999771002 GB Method statement Doka forming wagon T · 4 The FormworkExperts 999771002 - 08/2008 Ü Introduction User information Doka forming wagon T Elementary safety warnings User

The Formwork Experts

08/2008 Ü

GB999771002

User information

Method statement

Doka forming wagon T

9730-235-01

2 999771002 - 08/2008 Ü

User information Doka forming wagon T


Introduction

© by Doka Industrie GmbH, A-3300 Amstetten

3999771002 - 08/2008 Ü

Contents Page

User information Doka forming wagon T Introduction


Introduction .................................................................................................. 2

Elementary safety warnings ........................................................................ 4Eurocodes at Doka........................................................................................ 6System overview .......................................................................................... 7Areas of use .................................................................................................. 9Formwork configuration ............................................................................ 11Enlarging the Ready-to-use platform for Forming wagon T...................12Examples of the system in action .............................................................14Dimensioning of the ballast.......................................................................16Assembly instructions................................................................................18Pouring ........................................................................................................24Striking ........................................................................................................25Repositioning the forming-carriage units.................................................26Safety on the structure...............................................................................28Weatherproofing......................................................................................... 30Flexible adaptation to the requirements of the structure........................31Adjusting the forming wagons..................................................................32Multifunctional utilisation..........................................................................33Transporting, stacking and storing ...........................................................34Items needed...............................................................................................35

Component overview.................................................................................36

The Formwork Experts4 999771002 - 08/2008 Ü

Introduction User information Doka forming wagon T

Elementary safety warnings

User target groups

● This User Information booklet (Method State-ment) 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 sys-tem, and on correct, compliant utilisation of the system.

● All persons working with the product described herein must be familiar with the contents of this manual and with all the safety instructions it con-tains.

● Persons who are incapable of reading and under-standing this booklet, or who can do so only with difficulty, must be instructed and trained by the customer.

● The customer is to ensure that the information materials provided by Doka (e.g. User Informa-tion booklets, Instructions for Assembly and Use, Operating Instruction manuals, plans etc.) are available to all users, and that they have been made aware of them and have easy access to them at the usage location.

Remarks on this document

● This User Information booklet can also be used as a generic method statement or incorporated with a site-specific method statement.

● Many of the illustrations in this booklet show the situation during formwork assembly and are therefore not always complete from the safety point of view.

● Further safety instructions, especially warnings, will be found in the individual sections of this document!

Planning

● Provide safe workplaces for those using the formwork (e.g. for when it is being erected/dis-mantled, 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 cal-culations must be produced for checking, as well as supplementary assembly instructions.

Rules applying during all phases of

the assignment:

● The customer must ensure that this product is erected and dismantled, reset and generally used for its intended purpose under the direction and supervision of suitably skilled persons with the authority to issue instructions.

● Doka products are ONLY to be used in accord-ance with the Doka User Information booklets or other technical documentation provided by Doka.

● The stability of all components and units must be ensured during all phases of the construction work!

● The functional/technical instructions, safety warnings and loading data must all be strictly observed and complied with. Failure to do so can cause accidents and severe (even life-threaten-ing) damage to health, as well as very great material damage.

● Fire-sources are not permitted anywhere near the formwork. Heating appliances are only allowed if properly and expertly used, and set up a safe distance away from the formwork.

● The work must take account of the weather con-ditions (e.g. risk of slippage). In extreme weather, steps must be taken in good time to safeguard the equipment, and the immediate vicinity of the equipment, and to protect employees.

● All connections must be checked regularly to ensure that they still fit properly and are function-ing correctly.It is very important to check all screw-type con-nections and wedge-clamped joins whenever the construction operations require (particularly after exceptional events such as storms), and to tighten them if necessary.

Assembly

● The equipment/system must be inspected by the customer before use, to ensure that it is in suita-ble 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 con-tact Doka for advice first.

● The assembly work must be carried out by suita-bly qualified employees of the client's.

User information Doka forming wagon T Introduction

5999771002 - 08/2008 Ü The Formwork Experts

Erecting the formwork

● Doka products and systems must be set up in such a way that all loads acting upon them are safely transferred!

Pouring

● Do not exceed the permitted fresh-concrete pres-sures. Excessively high pouring rates lead to formwork overload, cause greater deflection and risk causing breakage.

Striking the formwork

● Do not strike the formwork until the concrete has reached sufficient strength and the person in charge has given the order for the formwork to be struck!

● When striking the formwork, never use the crane to break concrete cohesion. Use suitable tools such as timber wedges, special pry-bars or sys-tem features such as Framax stripping corners.

● When striking the formwork, do not endanger the stability of any part of the structure, or of any scaffolding, platforms or formwork that is still in place!

Transporting, stacking and storing

● Observe all regulations applying to the handling of formwork and scaffolding. In addition, the Doka slinging means must be used - this is a mandatory requirement.

● Remove any loose parts or fix them in place so that they cannot be dislodged or fall free!

● All components must be stored safely, following all the special Doka instructions given in the rele-vant sections of this User Information booklet!

Regulations; industrial safety

● Always observe all industrial safety regulations and other safety rules applying to the application and utilisation of our products in the country and/or region in which you are operating.

Instruction as required by EN 13374:● If a person or object falls against, or into, the

sideguard system and/or any of its accessories, the sideguard component affected may only con-tinue in use after it has been inspected and passed by an expert.

Maintenance

● Only original Doka components may be used as spare parts.

Symbols usedThe following symbols are used in this booklet:

MiscellaneousWe reserve the right to make alterations in the inter-ests of technical progress.Unless otherwise stated, all dimensions are given in cm.

Important note

Failure to observe this may lead to mal-function or damage.

Caution / warning / danger

Failure to observe this may lead to mate-rial 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.

Sight-check

Indicates that you need to do a sight-check to make sure that necessary actions have been carried out.

