Doka Automotif Climbing Formwork

User information

07/2006 Ü 999751002

Method statement

GB

Doka automatic climbing formwork SKE 50 and SKE 100

9751-210-01

The Th e Fo Formw rmwork ork Exp Experts erts

9751-219-01

General remarks

User information Doka automatic climbing formwork

© by Doka Industrie GmbH, A-3300 Amstetten

2

The Formwork Formwork Experts

999751002 - 07/2006

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General remarks


© by Doka Industrie GmbH, A-3300 Amstetten

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999751002 - 07/2006

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Contents

General remarks

Page

General remarks ................................................................................ ........... 4 General instructions for compliant utilisation............................................4 Elementary safety warnings ............................................................. ........... 5 System description................................................................................... .... 6 Functional principle principle of the Doka Doka automatic climbers SKE ........................ 8 Hydraulic system .................................................................. ...................... 10 Anchoring on the structure........................................................................12 SKE 50 ................................................................................................ ......... 16 Automatic climbing formwork SKE SKE 50...................................................... 16 Automatic climber SKE 50 ......................................................................... 17 Climbing phases ................................................................... ...................... 18 Climbing scaffold MF 240 ........................................................................ .. 20 Platform scaffolds.......................................................................................21 Automatic climbing formwork SKE 50 with gallows gallows ............................... 22 SKE 100 ................................................................................. ...................... 24 Automatic climbing formwork SKE 100....................................................24 Automatic climber SKE 100 ....................................................................... 25 Climbing phases ................................................................... ...................... 26 Climbing scaffold SKE SKE 100......................................................................... 28 Platform scaffold SKE 100..........................................................................29 Automatic climbing formwork SKE 100 with gallows gallows ............................. 30

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3


General remarks

General instructions for compliant utilisation 

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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 thereof. Doka products are ONLY to be used in accordance with the Doka User Information booklets or other technical documentation provided by Doka. The functional/technical instructions, safety warnings and loading data must all be strictly observed and complied with. Failure to comply with this requirement may cause accidents, injury and damage. If any deviation from these instructions is contemplated, or any application which goes beyond those described here, then revised static calculations must be produced for checking. The customer shall provide supplementary assembly instructions, and Doka's prior consent shall be required. The customer is to ensure that the User Information booklet (Method Statement) provided by Doka is available to all users and that they have been made aware of it and can easily access it. 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. 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. All materials must be inspected by the customer before use, to ensure that they are in suitable condition. Any components that are damaged, deformed, or weakened due to wear, corrosion or rot, must not be used. Only original Doka components may be used as spare parts. It could be dangerous to combine our formwork systems with those of other manufacturers. If you intend to combine different systems, please contact Doka for advice first.

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All persons working with the product described herein must be familiar with the contents of this manual and with all the safety instructions it contains. Persons who are incapable of reading and understanding this booklet, or who can do so only with difficulty, must be i nstructed and trained by the customer. 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 skille d persons with the authority to issue i nstructions.

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4

The Formwork Experts

Persons who are going to operate automatic climbers need special skills and knowledge which can only be imparted by skilled Doka personnel in a special instruction and training programme. As proof that they have received such special instruction, an "OPERATION LICENCE" is issued to persons who have undergone this training course.

Persons who do not have an "OPERATION LICENCE" are prohibited from putting the automatic climbers into service.

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General remarks

Elementary safety warnings 

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Doka products and systems must be set up in such a way that all loads acting upon them are safely transferred! The stability of all components and units must be ensured during all phases of the construction work! 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! Do not exceed the permitted fresh-concrete pressures. Excessively high pouring rates lead to formwork overload, cause greater deflection and risk causing breakage. 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 stripping the gang-form, never use the crane to break concrete cohesion. Use suitable tools such as timber wedges or a special prybar. 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! 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, f ollowing all the special Doka instructions given in the relevant sections of this User Information booklet! Further safety instructions may be found in each of the sections of this booklet! The faulty utilisations shown in the various sections of this booklet are only a selection of examples taken from our many years' experience in the field.

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Symbols used The following symbols are used in this booklet:

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Important note Failure to observe this may lead to malfunction or damage.

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 tak en by the user.

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

Tip Points out useful practical tips.

Miscellaneous We reserve the right to make alterations in t he interests of technical progress. Unless otherwise stated, all dimensions are given in cm.


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General remarks

System description Automatic climbing formwork SKE The crane-independent climbing formwork for structures of any shape and height The SKE system is used for raising:  large-area formwork elements  together with the climbing scaffold  in one single step  and without any crane assistance by one casting section at a time.

Safety is always absolutely paramount here

High load-bearing capacity Doka offers 2 models of automatic climber:  SKE 50, with 5 tonnes' lifting capacity per automatic climber, and  SKE 100, with 10 tonnes' lifting capacity per automatic climber This enables the formwork to be optimally dimensioned to suit each project, which in t urn greatly enhances the economic efficiency.

