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The Formwork Experts

10/2011

en-GB999804102

User information

Method statement

Composite formwork beams

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Introduction User information Composite formwork beams


Introduction

by Doka Industrie GmbH, A-3300 Amstetten

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User information Composite formwork beams Introduction

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Contents

4 Introduction

4 Elementary safety warnings

6 Doka services

8 Eurocodes at Doka

99 Product description

10 Instructions for assembly and use

12 Technical condition

15 Transporting, stacking and storing

16 Component overview
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Introduction

Elementary safety warnings

User target groups

This User Information booklet (Method Statement) isaimed at everyone who will be working with the Dokaproduct or system it describes. It contains informa-tion on the standard design for setting up this sys-

tem, and on correct, compliant utilisation of the sys-tem.

All persons working with the product describedherein 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, OperatingInstruction manuals, plans etc.) are available to all

users, and that they have been made aware of themand have easy access to them at the usage location.

In the relevant technical documentation and form-work utilisation plans, Doka shows the workplacesafety precautions that are necessary in order to usethe Doka products safely in the usage situationsshown.In all cases, users are obliged to ensure compliancewith 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 ahazard assessment at every job-site.This document serves as the basis for the site-spe-cific hazard assessment, and for the instructionsgiven to users on how to prepare and utilise the sys-tem. It does not substitute for these, however.

Remarks on this document

This User Information booklet can also be used as a

generic method statement or incorporated with asite-specific method statement.

Many of the illustrations in this booklet show thesituation during formwork assembly and aretherefore not always complete from the safetypoint 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 thisdocument!

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 toget to and from these workplaces via safe access

routes! If you are considering any deviation from the

details and instructions given in this booklet, orany application which goes beyond thosedescribed in the booklet, then revised static cal-culations must be produced for checking, as wellas supplementary assembly instructions.

Rules applying during all phases ofthe assignment:

The customer must ensure that this product iserected and dismantled, reset and generally used forits intended purpose under the direction and super-vision of suitably skilled persons with the authority toissue instructions.These persons' mental and physical capacity mustnot in any way be impaired by alcohol, medicines ordrugs.

Doka products are technical working applianceswhich are intended for industrial/commercial useonly, always in accordance with the respective DokaUser Information booklets or other technical docu-mentation authored by Doka.

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

The functional/technical instructions, safety warn-ings and loading data must all be strictly observedand complied with. Failure to do so can cause acci-dents and severe (even life-threatening) damage tohealth, as well as very great material damage.

Fire-sources are not permitted anywhere near theformwork. Heating appliances are only allowed ifproperly 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 theequipment, and the immediate vicinity of the equip-ment, and to protect employees.

All connections must be checked regularly to ensurethat 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 ifnecessary.

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Assembly

The equipment/system must be inspected by thecustomer before use, to ensure that it is in suitablecondition. Steps must be taken to rule out the use ofany components that are damaged, deformed, orweakened due to wear, corrosion or rot.

Combining our formwork systems with those of othermanufacturers could be dangerous, risking damageto both health and property. If you intend to combinedifferent systems, please contact Doka for advicefirst.

The assembly work must be carried out by suitablyqualified employees of the client's.

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

Erecting the formwork

Doka products and systems must be set up in sucha way that all loads acting upon them are safelytransferred!

Pouring

Do not exceed the permitted fresh-concrete pres-sures. Excessively high pouring rates lead to form-work overload, cause greater deflection and riskcausing breakage.

Striking the formwork

Do not strike the formwork until the concrete hasreached sufficient strength and the person in chargehas given the order for the formwork to be struck!

When striking the formwork, never use the crane tobreak concrete cohesion. Use suitable tools such astimber wedges, special pry-bars or system featuressuch as Framax stripping corners.

When striking the formwork, do not endanger thestability 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 offormwork and scaffolding. In addition, the Dokaslinging means must be used - this is a mandatoryrequirement.

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

All components must be stored safely, following allthe special Doka instructions given in the relevantsections of this User Information booklet!

Regulations; industrial safety

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

Instruction as required by EN 13374:

If a person or object falls against, or into, the edge

protection system and/or any of its accessories, theedge protection component affected may only con-tinue in use after it has been inspected and passedby an expert.

Maintenance

Only original Doka components may be used asspare parts. Repairs may only be carried out by themanufacturer or authorised facilities.

Symbols usedThe following symbols are used in this booklet:

MiscellaneousWe reserve the right to make alterations in the interestsof technical progress.

Important note

Failure to observe this may lead to malfunc-tion or damage.

CAUTION / WARNING / DANGER

Failure to observe this may lead to materialdamage, and to injury to health which mayrange up to the severe or even life-threaten-ing.