Tip

Points out useful practical tips.

Reference

Refers to other documents and materials.

☞


Introduction User information Doka forming wagon T

Eurocodes at DokaIn 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 pro-vide 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 stand-ard 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" (com-paring the actual stresses with the permissible stresses) has been superseded by a new safety con-cept in the EC.The EC contrast the actions (loads) with the resist-ance (capacity). The previous safety factor in the permissible stresses is now divided into several partial factors. The safety level remains the same!

Comparison of the safety concepts (example)

Ed Design value of effect of actions(E ... effect; d ... design)Internal forces from action Fd

(VEd, NEd, MEd)

Rd Design value of the resistance(R ... resistance; d ... design)Design capacity of cross-section(VRd, NRd, MRd)

Fd Design value of an actionSteel: Rd =

Rk Timber: Rd = kmod ·Rk

Fd = γF · Fk γM γM

(F ... force)Fk Characteristic value of an action

"actual load", service load(k ... characteristic)e.g. dead weight, live load, concrete pres-sure, wind

Rk Characteristic value of the resistancee.g. moment resistance to yield stress

γF Partial factor for actions(in terms of load; F ... force)e.g. for dead weight, live load, concrete pres-sure, windValues from EN 12812

γM Partial factor for a material property(in terms of material; M...material)e.g. for steel or timberValues from EN 12812

kmod Modification factor (only for timber – to take account of the moisture and the duration of load action)e.g. for Doka beam H20Values as given in EN 1995-1-1 and EN 13377

Ed

Rd

Permissible stress design EC/DIN concept

Factual≤ Fpermissible Ed≤ Rd

A Load factor

60 [kN]

60<70 [kN]

115.5 [kN]

� ~ 1.65

Fyield

Fpermissible

Factual

9801

3-10

0

A

90 [kN]

115.5 [kN]

90<105 [kN]

Rk

Rd

Ed

�M

= 1.1

�F

= 1.5

9801

3-10

2

A

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:γF = 1.5γM, timber = 1.3γM, steel = 1.1kmod = 0.9In this way, all the design values needed in an EC design calculation can be ascertained from the permissible values.



System overview

Doka forming wagon T – the site-

ready, travelling bridge-edge beam

formworkThe travelling Forming wagon T carries a large area of pre-assembled, repositionable bridge edge beam formwork that can be cycled with no need for dis-mantling. It stands out for its high carrying capacity.

Cost-effective areas of utilisation include the cast-ing of edge kerbs in the following cases:● longer bridge superstructures● high number of re-use cycles● "section-at-a-time" repositioning cycles● rehabilitation of existing bridge superstructuresThe system is also suitable for curved bridges with large radii.

The many plus-points of the Doka forming

wagon T:

● high flexibility in terms of different formwork configurations

● unlimited options regarding adjustability● quick to erect and dismantle, thanks to high

degree of pre-assembly (also means that less storage space is needed)

● easy to handle, permitting a rapid pace of work – daily rhythm

● multifunctional useage:- forming wagon- demolition wagon- basic construction for travelling of wall form-

work● galvanised, long-life constructional design

Example using Doka bridge edge beam formwork T:

For shorter bridge superstructures and bridges of medium length needing only a small number of repositioning cycles, the Doka bridge edge beam formwork T is ideal. This system can quickly be erected by hand. Please follow the directions in the "Doka-bridge edge beam formwork T" User Infor-mation booklet.

9770-200-01



The main system components

A Rails

B Bogie for Forming wagon TS

F Ballast

G Double jib for Forming wagon T

K Spindle strut GS T7 109/166cm

M Suspension beam for Forming wagon T

N Spindle strut T6 100/150cm

P Longitudinal beam for Forming wagon T

Q Railing strut for Forming wagon T

R Ready-to-use platform for Forming wagon T

S Spindle strut T6 73/110cm

T Handrail post T 0.70m

X Pressure prop T

Y Spindle strut GS T6 95/140cm (included with Item B)

9730-235-01

B

Y

N

R

T S

F

G

P M

X

Q

A K



Areas of useWide setting ranges and versatile scope for adjust-ments – leading to high flexibility and adaptability to just about any site situation. The system's ease of handling permits rapid working.

System dimensions:

a ... max. 596.0 cmb ...max. 60 cmc ... Track gauge 197.5 cmd ... 213.0 cme ... 200.0 cmf ... Adjusting range 4x30.0 cm = 120.0 cmg ... max. sidewalk space 200.0 cmh ... max. 80 cmi ... 18.0 cm

☞ Where forming carriages are erected over traffic routes (roads, navigated waterways, railways), then – in order to prevent objects being dropped and endangering passing traffic – the platform decking must be tightly laid and the railings must be fitted with screens as required by regulations.

A Ballast

±5°

±15°

±10°

9730-239-01

c

i

e

f

a

b

g

h

d

A



Plan view: (simplified drawing not showing bridge superstructure)

k ... 280.0 cml ... Standard platform length 490.0 cmm ... Standard formwork length 500.0 cm

Travel gearCentre-to-centre spacing of rails 197.5 cm. Parking wedges (A) on the double flanged wheels secure the Forming wagons T in their duty position. Clamping jaws can be used to provide additional fixing on / adaptation to the rail profile.

Tools needed: ● Fork spanner 13/17

9730-259-01

k l m

a ... 25.0 cm b ... max. 8.0 cm

9730-244-01

aA

9730-245-01 b



Formwork configurationThe forming wagons are designed for a formwork length of 5 m. Thanks to the flexible connection possibilities provided by the hole grid in the sus-pension beam, almost any formwork configuration is possible. The formwork elements can also be pre-assembled.