Makes work independent of climatic influences  

Permits safe working at wind speeds of up t o 70 km/h Climbing can take place regardless of climatic influences. Working platforms can be weatherproofed.

The advantages of "section-at-a-time" climbing SÜDDEUTSCHLAND S a t e t e s f y t e d

n i o d t c u r e t o o d i r n P o m

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The Doka automatic climbers are tested by independent institutes, who also certify their high quality and safety.

Superlative product quality  

Sturdy hot-dip galvanised components Certified to ISO 9002

Maximum safety in all phases of the work   

The climbing scaffold remains anchored to the concrete at all times. The lifting mechanism is safely coupled to the climbing profile in every situation. Wide working platforms, enclosed by handrails on all sides, enhance both safety and speed.

Hydromechanical drive provides optimum control and operational safety 

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Simultaneous controlling of: - up to 30 automatic climbers - by remote-control - from anywhere on the platform Isolation valves on the hydraulic cylinders Open ring main Closed ring main Hydraulic units equipped with all necessary control features


Freely selectable workflow with no need for "round-the-clock" working The cycles are optimised for the construction task in question, right from the planning stage. Project-specific live load ratings Rapid work rhythm Set up, strip, climb - with no need for a crane - in any weather - independently of other forming operations such as subsequently formed floor-slabs and walls - short repositioning time of 1-2 hours, depending on the height of the casting section and the number of automatic climbers

Optimum adaptability to every layout The Doka automatic climber SKE is a single-unit lifting appliance. This results in:  optimum configurations, irrespective of the shape of the layout  flexibility with regard to element widths  the most economical solution can be achieved for all layouts of buildings, piers or shafts.

Doka planning service Doka will be pleased to plan an economical formwork solution for you, and partial pre-assembly of the formwork by the Doka Ready-to-Use Service will save both man-hours and space on the site.

Doka field service Our supervising foremen and engineers will advise you right the way through from when the formwork is assembled to when it is first used, up to and including the typical operating sequence, and give the forming crew introductory training on-site.

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General remarks

SKE 50 system

SKE 100 system

Load capacity: 5 tonnes per bracket The SKE 50 system is the ideal solution for the majority of climbing assignments. Because it is a single-unit climbing scaffold, the brackets and automatic climbers can be freely positioned. Casting-section heights: up to 5.50 m

Load capacity: 10 tonnes per bracket When exceptionally tough requirements are made of the automatic climbing technology, the SKE 100 system really comes into its own - with its high 10t load capacity and a platform system that allows work to be carried out simultaneously at several levels. The extremely strong brackets permit variable and – where needed – extra-wide cantilever centres. Casting-section heights: up to 5.50 m

Formwork systems:  FF20 and Top 50 timber-beam formwork  Framax and Alu-Framax framed formwork

Formwork systems:  FF20 and Top 50 timber-beam formwork  Framax and Alu-Framax framed formwork

1 0 4 5 2 1 5 7 9

1 0 5 5 2 1 5 7 9

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General remarks

Functional principle of the Doka automatic climbers SKE The Doka automatic climbers SKE are hydromechanically driven lifting appliances. In conjunction with the DIN-4420-compliant scaffolds connected to them, they are used for raising formwork or other loads in the construction engineering field.

Climbing the profile

Retract the hydraulic cylinder (working stroke)  

The entire climbing scaffold is fastened to the structure by the suspension shoe (C) . The climbing profile is fixed in place by the bottom lifting mechanism (B) . (D) . hydraulic cylinder (E) pushes the bottom lifting mechanism (B) upwards until the top lifting mechanism (A) automatically engages in the climbing profile (D) once again.

➤ The

Precondition The control levers of the top l ifting mechanism (A) and the bottom lifting mechanism (B) must be in the upper position "PROFILE".

9751-232-01

Extend the hydraulic cylinder (idle stroke)  

The entire climbing scaffold is fastened to the structure by the suspension shoe (C) . The climbing profile is fixed in place by the top lifting mechanism (A) . (D) .

➤ The

hydraulic cylinder (E) pushes the bottom lifting mechanism (B) downwards until this automatically engages in the climbing profile (D) .

C A E B

D

1 0 6 7 2 1 5 7 9

C A E

B D

1 0 5 7 2 1 5 7 9

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Climbing the scaffold Precondition The control levers of the top lifting mechanism (A) and the bottom lifting mechanism (B) must be in the lower position "PLATFORM".

General remarks

Retract the hydraulic cylinder (idle stroke)  

The climbing profile (D) is attached to the structure by the top suspension shoe (F) . The top lifting mechanism (A) fixes the entire climbing scaffold to the climbing profile (D) . hydraulic cylinder (E) pushes the bottom lifting mechanism (B) upwards until this automatically engages in the cl imbing profile (D) .

