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Introduction
999791002 - 09/2013
Introduction
Contents
4 4 6 8 9 9 10 12 15 16 Introduction Elementary safety warnings Doka services Eurocodes at Doka
Product description Instructions for assembly and use Technical condition Transporting, stacking and storing Component overview
999791002 - 09/2013
Introduction
Symbols used
The following symbols are used in this booklet:
Hazard assessment
The customer is responsible for drawing up, documenting, implementing and continually updating a hazard assessment at every job-site. This document serves as the basis for the site-specific hazard assessment, and for the instructions given to users on how to prepare and utilise the system. It does not substitute for these, however.
CAUTION / WARNING / DANGER Failure to observe this may lead to material damage, and to injury to health which may range up to the severe or even life-threatening.
Instruction This symbol indicates that actions need to be taken by the user.
Planning
Provide safe workplaces for those using the formwork (e.g. for when it is being erected/dismantled, modified or repositioned etc). It must be possible to get to and from these workplaces via safe access routes! If you are considering any deviation from the details and instructions given in this booklet, or any application which goes beyond those described in the booklet, then revised static calculations must be produced for checking, as well as supplementary assembly instructions.
Sight-check Indicates that you need to do a sight-check to make sure that necessary actions have been carried out.
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Introduction
Pouring
Do not exceed the permitted fresh-concrete pressures. Over-high pouring rates overload the formwork, cause greater deflection and risk breakage.
Assembly
The equipment/system must be inspected by the
customer before use, to ensure that it is in suitable condition. Steps must be taken to rule out the use of any components that are damaged, deformed, or weakened due to wear, corrosion or rot. Combining our formwork systems with those of other manufacturers could be dangerous, risking damage to both health and property. If you intend to combine different systems, please contact Doka for advice first. The equipment/system must be assembled and erected in accordance with the applicable laws, Standards and rules by suitably skilled personnel of the customer's, having regard to any and all required safety inspections. It is not permitted to modify Doka products; any such modifications constitute a safety risk.
guard component and/or any of its accessories, the component affected may only continue in use after it has been inspected and passed by an expert.
Maintenance
Only original Doka components may be used as
spare parts. Repairs may only be carried out by the manufacturer or authorised facilities.
Miscellaneous
We reserve the right to make alterations in the interests of technical progress.
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Introduction
Doka services
Support in every stage of the project
Doka offers a broad spectrum of services, all with a single aim: to help you succeed on the site. Every project is unique. Nevertheless, there is one thing that all construction projects have in common and that is a basic structure with five stages. We at Doka know our clients' varying requirements. With our consulting, planning and other services, we help you achieve effective implementation of your formwork assignment using our formwork products in every one of these stages.
1
Project Development Stage
2
Bidding Stage
3
Project Management Planning Stage
Controlled, regular forming operations, for greater efficiency resulting from realistically calculated formwork concepts
Find precisely the right formwork solutions, with the aid of help with the bid invitation in-depth analysis of the initial situation objective evaluation of the planning, execution, and time-risks
Draw up potentially winning bids, by basing them on realistically calculated guideline prices making the right formwork choices having an optimum time-calculation basis
Plan cost-effectively right from the outset, thanks to detailed offers determination of the commissioning quantities co-ordination of lead-times and handover deadlines
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Introduction
4
Concrete Construction Stage
5
Project Close-out Stage
When we advise and support you right from the word "go", we can make sure that the right formwork systems are chosen and then used as planned. This lets you achieve optimum utilisation of the formwork equipment, and effective forming operations because your workflows will be correct. The advice and support we can give you in how to use the equipment correctly, and as planned, leads to greater safety on the job. Because our services and costs are completely transparent, there is no need for improvisation during the project and no unpleasant surprises at the end of it. Our professional advice on the selection, quality and correct use of the equipment helps you avoid damage, and minimise wear-andtear.
Transparency
Optimum resource utilisation with assistance from the Doka Formwork Experts Seeing things through to a positive conclusion with professional support
Workflow optimisation, thanks to thorough utilisation planning internationally experienced project technicians appropriate transport logistics on-site support
Doka Services are a byword for transparency and efficiency here, offering jointly handled return of rented formwork professional dismantling efficient cleaning and reconditioning using special equipment
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Introduction
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. They will thus supersede the DIN norms as the "Doka standard" for product design. The widely used "Permissible stress design" (comparing the actual stresses with the permissible stresses) has been superseded by a new safety concept in the EC. The EC contrast the actions (loads) with the resistance (capacity). The previous safety factor in the permissible stresses is now divided into several partial factors. The safety level remains the same!