Example:

Example: Formwork adjustable with Adjusting spindle T

A Location plate, adjustable in 5.3 cm increments (included with Suspension beam)

B Suspension beam for Forming wagon T

C Multi-purpose waling or Steel waling WS10 Top50

D Doka beam H20

E Tie-rod 15.0 (length = 45 cm)

F Super-plate 15.0

G Flange-clamp H20

H Connecting pin 10cm + Spring cotter 6mm

I Façade pre-cast member clamp V

Optimum accommodation of the stop-ends on the side facing the bridge is obtained by bracing the bottom steel waling (C) with squared timbers and wedges, or with the Façade pre-cast member clamp V (I) .

9730-240-01

A

B

C

C

D

E

F

G

H

I

A Adjusting spindle T

B Suspension beam for Forming wagon T

C Multi-purpose waling or Steel waling WS10 Top50

D Doka beam H20

E Tie-rod 15.0

F Super-plate 15.0

G Flange-clamp H20

H Connectin pin 10cm + Spring cotter 6mm

I Façade pre-cast member clamp V

J e.g. Spindle strut T6 100/150cm

K Flange claw

9730-315-01

A

B

C

C

DEF

G

K

H

C

J

I



Enlarging the Ready-to-use platform for Forming wagon T

Lowering and widening the work

deckWhere there are high edge-beams, the work deck (i.e. the "Ready-to-use platform for Forming wagon T") (B) can be hung 1 metre lower using the Sus-pension beam extension T 1.00m (A) .

When combined with:● Platform extension plate T (C) (incl. cable + turn-

buckle)● Multipurpose or standard steel waling

WS10 Top50 1.00m (D)

● squared timbers and deck-boards (E)

the existing ready-to-use platform can be enlarged into an up to 2.50 m wide working platform.

This makes for safe, convenient working:● on the formwork● on the cantilevering zones of the superstructure

(during inspection and site-erection work)

Slide-off protection can be provided using e.g. the Handrail clamp T (F) or the Handrail post 1.80m.The Handrail lengthening piece T 1.00m (G) pro-vides effective fall-arrest protection for work carried out on the top of the superstructure.

For this additional support, the following items are needed for each Forming wagon T:

9730-301-01

A

BCD

E

F

G

H

I

☞ Important note:

Where weatherproofing tarpaulins (H) are hung over the outside, the Handrail length-ening piece (G) must be given extra support using a Railing profile 740 (I) .

N° of items Name Part n°s

2 Railing profile 740 504348010

2 Hexagon screw M16x90, galv. DIN 601 019005

4 Hexagon screw M16x140, galv. DIN 931 019008

6 Spring washer A16, galv. DIN 127 0199006 Hexagon nut M16, galv. DIN 934 019303



Lengthening the work decke.g. to facilitate mounting of the stop-end at either end of the forming-wagon train.Easy to assemble, using parts from the Doka stand-ard range.

A Multi-purpose waling or Steel waling WS10 Top50

B Connecting pin 10cm + Spring cotter 6mm

C e.g. Handrail clamp S or Handrail post T 1.80m

D Extra platform planking unit

E Guard-rail boards

F Extra-long guard-rail boards of the Forming wagon T

9730-314-01

A

C

D

EF G

B



Examples of the system in action





Dimensioning of the ballast

As well as by the weights of the components involved and by the live loads, the dimensioning of the ballast will also be influenced by the following factors:● position of Pressure prop T● position of formwork unit as a whole● position of ballast● repositioning operation (no Pressure prop T)

Position of Pressure prop TThe Pressure prop T (A) can be attached to several possible positions on the double jib. This permits additional project-specific optimisation.

a1 ... 50.0 cma2 ... 120 cm (standard ex-factory setting)a3 ... 257.0 cm (for special applications)

Note:

Where distance a1=50 cm and a3=257 cm, the standard Spindle strut GS T6 95/140cm (C) cannot be used. On-site fixing is needed in this case.

Position of formwork unit as a

wholeThe position of the suspension beam, together with the platform and the formwork, can be continu-ously adjusted within the range indicated b, as required.The position set here will also have an influence on the size of the ballast (B) (see diagram on next page).

b ... 220.0 to 375.0 cm

☞ Important note:

The weight calculated for the ballast must be sufficient to permit all the forces to be sustained with an adequate margin of safety!

A Pressure prop T

B Ballast

C Spindle strut GS T6 95/140cm

9730-302-01a

a1

a2

a3

A

C

B

9730-303-01

b

B



Determining ballast weight

The diagram for determining ballast weight makes it easier to find which weight of ballast is required on a standard version of forming wagon. It makes the following design assumptions:● Length of formwork 5 m● Ballast position: dimension c=130 cm● Dimensions a and b: see diagram lines● Weight of formwork per unit: 400 kg● Dead weights incl. lowered platform (Suspension

beam extension 1.00m and 1.00 m extra width)● Pouring platform at same height as formwork● Live loads per unit:

- when Pressure prop T is in place Permitted service load: 1.5kN/m2 (150 kg/m2)Load Class 2 to EN 12811-1:2003

- when Pressure prop T is removed(situation during travel - 4 kN)

For project-specific deviations (e.g. deviations in the centre-of-gravity position), separate calcula-tions must be performed.

a ... Standard 120 cmb ...220.0 to 375.0 cmc ... min. 130.0 cmd ... max. 220.0 cm

Diagram for determining the ballast weight

Length of ballast

A Pressure prop T

B Centre of gravity of ballast

C Spindle strut GS T6 95/140cm

X Cross-section of the edge kerb having an effect on the load

Risk of tipping over!➤ Dimension "c" for the centre of gravity of

the ballast MUST be strictly observed!Sufficient ballast must be provided to ensure stability at all times, including during the erection and dismantling phases.

9730-258-01

ad

c

b

B

AC X

Bal

last

[kN

] (w

/o w

eath

erp

roo

fin

g t

arp

.)

