P K B L Basic Materials The surfaces of panels which are forming the tunnel form are made from THRU mm. steel plate (equal to St.44). They are stiffened by 50x60mm square tubes, welded at every 178 mm. Panels are assembled rigidly one to the other by special U-shaped centering pieces and bolts which enable only slight deformations of the dihedral. The lateral ends of the panels are made of 60x30x4mm cold rolled U-profiles, in which the connecting equipment is employed to ensure the correct fit of the consecutive units. Assembly is carried out using i Only the bottom edges of Vertical Panels are made of 15x120mm steel plates. The end of the deck panel, built of an 80x80-mm. steel angle section carries the key locks permitting the assembly of two units face to face. Generally the turn of the deck panels to verticals is 63 mm. The turns on the back panels are 93 mm. to vertical and deck panels. The connection between the panels is done with U-shaped alignments and bolts. 12

17 Introduction DIMENSIONS & PHYSICAL PROPERTIES Dimensions & Physical Properties System Section w g v WD1 WDE1 WDE2 WD2 a HQE TD HVE HQ HV HT h K s concrete already poured Detail A concrete to be poured HT :Tunnel Height WD :Deck Panel Width WDE :Deck Panel Extension Width HV :Inside Panel Height HVE :Inside Panel Extension Height HB :Back Panel Height HQ :Outside Panel Height HQE :Outside Panel Extension Height TD :Deck Panel Turn TB :Back Panel Turn K :Jack Height t :Height of Panel Touch to Kicker h : Floor Height s : Slab Thickness w : Wall Thickness g : Span between Walls a : Kicker Height v : Gap between two panels (=2mm) Floor Height (from Slab to Slab) Span between Two Adjacent Walls TD = 63mm TB = 93mm a = 120mm h = K + HV + TD + s g = ( WD1 + WDE1 ) + ( WD2 + WDE2 ) + v K = 87 mm t = 33 mm Net Floor Height (From Slab to Ceiling) Tunnel Height hnet (Net Floor Height) = h (Floor Height) - s (Slab Thickness) HT = HV + TH ERTF Feature HQ= HV Back Panel Height HB = HT Total Inside Panel Height HV + HVE = hnet - K - TD Total Outside Panel Height HQ + HQE = h + a - K a t K As a feature of ERTF Modular Tunnel Formwork System, Inside and Outside Panels are same and they are called as Vertical Panels. Detail A t = a - K 13

18 Introduction Dimensions & Physical Properties Standard Span & Floor Height Standard Spans g (mm) Standard Floor Heights hnet = h-s (mm) Other Span dimensions are provided by additional filler forms called as Exensions installed to Deck and Back Panels or introducing new Panels having required dimensions. Other Floor Height dimensions are provided by additional filler forms called as Exensions installed to Vertical Panels or introducing new Vertical Panels having required dimensions. Larger spans g than 5700 mm can be achieved by introducing table forms between two half tunnels. WD Combinations for Span g Preference Table for Standard Spans "g" (mm) (including v = 2 mm) WD1 + WDE WD2 + WDE Preference Order Best Better Rarely Never Frequently Used Tunnel Heights Tunnel and Panel Heights (mm) hnet HT HB HV HVE HQ HQE , s s s s s s s s s s 14

19 Introduction Dimensions & Physical Properties Physical Properties Inside, Outside and Back Panels are fitted to each other by three tie-rods located vertically. 260 Maximum horizontal distance between tie-rods is 1250 mm. Allowable load on Tie-Rods is 90 kn. If HV = 2500 mm then b=1000 mm If HV = 2700 mm then b=1200 mm Allowable hydrostatic pressure of concrete to be applied on Vertical Panels having maximum height of 2700 mm is 67.5 kn/m2. Maximum deflection on Vertical Panels under allowable concrete pressure is 1.45 mm b HV Stress Diagram Deflection Diagram 15

20 TechnicalInformation PARTS in DETAIL Parts in Detail A Half Tunnel The standard form (half-shell) take the form of a right hand dihedral, whose vertical plane HT is made up of a floor-height panel, less the slab thickness s and less K (= 87 mm) (or more if the kicker is high) for jacking down. 1 L WD WDE WD is the width and TD is the turn of Deck Panel. Turn is generally equal to 63 mm. It could also be 33 or 93 mm. WDE is the width of Deck Panel Extension. The sum of the widths of Deck Panels and their Extensions for a certain span is 2mm less than the span width g HV is the height of Vertical Panel. HVE is the height of Vertical Panel Extension. The-standard lengths L of the dihedrals are 2.50 m. and 1.25 m. According to the length of the bay, special panels can also be provided. TD HVE HV Legend Pcs. 1 Deck Panel 1 L g 2 Deck Panel Extension 1 3 Vertical Panel 1 4 Vertical Panel Extension 1 5 Foldable Prop 2 6 Wheel Support 2 7 Wheel Connector 1 8 Tunnel Driving Wheel 1 HT 9 Vertical Panel Jack 2 For wider spans, Table Forms are placed between the Deck Panels to ensure not to exceed the allowable deflection of the slab. 16

21 TechnicalInformation Parts in Detail 1 Deck Panel The surfaces of Deck Panels are made from THRU mm. steel plate. They are stiffened by 50x60 mm square tubes, welded at every 178 mm. They are assembled rigidly one to the other and to the Inside Panels by U-Alignments and bolts which enable only slight deformations of the dihedral. L The one end of the deck panel is built of a 60x60x4 mm. cold rolled U-profiles permitting the assembly of inside panel and/or inside panel extension. Generally turn of the deck panels to verticals is 63 mm. The connection between the panels is done with U- Alignments and bolts. WD The opposite end which is connected to the Extension Panel is made of 60x30x4mm cold rolled U- profile. TD The other two reciprocal ends which are connected to the other Deck Panels are also made of 60x30x4mm cold rolled U-profiles in which the connecting equipment is employed to ensure the correct fit of the consecutive units. Standard Dimension of Deck Panels ( W D + T D ) x L (mm) ( T D = 63 mm) WD L 1250 ( ) x 1250 ( ) x 1250 ( ) x 1250 ( ) x 1250 ( ) x 1250 ( ) x 1250 ( ) x ( ) x 2500 ( ) x 2500 ( ) x 2500 ( ) x 2500 ( ) x 2500 ( ) x 2500 ( ) x Deck Panel Extension The surfaces of Deck Panel Extensions are made from THRU mm. steel plate. They are stiffened by 50x60 mm square tubes in a reduced quantity. Standard Openings L WDE Three ends which are to be connected to Deck Panels or Extensions permanently are made of 60x30x4mm cold rolled U-profiles. The remaining end built of an 80x80-mm. steel angle section carries the key locks permitting the assembly of two units face to face. Extensions are connected to Vertical Panels with Centering U and bolts. WD WDE Total Dimensions with Std.Deck Panels and Std.Deck Panel Extensions ( W D + W DE ) (mm) The alignments of two panels are provided by the adjustment of Hinge Bolts. Standard lengths L are 1250 and 2500 mm. 17

