999804102_2013_03_online

-999804102 03/2013en-GB

The Formwork Experts.

User informationInstructions for assembly and use (Method statement)

Composite formwork beams

2 | 999804102 - 03/2013

User information Composite formwork beams

by Doka Industrie GmbH, A-3300 Amstetten


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Contents4 Introduction4 Elementary safety warnings6 Doka services8 Eurocodes at Doka

99 Product description

10 Instructions for assembly and use12 Technical condition15 Transporting, stacking and storing

16 Component overview

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Introduction User information Composite formwork beams

IntroductionElementary safety warningsUser target groups

This manual is aimed at all persons who will be work-ing with the Doka product or system that it describes. It contains information on the standard design for setting up this system, and on correct, compliant uti-lisation of the system.

All persons working with the product described herein must be familiar with the contents of this man-ual and with all the safety instructions it contains.

Persons who are incapable of reading and under-standing this booklet, or who can do so only with dif-ficulty, must be instructed and trained by the cus-tomer.

The customer is to ensure that the information mate-rials provided by Doka (e.g. User Information book-lets, 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.

In the relevant technical documentation and form-work utilisation plans, Doka shows the workplace safety precautions that are necessary in order to use the Doka products safely in the usage situations shown. In all cases, users are obliged to ensure compliance with national OH&S (occupational health and safety) rules throughout the entire project and to take appro-priate additional or alternative workplace safety pre-cautions where necessary.

Hazard assessment

The customer is responsible for drawing up, docu-menting, implementing and continually updating a hazard assessment at every job-site. This document serves as the basis for the site-spe-cific hazard assessment, and for the instructions given to users on how to prepare and utilise the sys-tem. It does not substitute for these, however.

Planning

Provide safe workplaces for those using the form-work (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 cal-culations must be produced for checking, as well as supplementary assembly instructions.

Remarks on this document

This manual 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.Any safety accessories not shown in these illustra-tions must still be used by the customer, in accord-ance with the applicable rules and regulations.

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

Symbols used

The following symbols are used in this booklet:

Important noteFailure to observe this may lead to malfunc-tion or damage.

CAUTION / WARNING / DANGERFailure to observe this may lead to material damage, and to injury to health which may range up to the severe or even life-threaten-ing.

InstructionThis symbol indicates that actions need to be taken by the user.

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

TipPoints out useful practical tips.

ReferenceRefers to other documents and materials.

User information Composite formwork beams Introduction

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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 super-vision of suitably skilled persons with the authority to issue instructions. These persons' mental and physical capacity must not in any way be impaired by alcohol, medicines or drugs.

Doka products are technical working appliances which are intended for industrial/commercial use only, always in accordance with the respective Doka User Information booklets or other technical docu-mentation authored by Doka.

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

The functional/technical instructions, safety warn-ings and loading data must all be strictly observed and complied with. Failure to do so can cause acci-dents and severe (even life-threatening) 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 dis-tance away from the formwork.

The work must take account of the weather condi-tions (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 equip-ment, and to protect employees.

All connections must be checked regularly to ensure that they still fit properly and are functioning cor-rectly. It is very important to check all screw-type connec-tions and wedge-clamped joins whenever the con-struction operations require (particularly after excep-tional 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 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 assembly work must be carried out by suitably qualified employees of the client's.

It is not permitted to modify Doka products; any such modifications constitute a safety risk.

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 form-work 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 system features such as Framax stripping corners.

When striking the formwork, do not endanger the stability of any part of the structure, or of any scaf-folding, 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 relevant sections of this manual!

Regulations; industrial safety

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

If a person or object falls against, or into, the side-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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Doka servicesSupport in every stage of the project

Doka offers a broad spectrum of services, all with a sin-gle 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.

Project Development Stage Bidding Stage Project Management Planning Stage

Taking well-founded decisions thanks to professional advice and consulting

Optimising the preliminary work with Doka as an experienced part-ner

Controlled, regular forming oper-ations, 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 sit-

uation objective evaluation of the plan-

ning, execution, and time-risks

Draw up potentially winning bids, by basing them on realistically calcu-

lated guideline prices making the right formwork

choices having an optimum time-calcula-

tion basis

Plan cost-effectively right from the outset, thanks to detailed offers determination of the commission-

ing quantities co-ordination of lead-times and

handover deadlines

1 2 3

User information Composite formwork beams Introduction

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The advantages for you thanks to professional advice and consulting

Cost savings and time gains 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 effec-tive forming operations because your workflows will be correct.

Maximised workplace safety The advice and support we can give you in how to use the equip-ment correctly, and as planned, leads to greater safety on the job.

Transparency Because our services and costs are completely transparent, there is no need for improvisation dur-ing the project and no unpleas-ant surprises at the end of it.

Reduced close-out costs Our professional advice on the selection, quality and correct use of the equipment helps you avoid damage, and minimise wear-and-tear.

