Doka self climbing system

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  • 1. The Formwork Experts 07/2006 Ü GB999751002 User information Method statement Doka automatic climbing formwork SKE 50 and SKE 100 9751-219-019751-210-01
  • 2. 2 999751002 - 07/2006 Ü User information Doka automatic climbing formwork The Formwork Experts General remarks © by Doka Industrie GmbH, A-3300 Amstetten
  • 3. 3999751002 - 07/2006 Ü Contents Page User information Doka automatic climbing formwork General remarks The Formwork Experts General remarks ...........................................................................................4 General instructions for compliant utilisation............................................4 Elementary safety warnings ........................................................................5 System description.......................................................................................6 Functional principle of the Doka automatic climbers SKE........................8 Hydraulic system ........................................................................................10 Anchoring on the structure........................................................................12 SKE 50 .........................................................................................................16 Automatic climbing formwork 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...............................22 SKE 100 .......................................................................................................24 Automatic climbing formwork SKE 100....................................................24 Automatic climber SKE 100 .......................................................................25 Climbing phases .........................................................................................26 Climbing scaffold SKE 100.........................................................................28 Platform scaffold SKE 100..........................................................................29 Automatic climbing formwork SKE 100 with gallows.............................30
  • 4. 4 999751002 - 07/2006 Ü User information Doka automatic climbing formwork The Formwork Experts General remarks General instructions for compliant utilisation G 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 thereof. G Doka products are ONLY to be used in accord- ance with the Doka User Information booklets or other technical documentation provided by Doka. G 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. G If any deviation from these instructions is con- templated, or any application which goes beyond those described here, then revised static calculations must be produced for check- ing. The customer shall provide supplementary assembly instructions, and Doka's prior con- sent shall be required. G The customer is to ensure that the User Infor- mation 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. G Always observe all industrial safety regulations and other safety rules applying to the applica- tion and utilisation of our products in the coun- try and/or region in which you are operating. G 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. G All materials must be inspected by the cus- tomer 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. G Only original Doka components may be used as spare parts. G It could be dangerous to combine our form- work systems with those of other manufactur- ers. If you intend to combine different systems, please contact Doka for advice first. G 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. G Persons who are incapable of reading and understanding this booklet, or who can do so only with difficulty, must be instructed and trained by the customer. G The customer must ensure that this product is erected and dismantled, reset and generally used for its intended purpose under the direc- tion and supervision of suitably skilled persons with the authority to issue instructions.
  • 5. G Persons who are going to operate auto- matic climbers need special skills and knowledge which can only be imparted by skilled Doka personnel in a special instruction and training programme. G As proof that they have received such special instruction, an "OPERATION LICENCE" is issued to persons who have undergone this training course. G Persons who do not have an "OPERATION LICENCE" are prohibited from putting the automatic climbers into service.
  • 6. User information Doka automatic climbing formwork General remarks 5999751002 - 07/2006 Ü The Formwork Experts Elementary safety warnings Symbols used The following symbols are used in this booklet: Miscellaneous We reserve the right to make alterations in the inter- ests of technical progress. Unless otherwise stated, all dimensions are given in cm. G Doka products and systems must be set up in such a way that all loads acting upon them are safely transferred! G The stability of all components and units must be ensured during all phases of the construc- tion work! G 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! G Do not exceed the permitted fresh-concrete pressures. Excessively high pouring rates lead to formwork overload, cause greater deflection and risk causing breakage. G 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! G When stripping the gang-form, never use the crane to break concrete cohesion. Use suitable tools such as timber wedges or a special pry- bar. G 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! G Observe all regulations applying to the hand- ling of formwork and scaffolding. In addition, the Doka slinging means must be used - this is a mandatory requirement. G Remove any loose parts or fix them in place so that they cannot be dislodged or fall free! G All components must be stored safely, follow- ing all the special Doka instructions given in the relevant sections of this User Information book- let! G Further safety instructions may be found in each of the sections of this booklet! G The faulty utilisations shown in the various sections of this booklet are only a selection of examples taken from our many years' experi- ence in the field. 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 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.