Cross-section (X) of the edge kerb [m2]

Curve Dimension a [cm] Dimension b [cm]A 120 220B 120 295C 50 220D 120 375E 50 295F w/o pressure prop 220G 50 375

Dimension e [cm]

max. 240.0If the ballast is longer than this, the rear spindle struts can no

longer be turned.

min. 220.0 Where the ballast is shorter

than this, a revised static calcu-lation must be produced for

the supporting profiles

9730-101

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

00.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50

A

C

EG

B

D

F

9730-300-01

e



Assembly instructionsThe assembly workflow outlined here is for the standard set-up. In practice, attention must also be paid to the relevant assembly plan or shop draw-ing!

Tools needed: ● Reversible ratchet 1/2"● Extension piece 11cm● Box nut 24● Fork spanner 22/24● Fork spanner 13/17

Position the Bogie for Forming

wagon TS➤ Lay the rails (A) .➤ Attach four-part lifting tackle to Bogie for Form-

ing wagon TS (B) .Spreading angle of lifting tackle: max. 60°.

Close-ups of crane hoisting points

➤ Lower the "Bogie for Forming wagon TS" onto the rails.

a ... Centre-to-centre spacing of rails = 197.5 cmx ... Distance from edge of bridge superstructure, as per shop drawing

Rear crane-hoisting pointFront crane-hoisting point, and parking wedge to immobilise

the bogie

Warning about accidental movement of bogie!➤ Fit parking wedges (C) to the "Bogie for

Forming wagon TS" to immobilise it in both directions during all stages of the erection operation

9730-203-01

B

9730-204-01

B

9730-204-01

C

B

9730-202-01

a

x

A

B



Tilt up the vertical frame, and bolt in

the frame strut➤ Use the crane to tilt up the vertical frame (D) of

the "Bogie for Forming wagon TS" into the verti-cal.

Close-up of crane hoisting point:

➤ Take the frame strut (E) out of the "Parked" posi-tion – in the horizontal – and bolt it into the verti-cal frame of the "Bogie for Forming wagon TS", securing it with a spring cotter.

View Z:

Place the ballast on the bogieFor details on the dimensioning and position of the ballast (F) see the shop drawing and/or "Dimension-ing of the ballast".

9730-205-01

Z

D

9730

-206

-01

9730-208-01

E

9730-211-01

F



Assemble the double jib➤ Set down the jibs with a centre-to-centre spacing

of b = 280.0 cm and stiffen with scaffolding tubes. Make sure that the horizontal scaffolding tubes all extend the same distance to either side of the jibs.

b ... 280.0 cm

➤ Adjust the position of the Jib slide (L) as shown in the assembly plan.

Note:

If the Jib slide (L) is positioned very far back, ensure that the suspension beam (M) can still be fitted through from above. This can be achieved by not fitting the two front scaffolding tubes until later.

c ... No stiffening tubes in this zone

Lift the double jib into the Bogie for

Forming wagon TS➤ Lift the assembled double jib (G) into the Bogie

for Forming wagon TS, bolt it into the vertical frame (D) with a peg-in unit (O) and secure it.

Close-up of peg-in unit (O)

➤ Bolt in the Spindle strut T6 (N) between the jib (G) and the Bogie for Forming wagon TS (B) , and secure it with a spring cotter.


H Scaffolding tube 48.3mm 4.50m

I Scaffolding tube 48.3,mm 3.00m

J Swivel coupler 48mm

K Spindle strut GS T7 109/166cm


L Jib slide (included in scope of supply of Item G)

M Suspension beam for Forming wagon T

Assembling the jib on an assembly bench with stop-bars and sleepers makes it easier to keep the double jib both parallel and the correct distance apart.

9730-212-01

b

G

H

I

J

K L

9730-213-01

c

G

LM

N Spindle strut T6 100/150cm

9730-214-01

N

O

G

9730-216-01

O

D

G

9730-215-01

N

B



Pre-assemble the suspension beam

unit➤ Set down the suspension beams (M) with a cen-

tre-to-centre distance of b = 280.0 cm.➤ Bolt on the longitudinal beam (P) using 4 hexag-

onal bolts M16x45 + nuts and spring washers.

b ... 280.0 cm

➤ Bolt on the railing struts (Q) using 4 hexagonal bolts M16x90 + nuts and spring washers.

➤ Bolt and secure the location plate (Z) ,in the height position shown in the plan.

Connect the suspension beam unit

to the platform➤ Lower the ready-to-use platform (R) by crane

onto an approx. 20 cm high base (U) (e.g. Doka beams H20).

➤ Lower the suspension beam unit by crane into the ready-to-use platform.

➤ Attach Scaffolding tube 48.3mm 4.50m (H) and Swivel coupler 48mm (J) . This stiffening is no longer necessary if the out-side railings are erected using Railings T.

➤ Insert the Handrail posts T 0.70m (T) into the plat-form, and secure them with a spring cotter.

➤ Bolt the railing struts (Q) onto the ready-to-use platform (R) with Connecting pins 10cm, and secure with spring cotters.

9730-217-01

b

M P

9730-218-01Q

Z

9730-220-01

J

S

T

H

H

R

U

M

Q

9730

-223

-01

R

Q



➤ Attach the suspension beams (M) to the ready-to-use platform (R) using swivel bolts d29/195, and secure with spring cotters.

➤ Mount the Spindle struts T6 73/110cm (S) (posi-tion as shown in assembly plan).

Mount formwork and safety railings➤ Mount the formwork as shown in the project

plan.

Erect railings:

➤ On the outside:Fasten the guard-rail boards (min. 20x4 cm) with square bolts M10x110 and hexagon nuts M10.

➤ On the inside:Insert guard-rail boards (min 20x4 cm) into the Handrail posts T 0.70m, and fix them in place.

