User information 06/2008 Ü 999759002 Method statement GB Doka heavy-duty supporting system SL-1 9759-254-01 The Formwork Experts
User information Doka heavy-duty supporting system SL-1 Introduction © by Doka Industrie GmbH, A-3300 Amstetten 2 The Formwork Experts 999759002 - 06/2008 Ü
User information Doka heavy-duty supporting system SL-1 Contents Introduction Page Introduction .................................................................................................. 2 Elementary safety warnings ........................................................................ 4 Eurocodes at Doka........................................................................................ 6 System description...................................................................................
Introduction User information Doka heavy-duty supporting system SL-1 Elementary safety warnings User target groups ● This User Information booklet (Method Statement) is aimed at everyone who will be working with the Doka product or system it describes. It contains information on how to set up this system, and on correct, compliant utilisation of the system.
User information Doka heavy-duty supporting system SL-1 Introduction Erecting the formwork Symbols used ● Doka products and systems must be set up in such a way that all loads acting upon them are safely transferred! The following symbols are used in this booklet: Pouring ● Do not exceed the permitted fresh-concrete pressures. Excessively high pouring rates lead to formwork overload, cause greater deflection and risk causing breakage.
User information Doka heavy-duty supporting system SL-1 Eurocodes at Doka In Europe, a uniform series of Standards known as Eurocodes (EC) was developed for the construction field by the end of 2007. These are intended to provide a uniform basis, valid throughout Europe, for product specifications, tenders and mathematical verification. The EC are the world's most highly developed Standards in the construction field. In the Doka Group, the EC are to be used as standard from the end of 2008.
User information Doka heavy-duty supporting system SL-1 System description Doka heavy-duty supporting system SL-1 - the versatile system for tunnel construction Areas of use Cut-and-cover tunnel construction The universal modular "kit" system of the Heavyduty supporting system SL-1 consists of steel girders and heavy-duty props that adapt easily and efficiently to any shape and load. All system components are available for rent.
User information Doka heavy-duty supporting system SL-1 Underground tunnel construction Underground tunnel construction under top cover Drive-through access openings beneath falsework Custom constructions In bridge-building 8 The Formwork Experts 999759002 - 06/2008 Ü
User information Doka heavy-duty supporting system SL-1 System overview A G D 9759-255-01 C F E B A Joints and dimensioning – System beams SL-1 (Page 16) B Lowering the heavy-duty supporting units (Page 38) C Tension-rod bracing (Page 25) D Bracing (Page 24) E Repositioning heavy-duty supporting units (Page 40) F Struts SL-1 (Page 48) G Clamping connections (Page 53) 999759002 - 06/2008 Ü The Formwork Experts 9
User information Doka heavy-duty supporting system SL-1 Tunnel structures built using the cut-and-cover method Tunnel formwork used in cut-and-cover construction should have large influence widths, only a small number of wall-ties, and be easy to reposition.
User information Doka heavy-duty supporting system SL-1 Tunnel structures built using underground construction methods Particularly in the building of tunnels using underground construction methods, the formwork has to feature large lowering distances and leave as much space as possible for the site crew. These special requirements are met by the combination of Multi-purpose walings SL-1 WU 16 and Spindle struts SL-1 T16.
User information Doka heavy-duty supporting system SL-1 Basic design of Heavy-duty supporting system SL-1 The procedures outlined below are based on the following basic types: ● Variant 1: Supporting frames with overhead longitudinal profiles ● Variant 2: Heavy-duty supporting unit with integral longitudinal profiles As the Heavy-duty supporting system SL-1 is a universal modular system, it can also be combined to make supporting constructions that differ greatly from the two basic types described here.
User information Doka heavy-duty supporting system SL-1 9759-242-01 ➤ Erect further supporting frames in the same way. ➤ Set down the overhead System beams (G) by crane, mount them to the supporting frames, and then detach them from the crane tackle. Provide a safe workplace that is suitable for carrying out this work (e.g. platforms or a platform trolley). 9759-297-01 G 9759-297-01 H 9759-241-01 ➤ Mount diagonal bracing. For details, see the section headed "Tension-rod bracing".