22 TechnicalInformation Parts in Detail 3 Vertical Panel ERTF - Vertical Panels are used as both Inside Panels of The Half Tunnels and Panels of the Outside Wallforms. Therefore, Outside Panel height HQ is equal to the height of Inside Panel HV on the Half Tunnel. L Same with the Deck Panels, the surfaces of Vertical Panels are also made from THRU mm. steel plate. They are stiffened by 50x60 mm square tubes, welded at every 178 mm. Three Main Stiffeners which are welded to the panels on the levels of Tie-Rods are made up of 50x100x5 mm Cold Rolled U-Profiles. These stiffeners are also used for connections of Wheel Supports, Foldable Props. HV = HQ All edges except the lower edge, are made of 60x30x4mm cold rolled U-profile. Vertical Panels are connected to each other or Extension Panels or Deck Panels by these edges with Centering U and bolts. The lower edge is made up of Steel Plate having 15x60mm section. This Plate increases the strength of the Panel against any impacts or buckling which might be occurred during striking from concrete with lever arms. HV=HQ Standard Dimensions (mm) There are two standard heights of Vertical Panels which are 2500 and 2700mm. L x x x x Vertical Panel Extension (Inside) All materials used in Vertical Panel Extension are same with that of Vertical Panels. The edges of Panel Extensions are made from 60x30x4mm cold rolled U-profile. Extensions are connected to Vertical Panels by this edge with Centering U and bolts. HV L Inside Vertical Panel Extension The alignments of two panels are provided by the adjustment of Hinge Bolts. Total Vertical Panel Height in Tunnel Formwork Sum of Vertical Panel and Vertical Panel Extension ( H V + H VE ) (mm) HVE HV

23 TechnicalInformation Parts in Detail 5 Telescopic Foldable Prop Inclined prop made of two nested tubes having Ø76 mm and Ø60 mm diameter (as outside and inside tubes) makes easy to adjust the nominal length of inclination to ensure the perpendicularity of vertical and deck panels by a screw jack. Telescopic feature of the prop provides the usage of it for all standard span lengths of Deck Panels. Required reverse deflection of the Deck Panel before concreting is easily adjusted and the Prop is fixed with the counter nut. After concreting, in order to draw down Deck Panel from the concrete the Folding Arm is turned on. Then Deck Panel will be dropped. By superposing the holes both on Inside and Outside tubes, The Length LJ could be adjusted with 50 mm incrementation. Table below shows the adjustments of Variable Lengths on Telescopic Foldable Props according to the selected Vertical and Deck Panels. Reverse deflection of Deck Panel before concreting operation will be provided by additional adjustment of the dimension LK of the Jack which will be described in the Booklet of User s Manual supplied by MESA. Types of Props LK LJ Lprop Folding Arm is closed LF Two Foldable PropTypes described as; Prop #1 : Foldable Prop 2500 Prop #2 : Foldable Prop 2700 LF Lprop = LF + LJ + LK Folding Arm is open LJ LK Lprop min max min max min max # # Foldable Prop Adjustment on Tunnel Formworks "Standard Vertical Panel Extensions" versus "Standard Deck Panel Widths" Height ( mm) Vertical Panel Vertical Panel Extension Standard Deck Panel Widths (W D) ( mm) HV HVE # LJ LK # LJ LK # LJ LK # LJ LK # LJ LK # LJ LK # LJ LK For Vertical Panel Height HV as 2500 mm, Deck Panel Width WD as 1150 mm and Vertical Panel Extension Height HVE as 100 mm, Then select ; Foldable Prop as #1, and take ; LJ = 350 mm & LK = 167 mm 19

24 TechnicalInformation Parts in Detail 6 Wheel Support ERTF Modular Half Tunnel is driven by means of a Special Wheel unit supported by a pair of Wheel Supports. Wheel Support is made up of Ø48mm hot deep galvanised tube. This support is connected to the Panel and the Wheel Unit with bolts via the holes at both ends of it. Length of Wheel Support LS varies with the Deck Panel width WD and the Vertical Panel height HV. LS Wheel Supports do not differs whether the Half Tunnel Length L is equal to 2500mm or 1250mm. HV Types of Wheel Supports "Deck Panel Width W D" versus "Vertical Panel Height H V " 850 WD WD WD 2650 Wheel Support (2500) Wheel Support (2500) Wheel Support (2500) L S=1857 L S=2123 L S=2357 Wheel Support (2700) Wheel Support (2700) Wheel Support (2700) L S=2040 L S=2289 L S=2478 Refer to section of Part List on this Manual for more information about types of Wheel Support. 7 Wheel Connector Wheel Connector joins the Panel, Wheel Support and the Tunnel Driving Wheel. LD Rigid body of the Wheel Connector is made up of Ø48mm tubes and specially shaped 8mm thick steel plates. Wheel Connectors do not differ whichever the Half Tunnel Length L is (2500mm or 1250mm) or the Vertical Panel Height HV is (2500mm or 2700mm). LC HV Types of Wheel Connectors "Deck Panel Width W D" versuss "Vertical Panel Height H V" 850 WD WD WD 2650 Dimensions of Wheel Connector LC and LD vary with the Deck Panel width WD only or 2700 Wheel Connector (85-115) L C=717 L D=1088 Wheel Connector ( ) L C= =1317 L D=10888 Wheel Connector ( ) L C=1617 L D=