☞ The platform stop (V) protects the ready-to-use platform (R) against slipping out, at all times – even when it is being lifted.● When dismantling, always:

remove the platform stop (V) first. The ready-to-use platform cannot be disman-tled until the platform stop has been removed.

● After dismantling, do not forget:Fix the platform stop (V) back on again!

9730-222-01

V

R

M

9730

-224

-01

S

M

R

To save time putting up the guard-railings, pre-assembled Railings T are also available.If these are used, stiffening tubes (H) and (J) are no longer needed.

9730-221-01

W

J

H

H

W



Mount the platform unit, complete

with the formwork

➤ Bolt the Pressure props T (X) into the double jib (G) and secure them with spring cotters.

➤ Press the Pressure prop T (X) onto the double jib (G) by turning the nuts (ensure that the Pressure prop T is in the vertical).

➤ Take the Spindle struts GS T6 95/140cm (Y) out of their "Parked" position, and bolt them in place and secure them so as to fix the Pressure prop T (X) onto the Bogie for Forming wagon TS (B) .

➤ Lift the platform unit into position by crane (guid-ing with tag-lines if necessary).

➤ Insert and secure the safety pins (Z) .

➤ Bolt the Spindle struts GS T7 109/166cm (K) into the suspension beam (M) and secure them with spring cotters.

9730-225-01

X

YK

G

9730-229-01

X

G

9730-228-01

Y

B

9730-262-01

9730-263-01

Z

9730-226-01

KM



Pouring

➤ Tension the spindles in the direction of the arrows until the play is eliminated – but not so far as to dislodge the formwork.

Extra working platformA working platform can easily be made for striking off the surface of the concrete.

Close-up A:

Tools needed: ● Fork spanner 13/17

☞ Before pouring:

Check that there is no play in the spindle set-tings

A9730-253-01

A Attachable platform support T(can be attached to the railing strut in 5 cm increments)

B Doka beam H20

C Platform planking (secure against slipping)

9730-200-01

A

B

C



Striking

1) Pull the bottom formwork off the concrete by turning the Spindle struts T6 73/110cm (A) .

2) Turn the Spindle struts GS T7 109/166cm (B) to push down the suspension beams, complete with the side formwork.

3) Shorten Pressure prop T (C) by approx. 5 cm.4) Unbolt the Spindle struts GS T6 95/140cm (D)

from the Bogie for Forming wagon TS and tie them to the Pressure props T (C) by cable.

5) Once the Spindle strut and Pressure prop are tied together, tilt them away together and tie them to the Bogie for Forming wagon TS (E) with a cable.

After the parking wedges have been removed, the Forming wagon is ready to be repositioned.

Warning!

➤ Do not carry out formwork stripping and repositioning at wind speeds higher than 55 km/h

9730-254-01

A

BC

DE

1

23

4

5



Repositioning the forming-carriage units

Preliminary remarks

Connecting forming wagons to one another

As a rule, several Forming wagons T are reposi-tioned jointly, and the casting sections are con-structed in a daily rhythm.

Connection point for the towing machines

Shifting

Variant 1

Disconnectable units for repositioning

Formwork (A) in 5 m sections.Before the Forming wagons T are repositioned, the formwork elements are separated and the gaps between the Forming wagons T are widened with the aid of the Spindle struts T7 (B) .

➤ Separate the connected formwork elements.➤ Turn the Spindle struts T7 (B) to increase the

spaces between the forming wagons to such an extent that nothing rubs or jams when the wag-ons are towed (especially on curved sections of track).

➤ Lay the rails (U-profiles) for the next section.➤ Only attach slinging chains to the Slinging plate

T (F) provided for this purpose, and to the towing machine.

➤ Remove the parking wedges (= wagon immobi-lisers).

➤ Tow the Forming wagons to their new operating position.

Before removing the towing machines:

➤ Replace the parking wedges, to immobilise the wagons.

☞ ● Max. speed 4 km/h (walking pace)● Avoid any jerking, jolting movements.● "Passenger transportation" is forbidden!● Caution on gradients:

Secure the carriage with a counteracting force!

Take particular care on gradients >3%.➤ Liaise with the responsible statical engi-

neering department.➤ Add extra bracing as statically required.➤ Increased caution needed during reposi-

tioning.➤ Take additional safety precautions to pre-

vent the carriage rolling away.

B Spindle strut T7 150/200cm

D Connecting pin 25cm(included in Scope of supply of Forming wagon T)

E Spring cotter 6mm(included in Scope of supply of Forming wagon T)

☞ For transferring loads during repositioning, a Slinging plate T (F) MUST be used.

Permitted tensile force: 50 kN (5000 kg)

9730-233-01BD

E

9730-232-01

F

D E

9730-260-01

A

A

A

B

B

C



Variant 2

Permanently connected units for repositioning

Continuous formwork (A) along the entire length of all Forming wagons T (no formwork joints).All the connections between the Forming wagons T are left unchanged when the wagons are reposi-tioned.

The Forming wagons T are linked to one another using Spindle struts T7 150/200cm (B) :● between the bogies

and also● between the suspension beams (H) , connected

with Stabilising plate T (I) .The spindles fix the Forming wagons T together and remain unchanged during the repositioning operation.

Recommended formwork construction:With multipurpose or WS10 Top50 steel walings (J) that are interlinked using splice plates in such a way as to resist tensile and compressive forces.

➤ Lay the rails (U-profiles) for the next section.➤ Only attach slinging chains to the Slinging plate

T (F) provided for this purpose, and to the towing machine.

➤ Remove the parking wedges (= wagon immobi-lisers).

➤ Tow the Forming wagons to their new operating position.

Before removing the towing machines:

➤ Replace the parking wedges, to immobilise the wagons.

9730-261-01

A

B

B

F

B

B

9730-231-01

H

B

I

☞ Important note:

The formwork elements are permanently interconnected and so are repositioned as a single unit. This means that in the forming operations, all the spindles of the Forming wagon T that are in the horizontal plane must be moved together.