User information Doka heavy-duty supporting system SL-1 ➤ Measure up the positions of the lowering wedges (A) as per shop drawing. Allow for the lowering distance needed for lowering the heavy-duty supporting unit. ➤ Pre-assemble the side supporting frames (B) , incl. Knee-braces SL-1 (C) , at ground level. ➤ Attach panel struts (D) to help stand the frames upright. ➤ Mount two system beams (E) as a cross connection at the top. Provide a safe workplace that is suitable for carrying out this work (e.g.
User information Doka heavy-duty supporting system SL-1 Notes 999759002 - 06/2008 Ü The Formwork Experts 15
User information Doka heavy-duty supporting system SL-1 Joints and dimensioning - System beams SL-1 The System beams SL-1 are modular, combinable steel girders from which universal heavy-duty supporting units can be assembled. Standardised joints: End-face join Butt-strap join Overview of variants System beams SL-1 TR585-200-01 TR585-201-01 Beam join with stacking piece 4.00m 3.00m 1.00m 0.75m The Offset pin SL-1 makes it easier to align the drilled holes during assembly.
User information Doka heavy-duty supporting system SL-1 Buckling diagram: System beam SL-1 not screwjointed c c 200 c 180 c y y 177 c 160 b c 140 Permitted moment M [kNm] O a 9759-236-01 a ... 22.6 cm b ...24.0 cm c ... System increment-grid 50.
User information Doka heavy-duty supporting system SL-1 Joints between System beams SL-1 Preliminary remarks End-face join All standardised joins are statically dimensioned as shear / bolt-bearing joins. A B TR585-200-01 Warning! Highly stressed threaded joints! Risk of fracture if unsuitable screws are used. ➤ When joining SL-1 system components, ALWAYS use the appropriate Screw sets SL-1 only. ➤ Use NEW Screw sets SL-1 every time the equipment is re-assembled.
User information Doka heavy-duty supporting system SL-1 Permitted internal forces Butt-strap join 200 9759-110a Q A C B 180 M Q N 9759-103-01 N M 160 F A System beam SL-1 B Connection splice plate SL-1 C Screw set for Connection splice plate SL-1 Permitted moment M [kNm] TR585-201-01 D 140 D 2 hexagonal bolts M22x120 8.
User information Doka heavy-duty supporting system SL-1 Beam join with stacking piece Permitted internal forces 200 B Q 177 180 M D Q N N 9759-106-01 M C 160 A G 140 9759-221-01 D A System beam SL-1 B System beam SL-1 C Screw-set M20x90 8.8, shank length 38mm, in the middle holes of Item B Permitted moment M [kNm] H 120 I 100 80 J 60 D Screw-set M20x90 8.
User information Doka heavy-duty supporting system SL-1 T-joint A C 9759-201-01 B A System beam SL-1 B Screw-set M20x90 8.
User information Doka heavy-duty supporting system SL-1 T-joint with connecting plate - loading case: "Vertical strut under pressure" By combining packing plates with thicknesses of 2, 3 and 4 mm, closures can be made in a 1 mm increment-grid.
User information Doka heavy-duty supporting system SL-1 T-joint with connecting plate - loading case: "Vertical strut under tension" By combining packing plates with thicknesses of 2, 3 and 4 mm, closures can be made in a 1 mm increment-grid.
User information Doka heavy-duty supporting system SL-1 Bracing with Knee-brace SL-1 For making a flexurally rigid 90° joint between two System beams SL-1. Caution! The bending moments transferred into the horizontal System beam SL-1 from the slab loads are then transferred through the kneebrace into the vertical beams. A C B 9759-260-01 A 9759-214-01 ➤ Counter-measures: e.g.
User information Doka heavy-duty supporting system SL-1 Tension-rod bracing using Bracing bolt SL-1 and Distance piece SL-1 Tension-rod bracing to the inside holes of the Bracing bolt Tension-rod bracing to the outside holes of the Bracing bolt SL-1 struts are wider than the System beams. For this reason, if vertical Struts SL-1 are being used, the tension-rod brace can only be fastened in the outside holes. The standard tension-rod brace on HD supporting units assembled from System beams SL-1.