Instruction

This symbol indicates that actions need to betaken by the user.

Sight-check

Indicates that you need to do a sight-checkto make sure that necessary actions havebeen carried out.

TipPoints out useful practical tips.

Reference

Refers to other documents and materials.

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Doka services

Support in every phase of theprojectDoka 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 onething that all construction projects have in common and that is a basic structure with five phases. We atDoka know our clients' varying requirements. With ourconsulting, planning and other services, we help youachieve effective implementation of your formworkassignment using our formwork products in every oneof these phases.

Project development phase Tendering phase Operations scheduling phase

Taking well-founded decisionsthanks to professional advice andconsulting

Optimising the preliminary workwith Doka as an experienced part-ner

Controlled, regular forming oper-ations, for greater efficiencyresulting from realistically calculatedformwork concepts

Find precisely the right formworksolutions, 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 formworkchoices

having an optimum time-calcula-tion basis

Plan cost-effectively right from theoutset, thanks to

detailed offers

determination of the commission-ing quantities

co-ordination of lead-times andhandover deadlines

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The advantages for you

thanks to professional advice andconsulting

Cost savings and time gainsWhen we advise and support youright from the word "go", we canmake sure that the right formworksystems are chosen and thenused as planned. This lets youachieve optimum utilisation of theformwork equipment, and effec-tive forming operations becauseyour workflows will be correct.

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

TransparencyBecause our services and costsare completely transparent, thereis no need for improvisation dur-ing the project and no unpleas-ant surprises at the end of it.

Reduced close-out costsOur professional advice on theselection, quality and correct useof the equipment helps you avoiddamage, and minimise wear-and-tear.

(Shell) construction phase (Shell) completion phase

Optimum resource utilisationwith assistance from the DokaFormwork Experts

Seeing things through to a posi-tive conclusionwith professional support

Workflow optimisation, thanks to

thorough utilisation planning

internationally experiencedproject technicians

appropriate transport logistics

on-site support

Doka Services are a byword fortransparency and efficiency here,offering

jointly handled return of rentedformwork

professional dismantling

efficient cleaning and recondition-ing using special equipment

4 5

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Eurocodes at Doka

In Europe, a uniform series of Standards known asEurocodes (EC) was developed for the constructionfield by the end of 2007. These are intended to providea uniform basis, valid throughout Europe, for productspecifications, 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 standardfrom the end of 2008. They will thus supersede the DINnorms 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 theEC.

The EC contrast the actions (loads) with the resistance(capacity). The previous safety factor in the permissiblestresses is now divided into several partial factors. Thesafety 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 resistancee.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, windValues from EN 12812

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

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

Ed

Rd

Permissible stress design EC/DIN concept

Factual Fpermissible Ed Rd

A Utilisation factor

60 [kN]

60

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Product description

Doka beam I tec 20Doka beams I tec 20 are solid-web beams made ofwood and derived timber products. They are intendedfor use in wall and floor-slab formwork only.

Other features include:

Timber-plastic composite formwork beam

Long service life ensured by the 'Top' beam-endreinforcement and the plastic sheet on the broadsideof the flange.

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

Reduces equipment quantities in both floor and wallformwork

Beam-flange markings in a 50 cm grid for theDokaflex 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 moisturecontent.

I tec 20

ApprovalNumber

Z-9.1-773

20

.0

4.

08.0

A Web

B Flange

C Distance-marks on beam-flanges, for Dokaflex system

D System holes

E End-reinforcement

F Notch for chalk line

G I tec sheet

The innovative end-reinforcement on the Dokabeam I tec 20 greatly reduces damage to thebeam-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 to12.00m 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 treatedwith I tec 20 beam-end sealant in order toensure the full lifespan of the beam.

A

B

E

C

D

F

G

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Instructions for assembly and use

Doka beams I tec 20 are formwork beams made ofwood and derived timber products. They are intendedfor use in load-bearing towers and formwork and areloaded in the direction of the height of the beam.

Practical example

In order to maximise durability, it is important to handlethe components with due care; this applies particularlywhen stripping out floor-slab formwork.

Deflection diagram

M ... permitted bending momentQ ... permitted shear forcep ... 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.m

These values allow for a F = 1.5, a kmod of 0.9 and aM = 1.3.

Based on a residual moisture content of 20 % or less.The values must be adjusted accordingly if conditionsof use differ.