9730-248-01

J J



Safety on the structure

with the Handrail clamp TThe Handrail clamp T makes it possible to erect fall-arrest barriers on bridge superstructures. Depend-ing on the structural condition and the local situa-tion, the Handrail clamp T can be attached in vari-ous different ways, without modification.

Variant 1

Fastened to reinforcement hoops

a ... clear gap between the reinforcement hoops min. 13.0 cmb ... min 5.5 cm, max. 35.0 cmc ... min. 12 cmd ... min. 1.0 cm

Variant 2

Fastened to end-face

In cases where there are no reinforcement hoops.

Variant 3

Floor-mounted

to the already-completed edge kerb.

A Handrail clamp T

B Guard-rail board

C Reinforcement hoop

9755-207-01

> 1.

0 m

a

A

B

C

9755-207-02

bdc

AB

C

A Handrail clamp T

B Guard-rail board

C Anchorage (Bridge edge beam anchor 15.0 - Tie-rod 15.0 - Super-plate 15.0)

A Handrail clamp T

B Guard-rail board

C Anchorage

D Edge kerb

Follow the directions in the "Handrail clamp T" User Information!

9755-205-01

A

B

> 1.

0 m

9755-205-02

A

B

C

9755-203-01

> 1.

0 m

A

B

9755-203-02

A

B

C

D



with Guard rail 1.10mThe Guard rail 1.10m is used for erecting safety rail-ings along slab-edges. Depending on the structural condition and the local situation, the Guard rail 1.10m can be attached in various different ways, without modification.

Variant 1

Fixed in an "Attachable sleeve 24mm"

c ... Distance from edge: min. 10cm

Variant 2

Fixed in a "Screw sleeve 20.0"

c ... Distance from edge: min. 10cm

Variant 3

Fixed in a hole subsequently drilled in the con-

crete

c ... Distance from edge: min. 10cmDrilled hole: Diameter 25 mm

A Guard rail 1.10m

B Guard-rail board

Follow the directions in the "Handrail post 1.10m" User Information!

A Guard rail 1.10m

B Attachable sleeve 24mm

9771-200-01

> 1.

0 m

A

B

9430-203-01

c

A

B

A Guard rail 1.10m

C Screw sleeve 20.0

A Guard rail 1.10m

9430-201-01

c

A

C

9430-207-01

c

A



WeatherproofingOnly a few extra scaffolding tubes are needed to create the ideal basis for an all-round enclosure. The enclosure can also stay in place on the forming carriage while this is being repositioned.

For details of the required items, see the section headed"Items needed".

Tools needed: ● Reversible ratchet 1/2"● Nut for box spanner 19● Extension piece 22 cm

☞ Important note:

The ballast must be increased by the follow-ing loads over and above the values deter-mined under the heading "Dimensioning of the ballast":● 15 kN (bogie-to-pressure-prop distance

120 cm)● 20 kN (bogie-to-pressure-prop distance

50 cm)● 28 kN (no pressure prop)

A Tarpaulin

B Scaffolding tube 48.3mm 4.50m

C Scaffolding tube 48.3mm 4.00m

D Swivel coupler 48mm

9730-230-01

A

B

C

D



Flexible adaptation to the requirements of the structure

Edge kerb with kerb-wallThe formwork for the kerb-wall is suspended from the "Double jib for Forming wagon T" on distribu-tion walings.

For transferring the loads on the edge kerb, it has been found advantageous to provide a back-stay (A) from the underside of the superstructure. In this way, the ballast weight can be considerably reduced – although it must still be sufficient to allow safe travelling as well!Must be dimensioned on a project-specific basis.

Special shapes of edge kerb

The system also offers complete flexibility when it comes to adapting the formwork to the shape of the edge kerb. In this way, even complex kerb cross-sections can be formed economically.

Situation when formwork is in place

Situation when formwork has been struck

9730-288-01

A

9730-308-01

For clean transitions when forming wider (i.e. heavier) kerbs, press the formwork up against the previous casting section with the aid of e.g. back-stays from components embedded in the existing superstructure.

9730-309-01



Adjusting the forming wagons

with Adjusting device for Forming

wagon T

● for executing major changes of direction (kinks or very tight radii)

● for exact positioning of the Forming wagon T● for dealing with incidents

The Adjusting device (A) for Forming wagon T con-sists of:

a ... Adjusting range 0 to 9 cm

Tools needed: ● Reversible ratchet 1/2"● Nut for box spanner 19● Box nut 30-1/2"

Major changes of direction

➤ For this, the Adjusting device must be positioned at the overall centre of gravity (G) under the bogie. (Should be facing in the desired direction of travel).

➤ Turn the spindles using the Adjusting device, so as to bring the bridge-edge forming wagon into the new travelling position.

Close-up

Exact positioning

To achieve exact positioning, follow the instruc-tions for executing major changes of direction.

Incidents

In the rough-and-tumble of work on the site, inci-dents will always happen from time to time – e.g. the rollers slipping off the rail profiles at the rail-joints, etc.➤ Because you can lift so simply using the Adjust-

ing device, you can quickly deal with incidents without having to call on a special lifting appli-ance (e.g. truck-mounted crane).

B Hydraulic lifting cylinder with integral pump element

C Pressure plate

Max. load: 12,000 kg (120 kN)

B

C

a

☞ ● Forces may only be transferred via the pressure plate!

G Overall centre of gravity

A Adjusting device for Forming wagon T

TR589-200-01

G

TR589-200-02

A



Multifunctional utilisationRight from the outset, the Forming wagon T was designed in such a way that it can be used for addi-tional areas of application. This considerably increases both the degree of utilisation of the equipment, and its cost-effectiveness.