➤ The

9751-231-01

F

Extend the hydraulic cylinder (working stroke)  

The climbing profile (D) is attached to the structure by the top suspension shoe (F) . The bottom lifting mechanism (B) is fixed in the climbing profile (D) .

➤ The

hydraulic cylinder (E) pushes the top lifting mechanism (A) – and with it, the entire climbing unit – upwards, until the top lifting mechanism automatically engages in the climbing profile (D) again.

C A E B

D

F 1 0 7 7 2 1 5 7 9

A E

B D

1 0 8 7 2 1 5 7 9

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General remarks

Hydraulic system The SKE automatic climbers are "jumped" with the aid of a hydraulic ring-main system. The ring-main system is based on a stationary hydraulic unit designed to provide uniform, simultaneous drive for up to 30 automatic climbers. The number of automatic climbers that can be raised jointly in one climbing cycle must be appropriate for the structure and the construction workflow, and not so many that it is no longer possible to "keep track" of them all.  

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Hydraulic unit RL Is supplied to the site ready for operation.

A high number of cylinders can be operated simultaneously Open and closed ring-mains are possible - open: for a small n° of automatic climbers - closed: for a large n° of automatic climbers. The pressure build-up takes place from 2 sides. The hydraulic unit is equipped with cooling and heating systems and a portable control panel Can be combined with a radio remote-control system

Hydraulic units Follow the directions in the Operating Instructions!

Number of cylinders that can be operated simultaneously: Hydraulic unit RL

Hydraulic unit RL-K

SKE 50

30

15

SKE 100

15

8

Note: If the unit needs to be lifted, i t should only be slung from, and lifted by, the crane hoisting lugs provided.

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Hydraulic unit RL-K Is supplied to the site ready for operation.

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General remarks

Legend

Hydraulic ring-main system Installation principle Ring-main system with stationary hydraulic unit. Suitable for driving SKE automatic climbers in an even, uniform way.

Number

Designation

(A)

Hydraulic unit

Symbol

(B)

Circular main 6.5 m - DN20

(C)

Cross distributor M

(D)

Cross distributor S

(E)

Hydraulic hose 4.5 m - DN8 (pre-mounted on the hydraulic cylinder)

(F)

Hydraulic hose 4.5 m - DN8 (pre-mounted on the hydraulic cylinder)

(G) (H)

Hydraulic cylinder Additional cylinder connections

Open ring main In this configuration, the Circular mains 6.50m are not routed back to the hydraulic unit. C

C

B

A D

D

B

SK radio remote-control system

E

Is supplied to the site ready for operation.

G

F 9218-240-01

Follow the directions in the Operating Instructions!

Closed ring main Both the pressure hoses and the return-flow hoses are routed back to the hydraulic unit here. This makes for a more uniform pressure build-up in longer hoselines.

F

E F C

D

X E

H

A

C

D

A

C

B

H

G B

D

B

I

H

G 9235-801

9218-241-01

For detailed information on installation, please refer to the "Hydraulic unit RL" and "Hydraulic unit RL-K" Operating Instructions

A Transmitter B Charging unit C 2 interchangeable rechargeable batteries D Carrying strap E Receiver F Receiver antenna (optionally, "Reflektomat" from GrossFunk) G Connecting cable from the receiver to the hydraulic unit H Plug connector for receiver I

Plug connector for hydraulic unit

X Charging unit (old version)

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General remarks

Anchoring on the structure Positioning point and suspension point

Anchoring systems

Components:

Load-bearing capacity of the Doka anchoring systems

The decisive criterion for the choice of anchoring system is the tensile forces that will occur.

F E

Form-tie system

Max. load to DIN 18216

15.0

90 kN

Max. load, allowing a 1.6 : 1 factor of safety against failure 120 kN

20.0

150 kN

220 kN

D

Form-tie system 15.0 A

F

C B

9751-237-01

Stop-anchor Stop-anchor Stop-anchor 15.0 40cm 15.0 16cm 15.0 11.5cm Minimum wall thickness

C Cone screw B 7cm D Stop-anchor (expendable anchoring component) E Pigtail anchor (expendable anchoring component)

Minimum wall thickness 

F Depth mark 

Both the positioning points and the suspension points are prepared using one single type of cone, the Universal climbing cone (A) . The Cone screw B 7cm (C) also fulfils 2 functions:  On the positioning point - for fastening the Universal climbing cone.  On the suspension point – as a safe means of suspending the climbing unit.

24 cm

19 cm

Form-tie system 20.0

A Universal climbing cone B Sealing sleeve K (expendable anchoring component)

48 cm

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Stop-anchor 20.0 45 cm

Stop-anchor 20.0 22 cm

53 cm

30 cm

Depth of concrete cover on "cone" side of wall: 5.5 cm Depth of concrete cover on "stop-anchor" side of a wall of the minimum thickness: 2 cm Arrange extra reinforcement steel as statically required, especially when using short stopanchors (anti-punch-through reinforcement).