Deflection[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 onside" (load direction at right

angles to web plane).Wall formwork

Floor formwork

WARNING

The uses illustrated below are prohibited, asare 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 condition

The 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 isnot 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 andup 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

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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 evincingdamage of this kind do not necessarily meet thequality criteria for Doka rental formwork

Drilled holes

Not permissible, with the exception of system holes:

- Waling attachment with beam screw

- Attachment of table head with beam screw

a ... 15 mmb ... 112 mmc ... 396 mmDrilled-hole diameter max. 10 mm

98041-207-01

a

98041-207-01

9791-209-02

a

9791-209-01

98041-208-01

a

98041-208-01

97

91

-207

-09

98041-203-01

b b

a

98041-203-02

c

a

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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. 21.5mm

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 overallcondition 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

TransportAlways use strap slings to lift stacked beams - do not

use chains.

Stacked beams

max. 3000 kg per stack

Always use edge protectors when strapping beamstogether. Edge protectors can be padding made ofplastic, wood or cardboard.

Ground conditions for stacking

Maximum angle of inclination of ground 3%.

The ground on which the stack is to be placed mustbe adequately firm and level. Best-case conditionsare concreted or paved storage areas.

Storage on asphalt:Depending on the parts stored, place wooden bat-tens, strips of formwork sheeting or metal sheetbetween the parts and the asphalt surface to ensurethat the weight is adequately spread.

Storage on other surfaces (sand, gravel...):Adopt suitable measures for storage (e.g. place thickplywood sheets underneath the loads).

Reprocessing scrap materialDoka formwork beams contain no wood preservativesand, consequently, they can be deposited for reproc-essing.

Reprocessing by incineration in suitable incinerationplants is recommended. It is advisable not to attempt toburn scrap material in open fires or domestic wood-burners.

Always comply with the applicable local or national reg-ulations.

Protect stacked beams from extreme climaticinfluences such as exposure to sunshine ormoisture by covering them (with breathable tar-paulins). This reduces cracking. Only coverthem never envelope them completely.

When moving beams not securely strappedtogether, take care that loose beams cannotslip.

Lengths of beam

Up to 6.50 m Over 6.50 m

Max. n of beams per stack 60 40

Minimum n of timber supports(min. 10 x 8 x 109 cm)

2 3

Dimension 'a' 108 cm

Dimension 'b' 78 cm 56 cm

98041-204-01 98041-204-02

98041-204-03

a

b

Packets of 60 beams Packets of 40 beams

Max. 2 packets on top of oneanother

Max. 4 packets on top of oneanother

98041-205-01 98041-206-01

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Article n[kg] Article n[kg]

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Component overview User information Composite formwork beams


ComponentoverviewDoka SystemComponentsBeam I tec20

Doka beam I tec 20 1.80m 10.1 188001000

Doka beam I tec 20 2.45m 13.7 188002000

Doka beam I tec 20 2.65m 14.8 188003000

Doka beam I tec 20 2.90m 16.2 188004000

Doka beam I tec 20 3.30m 18.5 188005000

Doka beam I tec 20 3.60m 20.2 188006000

Doka beam I tec 20 3.90m 21.8 188007000

Doka beam I tec 20 4.50m 25.2 188008000

Doka beam I tec 20 4.90m 27.4 188009000

Doka beam I tec 20 5.35m 30.0 188013000

Doka beam I tec 20 5.90m 33.0 188010000

Doka 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 yellow

Grey

Varnished yellow

Grey

Yellow

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The Doka beam I tec 20 a technologically superlative product

Day in, day out, thousands of Doka solid-web formwork beams do sterling service on building sites the world over.Our superior standard of manufacturing ensures uniformly high quality and load-bearing strength

for safe and dependable usage.

You can rent, lease or buy Doka formwork beams.

At any of the Doka branches in your region.

Why not give us a call?

The Doka Group's central plant at Amstetten, Austria

Kazakhstan

Latvia

Lithuania

Luxembourg

Marocco

Mexico

Netherlands

New Zealand

Oman

PanamaPoland

Portugal

Romania

Russia

Senegal

Serbia

Slovakia

Slovenia

Spain

Switzerland

Taiwan

Thailand

Ukraine

Vietnam

Doka international

Doka GmbHJosef Umdasch Platz 1, A 3300 Amstetten, Austria

Tel.: +43 (0)7472 605-0, Fax: +43 (0)7472 64430E-Mail: [email protected]

Internet: www.doka.com

AlgeriaSARL Doka Algrie24 A Route de la RassautaBordj-El-Kifane, BP 170, 16120 AlgerTelephone: +213 21 21 27 42

Telefax: +213 21 21 28 98E-Mail: [email protected]

CanadaDoka Canada Ltd.5404 - 36th Street S.E.