  • 7. The Formwork Experts6 999751002 - 07/2006 Ü General remarks User information Doka automatic climbing formwork 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: G large-area formwork elements G together with the climbing scaffold G in one single step G and without any crane assistance by one casting section at a time. Safety is always absolutely paramount here The Doka automatic climbers are tested by inde- pendent institutes, who also certify their high qual- ity and safety. Superlative product quality G Sturdy hot-dip galvanised components G Certified to ISO 9002 Maximum safety in all phases of the work G The climbing scaffold remains anchored to the concrete at all times. G The lifting mechanism is safely coupled to the climbing profile in every situation. G Wide working platforms, enclosed by handrails on all sides, enhance both safety and speed. Hydromechanical drive provides optimum control and operational safety G Simultaneous controlling of: - up to 30 automatic climbers - by remote-control - from anywhere on the platform G Isolation valves on the hydraulic cylinders G Open ring main G Closed ring main G Hydraulic units equipped with all necessary con- trol features High load-bearing capacity Doka offers 2 models of automatic climber: G SKE 50, with 5 tonnes' lifting capacity per auto- matic climber, and G SKE 100, with 10 tonnes' lifting capacity per auto- matic climber This enables the formwork to be optimally dimen- sioned to suit each project, which in turn greatly enhances the economic efficiency. Makes work independent of climatic influ- ences G Permits safe working at wind speeds of up to 70 km/h G Climbing can take place regardless of climatic influences. Working platforms can be weather- proofed. The advantages of "section-at-a-time" climb- ing G Freely selectable workflow with no need for "round-the-clock" working G The cycles are optimised for the construction task in question, right from the planning stage. G Project-specific live load ratings G 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, depend- ing 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 lift- ing appliance. This results in: G optimum configurations, irrespective of the shape of the layout G flexibility with regard to element widths G 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 form- work 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. SÜDDEUTSCHLAND Safety tested Production m onitored
  • 8. User information Doka automatic climbing formwork General remarks 7999751002 - 07/2006 Ü The Formwork Experts SKE 50 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 auto- matic climbers can be freely positioned. Casting-section heights: up to 5.50 m Formwork systems: G FF20 and Top 50 timber-beam formwork G Framax and Alu-Framax framed formwork SKE 100 system 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 varia- ble and – where needed – extra-wide cantilever cen- tres. Casting-section heights: up to 5.50 m Formwork systems: G FF20 and Top 50 timber-beam formwork G Framax and Alu-Framax framed formwork 9751-254-01 9751-255-01
  • 9. The Formwork Experts8 999751002 - 07/2006 Ü General remarks User information Doka automatic climbing formwork Functional principle of the Doka automatic climbers SKE The Doka automatic climbers SKE are hydrome- chanically 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 Precondition The control levers of the top lifting mechanism (A) and the bottom lifting mechanism (B) must be in the upper position "PROFILE". Extend the hydraulic cylinder (idle stroke) G The entire climbing scaffold is fastened to the structure by the suspension shoe (C) . G The climbing profile is fixed in place by the top lifting mechanism (A) . (D) . ➤ The hydraulic cylinder (E) pushes the bottom lift- ing mechanism (B) downwards until this auto- matically engages in the climbing profile (D) . Retract the hydraulic cylinder (working stroke) G The entire climbing scaffold is fastened to the structure by the suspension shoe (C) . G The climbing profile is fixed in place by the bot- tom lifting mechanism (B) . (D) . ➤ The hydraulic cylinder (E) pushes the bottom lift- ing mechanism (B) upwards until the top lifting mechanism (A) automatically engages in the climbing profile (D) once again. 9751-232-01 9751-275-01 A B C D E 9751-276-01 A B C D E