25 TechnicalInformation Parts in Detail 8 Tunnel Driving Wheel By connecting directly to the Wheel Connector and Wheel Supports, Tunnel Driving Wheel provides horizontal movement of ERTF-Modular Tunnel Formwork during erecting or stripping operations, as well as the vertical alignment of the Tunnel because of the included Jack on it. 5,000 kg loading capacity of the Wheel assembly has a long life of working period. 9 Vertical Panel Jack Whatever the length LS (1250mm or 2500mm) of the Half Tunnel Formwork is, each Vertical Panel is supplied with two Panel Jacks which are uninstalled. These Dismountable Jacks gives great versatility to the system when transporting of Vertical Panels or if maintenance or repairment is required. 21

26 TechnicalInformation Parts in Detail B Back Panel The surfaces of Back Panels are made from THRU mm. steel plate. They are stiffened by 50x60 mm square tubes, welded at every 178 mm. TB WD The one vertical end of the Back Panel is built of an 60x30x4 mm. cold rolled U-profiles so that the direction of it permits the assembly of Inside Panel and/or Inside Panel Extension. The turn of the Back Panels to verticals is 93 mm. The connection between the panels is done with Centering U pieces and bolts. If the side which has a turn of 93mm is on left, The Back Panel is called as Left Back Panel, otherwise The Panel is called as Right Back Panel. 1 2 HB The upper end of the Back Panel is built of an 60x30x4 mm. cold rolled U-profiles also. This turn permits the assembly of Deck Panel and/or Deck Panel Extension. The turn of the Back Panels to horizontal is also 93 mm. The connection between the panels is done with Centering U pieces and bolts. As in the half tunnel, vertical height of the Back Panel HB is the floor-height, less the slab thickness s and less the jack height K which is nominally equal to 87 mm (or more if the kicker is high) for jacking down. Legend 1 Back Panel 2 - Back Panel Wheeled Jack HB is the height of Back Panel which is equal to height of Vertical Panel HV plus the turn of Deck Panel TD. Width (mm) Standard Dimension (mm) 93 mm Left Turn 93 mm Right Turn Tunnel and Back Panel Heights (mm) hnet HT HB WD 1049 (1049 x HB).L93 (1049 x HB).R (1349 x HB).L93 (1349 x HB).R (1649 x HB).L93 (1649 x HB).R (1949 x HB).L93 (1949 x HB).R (2249 x HB).L93 (2249 x HB).R (2549 x HB).L93 (2549 x HB).R (2849 x HB).L93 (2849 x HB).R93 According to the width of the span, special back panels can also be provided but must be avoided for the sake of non-diversified inventory items and for future use. 22

27 TechnicalInformation Parts in Detail C Outside Wallform According to the width of the span, special vertical panels can also be provided but must be avoided for the sake of non-diversified inventory items and for future use. 1 Vertical Panel ERTF - Vertical Panels are used as both Inside Panels of The Half Tunnels and Outside Panels as described in Section Vertical Panels on Half Tunnels of this Manual. Therefore, the height of Vertical Panel HQ used in Outside Wallform is equal to the height HV of the Inside Panel on the Half Tunnel. a L=2500 mm L 2 Three Main Stiffeners which are welded to the panels on the levels of Tie-Rods, are made up of 50x100x5 mm Cold Rolled U-Profiles. These stiffeners are also used for connections of Platform Supports, Panel Supports and Ladder Connectors. HQE All edges except the lower edge are made of 60x30x4mm cold rolled U-profile. Outside Panels are connected to each other or to Inside Panels of Half Tunnels by these edges with Centering U and bolts. The lower edge is made up of Steel Plate having 15x60mm section. This Plate increases the strength of the Panel against any impacts or buckling which might be occurred during striking from concrete with lever arms. L Standard Dimension (mm) x HQ x HQ Tunnel and Panel Heights (mm) HQ Legend pcs a b 1 Vertical Panel Vertical Panel Ext Panel Support Platform Support Working Platform pcs a b 6 Platform Connector Guardrail Post Guardrail Connector Ladder (optional) Ladder Connector(opt) hnet HT HQ HQE b L=1250 mm s s s s s s s s s s HQE HQ L Total vertical height of the Outside Panels which is HQ + HQE is the floor height h plus the kicker height a (= 120 mm) and less K (= 87 mm) for jacking down

28 TechnicalInformation Parts in Detail 2 Vertical Panel Extension (Outside) L All materials used in Vertical Panel Extension are same with that of Vertical Panels. The edges of Panel Extensions are made from 60x30x4mm cold rolled U-profile. Extensions are connected to Vertical Panels with Centering U and bolts. HQE Total Vertical Panel Height in Outside Wallform Sum of Vertical Panel and Vertical Panel Extensions ( H Q + H QE )(mm) Lifting Hooks welded on Outside Panel Extensions are the only difference between Inside and Outside Panel Extensions. HQ HQE The alignments of two panels are provided by the adjustment of Hinge Bolts. 3 Panel Support Simplified Panel Support is easily connected to the Vertical Panel through the bottom and middle stiffeners on it. There is only one type of Panel Supports used on Vertical Panels having the height HQ of 2500 and 2700 mm. On the Outside Panel whose length is greater than 1250mm, always 2 pieces of Panel Supports must be connected. L Quantities of Panel Supports piece pieces 4 Platform Support Platform Supports are also connected to the Vertical Panels through the middle stiffeners on them. There are two standard Platform Supports according to the Vertical Panel heights HQ of 2500 and 2700 mm. HV=HQ Types of Platform Supports 2500 Platform Support Platform Support-2700 On the Outside Panel whose length is greater than 1250mm, always 2 pieces of Platform Supports must be connected. Quantities of Platform Supports L piece pieces 24