Preferably, stop-anchors (D) are used, or – depending on the characteristics of the structure – pigtail anchors (E) .

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Suspension shoes These ensure that the automatic climbers are safel y suspended in all phases of the work.

General remarks

Preparing the positioning point and suspension point Warning! ➤ Always screw the pigtail or stop-anchor into the Universal climbing cone until it fully engages (i.e. up to the depth mark). Not screwing the anchor sufficiently far into the cone may subsequently lead to reduced load-bearing capacity and to the failure of the suspension point – resulting in injury and damage. ➤ Never weld or heat tie-rods - risk of fracture! ➤ For the positioning point and suspension point, ONLY use Cone screws B 7 cm (head of screw is red, to indicate its high load-bearing capacity)!

Suspension shoe SKE 50 rigid

Is used for safe suspension of the cl imbing carriage and of the climbing profile. Is fastened in the  Universal climbing cone using the  Cone screw B 7 cm.

➤ Do not place concrete directly above the pigtail or

Suspension shoe SKE 100

Is used for safe suspension of the climbing carriage and of the climbing profile.

stop-anchors. ➤ Do not allow the vibrator to touch the pigtail or stop-anchors.

Consisting of:  Suspension beam (L) and  Drop-in shoe (M)

These measures prevent the anchors working loose during pouring and vibration.

The Suspension beam is fastened in the  Universal climbing cones using  Cone screws B 7 cm (2 of each per Suspension beam).

Make marks on the top edge of the formwork so that you can easily see where the anchoring points are during pouring. ➤ Every

time the Universal climbing cones are used, fit them with new sealing sleeves first.

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L

 M

The axis of the universal climbing cone must be at right-angles to the surface of the concrete – maximum angle of deviation: 2°. Tolerance for locating the positioning points and suspension points: ±1 cm in the horizontal and the vertical.

9751-236-01

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General remarks

Positioning point: Standard solution with hole drilled through form-ply and Cone screw B 7cm

a

Positioning point: With hole drilled through form-ply and Positioning clamp M30 Because the hole only needs to be drilled with a diameter of 9-10 mm, the positioning-point can be relocated at smaller intervals than would be possible with the Cone screw B 7cm.

D G

H I

D C

F

A

F

A

9751-204-02

a ... 35 to 45 mm

Tools needed:  Reversible ratchet 3/4"  Spanner for Universal climbing cone 15.0/20.0  Extension 20cm 3/4"  Box nut 50 (for Cone screw B 7cm) Note: The pigtail anchor must be facing downwards ➤ Fasten a packing plate (G)

(e.g. Dokaplex 15 mm) to the form-ply (position as per project plan). ➤ Drill a diam. 30 mm hole in the form-ply (position as shown in the project plan). ➤ Push the Cone screw B 7cm (C) through the formply, screw it into the Universal climbing cone (A) and tighten it firmly. ➤ Screw the Stop-anchor or Pigtail anchor (D) into the Universal climbing cone (A) , until it engages (up to the depth mark) (F) .

9751-204-03

Tools needed:  Reversible ratchet 3/4"  Spanner for Universal climbing cone 15.0/20.0  Extension 20cm 3/4"  Box nut 50 (for Cone screw B 7cm)  Reversible ratchet 1/2"  Extension 1/2" ➤ Drill

a diam. 9-10 mm hole in the form-ply (position as shown in the project plan). Nail an M8 wing bolt (H) onto the form-ply to make it easier to mount the cone. Shortened double-headed nails make it easier to dismount the wing bolt.

9751-204-04

➤ Screw a Socket connector M30 (I)

all the way into the Universal climbing cone 15.0 (A) and tighten it. ➤ Screw the Stop-anchor or Pigtail anchor (D) into the Universal climbing cone (A) , until it engages (up to the depth mark) (F) . ➤ Screw the pre-assembled unit onto the M8 wing bolt (H) (make sure that it seals against the formwork).

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Positioning point: With no hole drilled through the form-ply, and a Positioning disc M30 For special applications only, when it is not possible to screw through the form-ply.

General remarks

Before pouring ➤ Check

all positioning points and suspension points once again. 

J



D



F

A

The axis of the universal climbing cone must be at right-angles to the surface of the concrete – maximum angle of deviation: 2°. Tolerance for locating the positioning points and suspension points: ±1 cm in the horizontal and the vertical. The depth mark on the pigtail anchor or stop-anchor must be right up against the Universal climbing cone = must be screwed in to the full depth.

Repeat use 9751-204-01



Important!

It is not permitted to use the Positioning disc M30 more than once in the same position, as it cannot be fixed firmly and securely in the old nail-holes.