  • 10. User information Doka automatic climbing formwork General remarks 9999751002 - 07/2006 Ü The Formwork Experts 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". Extend the hydraulic cylinder (working stroke) G The climbing profile (D) is attached to the struc- ture by the top suspension shoe (F) . G 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. Retract the hydraulic cylinder (idle stroke) G The climbing profile (D) is attached to the struc- ture by the top suspension shoe (F) . G The top lifting mechanism (A) fixes the entire climbing scaffold to the climbing profile (D) . ➤ The hydraulic cylinder (E) pushes the bottom lift- ing mechanism (B) upwards until this automati- cally engages in the climbing profile (D) . 9751-231-01 9751-278-01 A B F D E 9751-277-01 A B C F D E
  • 11. The Formwork Experts10 999751002 - 07/2006 Ü General remarks User information Doka automatic climbing formwork 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. G A high number of cylinders can be operated simultaneously G 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. G The hydraulic unit is equipped with cooling and heating systems and a portable control panel G Can be combined with a radio remote-control system Hydraulic units Number of cylinders that can be operated simulta- neously: Note: If the unit needs to be lifted, it should only be slung from, and lifted by, the crane hoisting lugs pro- vided. Hydraulic unit RL Is supplied to the site ready for operation. Hydraulic unit RL-K Is supplied to the site ready for operation. Follow the directions in the Operating Instructions! Hydraulic unit RL Hydraulic unit RL-K SKE 50 30 15 SKE 100 15 8
  • 12. User information Doka automatic climbing formwork General remarks 11999751002 - 07/2006 Ü The Formwork Experts Hydraulic ring-main system Installation principle Ring-main system with stationary hydraulic unit. Suitable for driving SKE automatic climbers in an even, uniform way. Open ring main In this configuration, the Circular mains 6.50m are not routed back to the hydraulic unit. 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. Legend SK radio remote-control system Is supplied to the site ready for operation. For detailed information on installation, please refer to the "Hydraulic unit RL" and "Hydraulic unit RL-K" Operating Instructions 9218-240-01 A B B C C D D E GF 9218-241-01 A B B C C D D E F G H H Number Designation Symbol (A) Hydraulic unit (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) Hydraulic cylinder (H) Additional cylinder connections Follow the directions in the Operating Instructions! A Transmitter B Charging unit C 2 interchangeable rechargeable batteries D Carrying strap E Receiver F Receiver antenna (optionally, "Reflektomat" from Gross- Funk) 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) C E G HI F A D X B 9235-801
  • 13. The Formwork Experts12 999751002 - 07/2006 Ü General remarks User information Doka automatic climbing formwork Anchoring on the structure Positioning point and suspension point Components: 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: G On the positioning point - for fastening the Uni- versal climbing cone. G On the suspension point – as a safe means of sus- pending the climbing unit. Preferably, stop-anchors (D) are used, or – depend- ing on the characteristics of the structure – pigtail anchors (E) . Anchoring systems The decisive criterion for the choice of anchoring system is the tensile forces that will occur. Load-bearing capacity of the Doka anchoring sys- tems Form-tie system 15.0 Form-tie system 20.0 A Universal climbing cone B Sealing sleeve K (expendable anchoring component) C Cone screw B 7cm D Stop-anchor (expendable anchoring component) E Pigtail anchor (expendable anchoring component) F Depth mark 9751-237-01 A B C E F D F Form-tie system Max. load to DIN 18216 Max. load, allowing a 1.6 : 1 factor of safety against failure 15.0 90 kN 120 kN 20.0 150 kN 220 kN Stop-anchor 15.0 40cm Stop-anchor 15.0 16cm Stop-anchor 15.0 11.5cm Minimum wall thick- ness 48 cm 24 cm 19 cm Stop-anchor 20.0 45 cm Stop-anchor 20.0 22 cm Minimum wall thick- ness 53 cm 30 cm G Depth of concrete cover on "cone" side of wall: 5.5 cm G Depth of concrete cover on "stop-anchor" side of a wall of the minimum thickness: 2 cm G Arrange extra reinforcement steel as statically required, especially when using short stop- anchors (anti-punch-through reinforcement).