29 TechnicalInformation Parts in Detail 5&6 Working Platform & Platform Connector MESA-Universal Working Platforms are suitable for Outside Wallforms used in ERTF-Modular Tunnel Formwork System. Working Platform LPL Each Walking Platform is connected to the Vertical Panel by two pieces of Platform Connectors. Panel Length "L" Platform Length "LPL" 800 > L > L > L > L > L > L > L L Working Platform with Shutter Platform Connector Walking Platforms with Shutter have only two different Lengths LPL which are 1200 and 2400 mm. 7&8 Guardrail Post & Connector Two pieces of Guardrail Post are installed to the Working Platforms whatever the Platform Length LPL is. On the Working Platforms whose LPL is smaller than 1500mm, Guardrail Post is installed to the Platform with a Post Connector. The nominal height of the MESA-Universal Guardrail Post used in ERTF-Outside Wallforms is 1200mm. Platform Length "LPL" Guardrail Post Quantities Post Connector Guardrail Connector Guardrail Post (1200) 9&10 Ladder & Ladder Connectors Ladders are designed for maximum safety. In order to install the Ladder, Working Platform with Shutter must be selected as the Working Platform. The Ladder Connector provides rigid connection of the Ladder and the Vertical Panel. 25

30 TechnicalInformation Parts in Detail Summary of Quantities varying with the Panel Length L Panel Length "L" Platform Length "LPL" Panel Support Platform Support Platform Connector Guardrail Post Post Connector 800 > L pc 1 pc 2 pcs. 2 pcs. 2 pcs > L pc. 1 pc. 2 pcs. 2 pcs. 2 pcs > L pc. 1 pc. 2 pcs. 2 pcs. 2 pcs > L pc. 1 pc. 2 pcs. 2 pcs. 2 pcs > L pcs. 2 pcs. 2 pcs. 2 pcs > L pcs. 2 pcs. 2 pcs. 2 pcs > L pcs. 2 pcs. 2 pcs. 2 pcs L pcs. 2 pcs. 2 pcs. 2 pcs. 0 26

31 TechnicalInformation Parts in Detail D Lifting Beam E D A L =2500mm L =2500mm L =1250mm A D E Half Tunnel Lifting Beam Lifting Triangle LL The lifting beams are for hoisting the tunnel form arrays. The deflection of a tunnel form array is controlled by them. They increase the strength of Tunnels during stripping and lifting operations. Length of the Lifting Beam is determined according to the total lengths of Tunnels to be stripped together. Number of Half Tunnels L=2500 mm L=1250 mm Determination of Length of Lifting Beam Total Length of Tunnel LT (mm) Standard Lengths of Lifting Beam LL (mm) Lifting Beams are installed to the Tunnel Form with special Lifting Beam NPL and special bolts. For the Tunnels having the total length greater than 7500 mm, Trusssed Lifting Beam should be used, refer to MESA advisory. In non-standard total lenght of half tunnels units which are not listed above, Length of the Lifting Beam should be choosen from the standard values regarding the below formula ; 500 mm < ( LT LL ) < 1500 mm 27

32 TechnicalInformation Parts in Detail E Lifting Devices 1 Assembly Device This is only used for assembly at the beginning. During this operation some loading may occur which try to bend the Bearing Rod. Frequently this will end by an observed bending on the Bearing Rod. This apparatus is supplied only to protect the Lifting Triangle from these types of loads and bending as it is not used at this stage. Assembly Device cannot be used for carrying the Tunnel Formwork. 2 Lifting Triangle (Classic) This is used for lifting and carrying operations of the Tunnel Formworks. The Cylindrical Bearing minimizes the effect of the bending moments. The Wing Nut has to be tightened thoroughly for a smooth operation. Load Test of Classic Lifting Triangle; Nominal load: 4000 kg.s Test load : 6750 kg.s No permanent deformation has been observed under 6750 kg.s. Hook Bed Main Frame Cylindrical Bearing Rubber Wedge Bearing Rod Wing Nut Test during operation: Satisfactory results have been obtained from a number of accelerated tests applied to the Bearing Rod under mock site conditions. Maximum usage of the Bearing Rod could not be greater than 300 times. For safety regulations, Lifting Triangle should be operated according to the rules described in ERTF User Manual 28

33 TechnicalInformation Parts in Detail 2 Lifting Triangle (Asymetrical) The Asymetrical Lifting Triangle is designed so that it can be set in place with the centre of gravity LG of the Half Tunnel still inside the building by the help of its asymmetrical shape. In this way the load of tunnels which are moved on the rollers will not be taken by the Stripping Platforms. LTOT LG LLT = Total Length of Half Tunnel Unit = Dimension from Tunnel end to Axis of Center of Gravity (equal to dimension from Tunnel end to Axis of Crane Rope) = Dimension from Tunnel end to Axis of Asymetrical Lifting Triangle Connection It is easier to handle and transport the Asymetrical Lifting Triangle than the Classic Lifting Triangle. Asymetrical Lifting Triangle will give the best benefits when the timbers on Stripping Platforms are mounted under-slab. Such a solution enables to use the same platform at several floors with different slab finish lines. For slabs with poor concrete finishing, assembly of platform requires less workmanship since the timber surface is inserted under the slab. Platform timber under slab Stripping Half Tunnel Load Test of Asymetrical Lifting Triangle; LTOT Nominal load: 4000 kg.s Test load : 6750 kg.s No permanent deformation has been observed under 6750 kg.s. LG LLT LG > LLT Test during operation: Satisfactory results have been obtained from a number of accelerated tests applied to the Bearing Rod under mock site conditions. Maximum usage of the Bearing Rod could not be greater than 300 times. 29

34 TechnicalInformation Parts in Detail F Roller Half-tunnels can easily be moved and stripped on platforms by the help of rollers which are used instead of wheels. It is placed under vertical panel of half-tunnels above the slab. It reduces vertical panel price by cancelling the wheels and also simplify storage of vertical panels. Formwork weight will not affect stripping platform as the tunnel forms are carried by the rollers during their movement. There are two types of Rollers used for different operations ; HR = 53mm : for stripping the Tunnel Forms HR = 73mm : for setting up the Tunnel Forms HR 30

35 TechnicalInformation Parts in Detail G Kicker Form Set Kicker Forms are 120x80 mm steel angle sections (or larger if necessary) in accordance with the line of the building walls. These angle sections, marked with respect to one another, are assembled at site in accordance with the assembly plan provided. Tunnel Form segment is set in place using the Kicker Form as a guide. View A View B 8 7 K 3 4 K K They are erected by means of steel rests and spacers on the tunnel forms prior to concreting. Their location automatically ensures the correct positioning of the wallsand the door openings. w s Deck Panel Vertical Panel (inside) Vertical Panel (outside) Concrete Stoper Straight Kicker Form Kicker Clamp (Two Sided) Kicker Spacer (Two Sided) Corner Kicker Form Inner Kicker Form Kicker Spacer (One Sided) Kicker Clamp (One Sided) View A View B 31