User information Doka heavy-duty supporting system SL-1 using Bracing bolt SL-1 and Brace stirrup SL-1 ☞ Tension-rod bracing is only permitted to the inside holes "a", as otherwise it would not be possible to centre the Bracing bolt! a d1 9759-257-01 a ... 330 mm d1 ... diameter 24 mm (for Tie-rods 15.0 and 20.0mm) This type of tension-rod brace is mainly used in cases where the HD supporting units are travelled on Heavy duty roller gear SL-1.
User information Doka heavy-duty supporting system SL-1 using Fixing bracket SL-1 Variant 2 Variant 1 ● for tension-rod bracing SL-1 constructions into finished casting sections. ● for bracing SL-1 constructions with Tie-rods 15.0. Can be mounted in 50 cm increments. Permitted tensile force: 50 kN Close-up showing how fixed in concrete: Permitted tensile force: 56 kN I H A C E A 9759-263-01 G D A Fixing bracket SL-1 C Split nut SL-1 15.0 or Hexagon nut 15.0 D Hexagon nut 15.
User information Doka heavy-duty supporting system SL-1 using the Split nut SL-1 15.0 Caution! with all pre-tensioning methods - risk of fracture from one-sided loading and overloading! ➤ Pre-tensioning and loosening should always be done alternately - approx. 1 turn per nut. ➤ The tensioning distances (required tensioning force) will be decided by the Doka statics departments alone. ☞ a Pre-tensioning procedure: ➤ Screw the Split nut SL-1 together completely, by hand.
User information Doka heavy-duty supporting system SL-1 Notes 999759002 - 06/2008 Ü The Formwork Experts 29
User information Doka heavy-duty supporting system SL-1 Connecting up Top 50 components The Strut connection SL-1 is fastened onto the System beam SL-1 and is used for connecting up components from the Doka large-area formwork Top50 (e.g. spindle struts, panel struts, connecting plates etc.
User information Doka heavy-duty supporting system SL-1 Connecting up platforms e.g. with Corner connecting plates and multipurpose walings. Permitted moment of the Corner connecting plate: 6 kNm A E B C F D 204-03 F A System beam SL-1 B Strut connection SL-1 C Screw-set M20x65 DIN 931 8.
User information Doka heavy-duty supporting system SL-1 Connecting up Spindle struts SL-1 T16 The connectors are attached to the System beam SL-1 using the Screw set for Knee-brace SL-1. B A A ☞ B Strut connection SL-1 T16 Permitted internal forces Important note: ● Arrange the spindle struts as symmetrically as possible! ● Make sure that the max. permitted load on the knee-brace is not exceeded when forces are transferred into the heavy-duty supporting units.
User information Doka heavy-duty supporting system SL-1 How to mount: Lowering shoe SL-1 For taking the load off the spindle struts in cases where compressive loading occurs in the wall zone. A ☞ Important note: ➤ Make allowance for the subsequent position of the spindle struts . ➤ Attach the Lowering shoe SL-1 using the Screw set for Knee-brace SL-1. B The wedge must be pushed in while the Lowering shoe SL-1 is being mounted.
User information Doka heavy-duty supporting system SL-1 Spindle struts SL-1 T16 ● Four sizes with usable lengths of 100 cm to 375 cm ● Overlap with next size: 55 cm ● Couplers for connecting up the scaffolding-tube bracing are permanently attached Usable length Spindle strut SL-1 T16 100/140cm min. max. 100 cm 140 cm Permitted load ComTensile pressive 160 kN 160 kN Overlap By choosing the right spindle strut from the 4 available overlapping lengths, the optimum striking-distance can be obtained.
User information Doka heavy-duty supporting system SL-1 Multi-purpose walings SL-1 WU16 ● Waling lengths from 0.625 m to 3.00 m ● 20 mm diam. hole-grid (of the WS 10), to permit utilisation with Top 50 components ● 32 mm diam. hole-grid for connecting the Spindle struts SL-1 T16, and for flexurally rigid joints. ● Higher permitted loads, permitting greater influence widths Practical examples Connection for Spindle struts SL-1 T16 in the diam.