Tools needed:  Reversible ratchet 3/4"  Spanner for Universal climbing cone 15.0/20.0  Extension 20cm 3/4"  Box nut 50 (for Cone screw B 7cm)  Reversible ratchet 1/2"  Extension 1/2"

Universal climbing cones are supplied with Sealing sleeves K (B) . Every time the Universal climbing cones are used again, fit them with new sealing sleeves first!

Suspension point ➤ Fix the Suspension shoe SKE (K)

in the Universal climbing cone 15.0 (A) with a Cone screw B 7cm (C) . A tightening torque of 100 Nm (20 kg assuming a ratchet-length of approx. 50 cm) is sufficient.

A

the Positioning disc M30 (J) to the form-ply, using 28x60 nails (position as per plan). ➤ Screw the Stop-anchor or Pigtail anchor (D) into the Universal climbing cone (A) , until it engages (up to the depth mark) (F) . ➤ Screw the Universal climbing cone (A) onto the Positioning disc M30 (J) and tighten it.

K

➤ Nail

C

B

9751-204-05

Forcibly tightening the Cone screw B 7cm any more than this may cause damage and even cause the form-tie to break! The only tool allowed to be used for screwing in and fixing the Cone screw B 7cm in the Universal climbing cone is the Reversible ratchet 3/4" in conjunction with an Extension 20cm 3/4" and a Box nut 50. Reversible ratchet 3/4"

Reversible ratchet 3/4" with extension

Ratchet MF 3/4"

Tr687-200-01 Tr687-200-01

Tr687-200-01

Concrete strength on initial loading: min. 10 N/mm2 (100 kg/cm2)

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SKE 50

Automatic climbing formwork SKE 50 E Automatic climber SKE 50

Typical cross-section

F Suspension platform SKE/MF 425 (see "Platform scaffolds") Level +1

Pouring platform For reinforcement and concrete-placing work.

Level 0

Working platform For manipulating the formwork elements.

Level -1

Suspended platform For manipulating the automatic climbers and – in some cases – for doing finishing-work on the concrete.

Level -2

Suspended platform For dismounting the suspension shoe, for closing off the cone holes and for doing finishing-work on the concrete.

A

+1

B

Utilisation in conjunction with Climbing formwork MF 240 The Doka automatic climbers SKE 50 are designed to hold a standard Climbing formwork MF 240. Both timber-beam formwork and framed formwork may be used here.

C

For more information, please refer to the following documentation:

 0

 

User Information booklet MF 240 Method Statement for Doka Climbing formwork MF 240 For documentation on how to use the system, see the section headed "Climbing phases".

E D

-1

F

-2

1 0 4 5 2 1 5 7 9

A Pouring platform, e.g. Universal bracket 90 B Formwork element, e.g. Top50 C Travelling unit MF D Climbing bracket MF 240

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SKE 50

Automatic climber SKE 50 Loading data In line with standard building practice, the statical design for the SKE 50 automatic climbers must allow for two different load situations: 

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Loads imposed in the statically anchored situation, i.e. while construction tasks are being carried out. Loads imposed during climbing, i.e. while the connected platforms are being moved into their new working position.

B

Max. permitted loads Statical When climbing A

A1

C

D

B1 E

a

F

G

C1

A2

H

b

I

B2 K

C2

L

c

c

1 0 5 3 2 8 1 2 9

1 0 6 3 2 8 1 2 9

A2 ... 55.0 kN B2 ... 50.0 kN

9751-213-01

J

M

C1 ... 69.0 kN

C 2 ... 33.0 kN D2 ... 21.2 kN

— A Suspension shoe SKE 50 rigid B Climbing profile SKE 50 C Climbing carriage SKE 50 D Safety pin SKE 50

a ... 1494 mm b ... max. 5500 mm (Climbing profile SKE 50/550/S355) b ... max. 4250 mm (Climbing profile SKE 50/425/S355) c ... ca. 700 mm

E Suspension pin SKE 50

Max. permitted loads (statical)

F Lifting mechanism SKE 50, top

100

G Hydraulic cylinder SKE 50 RL H Lifting mechanism SKE 50, bottom I

Supporting carriage SKE 50

J Supporting shoe SKE 50 K Profile protection plate SKE 50 top L Profile protection SKE 50 M Profile protection plate SKE 50 bottom

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D2

80 ] N k [

60 40

1

B

20 0

9218-100

0

20

40

60

80

A1 [kN]


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SKE 50

Climbing phases Schematic workflow

Read and observe the following documents:

Automatic climbers can cover a wide area of practical applications. Their modular design enables them to be combined in many different ways. This means that in some projects, they will be put together differently, and a different sequence of operations will be needed, from the schematic workflow shown here (e.g. for sloping walls).



All assembly and disassembly work, the first time of putting into service and the first typical climbing sequence must be supervised by a Doka supervising foreman or an authorised technician.