Demolition wagonIn bridge rehabilitation work, the bridge edge kerbs have to be demolished. Thanks to its height-adjust-able working platform, the Forming wagon T can also be used as a demolition wagon.After the demolition work is completed, the work-ing platform can be lowered to its normal position by crane, or by block-and-tackle. The formwork for constructing the new edge beam can now start to be erected.

Horizontal repositioning of large-

area formwork

The following parts can also be used for projects where large-area formwork elements have to be horizontally repositioned (e.g. walls of cut-and-cover tunnels):● Horizontal frame for Forming wagon T (A)

● Flanged wheels T (B) of the bogie● Double jib for Forming wagon T (C)

9730-299-01

A

9730-296-01

A

B

C



Transporting, stacking and storing

Space-saving, and safe against over-

turningThe Bogie for Forming wagon TS is delivered to your site ready-assembled.When collapsed, the bogies are easy to transport and store. The dimensions are designed to facilitate haulage by truck.

Example

Stack of 3 Bogies for Forming wagon TS

a ... 230.0 cmb ... 224.0 cmc ... 72.0 cm

View Z

d ... 330.0 cm

Please secure the stacked bogies against accidental rolling, as shown here – also when dispatching return consignments.

Caution!

➤ Secure the whole stack against accidental rolling, e.g. with intermediate timber 8x8 cm and nailed-on battens (A) !

➤ Prevent the flanged wheels digging into the ground!

➤ Bind the stack together with tension straps (B) !

9730-306-01

a

c

bZ

9730-307-01

d

A

B



Items needed

Items needed for one Forming

wagon T (standard assignment)

Without Railings T

With Railings T

For connecting the forming wagons to one another:Variant 1 (disconnectable units for repositioning)

Variant 2 (permanently connected units for reposi-tioning)

For connecting up towing machines

Extra working platforms

Weatherproofing

Note:

As so many different individual formwork configu-rations are possible, the formwork is not included in the above schedule of items needed. The necessary Doka beams, formwork sheets, steel walings, ties and anchors – and accessories such as triangular ledges etc. – must be determined on a project-spe-cific basis.Ballast plates available in Germany on request.

Name N° of itemsBogie for Forming wagon TS 1Double jib for Forming wagon T 2Spindle strut T6 100/150cm 2Spindle strut GS T7 109/166cm 2Suspension beam for Forming wagon T 2Longitudinal beam for Forming wagon T 1Railing strut for Forming wagon T 2Spindle strut T6 73/110cm 2Ready-to-use platform for Forming wagon T 1Handrail post T 0.70m 2Pressure prop T 2Swivel coupler 48mm 7Scaffolding tube 48.3mm 3.00m 4Scaffolding tube 48.3mm 4.50m 5Square bolt M10x100 DIN 603 (ID n° 019190) 18

Hexagon nut M10 DIN 934(ID n° 019309) 18

Name N° of itemsBogie for Forming wagon TS 1Double jib for Forming wagon T 2Spindle strut T6 100/150cm 2Spindle strut GS T7 109/166cm 2Suspension beam for Forming wagon T 2Longitudinal beam for Forming wagon T 1Spindle strut T6 73/110cm 2Ready-to-use platform for Forming wagon T 1Railing T (bottom) 1Railing T (top) 1Handrail post T 0.70m 2Pressure prop T 2Swivel coupler 48mm 6Scaffolding tube 48.3mm 3.00m 4Scaffolding tube 48.3mm 4.50m 3

Name N° of itemsSpindle strut T7 150/200cm 1

Name N° of itemsSpindle strut T7 150/200cm 2Stabilising plate T 2

Name N° of itemsSlinging plate T 1

Name N° of itemsAttachable platform support T 2Site-provided guard-rail boards and beams

Name N° of itemsSwivel coupler 48mm 6Scaffolding tube 48.3mm 4.00m 3Scaffolding tube 48.3mm 4.50mm 5Tarpaulin 8.0x5.50m (on enquiry) 1

Article n°[kg] Article n°[kg]

36 999771002 - 08/2008 Ü



Component overview

Bogie for forming wagon TS 936.0 584336000Grundgestell Schalwagen TSconsisting of:(A) Horizontal frame for forming wagon T 505.0 584337000(B) Vertical frame for forming wagon T 177.0 584338000(C) Frame strut for forming wagon T 13.5 584339000

2 pcs.(D) Spindle strut GS T6 95/140cm 10.3 584340000

2 pcs.Galvanised

(E) Flanged wheel T 51.0 5843410004 pcs.

Double jib for forming wagon T 357.0 584342000Ausleger Schalwagen Tconsisting of:(A) Jib frame for forming wagon T 294.0 584343000(B) Jib slide for forming wagon T 63.0 584344000

GalvanisedLength: 64.4-102.2 cm

Spindle strut T6 73/110cm 10.2 584355000Spindelstrebe T6 73/110cm



Spindle strut GS T7 109/166cm 21.6 584345000Spindelstrebe GS T7 109/166cm

Pressure prop T 37.7 584349000Druckstütze T

Suspension beam for forming wagon T 175.0 584346000Hängeträger Schalwagen T

Longitudinal beam for forming wagon T 36.0 584351000Längsträger Schalwagen T

GalvanisedLength: 330 cmWidth: 229 cmHeight: 214 cmDelivery condition: folded closed

GalvanisedLength: 580 cmHeight: 127 cm

Galvanised

Galvanised

Painted blue

Galvanised

GalvanisedHeight: 194 cm


GalvanisedLength: 301 cm


37999771002 - 08/2008 Ü

User information Doka forming wagon T Component overview


Ready-to-use platform for forming wagon T 347.5 584347000Fertigbühne Schalwagen T