Ed
Ed Design value of effect of actions (E ... effect; d ... design) Internal forces from action Fd (VEd, NEd, MEd) Design value of an action Fd = F Fk (F ... force) Characteristic value of an action "actual load", service load (k ... characteristic) e.g. dead weight, live load, concrete pressure, wind Partial factor for actions (in terms of load; F ... force) e.g. for dead weight, live load, concrete pressure, wind Values from EN 12812
Rd
Rd Design value of the resistance (R ... resistance; d ... design) Design capacity of cross-section (VRd, NRd, MRd) Rk Rk Steel: Rd = Timber: Rd = kmod M M Characteristic value of the resistance e.g. moment resistance to yield stress
Fd
Fk
Rk
Partial factor for a material property (in terms of material; M...material) e.g. for steel or timber Values from EN 12812 Modification factor (only for timber to take account of the moisture and the duration of load action) e.g. for Doka beam H20 Values as given in EN 1995-1-1 and EN 13377 The "permissible values" communicated in Doka documents (e.g.: Qpermissible = 70 kN) do not correspond to the design values (e.g.: VRd = 105 kN)! Avoid any confusion between the two! Our documents will continue to state the permissible values. Allowance has been made for the following partial factors: F = 1.5 M, timber = 1.3 M, steel = 1.1 kmod = 0.9 In this way, all the design values needed in an EC design calculation can be ascertained from the permissible values.
kmod
EC/DIN concept
115.5 [kN] 90<105 [kN] Rk Rd gM = 1.1 Ed
A
gF = 1.5
98013-100
98013-102
Ed Rd
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Product description
Doka formwork beams
Doka formwork beams are solid-webbed beams made of wood or wood-based material to EN 13377 and in accordance with the approvals issued by the German Institute for Construction Engineering, Berlin (Z-9.1***), exclusively for use in wall and floor formwork. Other features include: Beam-flange markings in a 50 cm grid for the Dokaflex and Dokaflex 30 tec systems Option of adding "customer name" to wording (indicated by the suffix "BS" in the article designation.). Wood for flanges is graded by automatic grading machines for maximised dependability Meanings of the code letters used in the article designation
Code letter P Web made of special flat-pressed sheet N Web made of three-ply Innovative polyurethane end reinforcement for highly top effective protection of the formwork beam Tried-and-tested end reinforcement in the form of eco bevelled ends with plastic rivet in the beam flange
Types of beam
H16 N H16 P H20 N H20 P
20.0
16.0
16.0
4.0
3.5
6.5
6.5
3.5
8.0
8.0
Approval Number Z-9.1-391 Z-9.1-21 Z-9.1-391 or EN 13377 Doka beams with no EN mark (i.e. those produced on or before 3rd Nov. 2008) are covered by the above-mentioned DIB ( German Institute of Building Technology) Approval. Doka beams with an EN mark (i.e. those produced from 4th Nov. 2008 onward) are covered by EN 13377. Z-9.1-222 Overall height tolerance 1.0 mm, assuming 12% timber moisture content. H24 N H30 H36
5.4
9736-252-01
24.0
30.5
8.0
4.0
A C
9.7
9.7
Z-9.1-317
Z-9.1-21
Overall height tolerance 1.0 mm, assuming 12% timber moisture content.
A B C D E
Web (yellow) Flange (yellow) Beam-flange markings for the Dokaflex system System holes End reinforcement (blue plastic cap for Doka beam H20 top, rivet for Doka beam H20 eco) F Notch for chalking line
The innovative end reinforcement of the Doka beam H20 top significantly reduces damage to the beam ends.