User information Doka heavy-duty supporting system SL-1 Connection methods for panel struts Horizontal waling Connecting up platforms Vertical waling 9759-289-01 A A 9759-289-02 A Connecting pin 10cm + Spring cotter 6mm A Waling connector SL-1 WU16 0.75m B Flexurally rigid link Flexurally rigid mounting of the Waling connector SL-1 WU16 0.75m on the Multi-purpose waling SL1 WU16 0.625m is only possible from one side. ➤ Be careful to mount in the right direction.
User information Doka heavy-duty supporting system SL-1 Placing and attaching the Doka beams Doka beams and walings are quickly assembled into finished elements, using simple connecting devices - either on-site or by the Doka "Ready-toUse" Service. Flange-clamp G - for fastening the Doka beam H20 anywhere on the waling. Can also be used on steel girders such as I-girders etc.
User information Doka heavy-duty supporting system SL-1 Lowering the heavy-duty supporting units Lowering wedge SL-1 420kN for adjusting the height of the HD supporting units, and taking loads off them. Lowering using the "Lowering cylinder SL-1 250kN" Several different types of traveller units are available for repositioning the HD supporting units. Regardless of which type is used, the unit always has to be lowered onto the relevant travelling construction first.
User information Doka heavy-duty supporting system SL-1 Bracket SL-1 This is used if there are no suitable points of application for the lowering cylinder beneath the Heavyduty supporting unit (either because the clearance between the System beam and the ground is too small, or because there are no cross-profiles) Where large HD supporting units are used under straight cover-slabs, the entire slab load momentarily rests on the lowering cylinders when the load is taken off the lowering wedges.
User information Doka heavy-duty supporting system SL-1 Repositioning using heavy-duty rollers for straight-line repositioning of HD supporting units where there is not a continuous base slab with sufficient load-bearing capacity. Repositioning procedure: ➤ Lower the HD supporting unit with the lowering cylinder (see "Lowering the heavy-duty supporting units"). ➤ Move the HD supporting unit over the heavy-duty rollers (oblique pull is not permitted).
User information Doka heavy-duty supporting system SL-1 The Heavy duty roller gear SL-1 300kN may only be used to travel heavy constructions in a straight line on level trackways with sufficient load-bearing capacity. ☞ Repositioning procedure: ➤ Lower the HD supporting unit with the hydraulic jack (see "Lowering the heavy-duty supporting units"). ➤ Move the HD supporting unit over the heavy-duty rollers (oblique pull is not permitted).
User information Doka heavy-duty supporting system SL-1 Repositioning with the Flanged wheel SL-1 For rail-guided, straight-line repositioning of HD supporting units. ● A suitable holdback restraint must be in place for upslopes or downslopes. ● Max. travel speed 1.5m/min. ● "Passenger transportation" is forbidden. ● Can be travelled either hydraulically or with suitable towing machines. ● There must be a firm (e.g. concrete) floor capable of supporting the load.
User information Doka heavy-duty supporting system SL-1 Repositioning using towing machine How to mount: ➤ Bring the Flanged wheel SL-1 to the installation position on the system beam and attach it with hexagonal bolts. Repositioning procedure: ➤ Fasten slinging means to the brackets and to the towing machine (oblique pull is not permitted). ➤ Lower the HD supporting unit with the lowering cylinder (see "Lowering the heavy-duty supporting units").
User information Doka heavy-duty supporting system SL-1 How to mount: Smooth long-term operation can only be ensured if the Hydraulic drive SL-1 has been correctly installed onto the travel-system. ➤ Insert the toothed shaft into the housing on the Hydraulic drive SL-1. ➤ Push the bolts through the holes in the gear-unit housing. ➤ Bolt the Hydraulic drive SL-1 to the gear-unit housing. ➤ Push the Flanged wheel SL-1 onto the toothed shaft.
User information Doka heavy-duty supporting system SL-1 Repositioning procedure: ➤ Lower the HD supporting unit with the lowering cylinder (see "Lowering the heavy-duty supporting units"). Drive hydraulic unit SL-1 Hydraulic unit for driving up to 2 Hydraulic drives SL-1. Before setting down the HD supporting unit, check to ensure that the rail is in the correct location in relation to the flanged wheel. ➤ Move the HD supporting unit to its new service position with the Hydraulic drive SL-1.