Railing strut for forming wagon T 18.0 584348000Geländerstreben Schalwagen T

Handrail post T 0.70m 2.8 584353000Geländerholm T 0,70m

Handrail clamp S 11.5 580470000Schutzgeländerzwinge S

Suspension beam extension T 1.00m 89.5 584361000Hängeträgerverlängerung T 1,00m

Platform extension plate T 24.0 584362000Bühnenverbreiterung T

Handrail lengthening piece T 1.00m 9.8 584363000Geländerverlängerung T 1,00m

Stabilising plate T 2.5 584367000Stabilisierungslasche T

Slinging plate T 8.3 584368000Anhängelasche T

Attachable platform support T 2.5 584369000Bühnenauflage T

Connecting pin 10cm 0.34 580201000Verbindungsbolzen 10cm

Spring cotter 6mm 0.06 580204000Federvorstecker 6mm

Railing T top 86.0 584376000Fertiggeländer T oben

Railing T bottom 98.0 584377000Fertiggeländer T unten

Timber parts varnished yellowSteel parts galvanisedLength: 490 cmWidth: 170 cm

GalvanisedHeight: 300 cmDelivery condition: folded closed

GalvanisedLength: 86.6 cm

GalvanisedHeight: 123 - 171 cm


GalvanisedWidth: 95 cmHeight: 36 cmDelivery condition: cable coiledTurnbuckle included in scope of sup-ply

Galvanised

GalvanisedLength: 13 cmWidth: 12 cmHeight: 8 cm

GalvanisedLength: 28 cmWidth: 14 cmHeight: 8 cm

GalvanisedLength: 12.6 cmWidth: 11 cmHeight: 29.6 cm

GalvanisedLength: 14 cmPacked in units of 75

GalvanisedLength: 13 cmPacked in units of 200

Steel parts galvanisedTimber parts varnished yellowLength: 490 cmHeight: 156 cm



38 999771002 - 08/2008 Ü

Component overview User information Doka forming wagon T


Handrail clamp T 12.3 584381000Schutzgeländerzwinge T

Handrail post 1.10m 5.6 584384000Schutzgeländer 1,10m

Attachable sleeve 24mm 0.03 584385000Steckhülse 24mm

Screw sleeve 20.0 0.03 584386000Schraubhülse 20,0

Adjusting spindle T 17.1 584374000Justierspindel T

Vertical extension rail T 107.0 584378000Aufsatzgeländer T

Adjusting device for forming wagon T 22.9 584383000Justiereinrichtung für Schalwagen T

Scaffold tube 48.3mm 1.00m 4.0 682014000Scaffold tube 48.3mm 1.50m 6.0 682015000Scaffold tube 48.3mm 2.00m 8.0 682016000Scaffold tube 48.3mm 2.50m 10.0 682017000Scaffold tube 48.3mm 3.00m 12.0 682018000Scaffold tube 48.3mm 3.50m 14.0 682019000Scaffold tube 48.3mm 4.00m 16.0 682021000Scaffold tube 48.3mm 4.50m 18.0 682022000Scaffold tube 48.3mm 5.00m 20.0 682023000Scaffold tube 48.3mm 5.50m 22.0 682024000Scaffold tube 48.3mm 6.00m 24.0 682025000Scaffold tube 48.3mm .....m 4.0 682001000Gerüstrohr 48,3mm

Scaffold tube connection 0.27 584375000Gerüstrohranschluss

Swivel coupler 48mm 1.5 582560000Drehkupplung 48mm

Screw-on coupler 48mm 50 0.84 682002000Screw-on coupler 48mm 95 0.71 586013000Anschraubkupplung

Normal coupler 48mm 1.2 682004000Normalkupplung 48mm

GalvanisedHeight: 122 - 155 cm


GreyLength: 16.5 cmDiameter: 2.7 cm

YellowLength: 20 cmDiameter: 3.1 cm



Painted blueHeight: 28.5-55.2 cmMax. load: 12000 kg

Galvanised


GalvanisedWidth-across: 22 mm




39999771002 - 08/2008 Ü

User information Doka forming wagon T Component overview


Tool box GF 6.5 580390000GF-Werkzeugboxincluded in scope of supply:(A) Reversible ratchet 1/2" 0.73 580580000


(B) Fork wrench 13/17 0.08 580577000(C) Fork wrench 22/24 0.22 580587000(D) Fork wrench 30/32 0.80 580897000(E) Ring spanner 17/19 0.27 580590000(F) Extension 11cm 1/2" 0.20 580581000(G) Extension 22cm 1/2" 0.31 580582000(H) Universal joint coupling 0.16 580583000(I) Nut for box spanner 19 1/2" L 0.16 580598000(J) Box nut 13 1/2" 0.06 580576000(K) Box nut 24 1/2" 0.12 580584000(L) Box nut 30 1/2" 0.20 580575000

Reversible ratchet 3/4" 1.5 580894000Umschaltknarre 3/4"

Extension 20cm 3/4" 0.68 580683000Verlängerung 20cm 3/4"

Box nut 50 3/4" 0.81 581449000Stecknuss 50 3/4"


The Formwork Experts999771002 - 08/2008 Ü

The site-ready, completely travellable bridge edge beam formwork for edge kerbs

The travelling, heavy-duty Forming wagon T carries a large-area of pre-assembled bridge edge beam form-work which can be repositioned in one piece – helping work to progress very rapidly. This provides a highly economical way of casting edge kerbs for long bridge superstructures with a high number of re-use cycles,

and in situations where it is not possible to suspend formwork from the underside of the cantilever slab. The Forming wagon T is also ideal for carrying out rehabilitation work on existing bridges.

The Doka forming wagon T is available for rental, leasing or purchase.At any of the Doka branches in your region.

Why not give us a call?

The Doka Group's central plant at Amstetten, Austria

999771002 GB Method statement Doka forming wagon T · 4 The FormworkExperts 999771002 - 08/2008 Ü Introduction User information Doka forming wagon T Elementary safety warnings User

Documents