  • 14. User information Doka automatic climbing formwork General remarks 13999751002 - 07/2006 Ü The Formwork Experts Suspension shoes These ensure that the automatic climbers are safely suspended in all phases of the work. Suspension shoe SKE 50 rigid Is used for safe suspension of the climbing carriage and of the climbing profile. Is fastened in the G Universal climbing cone using the G Cone screw B 7 cm. Suspension shoe SKE 100 Is used for safe suspension of the climbing carriage and of the climbing profile. Consisting of: G Suspension beam (L) and G Drop-in shoe (M) The Suspension beam is fastened in the G Universal climbing cones using G Cone screws B 7 cm (2 of each per Suspension beam). Preparing the positioning point and suspension point ➤ Do not place concrete directly above the pigtail or stop-anchors. ➤ Do not allow the vibrator to touch the pigtail or stop-anchors. These measures prevent the anchors working loose during pouring and vibration. ➤ Every time the Universal climbing cones are used, fit them with new sealing sleeves first. 9751-236-01 M L 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 frac- ture! ➤ 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)! Make marks on the top edge of the form- work so that you can easily see where the anchoring points are during pouring.
  • 15. G The axis of the universal climbing cone must be at right-angles to the surface of the concrete – maximum angle of devia- tion: 2°. G Tolerance for locating the positioning points and suspension points: ±1 cm in the horizontal and the vertical.
  • 16. The Formwork Experts14 999751002 - 07/2006 Ü General remarks User information Doka automatic climbing formwork Positioning point: Standard solution with hole drilled through form-ply and Cone screw B 7cm a ... 35 to 45 mm Tools needed: G Reversible ratchet 3/4" G Spanner for Universal climbing cone 15.0/20.0 G Extension 20cm 3/4" G 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 form- ply, 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) . 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 possi- ble with the Cone screw B 7cm. Tools needed: G Reversible ratchet 3/4" G Spanner for Universal climbing cone 15.0/20.0 G Extension 20cm 3/4" G Box nut 50 (for Cone screw B 7cm) G Reversible ratchet 1/2" G Extension 1/2" ➤ Drill a diam. 9-10 mm hole in the form-ply (posi- tion as shown in the project plan). ➤ 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 form- work). 9751-204-02 a A D F C G Nail an M8 wing bolt (H) onto the form-ply to make it easier to mount the cone. Shortened double-headed nails make it eas- ier to dismount the wing bolt. 9751-204-03 H I A D F 9751-204-04
  • 17. User information Doka automatic climbing formwork General remarks 15999751002 - 07/2006 Ü The Formwork Experts 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. Tools needed: G Reversible ratchet 3/4" G Spanner for Universal climbing cone 15.0/20.0 G Extension 20cm 3/4" G Box nut 50 (for Cone screw B 7cm) G Reversible ratchet 1/2" G Extension 1/2" ➤ Nail 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. Before pouring ➤ Check all positioning points and suspension points once again. Repeat use 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 assum- ing a ratchet-length of approx. 50 cm) is suffi- cient. 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 con- junction with an Extension 20cm 3/4" and a Box nut 50.