User information Doka heavy-duty supporting system SL-1 Hydraulic system Note: The EC "Machinery" Directive 89/392/EEC stipulates that all formwork systems that are moved either electrically or hydraulically are subject to mandatory CE labelling requirements. For this reason, a hazard analysis and an Operating Instructions manual must be drawn up for the entire system, in every case. The formwork is moved by means of a hydraulic branch-line system. ● The hydraulic unit has 6 hydraulic outlets.
User information Doka heavy-duty supporting system SL-1 Cylinder connection directly on the hydraulic unit Hydraulic branch-line system Cylinder connection via distributor blocks C A C A B 9759-293-01 A Hydraulic cylinder 9759-292-01 C Lowering brake-valve A Hydraulic cylinder B Distributor blocks C Lowering brake-valve 999759002 - 06/2008 Ü The Formwork Experts 47
User information Doka heavy-duty supporting system SL-1 Heavy-duty props for stationary sub-structures Struts SL-1 The Strut SL-1 is a segment-based modular system. ☞ Connecting the Strut SL-1 to the Prop spindle SL-1 Important note: A The Strut SL-1 is a pressure strut only. It cannot transfer tensile forces. Overview of variants C Strut SL-1 A C 9759-202-01 B A Strut SL-1 2.50m 1.25m 0.625m 0.312m 0.156m B Prop spindle SL-1 C Screw-set M16x40 DIN 933 8.
User information Doka heavy-duty supporting system SL-1 with the Basic plate SL-1 ☞ Important note: ● Only permitted if there is no risk of deformation to the beam! ● Ensure that no bending moments will be transferred into the Strut SL-1 (e.g. position a lowering wedge directly under the prop)! ● Always mount the Basic plate SL-1 in such a way that the milled-out recess is facing the Strut SL-1.
User information Doka heavy-duty supporting system SL-1 Head and foot with Prop spindle SL-1; wind on the prop 420 9759-116a 410 Permitted load [kN] 400 390 380 370 360 350 340 9759-209-01 4.0 6.0 5.0 7.0 Height of strut [m] Height of strut [m] min. max. 0.312 m 0.625 m 1.250 m 2.500 m 1.40 1.52 1.83 2.14 2.45 2.77 3.08 3.39 3.70 4.02 4.33 4.64 4.95 5.27 5.58 5.89 6.20 6.52 6.83 1.64 1.96 2.27 2.58 2.89 3.21 3.52 3.83 4.14 4.46 4.77 5.08 5.39 5.71 6.02 6.33 6.64 6.96 7.
User information Doka heavy-duty supporting system SL-1 Head with Prop spindle SL-1; foot with Basic plate SL-1; wind on the prop 440 9759-117a 430 Permitted load [kN] 420 410 400 390 380 370 360 350 9759-210-01 340 3.0 4.0 5.0 7.0 6.0 145 167 157 179 186 209 178 200 207 230 219 242 249 271 223 246 253 275 265 287 294 316 286 308 315 337 327 349 356 379 331 354 361 999759002 - 06/2008 Ü 5.94 6.10 6.26 6.41 6.57 6.73 6.88 7.04 7.19 7.35 6.16 6.32 6.48 6.63 6.79 6.95 7.10 7.26 7.41 7.
User information Doka heavy-duty supporting system SL-1 Techniques to facilitate assembly Connecting up panel struts with Connection adapter SL-1 A 9759-295-01 B C A Struts SL-1 B Connection adapter SL-1 C Panel strut 340 or 540 Connecting up multipurpose or steel walings e.g. as stiffening reinforcements during assembly.
User information Doka heavy-duty supporting system SL-1 Clamping-connections using the Beam clamp SL-1 for connecting steel sections with parallel flanges. Clamping two System beams SL-1 ➤ Locate two Beam clamps SL-1 diagonally to one another. Clamping range: 16 to 70 mm Width-across 24 mm A B Caution! Beam clamps SL-1 may only be used for fixing components in the right positions to one another.