36 TechnicalInformation Parts in Detail 2, 5, 6 Kicker Forms Kicker Forms work such a formwork having 120 mm height. LS Straight Kicker Forms are used throughoutly the length of the Half Tunnels. 2 Onto the Back Panels, two Corner Kicker Forms (left and right) and one Inner Kicker Form between the two are located so that the span g between two walls are achieved. LI 6 Standard Kicker Form Lengths (mm) LCT LS LI LC + LCT (Right) LC (Left) Concrete Stoper 2 - Straight Kicker Form 5 - Corner Kicker Form 6 - Inner Kicker Form 4 - Kicker Spacer (Two Sided) 7 - Kicker Spacer (One Sided) 3 - Kicker Clamp (Two Sided) 8 - Kicker Clamp (One Sided) 1, 3, 4, 7, 8 Clamps and Spacers s s Kicker Spacers provides the width of the kicker to be same as the wall thickness by preventing the Kicker Forms to close to each other. w 7 w 3 Two sided Kicker Spacer fits onto the Deck Panels from two sides. One sided Kicker Spacer fit onto the Deck Panels from one side only. The other side is in contact with the Outer Vertical Panel. Conical shaped arms allow the Spacers to extract from the concrete. In contrast with the Kicker Spacers, Kicker Clamps do not allow the Kicker Forms to apart from each other Dimensions of Spacers and Clamps are determined according to the wall and slab thicknesses. 32

37 TechnicalInformation Parts in Detail H & I Stopends All surfaces of stop-ends are made from the same steel that panels are made. WD1 WDE1 g The lateral ends of the stop-ends are made of 60x30x4mm. Cold rolled U-profiles. v WDE2 WD2 ww s Slab Stopend The thickness of the Slab Stopend is same with the slab thickness s. HQ Width of the Slab Stopend WSS is 4 mm less than the sum of the Deck Panel width WD and Deck Panel Extension width WDE on which it is located. Slab Stopend Wall Stopend WSS = WD + WDE 4 mm Standard Dimension of Slab Stopends ( W SS + T B ) x s (mm) ( T B = 93 mm) WD + WDE ( ) x s ( ) x s ( ) x s ( ) x s ( ) x s ( ) x s ( ) x s Wall Stopend The thickness of the Wall Stopend ww is 2 mm less than the wall thickness w. Height of the Wall Stopend is same with the Outer Vertical Wallform height HQ. hnet HT HQ Standard Dimensions of Wall Stopends H Q x ( w w ) (mm) HQ x ( ww ) s ( s ) x ( ww ) s ( s ) x ( ww ) s ( s ) x ( ww ) s ( s ) x ( ww ) s ( s ) x ( ww ) s ( s ) x ( ww ) s ( s ) x ( ww ) s ( s ) x ( ww ) 33

38 TechnicalInformation Parts in Detail J Slab Boxouts ( a x b x s ) All surfaces of Slab Boxouts are made from the same surface material (st-37 steel) that panels are made. a 2 b The backs of the surface material are made of 3 mm Cold rolled U-profiles which has the dimension same with the slab thickness s. One set of Slab Boxout consists four pieces of L- shaped units which are connected to each other. v d 1 d 4 s c 3 c v Connection principle of these four units is the same with the connection of two Deck Panels on the Half- Tunnels so that the gap v between two units will be 2 mm. d = (b / 2) 1mm c = (a / 2) 1mm K Door Boxouts ( a x b x y ) b d d v y Materials are same with that of Slab Boxouts. One set of Door Boxout consists two pieces of L- shaped units which are connected to each other. 1 2 a Connection principle of these two units is the same with the connection of four Slab Boxout units. Jacks at the bottom provides to lower the Door Boxout during stripping operation same as in Half Tunnel operations. d = (b / 2) 1mm y = w 2mm L Window Boxouts ( a x b x y ) c = (a / 2) 1mm Materials are same with that of Door Boxouts. d = (b / 2) 1mm 2 c One set of Window Boxout consists four pieces of L- shaped units like in Slab Boxouts. y 1 v c a Connection principle of these four units is the same with the connection of four Slab Boxout units. The thickness of the Window Boxout y is 2 mm less than the wall thickness w. 4 d 3 d b y = w 2mm 34

39 TechnicalInformation Parts in Detail P Tie Rod & Cone Set Tie Rods are horizontally located on each 1250 mm of Vertical Panels. w - 2 three. The number of Tie-rods in vertical position is In each Tie-Rod & Cone set, there are ; One piece of Tie-Rod One piece of Composite Cone One piece of Wing Nut One piece of Steel Plate (100x100mm) One piece of Flange Nut Wing Nut and Steel Plate are used together on the same side. Tightening operation is realised on the side where the Wing Nut and Steel Plate exist. Then the Flange Nut is tightened automatically. Plate 100x100 Flange Nut Cone length should be 2mm less than the wall thickness. Tie-Rod length is selected according to the wall thickness. Composite Cone Tie-Rods used on the extension joints or dilatations are different. Wing Nut Tie-Rod Tie Rod and Cone Lengths w Cone length Tie-Rod Length (mm) (w-2) mm > (w + 326) mm Thread standard on Tie-Rod, Wing Nut and Flang Nut is M23 (10mm rounded pitch). 35