  • 18. 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. 9751-204-01 J A D F G The axis of the universal climbing cone must be at right-angles to the surface of the concrete – maximum angle of devia- tion: 2°. G Tolerance for locating the positioning points and suspension points: ±1 cm in the horizontal and the vertical. G 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. Reversible ratchet 3/4" Reversible ratchet 3/4" with extension Ratchet MF 3/4" Concrete strength on initial loading: min. 10 N/mm2 (100 kg/cm2) 9751-204-05 A B K C Tr687-200-01 Tr687-200-01 Tr687-200-01
  • 19. 16 999751002 - 07/2006 Ü User information Doka automatic climbing formwork The Formwork Experts SKE 50 Automatic climbing formwork SKE 50 Typical cross-section 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. G User Information booklet MF 240 G Method Statement for Doka Climbing formwork MF 240 G For documentation on how to use the system, see the section headed "Climbing phases". A Pouring platform, e.g. Universal bracket 90 B Formwork element, e.g. Top50 C Travelling unit MF D Climbing bracket MF 240 9751-254-01 A B C D E F +1 0 -1 -2 E Automatic climber SKE 50 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 con- crete. Level -2 Suspended platform For dismounting the suspension shoe, for closing off the cone holes and for doing finishing-work on the concrete. For more information, please refer to the fol- lowing documentation:
  • 20. User information Doka automatic climbing formwork SKE 50 17999751002 - 07/2006 Ü The Formwork Experts 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: G Loads imposed in the statically anchored situa- tion, i.e. while construction tasks are being car- ried out. G Loads imposed during climbing, i.e. while the connected platforms are being moved into their new working position. 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 A Suspension shoe SKE 50 rigid B Climbing profile SKE 50 C Climbing carriage SKE 50 D Safety pin SKE 50 E Suspension pin SKE 50 F Lifting mechanism SKE 50, top 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 M L K I J E D A B C F G H 9751-213-01 Max. permitted loads Statical When climbing A2 ... 55.0 kN B2 ... 50.0 kN C1 ... 69.0 kN C2 ... 33.0 kN — D2 ... 21.2 kN Max. permitted loads (statical) B1[kN] A1 [kN] A1 B1 C1 a 9218-235-01 c A2 D2 C2 B2 b 9218-236-01 c 9218-100 100 80 60 40 20 0 0 20 40 60 80
  • 21. The Formwork Experts18 999751002 - 07/2006 Ü SKE 50 User information Doka automatic climbing formwork Climbing phases Schematic workflow Automatic climbers can cover a wide area of practi- cal 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). G Shop drawings and assembly plans G Work instructions G Operating Instructions for SKE 50 G Operating Instructions for radio remote-control system G Operating Instructions for hydraulic unit G Any additional documents which may have been drawn up by Doka for the project in question
  • 22. Important note: All assembly and disassembly work, the first time of putting into service and the first typ- ical climbing sequence must be supervised by a Doka supervising foreman or an author- ised technician. Read and observe the following documents: Start-up phases Pouring 1st casting section Pouring 2nd casting section First hydraulic climb 1. Set up one side of the formwork 2. Mount the positioning-points 3. Place the reinforcement 4. Close the formwork 5. Pour this section 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 scaf- fold 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 Main vertical profile MF 160 of the Climbing bracket must be parallel to the concrete wall. 4. Lift the Climbing profile into place by crane 5. Mount the "Profile protection SKE 50" 6. Hydraulically "climb" the entire Climbing scaffold plus formwork 9751-207-01 9751-208-01 9751-209-01
  • 23. User information Doka automatic climbing formwork SKE 50 19999751002 - 07/2006 Ü The Formwork Experts Typical phases Pouring 3rd casting section Climbing Pouring 1. Mount the suspended platform (Level -2) 2. Set up one side of the formwork 3. Mount the positioning-points 4. Place the reinforcement 5. Close the formwork 6. Pour this section 1. Strip the formwork 2. Clean the formwork and the platforms 3. Mount the top suspension shoe 4. Hydraulically raise the climbing profile 5. Dismount the bottom suspension shoe 6. Hydraulically "climb" the entire Climbing scaffold plus formwork 1. Set up one side of the formwork 2. Mount the positioning-points 3. Place the reinforcement 4. Close the formwork 5. Pour this section From this point on, the sequence consists of the alternating succession of the typical phases. 9751-210-02 9751-211-01 9751-210-03