Concrete Construction Stage Project Close-out Stage

Optimum resource utilisation with assistance from the Doka Formwork Experts

Seeing things through to a posi-tive conclusion with professional support

Workflow optimisation, thanks to thorough utilisation planning internationally experienced pro-

ject 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 recondition-

ing using special equipment

4 5

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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 provide a uniform basis, valid throughout Europe, for product specifications, tenders and mathematical verification.The EC are the world's most highly developed Stand-ards 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" (compar-ing 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!

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 action Steel: Rd =Rk Timber: Rd = kmod

RkFd = F Fk M M(F ... force)

Fk Characteristic value of an action "actual load", service load (k ... characteristic) e.g. dead weight, live load, concrete pressure, wind

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

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

M Partial factor for a material property (in terms of material; M...material) e.g. for steel or timber Values 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 H20 Values as given in EN 1995-1-1 and EN 13377

Ed

Rd

Permissible stress design EC/DIN concept

Factual Fpermissible Ed RdA Utilisation factor

60 [kN]60


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Product descriptionDoka beam I tec 20

Doka beams I tec 20 are solid-web beams made of wood and derived timber products. They are intended for use in wall and floor-slab formwork only.Other features include: Timber-plastic composite formwork beam Long service life ensured by the 'Top' beam-end

reinforcement and the plastic sheet on the broadside of the flange.

Increases load-bearing capacity by approx. 80 % compared to the Doka beam H20

Reduces equipment quantities in both floor and wall formwork

Beam-flange markings in a 50 cm grid for the Dokaf-lex and Dokaflex 30 tec systems

Same overall height and width as Doka beams H20, so compatible with existing Doka systems

Overall height tolerance 1.0 mm, assuming 12% timber moisture content.

I tec 20

Approval NumberZ-9.1-773

20.0

4.08.0

A WebB FlangeC Distance-marks on beam-flanges, for Dokaflex systemD System holesE End-reinforcementF Notch for chalk lineG I tec sheet

The innovative end-reinforcement on the Doka beam I tec 20 greatly reduces damage to the beam-ends.

All standard and custom lengths, from 1.80m to 5.90m, come fitted with the 'Top' beam-end reinforcement.

Doka beams I tec 20 of over 5.90m and up to 12.00m in length are square-cut and treated with I tec 20 beam-end sealant.

If the ends of beams are square-cut at Doka branches or at jobsites, they must be treated with I tec 20 beam-end sealant in order to ensure the full lifespan of the beam.

A

B

E

C

D

F

G

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Instructions for assembly and useDoka beams I tec 20 are formwork beams made of wood and derived timber products. They are intended for use in load-bearing towers and formwork and are loaded in the direction of the height of the beam.

Practical example

In order to maximise durability, it is important to handle the components with due care; this applies particularly when stripping out floor-slab formwork.

Deflection diagram

M ... permitted bending moment Q ... permitted shear force p ... actual load (service load)

9768-200-01

Technical data: Permitted bending moment: 9 kNm Permitted shear force: 20 kN Rigidity: 640 kNm2 Weight: 5.6 kg/lin.mThese 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.

Def

lect

ion

[mm

]

Support centres L [m]

L

p [kN/m]

30

25

20

15

10

5

0

1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

98036-100

Q

M

L/250

L/500

0.5 kN/m

1

2

2.53

3.54

4.5

5

6

7

8

9

10

12.5

15

20

25

30

1.5


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Possible incorrect usages

WARNING Always position Doka formwork beams

"upright".

Correct "upright" positioning(load direction is parallel to web

plane).

Incorrect positioning "turned on side" (load direction at right

angles to web plane).Wall formwork

Floor formwork

WARNING The uses illustrated below are prohibited, as

are other, similar uses!

Do not use as scaffold flooring.

Do not use as traffic-route flooring.

9791

-206

-01

9791

-205

-01

9791

-219

-01

9791

-220

-01

9791

-200

-01

9791

-201

-01

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Technical conditionThe following quality criteria define the extent of dam-age permissible in terms of load-bearing strength. Use is prohibited if damage is beyond these limits.

Flange

Angled cracks (across the grain)

Not permissible.

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.

Splintering at side

permissible up to depth a = 10 mm and length b = 500 mm on one side.

Angled splintering across the edge

permissible up to a = 30 mm across the diagonal and up length b = 500 mm.

98041-200-01

98041-200-01

98041-200-01

98041-201-01

a

b

98041-201-01

98041-201-01

a

b

98041-201-01

98041-201-01


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Openings in joints

permissible up to a = 1 mm.

Saw cuts

Superficial saw cuts up to depth a = 2 mm are per-missible.