Calgary AB T2C 1P1Telephone: +1 403 243-6629Telefax: +1 403 243-6787

E-Mail: [email protected]

China

Doka Formwork (Shanghai) Co., Ltd.No. 3883 Yuanjiang RoadMinhang District, Building 2Shanghai 201109

Telephone: +86 21 6 090 0899Telefax: +86 21 6090 1099E-Mail: [email protected]

IndiaDoka India Pvt. Ltd.Plot No. 26 A, Sector-7, Khargar MahavirLandmark Bldg.601 to 606, 6th Floor,410210 Navi Mumbai

Telephone: +91 22 2774 6452Telefax: +91 22 2774 6451


IrelandDoka Ireland Formwork Techn. Ltd.Monasterboice, Drogheda

Tinure Industrial Complex CountyLouthTelephone: +353 41 686 1620Telefax: +353 41 686 1525


JapanDoka Japan K.K.Miwanoyama 744-6 Nagareyama-shi270-175 Chiba-KenTelephone: +81 471 78 8808

Telefax: +81 471 78 8812E-Mail: [email protected]

www.dokajapan.co.jp

KoreaDoka Korea Ltd.444-1, Yongdoo-ri, Gongdo-eup

456-821 Anseong-Si, Gyeonggi-DoTelephone: +82 31 8053 0700Telefax: +82 31 8053 0701


KuwaitDoka KuwaitDiv. of Riham Gen. Trad. & Cont. Co.Street No. 1, Plot 157-173,Shuwaikh Port Authority AreaP.O. Box 221722023 Salmiyah

Telephone: + 965 2 4822 462Telefax: +965 2 4822 472


LebanonDoka GmbH - Branch LebanonDamascus Street, Sodeco Square, Block C /9th floor - Ashrafieh

BeirutTelephone: +961 1 612 569Telefax: +961 1 612 570


NorwayDoka Norge ASHeggstadmoen 47080 HeimdalTelephone: +47 72 89 38 10

Telefax: +47 72 89 38 11E-Mail: [email protected]

Other subsidiaries andrepresentatives:

Angola

Azerbaijan

Bahrain

Belgium

Belarus

Bosnia and

Herzegovina

Brazil

Bulgaria

ChileCroatia

Czech Republic

Denmark

Egypt

Estonia

Finland

France

Germany

Greece

Hungary

Iceland

Iran

Italy

Jordan

QatarDoka Qatar WLL2nd Gate, Light Industrial Area,

Mesaieed-QatarP.O. Box 23439, Doha-QatarTelephone: +974 4 4500 628

Telefax: +974 4 4500 608


Saudi ArabiaDoka Formwork TechnologyMahmoud Othman & Sons LLCThalia Street, Al-Jol Building,4th Floor, Flat 303/403/404P.O. Box 7620Jeddah 21472Telephone: +966 0)2 669 10 08

Telefax: +966 (0)2 664 86 25E-Mail: [email protected]

SingaporeDoka Formwork Pte. Ltd.9 Gul CircleSingapore 629565Telephone: +65 6897 7737Telefax: +65 6897 8606


South AfricaDoka South Africa (Pty) Ltd.Johannesburg Branch2 Sebasa Road, Chloorkop Ext.10Kempton Park 1619, P.O.Box 8337,Halfway House, 1685 JohannesburgTelephone: +27 11 310 9709Telefax: +27 11 310 9711


SwedenDoka Sverige ABKurdsvgen 2045155 UddevallaTelephone: +46 10 45 16 300Telefax: +46 10 45 16 309E-Mail: [email protected]

TunisiaDoka Tunisia Ltd.Rue de lusine,Le Kram, Zone Industrielle2015 TunisTelephone: +216 71 977 350Telefax: +216 71 977 856


TurkeyDoka Kalip-IskeleSanayi ve Ticaret A.S.Gzeller Org. San. BlgesiInn Mah. Nazarbayev Sok. No:19

41400 Gebze, KocaeliTelephone: +90 262 751 50 66Telefax: +90 262 751 50 05

E-Mail: [email protected] Arab EmiratesDoka Gulf FZEP.O. Box 61407Jebel Ali Free Zone, Dubai

Telephone: +971 4 870 8700Telefax: +971 4 870 8702


United KingdomDoka UK Formwork Technologies LtdMonchelsea Farm, Heath RoadBoughton MonchelseaMaidstone, Kent, ME17 4JD

Telephone: +44 1622 74 90 50Telefax: +44 1622 74 90 33

E-Mail [email protected]

USADoka USA, Ltd.214 Gates RoadLittle Ferry, NJ 07643Telephone: +1 201 329-7839Telefax: +1 201 641-6254E-Mail: [email protected]: www.dokausa.com

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