User information Doka heavy-duty supporting system SL-1 Examples of the system in action TR585-207-01 54 The Formwork Experts 999759002 - 06/2008 Ü
User information Doka heavy-duty supporting system SL-1 TR585-211-01 999759002 - 06/2008 Ü The Formwork Experts 55
General remarks User information Doka heavy-duty supporting system SL-1 Doka service offerings Doka "Ready-to-Use" Service Ready-to-use formworks - for even the most unusual assignments Whatever it is you need to construct from concrete, the Doka Ready-to-Use Service can put together the right formwork for you - quickly, and in guaranteed Doka quality. No matter whether you are looking for a special concrete finish or a custom solution for a tunnel or bridge.
User information Doka heavy-duty supporting system SL-1 General remarks Doka Reconditioning Service Doka customer training So that your formwork is in "top form" for its next assignment Formwork training pays Inspecting, cleaning and maintaining your Doka framed formwork - all tasks that the Doka Reconditioning Service will be pleased to take off your hands. Its highly qualified staff and special equipment will quickly get your formwork back in top form - quickly and economically.
User information Doka heavy-duty supporting system SL-1 Component overview [kg] Article n° [kg] Article n° Doka Load-bearing Load-bearing tower Towers SL-1 System beam SL-1 5.00m System beam SL-1 4.00m System beam SL-1 3.00m System beam SL-1 1.00m System beam SL-1 0.75m 598.0 496.7 371.0 148.0 113.0 Systemträger SL-1 582800000 582801000 582802000 582803000 582804000 Screw set for kneebrace SL-1 2.
User information Doka heavy-duty supporting system SL-1 Component overview [kg] Article n° Hexagon nut 15.0 0.23 581964000 Sechskantmutter 15,0 Heavy duty roller gear SL-1 300kN Wälzwagen SL-1 300kN Guidance for heavy duty roller gear SL-1 Wälzwagenführung SL-1 Galvanised Height: 33.4 cm Screw set guid. f. heavy duty roller g. SL-1 Fixing bracket SL-1 7.5 582849000 Spannkonsole SL-1 Galvanised Length: 22 cm Width: 13 cm Height: 12 cm 22.
Component overview User information Doka heavy-duty supporting system SL-1 [kg] Article n° Lowering wedge SL-1 420kN Absenkkeil SL-1 420kN 30.0 582821000 [kg] Article n° Hydraulic distributor 23.0 580808000 Hydraulikverteiler Galvanised Height: 16.8 - 26.8 cm Lowering zylinder SL-1 250kN Absenkzylinder SL-1 250kN 27.2 582870000 Painted blue Height: 28-56 cm Max.
User information Doka heavy-duty supporting system SL-1 Component overview [kg] Article n° Spring cotter 6mm 0.06 580204000 Federvorstecker 6mm [kg] Article n° Connection adapter SL-1 4.3 582810000 Anschlussadapter SL-1 Galvanised Length: 13 cm Packed in units of 250 Waling connector SL-1 WU16 0.75m Riegelverbinder SL-1 WU16 0,75m Galvanised Length: 75 cm Angle tie bracket 20,0 SL-1 WU16 Winkelspanner 20,0 SL-1 WU16 Galvanised Length: 35 cm Width-across: 22 mm 31.0 582886000 Beam clamp SL-1 1.
Component overview User information Doka heavy-duty supporting system SL-1 [kg] Article n° Doka mobile scaffold tower Z Ladder extension XS 2.30m Doka-Fahrgerüst Z consisting of: (A) (B) (C) (D) (E) (F) (G) (H) (I) (J) (K) [kg] Article n° 19.1 588641000 Leiternverlängerung XS 2,30m Galvanised Attachable frame Z 1.00m Attachable frame Z 2.00m Railing frame Z 1.00m Handrail post Z 1.80m Platform Z with manhole flap 1.80m Platform Z without manhole flap 1.80m Cross board Z 1.
User information Doka heavy-duty supporting system SL-1 [kg] Article n° 999759002 - 06/2008 Ü Component overview [kg] Article n° The Formwork Experts 63
Doka heavy-duty supporting system SL-1 the safe way of transferring heavy loads The Heavy-duty supporting system SL-1 from Doka can be efficiently adapted to any shape and load. Its high load-bearing capacity and fast, cost-saving mode of assembly make this heavy-duty supporting system extremely efficient and economical. All components of the system can be rented, so it is a great solution for shorter-duration sites as well.