Flange end

Splintering a up to length = 60 mm is permissible. Damage to the plastic cap has no effect on load-

bearing strength, but beams damaged evincing damage of this kind do not necessarily meet the quality criteria for Doka rental formwork

Drilled holes

Not permissible, with the exception of system holes:

- Waling attachment with beam screw

a ... 15 mmb ... 112 mmDrilled-hole diameter max. 10 mm

- Attachment of table head with beam screw

a ... 15 mmc ... 396 mmDrilled-hole diameter max. 10 mm

- Attachment of profiled timber formers

d ... 113 mmDrilled-hole diameter max. 12 mm

98041-207-01

a

98041-207-01

9791-209-02

a

9791-209-01

98041-208-01

a

98041-208-01

9791

-207

-09

98041-203-01

b b

a

98041-203-02

c

a

d

98041-209-01

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Web

Damage to web

permissible only if slight and at one side of the beam.

Damage to web end

permissible up to max. a = 20 mm

Drilled holes in web

Permissible drilled holes: Standard holes

- Each standard beam has 2 drilled holes, dia. 21.5 mm

Additional system holes for:- Flange claw- Fastening plate- Connection splice plate- Table head 30- Lifting bracket- Portal head

One drilled hole of maximum diameter 20 mm per run-ning metre in addition to the system holes is permissi-ble.If the incidence of drilled holes is frequent the overall condition of the beam is definitive.

Detachment of flange from web

Not permissible.

9791-216-01

9791-216-01

98041-202-01

a

98041-202-01

98041-207-01

98041-207-01

9791-207-05


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Transporting, stacking and storing

Transport

Always use strap slings to lift stacked beams - do not use chains.

Stacked beams

max. 3000 kg per stack

Always use edge protectors when strapping beams together. Edge protectors can be padding made of plastic, wood or cardboard.

Ground conditions for stacking

Maximum angle of inclination of ground 3%. The ground on which the stack is to be placed must

be adequately firm and level. Best-case conditions are concreted or paved storage areas.

Storage on asphalt: Depending on the parts stored, place wooden bat-tens, 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).

Reprocessing scrap material

Doka formwork beams contain no wood preservatives and, consequently, they can be deposited for repro-cessing.Reprocessing by incineration in suitable incineration plants is recommended. It is advisable not to attempt to burn scrap material in open fires or domestic wood-burners.Always comply with the applicable local or national reg-ulations.

Protect stacked beams from extreme climatic influences such as exposure to sunshine or moisture by covering them (with breathable tar-paulins). This reduces cracking. Only cover them never envelope them completely.

When moving beams not securely strapped together, take care that loose beams cannot slip.

Lengths of beamUp to 6.50 m Over 6.50 m

Max. n of beams per stack 60 40Minimum n of timber supports (min. 10 x 8 x 109 cm) 2 3

Dimension 'a' 108 cmDimension 'b' 78 cm 56 cm

98041-204-01 98041-204-02

98041-204-03a

b

Packets of 60 beams Packets of 40 beams

Max. 2 packets on top of one another

Max. 4 packets on top of one another

98041-205-01 98041-206-01

Article n[kg] Article n[kg]

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Component overview User information Composite formwork beams

Component overview[kg]Article nDoka System ComponentsBeam I tec 20

Doka beam I tec 20 1.80m 10.1 188001000Doka beam I tec 20 2.45m 13.7 188002000Doka beam I tec 20 2.65m 14.8 188003000Doka beam I tec 20 2.90m 16.2 188004000Doka beam I tec 20 3.30m 18.5 188005000Doka beam I tec 20 3.60m 20.2 188006000Doka beam I tec 20 3.90m 21.8 188007000Doka beam I tec 20 4.50m 25.2 188008000Doka beam I tec 20 4.90m 27.4 188009000Doka beam I tec 20 5.35m 30.0 188013000Doka beam I tec 20 5.90m 33.0 188010000Doka beam I tec 20 .....m 5.6 188011000Doka-Trger I tec 20

Doka beam I tec 20 12.00m 67.2 188012000Doka-Trger I tec 20 12,00m

I tec 20 beam-end sealant 2.5l 2.5 188014000I tec 20-Endenversiegelung 2,5l

Varnished yellowGrey

Varnished yellowGrey

Yellow

User information Composite formwork beams Component overview

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Component overview User information Composite formwork beams

User information Composite formwork beams Component overview

| 19999804102 - 03/2013

999804102 - 03/2013Doka GmbH | Josef Umdasch Platz 1 | 3300 Amstetten | Austria | T +43 7472 605-0 | F +43 7472 66430 | [email protected] | www.doka.com

Near to you, worldwide

Doka is one of the world leaders in developing, manu-facturing and distributing formwork technology for use in all fields of the construction sector.With more than 160 sales and logistics facilities in over 70 countries, the Doka Group has a highly efficient dis-tribution network which ensures that equipment and

technical support are provided swiftly and profession-ally.An enterprise forming part of the Umdasch Group, the Doka Group employs a worldwide workforce of more than 5600.

IntroductionElementary safety warningsDoka servicesEurocodes at Doka

Product descriptionInstructions for assembly and useTechnical conditionTransporting, stacking and storingComponent overview

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