40 TechnicalInformation Complementary Equipments COMPLEMENTARY EQUIPMENTS Heating Equipments ERTF-Tools After concreting (which is completed usually late afternoon), especially in cold weather, it is often necessary to heat the concrete for striking the forms next morning. Heating will decrease the duration for setting of concrete. Heating procedure is not necessary for high temperature zones. But generally, it is recommended. MESA presents two types of Heaters o In normal temperatures; LPG-Heater (fuel type is LPG). o In considerably low temperatures; Radiant Burner (fuel type is diesel oil). LPGHeater RadiantBurner Heating Capacity 15,000 kcal/hour Heating Capacity 28,500 kcal/hour Isolation Equipments Curtains covering the open ends of tunnel forms are made from plastic based 1100 dny material. In low temperature zones, double layer curtains with extra insulation between the layers should be preferred. Tools given with full Set of Tunnel Formwork are separated into two groups; ERTF-Tool box Socket Wrench 13 (1/2) 1 Socket Wrench 14 (1/2) 1 Socket Wrench 19 (1/2) 1 Socket Wrench 22 (1/2) 4 Socket Wrench 24 (1/2) 2 Socket Wrench 27 (1/2) 2 Hexagon Key Wrench 14 1 Ratchet for Jack Ø38 (31K-20") 2 Ratchet 1/2" w/lock 4 Ratchet Arm 5" (1/2) 2 2-Ended Open Jaw Spanner Ended Open Jaw Spanner Ended Open Jaw Spanner Open Ended Slogging Spanner Ø 36 1 Open Ended Slogging Spanner Ø 46 1 Open Ended Slogging Spanner Ø 60 1 Drift Punch A Punch Ø16 2 Punch Ø20 5 Punch Ø27 2 Punch Ø35 1 Hammer (1.5 kg) 2 Magnetic Plumb 2 Chalk Line 1 Steel Tape (5 metre) 2 Metal Marker 2 ERTF-Special Tools Deck Panel Wrench 1 Back Panel Wrench 1 Punch to Remove Cones 1 Punch to Remove Dilatation Cones 1 Spatula 1 Lever 1 36

41 TechnicalInformation TYPES of CONNECTION Types of Connection Assembly Conditions Profiles at the Panel Ends Connections for assembly of Tunnel Formwork elements could be collected into two main groups ; Connections can also be classified according to the profiles at the end of the standard panels ; o Permanent Assemblies ; o UPF30x60x4 ; Half Tunnels, Formworks or other sets ( Kicker Forms etc.) are connected properly at once. These sets are not disassembled until the job is finished. - Both vertical ends of standard Vertical Panels, - Four sides of standard Deck Panels - One vertical end of standard Back Panels have this type of profile. o Temporary Connections ; According to the Formwork Layout of the project, Some of the Permanent Assemblies may be connected during erecting, concreting and stripping stages. These assemblies make also easy the lifting and transporting operations as well as the erecting and stripping stages. o NPL 80 ; - One side of standard Deck Panels - One vertical end of standard Back Panels have this type of profile. Refer to Section of Part List of this Manual to see the details of Connector Parts listed on the following pages. Standard types of connections are done between two UPF30x60x4 profiles, and between two NPL80 profiles. 37

42 Introduction PERMANENT ASSEMBLIES 1 Permanent Assemblies Assembly of a Half Tunnel One Simple ERTF-Modular Half Tunnel includes one Deck Panel and it s Extension, one Vertical Panel and it s Extension, two Foldable Props, one Tunnel Driving Wheel, two Wheel Supports and one Wheel Connector as described in the Section Parts in Detail of this Manual. In some cases, a Back Panel could also be added on the Assembly. Connections 1 Vertical Panel Extension & Deck Panel 1 set 2 Back Panel & Vertical Panel Extension 1 set 3 Vertical Panel & Vertical Panel Extension 1 set 4 Deck Panel & Deck Panel Extension 1 set 5 Back Panel & Deck Panel Extension 1 set 6 Deck Panel & Back Panel 1 set 7 Vertical Panel & Back Panel 1 set 8 Deck Panel & Foldable Prop 2 sets 9 Vertical Panel & Wheel Support 2 sets 10 Vertical Panel & Foldable Prop 2 sets 11 Vertical Panel & Wheel Connector 1 set 12 Vertical Panel & Vertical Panel Jack 2 sets 13 Wheel Support & Wheel Connector 2 sets 14 Back Panel & Back Panel Wheeled Jack 1 set 15 Wheel Connector & Tunnel Driving Wheel 1 set Quantities of Connectors on the connection no s 1-3 and 4 differ according to the Deck Panel length L. Quantities of Connectors x, y and z and p, q and r on the connections 6 and 7 are tabulated on the next page. Tables below give the quantities of connectors for one set of connection ; L = 1250 mm Connection No. Connectors Quantities of Connectors in One Connection U ALIGNMENT (45mm) 1 1 x p HINGE BOLT SET 2 HEXAGON BOLT,NUT&WASHER (M14x30) HEXAGON BOLT,NUT&WASHER (M14x50) 1 y q HEXAGON BOLT,NUT&WASHER (M14x80) z r HEXAGON BOLT,NUT&WASHER (M16x30) 4 HEXAGON BOLT,NUT&WASHER (M16x100) L = 2500 mm Connection No. Connectors U ALIGNMENT (45mm) 1 1 x p HINGE BOLT SET 3 HEXAGON BOLT,NUT&WASHER (M8x80) HEXAGON BOLT,NUT&WASHER (M14x30) HEXAGON BOLT,NUT&WASHER (M14x50) 1 y q HEXAGON BOLT,NUT&WASHER (M14x80) z r HEXAGON BOLT,NUT&WASHER (M16x30) 4 HEXAGON BOLT,NUT&WASHER (M16x100)

43 Introduction Permanent Assemblies x, y and z values Quantities of Connectors x, y and z on Deck Panel & Back Panel connection (No.6) depend on the Deck Panel width WD. Quantities of x, y and z for Connection no.6 Deck Panel Width "W D" ( mm) Connectors x U ALIGNMENT (45mm) y HEXAGON BOLT,NUT&WASHER (M14x50) z HEXAGON BOLT,NUT&WASHER (M14x80) p, q and r values Quantities of Connectors p, q and r on Vertical Panel & Back Panel connection (No.7) depend on the Vertical Panel height HV. p q r Quantities of p, q and r for Connection no.7 Connectors U ALIGNMENT (45mm) HEXAGON BOLT,NUT&WASHER (M14x50) HEXAGON BOLT,NUT&WASHER (M14x80) Vertical Panel Height "H V" ( mm) Hinge Bolt Set One Hinge Bolt Set includes the components listed on right. Connectors Quantities of Connectors in A Hinge Bolt Set Quantity HINGE BOLT 1 NUT for HINGE BOLT 1 HEXAGON BOLT,NUT&WASHER (M14x80) 1 The length of Hinge Bolt is selected according to the height of Vertical Panel Extension HVE and width of Deck Panel Extension WDE. Length of Hinge Bolts for Vertical and Deck Panel Extensions Hinge Bolts (L HB) HINGE BOLT (120) HINGE BOLT (190) HINGE BOLT (250) Vertical Panel Extension "H VE" range ( mm) 120 < HVE < < HVE < < HVE < 290 Deck Panel Extension "W DE " range ( mm) 119 < WDE < < WDE < < WDE < 299 HINGE BOLT (300) 291 < HVE < < WDE < 349 HINGE BOLT (350) 341 < HVE < < WDE < 399 HVE Deck Panel LHB Nut for Hinge Bolt Hinge Bolt Vertical Panel Extension M14x80 Hexagon Bolt,Nut & Washer Deck Panel Extension Vertical Panel WDE LHB 39