   

Important note:

9751-207-01



9751-208-01



Shop drawings and assembly plans Work instructions Operating Instructions for SKE 50 Operating Instructions for radio remote-control system Operating Instructions for hydraulic unit Any additional documents which may have been drawn up by Doka for the project in question

9751-209-01

Start-up phases Pouring 1st casting section

Pouring 2nd casting section 1. 2.

1. 2. 3. 4. 5.

18

Set up one side of the formwork Mount the positioning-points Place the reinforcement Close the formwork Pour this section


3. 4. 5. 6. 7.

First hydraulic climb 1. Strip the formwork Mount the suspension shoes 2. Clean the formwork Hang the climbing scaffold into place on 3. Mount the top suspension shoe the suspension shoes (if possible with - Note: the Level -1 suspended platform) The Main vertical profile MF 160 of Place the formwork on the climbing scafthe Climbing bracket must be parallel fold to the concrete wall. Mount the positioning-points 4. Lift the Climbing profile into place by crane Place the reinforcement 5. Mount the "Profile protection SKE 50" Close the formwork 6. Hydraulically "climb" the entire Climbing Pour this section scaffold plus formwork

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9751-210-02

Pouring 3rd casting section 1. 2. 3. 4. 5. 6.

Mount the suspended platform (Level -2) Set up one side of the formwork Mount the positioning-points Place the reinforcement Close the formwork Pour this section

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9751-211-01

SKE 50

9751-210-03

Typical phases Climbing 1. 2. 3. 4. 5. 6.

Pouring 1. Set up one side of the formwork Strip the formwork 2. Mount the positioning-points Clean the formwork and the platforms 3. Place the reinforcement Mount the top suspension shoe 4. Close the formwork Hydraulically raise the climbing profile 5. Pour this section Dismount the bottom suspension shoe From this point on, the sequence consists Hydraulically "climb" the entire Climbing of the alternating succession of the typical scaffold plus formwork phases.


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SKE 50

Climbing scaffold MF 240 The Climbing scaffold MF 240 is made up of the Travelling unit MF, consisting of Items (G) to (I) , and the Climbing bracket MF240, consisting of Items (C) to (F) . The climbing scaffold as a whole is joined to the Automatic climber SKE 50 by way of the Main vertical profile MF160.

Platform extension 1.25 Where needed, the Platform extension 1.25m (J) is fastened onto the Horizontal profile MF of the Climbing bracket MF240 and widens the main platform by 1.25 m.

For a detailed description, see the SKE 50 Operating Instructions

➤ Fix

the climbing carriage on the scaffold with Connection bolts MF-SKE and secure with linchpins 6x42. ➤ Bolt together the supporting carriage, the vertical profile and the "Profile protection plate SKE 50 top", using 4 of each of the following: hexagonal bolts M16x50, spring washers A16 and hexagon nuts M16. Width-across 24.

J

1 0 3 5 2 1 5 7 9

Other ways of adapting the system Handrail post 1.80m The Handrail post 1.80m (K) is attached to the Horizontal profile MF and is used for constructing a stronger, higher railing, e.g. for attaching an enclosure to the scaffold.

I

H G

K F A E

D

C

B

1 0 0 6 2 1 5 7 9

1 0 3 7 2 1 5 7 9

A Climbing carriage SKE 50 B Supporting carriage SKE 50 C Main vertical profile MF160 D Pressure strut MF long E Pressure strut MF short F Horizontal profile MF with handrail post G Travelling gear MF H Plumbing spindle MF I

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Vertical waling MF


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SKE 50

Platform scaffolds Suspended platform SKE/MF 425

Suspended platform extension SKE/MF 550

The Suspended platform SKE/MF425 is suitable for pour-heights of up to 4.25 m and has 2 work-deck levels: One for operating the climbing unit (width 220 cm) and another for dismounting the Suspension shoes and for carrying out other finishing work (width 150 cm).

This is used for extending the Suspended platform SKE/MF 425 for dealing with pour-heights of over 4.25 m and up to 5.50 m. It is screwed onto the Connection profile / the Front suspension profile, between the platforms.

G

G

A B

C

E

D

9751-259-02

G Suspended platform extension SKE/MF 550

D

F 9751-258-01

The Suspended platform SKE/MF 425 425 consists of: A Back suspension profile (complete) B Front suspension profile (complete) C Horizontal profile 1911 (complete) D Suspension profile (complete – 2 units)

Pouring and intermediate platforms In the same way as with the Climbing formwork MF 240, the pouring platform and any intermediate platforms needed for manipulating the anchors etc. can be constructed using e.g. the Screw-on access bracket MF75 or the Universal bracket 90. Follow the directions in the "Doka climbing formwork MF" Method Statement and User Information!