  • 24. The Formwork Experts20 999751002 - 07/2006 Ü SKE 50 User information Doka automatic climbing formwork 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 verti- cal profile MF160. ➤ Fix the climbing carriage on the scaffold with Connection bolts MF-SKE and secure with linch- pins 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. 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 plat- form by 1.25 m. Other ways of adapting the system Handrail post 1.80m The Handrail post 1.80m (K) is attached to the Hori- zontal profile MF and is used for constructing a stronger, higher railing, e.g. for attaching an enclo- sure to the scaffold. For a detailed description, see the SKE 50 Operating Instructions 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 Vertical waling MF 9751-273-01 C F A B E D G I H 9751-253-01 J 9751-260-01 K
  • 25. User information Doka automatic climbing formwork SKE 50 21999751002 - 07/2006 Ü The Formwork Experts Platform scaffolds Suspended platform SKE/MF 425 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). The Suspended platform SKE/MF 425 425 consists of: Suspended platform extension SKE/MF 550 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 Con- nection profile / the Front suspension profile, between the platforms. 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. A Back suspension profile (complete) B Front suspension profile (complete) C Horizontal profile 1911 (complete) D Suspension profile (complete – 2 units) E Connection profile (complete) F Horizontal profile 1250 (complete) 9751-258-01 A B C D D E F G Suspended platform extension SKE/MF 550 Follow the directions in the "Doka climbing formwork MF" Method Statement and User Information! 9751-259-02 G G
  • 26. The Formwork Experts22 999751002 - 07/2006 Ü SKE 50 User information Doka automatic climbing formwork 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 (sus- pended from the gallows on the other side) can eas- ily be aligned with the fixed formwork. The wide platforms on top of the gallows construc- tion 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. Typical cross-section: View A: Suspended formwork with working platform 9751-257-02 9751-257-03 A 9751-257-01
  • 27. User information Doka automatic climbing formwork SKE 50 23999751002 - 07/2006 Ü The Formwork Experts 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 con- struction sequence. Note: You can obtain more information in the Automatic Climbing Technology Expertise Centre. Typical cross-section: 9751-262-01 9751-262-02
  • 28. 24 999751002 - 07/2006 Ü User information Doka automatic climbing formwork The Formwork Experts SKE 100 Automatic climbing formwork SKE 100 Typical cross-section Combining with Climbing scaffold SKE 100 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. G User Information booklet MF 240 G Method Statement for Doka Climbing formwork MF 240 G For documentation on how to use the system, see the section headed "Climbing phases". A Pouring platform SKE 100 B Formwork element, e.g. Top50 C Climbing scaffold SKE 100 D Automatic climber SKE 100 9751-255-01 D AB C C +2 +1 0 -2 -1 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. 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 con- crete. Level -2 Suspended platform For dismounting the suspension shoe, for closing off the cone holes and for doing finishing-work on the concrete. For more information, please refer to the fol- lowing documentation:
  • 29. User information Doka automatic climbing formwork SKE 100 25999751002 - 07/2006 Ü The Formwork Experts 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: G Loads imposed in the statically anchored situa- tion, i.e. while construction tasks are being car- ried out. G Loads imposed during climbing, i.e. while the connected platforms are being moved into their new working position. 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 A Suspension shoe SKE 100 B Climbing profile 425 SKE 100 C Climbing carriage SKE 100 D Safety pin SKE 100 E Suspension pin SKE 100 F Lifting mechanism SKE 100 G Hydraulic cylinder SKE 100 RL H Supporting carriage SKE 100 9751-206-01 B C F G H F E D A I Max. permitted loads Statical When climbing Climbing profile 425 SKE 100 425/S355 and 550/S355 Climbing profile 425 SKE 100 425/S355 550/S355 A1 ... 130.0 kN A2 ... 125.0 kN A2 ... 100.0 kN B1 ... 130.0 kN B2 ... 100.0 kN B2 ... 100.0 kN C1 ... 130.0 kN C2 ... 125.0 kN C2 ... 100.0 kN — D2 ... 125.0 kN D2 ... 100.0 kN 9227-202-01 C1ac A1 B1 9227-203-01 b c C2 A2 D2 B2
  • 30. The Formwork Experts26 999751002 - 07/2006 Ü SKE 100 User information Doka automatic climbing formwork Climbing phases Schematic workflow Automatic climbers can cover a wide area of practi- cal 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). G Shop drawings and assembly plans G Work instructions G Operating Instructions for SKE 100 G Operating Instructions for radio remote-control system G Operating Instructions for hydraulic unit G Any additional documents which may have been drawn up by Doka for the project in question