44 Introduction Permanent Assemblies Assembly of an Outside Wallform L=2500 mm L=1250 mm L L Detail A Detail A 16 17a-17b 16 17a 17b 21 18a-18b a a 19b Connections No.of Connections L=1250 L= Vertical Panel & Vertical Panel Extension (*) a Vertical Panel & Platform Connector b Platform Connector & Working Platform a Working Platform & Platform Support b Platform Support & Guardrail Post a Working Platform & Guardrail Connector b Guardrail Connector & Guardrail Post Vertical Panel & Platform Support Working Platform & Ladder (optional) Vertical Panel & Ladder Connector (optional) Ladder & Ladder Connector (optional) Vertical Panel & Panel Support Vertical Panel & Vertical Panel Jack 2 2 One Simple Outside Wallform includes; One set of Vertical Panel and Extension One of Working Platform (could be the type which has a shutter), Two of Panel Supports (the quantity of Panel Support is one if the length of the wallform is 1250 mm or less), Two of Platform Supports (the quantity of Platform Support is one if the length of the wallform is 1250 mm or less), One set of Ladder (optional), Two of Guardrail Posts, Two of Vertical Panel Jack. M14x80 Bolt, Nut & Washer Nut for Hinge Bolt Hinge Bolt Upper Panel Support Vertical Panel Extension M14x80 Bolt, Nut & Washer Vertical Panel Detail A LHB LHB = 120mm LUS (*) See details on the next page Detail A on above sketch, shows the connection of Upper Panel Support and the Vertical Panel as well as the Upper Panel Support Set. As the Length L of Outside Wallform varies, both the number of components and connectors varies also. Tables on the next page give the quantities of connectors for one set of connection. 40

45 Introduction Permanent Assemblies L = 1250 mm Connection No. Quantities of Connectors in One Connection Connectors 16 17a 17b 18a 19a 19b U ALIGNMENT (45mm) UPPER PANEL SUPPORT SET 2 HEXAGON BOLT,NUT&WASHER (M14x30) HEXAGON BOLT,NUT&WASHER (M14x50) HEXAGON BOLT,NUT&WASHER (M14x80) HEXAGON BOLT,NUT&WASHER (M14x100) 1 L = 2500 mm Connection No. Connectors 16 17a 17b 18a 18b U ALIGNMENT (45mm) UPPER PANEL SUPPORT SET 2 HEXAGON BOLT,NUT&WASHER (M14x30) HEXAGON BOLT,NUT&WASHER (M14x50) HEXAGON BOLT,NUT&WASHER (M14x80) HEXAGON BOLT,NUT&WASHER (M14x100) 1 Upper Panel Support Set One Upper Panel Support Set includes the components listed on right. The Length LHB of Hinge bolt is 120 mm. Length LUS of Upper Panel Support Set is 55 mm longer than the height HVE of Vertical Panel Extension. Connectors Quantities of Connectors in An Upper Panel Support Set UPPER PANEL SUPPORT HINGE BOLT (120) NUT for HINGE BOLT HEXAGON BOLT,NUT&WASHER (M14x80) Quantity

46 Introduction Permanent Assemblies Assembly of a Half Tunnel Set These Sets are assembled at once and they are used during the all concrete operations of site until the whole job is finished. Half Tunnel Set consists of two or more Half Tunnel s and/or a Back Pannel. In some cases one or more Outside Wallforms might be added to the Set The quantity of Half Tunnel s determines the connection quantities. 26 Figure shows the connection of two sets of Half Tunnel (L1=2500mm, L2=2500mm). L1 L2 Connections Profiles on Connection No.26,27,28 and 29 are UPF30x60x4. 26 Vertical Panel & Vertical Panel 1 set 27 Vertical Panel Extension & Vertical Panel Extension 1 set 28 Deck Panel & Deck Panel 1 set 29 Deck Panel Extension & Deck Panel Extension 1 set 30 Deck Panel & Lifting Beam 1 set Tables below give the quantities of connectors for one set of connection ; Quantities of Connectors in One Connection Connection No. Connectors U ALIGNMENT (45mm) k p t x LIFTING BEAM NPL 2 U ALIGNMENT (89) 6 HEXAGON BOLT,NUT&WASHER (M14x50) l q u HEXAGON BOLT,NUT&WASHER (M14x80) m r v y HEXAGON BOLT,NUT&WASHER (M16x160) 4 Quantities of Connectors k,ly and m, p, q and r t, u and v and x and y on the connections 26, 27, 28 and 29 are tabulated on the next page. 42

47 Introduction Permanent Assemblies k, l and m values Quantities of connectors k, l and m between Vertical Panels (No.26) depends on the height of Vertical Panel Hv. k l Quantities of k, l and m for Connection no.26 Connectors U ALIGNMENT (45mm) HEXAGON BOLT,NUT&WASHER (M14x50) Vertical Panel Height "H V " ( mm) m HEXAGON BOLT,NUT&WASHER (M14x80) p, q and r values Quantities of connectors p, q and r between Vertical Panel Extensions (No.27) depends on the height of Vertical Panel Extensions HVE. p q r Quantities of p, q and r for Connection no.27 Connectors U ALIGNMENT (45mm) HEXAGON BOLT,NUT&WASHER (M14x80) HEXAGON BOLT,NUT&WASHER (M14x80) If HVE is greater than 360mm,then Upper Panel Support Sets are used as the following quantities ; 2 sets for L=1250mm, 3 sets for L=2500mm as per in the Outside Wallforms. Range of Vertical Panel Extension Height "H VE" ( mm) 0 < H VE < < H VE < < H VE < < H VE < t, u and v values Quantities of connectors t, u and v between Deck Panels (No.28) depends on the width of Deck Panels WD. Quantities of t, u and v for Connection no.28 Deck Panel Width "W D" ( mm) Connectors t U ALIGNMENT (45mm) u HEXAGON BOLT,NUT&WASHER (M14x50) v HEXAGON BOLT,NUT&WASHER (M14x80) x and y values Quantities of connectors x and y between Deck Panel Extensions (No.29) depends on the width of Deck Panel Extensions WDE. Quantities of x and y for Connection no.29 Range of Deck Panel Extension Width "W DE" ( mm) Connectors 0 < W DE < < W DE < < W DE < < W DE < 600 x U ALIGNMENT (45mm) y HEXAGON BOLT,NUT&WASHER (M14x80)