E Connection profile (complete) F Horizontal profile 1250 (complete)

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SKE 50

Automatic climbing formwork SKE 50 with gallows In this variant of the automatic climbing formwork, the automatic climbers are only needed on one side of the wall. As in the standard variant, the formwork is permanently attached to the climbing scaffold and so can be plumbed and aligned very exactly. This means that the opposing formwork (suspended from the gallows on the other side) can easily be aligned with the fixed formwork. The wide platforms on top of the gallows construction greatly facilitate the preliminary reinforcement work, pouring, and equipment storage.

Typical cross-section:

Variant 1 Is mostly used for façades and walls that are poured ahead of (i.e. separately from) the floor slabs. A

9751-257-03

View A: Suspended formwork with working platform

9751-257-02

9751-257-01

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SKE 50


Variant 2 In this variant, the wall and floor-slab are cast in one single pour. By doing away with complicated floor junctions, this expedites and simplifies the construction sequence.

9751-262-02

1 0 2 6 2 1 5 7 9

Note: You can obtain more information in the Automatic Climbing Technology Expertise Centre.

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SKE 100

Automatic climbing formwork SKE 100 Typical cross-section

Level +2

Reinforcement-placing platform For performing the preliminary reinforcement work for this casting section.

Level +1

Pouring platform For reinforcement and concrete-placing work. Working platform For manipulating the formwork elements.

Level 0

+2

Level -1

Suspended platform For manipulating the automatic climbers and – in some cases – for doing finishing-work on the concrete.

Level -2

Suspended platform For dismounting the suspension shoe, for closing off the cone holes and for doing finishing-work on the concrete.

Combining with Climbing scaffold SKE 100 +1

B

The Doka automatic climbers SKE 100 are designed to hold the Climbing scaffold SKE 100. Both timber-beam formwork and framed formwork may be used here.

A

For more information, please refer to the following documentation:

  

User Information booklet MF 240 Method Statement for Doka Climbing formwork MF 240 For documentation on how to use the system, see the section headed "Climbing phases".

C 0

D C

-1

-2

9751-255-01

A Pouring platform SKE 100 B Formwork element, e.g. Top50 C Climbing scaffold SKE 100 D Automatic climber SKE 100

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SKE 100

Automatic climber SKE 100 Loading data In line with standard building practice, the statical design for the SKE 100 automatic climbers must allow for two different load situations: 

 B

Loads imposed in the statically anchored situation, i.e. while construction tasks are being carried out. Loads imposed during climbing, i.e. while the connected platforms are being moved into their new working position.

A D

C

E

F

Max. permitted loads Statical When climbing

A1 G

a

B1

A2

F

C1 b

H B2 C2

c

c

D2 9227-202-01

9227-203-01

Climbing profile 425 SKE 100 425/S355 and 550/S355 9751-206-01

I

A Suspension shoe SKE 100 B Climbing profile 425 SKE 100 C Climbing carriage SKE 100 D Safety pin SKE 100

Climbing profile 425 SKE 100

A1 ... 130.0 kN

425/S355 A 2 .. . 125.0 kN

550/S355 A 2 ... 100.0 kN

B1 ... 130.0 kN C1 ... 130.0 kN

B 2 .. . 100.0 k N C 2 .. . 125.0 k N

B 2 ... 100.0 kN C 2 ... 100.0 kN

—

D2 .. . 125.0 kN

D 2 ... 100.0 kN

a ... 1940 mm b ... max. 5500 mm (Climbing profile 425 SKE 100/550/S355) b ... max. 4250 mm (Climbing profile 425 SKE 100/425/S355) c ... ca. 850 mm

E Suspension pin SKE 100 F Lifting mechanism SKE 100 G Hydraulic cylinder SKE 100 RL H Supporting carriage SKE 100

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SKE 100

Climbing phases Schematic workflow

Read and observe the following documents:

Automatic climbers can cover a wide area of practical applications. Their modular design enables them to be combined in many different ways. This means that in some projects, they will be put together differently, and a different sequence of operations will be needed, from the schematic workflow shown here (e.g. for sloping walls).



All assembly and disassembly work, the first time of putting into service and the first typical climbing sequence must be supervised by a Doka supervising foreman or an authorised technician.

   

Important note:

9751-207-02



9751-214-01



Shop drawings and assembly plans Work instructions Operating Instructions for SKE 100 Operating Instructions for radio remote-control system Operating Instructions for hydraulic unit Any additional documents which may have been drawn up by Doka for the project in question

9751-215-01

Start-up phases Pouring 1st casting section

Pouring 2nd casting section

First hydraulic climb

1. 2. 3. 4. 5.

1. Mount the suspension shoes 2. Hang the climbing scaffold into place on the suspension shoes (if possible with the Level -1 suspended platform) 3. Place the formwork on the climbing scaffold 4. Mount the positioning-points 5. Place the reinforcement 6. Close the formwork 7. Pour this section

1. Strip the formwork 2. Clean the formwork 3. Mount the top suspension shoe - Note: The Vertical profile SKE 100 of t he Climbing scaffold must be parallel to the concrete wall. 4. Lift the Climbing profile into place by crane 5. Hydraulically "climb" the entire Climbing scaffold plus formwork

26

Set up one side of the formwork Mount the positioning-points Place the reinforcement Close the formwork Pour this section


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9751-216-01

Pouring 3rd casting section 1. 2. 3. 4. 5. 6.