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5.4
36.0
4.0
20.0
Deflection diagrams
Doka formwork beams H20 N and P
2.5
9732-105
p [kN/m]
16 14 12
Deflection [mm]
10
Q
M
8
7.5
L/500 1
6 4 2
30
20
10 0.5 kN/m 15
9768-200-01
40
1.0
2.0
3.0
4.0
5.0
In order to maximise durability, it is important to handle the components with due care; this applies particularly when stripping out floor-slab formwork. You will also find information on correct usage in the in user information for the individual products, for example: Large-area formwork Top 50 Dokaflex Doka Xtra To prevent any staining of the concrete from direct contact with new formwork beams, we recommend covering the formwork beams with a non-woven fabric. Permissible values from EN 13377, Schedule E
perm. Q [kN] perm. M [kNm] E J [kNm2] perm. span [m] H20 N and P 11.0 5.0 450 4.00 H16 P H16 N H24 H30* H36* 8.5 2.7 250 3.20 7.5 12.5 15.0 17.0 2.7 6.5 13.5 17.0 250 700 1250 1850 3.20 4.80 6.00 6.00
Support centres L [m] M ... permitted bending moment Q ... permitted shear force p ... actual load (service load)
9732-110
p [kN/m]
Deflection [mm]
10 8
Q
3 3.5 4 5 4.5
2.5
M
1.5 L/500 1 0.5 kN/m
6 4 2 0
40 30 10
20
7.5 15
0.5
1.0
1.5
2.0
2.5
3.0
3.5
These values allow for a F = 1.5, a kmod of 0.9 and a M = 1.3. Based on a residual moisture content of 20 % or less. The values must be adjusted accordingly if conditions of use differ. *According to approval issued by the Institute for Construction Engineering, Berlin
Support centres L [m] M ... permitted bending moment Q ... permitted shear force p ... actual load (service load)
10
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16 14 12
9732-111
1.5
Deflection [mm]
10
7. 5
4.5 5
1 L/500
8 6 4 2
40 30
20
10
0.5 kN/m
15
Support centres L [m] M ... permitted bending moment Q ... permitted shear force p ... actual load (service load)
Floor formwork
9791-206-01
16 14 12
9732-112
p [kN/m]
Deflection [mm]
10 8
15
WARNING The uses illustrated below are prohibited, as are other, similar uses!
Do not use as scaffold flooring.
6 4 2 0
40 30
20
0.5 kN/m
10 Q
1.0
2.0
3.0
4.0
5.0
6.0
7.0
Support centres L [m] M ... permitted bending moment Q ... permitted shear force p ... actual load (service load)
16 14 12
Deflection [mm]
10
1
8 6 4
15
10
2 0
40 30
20
1.0
2.0
0.5 kN/m
3.0
4.0
5.0
6.0
7.0
Support centres L [m] M ... permitted bending moment Q ... permitted shear force p ... actual load (service load)
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9791-201-01
9791-200-01
9791-220-01
9791-205-01
1.0
2.0
3.0
4.0
5.0
6.0
11
Technical condition
The following quality criteria define the extent of damage permissible in terms of load-bearing strength. Use is prohibited if damage is beyond these limits.
Flange
Angled cracks (across the grain) Not permissible.
9791-210-02
b a
9791-208-01 9791-211-02
Straight cracks (parallel to the flange) parallel to flange, permissible up to width a = 2 mm. If the flange can be parted at the crack the beam is
not in usable condition.
a
Angled splintering across the edge permissible up to a = 30 mm across the diagonal and
up length b = 500 mm.
9791-213-01 9791-214-01
9791-207-01
9791-214-01
9791-207-02
12
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a
9791-207-09
9791-207-08 9791-209-01
9791-221-01
9791-212-02
Damage to the plastic cap has no effect on loadbearing strength, but beams damaged evincing damage of this kind do not necessarily meet the quality criteria for Doka rental formwork
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13
Web
Damage to web permissible only if slight and at one side of the beam.
9791-216-01
9791-207-04
9791-207-06
9791-217-01
9791-207-03
14
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Protect stacked beams from extreme climatic influences such as exposure to sunshine or moisture by covering them (with breathable tarpaulins). This reduces cracking. Only cover them never envelope them completely.
Always use edge protectors when strapping beams together. Edge protectors can be padding made of plastic, wood or cardboard.
Transport
Always use strap slings to lift stacked beams - do not
use chains.
Packs of up to 90 units
Packs of up to 45 units.
9791-218-02
9791-218-01
When moving beams not securely strapped together, take care that loose beams cannot slip.
9791-202-03
9791-203-03
Stacked beams
max. 2500 kg per stack
Max. 2 packs stacked one on top Max. 4 packs stacked one on top of the other of the other
Ground conditions for stacking Maximum angle of inclination of ground 3%. The ground on which the stack is to be placed must
9791-202-01
be adequately firm and level. Best-case conditions are concreted or paved storage areas. Storage on asphalt: Depending on the parts stored, place wooden battens, strips of formwork sheeting or metal sheet between the parts and the asphalt surface to ensure that the weight is adequately spread. Storage on other surfaces (sand, gravel...): Adopt suitable measures for storage (e.g. place thick plywood sheets underneath the loads).
Max. number of beams per stack Minimum number of wooden battens (min. 8 x 8 x 100 cm) Size a Size b for beam H20 P Size b for beam H20 N
Always sort beams for stacking, in other words do not stack beams N and P together in a mixed stack.