48 Introduction Permanent Assemblies Assembly of an Outside Wallform Set These sets are assembled at once and they are used during the all concrete operations on site until the whole job is finished as in Half Tunnel Sets. L2 L1 Outside Wallform Set consist two or more Outside Wallform s. As in the assembly of Half Tunnel Set s, quantities of connectors depend on the height of Vertical Panel HV and height of Vertical Panel Extension HVE. Hve 32 Figure shows the connection of one set of Outside Wallform (L1=2500mm) and one set of Outside Wallform (L2=1250mm). Hv 31 Qquantities of Connectors do not depend on the Vertical Panel Lengths L. Connections 31 Vertical Panel & Vertical Panel 1 set 32 Vertical Panel Extension & Vertical Panel Extension 1 set Tables below give the quantities of connectors for one set of connection. Profiles on Connections No.31 and 32 are UPF30x60x4. Connectors Quantities of Connectors for Connection no.31 U ALIGNMENT (45mm) HEXAGON BOLT,NUT&WASHER (M14x50) HEXAGON BOLT,NUT&WASHER (M14x80) U ALIGNMENT (89) Vertical Panel Height "H V" ( mm) Connectors Quantities of Connectors for Connection no.32 U ALIGNMENT (45mm) HEXAGON BOLT,NUT&WASHER (M14x80) HEXAGON BOLT,NUT&WASHER (M14x80) Range of Vertical Panel Extension Height "H VE" ( mm ) 0 < H VE < < H VE < < H VE < < H VE <

49 Introduction TEMPORARY CONNECTIONS Temporary Connections Longitudinal Connection of Half Tunnel Sets and/or Outside Wallform Sets Permanently assembled two or more Half Tunnel Set s are sometimes to be connected temporarily during concreting. These two sets will be dismantled from each other before striking operation. LA LB Longitudinal connections provide more strength to the concrete pressure. The quantity of Set s determines the connector quantities. 1 The quantities of Connectors do not differ with the Tunnel Height HT. Half Tunnel Set - A Half Tunnel Set - B Figure shows the connection of the Half Tunnel Set A (L1=2500mm, L2=2500mm) and another Half Tunnel Set B (L1=2500mm, L2=2500mm). LA + LB Set A and Set B could be a Half Tunnel Set or an Outside Wallform Set. 2 Connectors Quantities of Connectors for Connection no.33 SPRING and ARM U ALIGNMENT (89) HEXAGON BOLT,NUT&WASHER (M10x60) HEXAGON BOLT,NUT&WASHER (M14x80) Connection No Connection Half Tunnel Set & Half Tunnel Set 1 set Profiles on Connection No.21 are UPF30x60x4. 45

50 Introduction Temporary Connections Reciprocal Connection of Two Half Tunnel Sets 34 Permanently assembled two resiprocal Half Tunnel Sets are connected temporarily during concreting. These two Sets will be dismantled from each other before striking operation. The Deck Panel Length L and Back Panel Height HB of Set s determines the connection quantities. Principle of this type of connection based on the joining of two resiprocal Roof Key Bolts welded on each Panels with a Roof Key, so that 2mm gap between two panels is obtained. This gap makes easy the removing of panels from concrete during dismantling. Figure shows the connection of the Half Tunnel A (L=2500mm) and another Half Tunnel B (L=2500mm). 34 Reciprocal Connection is also realised between Back Panels if exist (connection no.35) in the same manner. 35 Same connection principle is also operative between two Outside Wallforms if 2mm gap is required in order to remove the Outside Wallforms from concrete (such as in Lift Shafts or Stair Shafts). Profiles on Connection No.34 & 35 are NPL80. Connections A B 34 Deck Panel & Deck Panel 1 set 35 Back Panel & Back Panel 1 set Connectors ROOF KEY Quantities of Connectors for Connection no.34 HEXAGON NUT&WASHER (M18) Deck Panel Length "L" ( mm) Roof Key M18 Nut & Washer Roof KeyBolt (welded) Quantities of Connectors for Connection no.35 Back Panel Height "H B" ( mm) Connectors H B < 2763 mm H B > 2763 mm ROOF KEY HEXAGON NUT&WASHER (M18)

51 Introduction Temporary Connections Assembly of Kicker Forms Kicker Forms are assembled similarly as in the assembly of Half Tunnel Set s. Straight Kicker Forms could be permanently connected to each other with two sets of M14x30 bolt and nuts, if it is not to be disasembled after concreting. Corner Kickers and Inner Kickers are always temporarily connected to each other so that the same principle of reciprocal connection of two Deck Panels or two Back Panels could be realised. Therefore, 2mm gap between each part is obtained. Figure shows the basic connection of Kicker Forms in a Room of an Half Tunnel. As increasing the length, the length of Straight Kicker Forms will increase. In each 1250 mm, one piece of Kicker Spacer and one piece of Kicker Clamp is located. Connections 37 or Inner Kicker & Corner Kicker 1 set 37 Straight Kicker & Corner Kicker 1 set 38 Straight Kicker & Straight Kicker 1 set On each open ends of the Kicker Forms, one piece of Kicker Stoper is required. Connection No.36 Connection No.37 & 38 Quantities in One Connection Connectors Connection No ROOF KEY 1 HEXAGON NUT&WASHER (M18) 2 HEXAGON BOLT,NUT&WASHER (M14x30)