  • 31. Important note: All assembly and disassembly work, the first time of putting into service and the first typ- ical climbing sequence must be supervised by a Doka supervising foreman or an author- ised technician. Read and observe the following documents: Start-up phases Pouring 1st casting section Pouring 2nd casting section First hydraulic climb 1. Set up one side of the formwork 2. Mount the positioning-points 3. Place the reinforcement 4. Close the formwork 5. Pour this section 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 scaf- fold 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 the 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 9751-207-02 9751-214-01 9751-215-01
  • 32. User information Doka automatic climbing formwork SKE 100 27999751002 - 07/2006 Ü The Formwork Experts Typical phases Pouring 3rd casting section Climbing Pouring 1. Mount the suspended platform (Level -2) 2. Set up one side of the formwork 3. Mount the positioning-points 4. Place the reinforcement 5. Close the formwork 6. Pour this section 1. Strip the formwork 2. Clean the formwork and the platforms 3. Mount the top suspension shoe 4. Hydraulically raise the climbing profile 5. Dismount the bottom suspension shoe 6. Hydraulically "climb" the entire Climbing scaffold plus formwork 1. Set up one side of the formwork 2. Mount the positioning-points 3. Place the reinforcement 4. Close the formwork 5. Pour this section From this point on, the sequence consists of the alternating succession of the typical phases. 9751-216-01 9751-217-01 9751-216-02
  • 33. The Formwork Experts28 999751002 - 07/2006 Ü SKE 100 User information Doka automatic climbing formwork Climbing scaffold SKE 100 The single-unit Travelling unit MF, consisting of Items (E) to (H) , can be freely positioned irrespec- tive of how widely or closely the Automatic climb- ers (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 hex- agonal bolts M20x70, 4 spring washers A20 and 4 hexagonal nuts M20. Width-across 30. For a detailed description, see the SKE 100 Operating Instructions 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 Platform beam IPB 200 9751-251-01 A B C D E F G H I
  • 34. User information Doka automatic climbing formwork SKE 100 29999751002 - 07/2006 Ü The Formwork Experts Platform scaffold SKE 100 Example – pour-heights from 3.86 to 4.45 m 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 re- set, all the platform levels are always enclosed by all-round handrails. Forming and reinforcement- placing operations can be carried out above one another, at the same time. The Platform scaffold can be freely positioned, irre- spective of how widely or closely the Climbing units are spaced. This enables it to be optimally adapted to suit the requirements of the structure. Folding platform 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. Platform folded down Platform folded up A Climbing unit B Climbing bracket SKE 100 C Travelling unit MF D Vertical strut 3.25 N 9751-252-01 A B C E EH I J J N N O P DD F F F G I K K K K K K L M M Q E Vertical strut 1.90 F Vertical strut 2.30 G Diagonal brace 3.25 H Diagonal brace 1.90 I Diagonal brace 2.30 J Diagonal plate 100 K Diagonal plate 80 L Horizontal profile U 100 M Folding platform (complete) N Suspension profile 1HB O Horizontal profile 1HB P Horizontal profile 2HB Q Platform beam IPB 200 (with welded-on connecting plates for fastening the Vertical struts and Suspension profiles) 9751-215-03 M 9751-215-02 M
  • 35. The Formwork Experts30 999751002 - 07/2006 Ü SKE 100 User information Doka automatic climbing formwork 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 (sus- pended from the gallows on the other side) can eas- ily be aligned with the fixed formwork. The wide platforms on top of the gallows construc- tion 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. Typical cross-section: View A: Suspended formwork with working platform 9751-218-03 9751-218-01 A 9751-218-02
  • 36. User information Doka automatic climbing formwork SKE 100 31999751002 - 07/2006 Ü The Formwork Experts 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 con- struction sequence. Note: You can obtain more information in the Automatic Climbing Technology Expertise Centre. Typical cross-section: 9751-263-01 9751-263-02
  • 37. The Formwork Experts The safe way to “rise high”: With automatic climbing systems from Doka Form structures of any shape and height – independently of the crane: Doka offers system solutions for all areas of work where craneless repositioning of the formwork is required or is the most economical solution. Complemented by the relevant know-how of the Doka Formwork Experts, Doka automatic climbing formwork SKE is ideal for all tall structures, of whatever type or shape. At any of the Doka branches in your region. Why not give us a call? The Doka Group's central plant at Amstetten, Austria