P
N
N
N
P
P
P N N
N
P N
9791-204-01
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15
User information Timber formwork beams Article n 189011000 189012000 189013000 189014000 189015000 189016000 189017000 189018000 189019000 189020000 189010000 189021000 Doka beam H20 eco N 1.25m Doka beam H20 eco N 12.00m
Doka-Trger H20 eco N Varnished yellow
[kg]
Article n
Doka beam H20 top N 1.80m Doka beam H20 top N 2.45m Doka beam H20 top N 2.65m Doka beam H20 top N 2.90m Doka beam H20 top N 3.30m Doka beam H20 top N 3.60m Doka beam H20 top N 3.90m Doka beam H20 top N 4.50m Doka beam H20 top N 4.90m Doka beam H20 top N 5.90m Doka beam H20 top N .....m Doka beam H20 top N .....m BS
Doka-Trger H20 top N Varnished yellow
9.5 12.8 13.8 15.0 17.0 18.5 20.0 23.0 25.0 30.0 5.2 5.2
Doka beam H20 top P 1.80m Doka beam H20 top P 2.45m Doka beam H20 top P 2.65m Doka beam H20 top P 2.90m Doka beam H20 top P 3.30m Doka beam H20 top P 3.60m Doka beam H20 top P 3.90m Doka beam H20 top P 4.50m Doka beam H20 top P 4.90m Doka beam H20 top P 5.90m Doka beam H20 top P .....m Doka beam H20 top P .....m BS
Doka-Trger H20 top P Varnished yellow
9.9 13.2 14.3 15.6 17.7 19.2 20.8 23.9 26.0 31.2 5.4 5.4
189701000 189702000 189703000 189704000 189705000 189706000 189707000 189708000 189709000 189710000 189700000 189711000
Doka beam H20 eco P 1.80m Doka beam H20 eco P 2.45m Doka beam H20 eco P 2.65m Doka beam H20 eco P 2.90m Doka beam H20 eco P 3.30m Doka beam H20 eco P 3.60m Doka beam H20 eco P 3.90m Doka beam H20 eco P 4.50m Doka beam H20 eco P 4.90m Doka beam H20 eco P 5.90m Doka beam H20 eco P 9.00m Doka beam H20 eco P .....m Doka beam H20 eco P .....m BS
Doka-Trger H20 eco P Varnished yellow
9.4 12.7 13.8 15.1 17.2 18.7 20.3 23.4 25.5 30.7 46.8 5.2 5.2
189940000 189936000 189937000 189930000 189941000 189942000 189931000 189943000 189932000 189955000 189956000 189999000 189957000
Doka beam H20 eco P 1.25m Doka beam H20 eco P 12.00m
Doka-Trger H20 eco P Varnished yellow
Doka beam H20 eco N 1.80m Doka beam H20 eco N 2.45m Doka beam H20 eco N 2.65m Doka beam H20 eco N 2.90m Doka beam H20 eco N 3.30m Doka beam H20 eco N 3.60m Doka beam H20 eco N 3.90m Doka beam H20 eco N 4.50m Doka beam H20 eco N 4.90m Doka beam H20 eco N 5.90m Doka beam H20 eco N .....m Doka beam H20 eco N .....m BS
Doka-Trger H20 eco N Varnished yellow
9.0 12.3 13.3 14.5 16.5 18.0 19.5 22.5 24.5 29.5 5.0 5.0
189283000 189271000 189272000 189273000 189284000 189285000 189276000 189286000 189277000 189287000 189299000 189289000
Doka beam H16 N 1.80m Doka beam H16 N 2.45m Doka beam H16 N 2.90m Doka beam H16 N 3.30m Doka beam H16 N 3.90m Doka beam H16 N 4.90m Doka beam H16 N 9.00m Doka beam H16 N .....m
Doka-Trger H16 N Varnished yellow
16
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User information Timber formwork beams [kg] Doka beam H16 P 1.80m Doka beam H16 P 2.45m Doka beam H16 P 2.90m Doka beam H16 P 3.30m Doka beam H16 P 3.90m Doka beam H16 P 4.90m Doka beam H16 P 9.00m Doka beam H16 P .....m
Doka-Trger H16 P Varnished yellow
Component overview Article n 189969000 189961000 189962000 189963000 189966000 189967000 189970000 189960000 [kg] Article n
Doka formwork beam H24 N 4.90m Doka formwork beam H24 N 7.40m
Doka-Schalungstrger H24 N Varnished yellow
8.0 189099000
9.0 189199000
5.0 176005000
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17
Component overview
18
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Component overview
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19
Doka GmbH | Josef Umdasch Platz 1 | 3300 Amstetten | Austria | T +43 7472 605-0 | F +43 7472 66430 | oesterreich@doka.com | www.doka.com
999791002 - 09/2013