Mount the suspended platform (Level -2) Set up one side of the formwork Mount the positioning-points Place the reinforcement Close the formwork Pour this section

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9751-217-01

SKE 100

9751-216-02

Typical phases Climbing 1. 2. 3. 4. 5. 6.

Pouring 1. Set up one side of the formwork Strip the formwork 2. Mount the positioning-points Clean the formwork and the platforms 3. Place the reinforcement Mount the top suspension shoe 4. Close the formwork Hydraulically raise the climbing profile 5. Pour this section Dismount the bottom suspension shoe From this point on, the sequence consists Hydraulically "climb" the entire Climbing of the alternating succession of the typical scaffold plus formwork phases.


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SKE 100

Climbing scaffold SKE 100 The single-unit Travelling unit MF, consisting of Items (E) to (H) , can be freely positioned irrespective of how widely or closely the Automatic climbers (A) are spaced. This permits variable and – where needed – extra-wide spacing of the Climbing brackets, each consisting of Items (B) to (D) . The Travelling unit MF is mounted to the Vertical profile SKE 100 on the Automatic climber SKE 100.

➤ Bolt

the climbing carriage to the vertical scaffold using SKE bolts, and secure with Spring cotters 6mm. ➤ Bolt together the supporting carriage with 4 hexagonal bolts M20x70, 4 spring washers A20 a nd 4 hexagonal nuts M20. Width-across 30.

For a detailed description, see the SKE 100 Operating Instructions

F

G

H

E

I C

A

B

D

1 0 1 5 2 1 5 7 9

A Automatic climber SKE 100 B Vertical profile SKE 100 C Horizontal profile SKE 100 D Spindle strut SKE 100 E Travelling profile MF SKE 100 F Vertical waling MF G Plumbing spindle MF H Travelling gear MF I

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Platform beam IPB 200

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SKE 100

Platform scaffold SKE 100 Example – pour-heights from 3.86 to 4.45 m

E Vertical strut 1.90 F Vertical strut 2.30

F

G Diagonal brace 3.25

K

H Diagonal brace 1.90 I

Diagonal brace 2.30

J Diagonal plate 100 K Diagonal plate 80

I

L Horizontal profile U 100 M

M Folding platform (complete) N Suspension profile 1HB K

O Horizontal profile 1HB P Horizontal profile 2HB

K

I

F

Q Platform beam IPB 200 (with welded-on connecting plates for fastening the Vertical struts and Suspension profiles)

F

The Platform scaffold of the SKE 100 is the basis for a complete, self-contained platform system. The number of platform-levels varies from project to project. Even when the formwork is being removed and reset, all the platform levels are always enclosed by all-round handrails. Forming and reinforcementplacing operations can be carried out above one another, at the same time. The Platform scaffold can be freely positioned, irrespective of how widely or closely the Climbing units are spaced. This enables it to be optimally adapted to suit the requirements of t he structure.

M

K K

E

H

E

C

K J L

D

D

Folding platform

G

The folding platform widens the platform-level, making reinforcement work much easier. To make it possible to manoeuvre the climbing profiles into place, and to transport materials downwards, the platform can simply be swung up out of the way.

Q

J

Platform folded down B

A

M N

N

O 9751-215-03

Platform folded up N

P

M

1 0 2 5 2 1 5 7 9

9751-215-02

A Climbing unit B Climbing bracket SKE 100 C Travelling unit MF D Vertical strut 3.25

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SKE 100

Automatic climbing formwork SKE 100 with gallows In this variant of the automatic climbing formwork, the automatic climbers are only needed on one side of the wall. As in the standard variant, the formwork is permanently attached to the climbing scaffold and so can be plumbed and aligned very exactly. This means that the opposing formwork (suspended from the gallows on the other side) can easily be aligned with the fixed formwork. The wide platforms on top of the gallows construction greatly facilitate the preliminary reinforcement work, pouring, and equipment storage.


Variant 1 Is mostly used for façades and walls that are poured ahead of (i.e. separately from) the floor slabs.

A

1 0 8 1 2 1 5 7 9

View A: Suspended formwork with working platform

9751-218-03

9751-218-02

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SKE 100


Variant 2 In this variant, the wall and floor-slab are cast in one single pour. By doing away with complicated floor junctions, this expedites and simplifies the construction sequence.

2 0 3 6 2 1 5 7 9 1 0 3 6 2 1 5 7 9

Note: You can obtain more information in the Automatic Climbing Technology Expertise Centre.

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31

Doka Automotif Climbing Formwork

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