WedgeJack Method Statement

Wedge jacks

Methodstatement

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Ischebeck Titan | Method statement | Wedge Jacks April 2009

MethodstatementWedge jacks

Introduction

Ischebeck Titan is renowned as one of theleading manufacturers and suppliers ofequipment to the construction and civilengineering industries.

Our commitment to safety and site efficiencyis evident in the design performance andquality of our products, which offer safeaccess and secure working platforms for anenormous variety of applications.

The enclosed method statement underlinesour devotion to site safety by providingrecommendations, based on tried andtrusted methods, for the proper use andapplication of Ischebeck Titan wedge jacks.

Please take time to read and understand theinformation presented before using theproducts covered. If you need further adviceor assistance consult a suitably qualifiedperson within your own company or contactIschebeck Titan.

Disclaimer

The methods presented in this document aresolely for the use of Ischebeck Titanequipment and are intended for guidanceonly. When familiarity has been gained withthe equipment preferred methods may beadopted, provided they do not contravenehealth and safety regulations or acceptedsafe working practices. The information iscorrect at time of publication, but IschebeckTitan reserves the right to change, withoutprior notice, the specifications and methodsmentioned. No responsibility whatsoever canbe accepted for any errors or omissions in,or misrepresentation of, the contents. Forspecific information refer to Ischebeck TitanLimited.

Copyright reserved.

ContentsPage

Introduction 2Disclaimer 2Site safety 3Your responsibilities 3Safe working practice 4Personal protective equipment 41. The wedge jacks and their use 52. Design and function 63. Verification of stability

based on strucutral analysis 94. Description of load cases

and static calculation models 95. Maximum permissible load

for the wedge jack 105.1 Maximum permissible centric load 105.2 Maximum permissible eccentric load 105.3 Maximum permissible loads

at simultaneous horizontal (Fx or Fy)and centric vertical (Fz) loads 13

5.4 Maximum permissible loads at a double eccentric offset load 15

6 Operating instructions and conditions 156.1 Assembly and placement of the wedge jack 156.2 Structural members on wedge jacks 166.3 Flexible beams on wedge jacks 166.4 Wedge jacks for the support of inclined beams 176.5 Wedge jacks for the support of props 177. Lowering of formwork with wedge jacks 188. Suggestions for common applications 198.1 Example I:

Using wedge jacks for falsework 198.2 Example II:

Wedge jacks for direct support of primary beams 21

8.3 Example III:Wedge jacks on steel beam brackets 23

8.4 Example IV:Wedge jacks for support of individual props 25

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Site safety is yourresponsibility

The importance of site safety cannot be overemphasized. You have a responsibility toyourself, your colleagues, site visitors, family,friends and others to ensure you do notinjure yourself or take actions, which put thelives and health of other people at risk.

Site safety rules will form part of every site’shealth and safety plan. You should familiariseyourself with these rules and make sure thatyou and fellow workers do not contravenetheir requirements. A prominent notice willidentify personnel with overall responsibilityfor site safety.

You will have contractual and legal obligationto follow these rules and adhere to relevantlegislation, such as the Health and Safety atWork Act, which place specificresponsibilities on you and your employer toprevent accidents.

Site safety is the responsibility of everyoneon site. If you have a reason to believe thatsafety is being compromised, you shouldreport it to the appropriate personnel.

Your responsibilities

Following are a few suggestions to help youwork safely and contribute to safety on yoursite:

• Make sure you fully understand the safeand proper way to do any job.

• If in doubt, ask your supervisor – do notguess.

• Always conduct yourself in a responsibleand safe manner.

• Do not expose others to danger throughyour actions.

• Always use the correct tools and equipmentfor the job.

• Always use the appropriate safetyequipment and protective clothing.

• Report ALL defects in plant and equipment.• Observe and comply with warning and

hazard notices.• Advise newcomers of safe working

practices.• Make sure you know where to go for first

aid treatment.• Report any injury and ensure it is entered

in the accident book.• Never indulge in horseplay or practical

jokes at work.• Never attempt to work whilst under the

influence of alcohol or drugs.• Make sure you have read and understood

the sites health and safety requirements.• Report any situation which might

compromise site safety to the sites safetyofficer.

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Safe working practice

• Consider health and safety first. If you arenot sure of procedures ask.

• Do not take shortcuts – use the accessprovided.

• Do not remove handrails or ladders fromscaffolds unless instructed to do so andreplace them as soon as possible.

• Play your part in keeping the site tidy andsafe.

• Look out for hazard warning notices andobey them.

• Never attempt to operate machinery unlessyou have been trained and authorized to doso.

• Attempting to lift heavy objects or materialscan cause injury – obtain assistance wherenecessary.

• Study you company’s policy.• Remember you have a legal duty to take

reasonable care of your own health andsafety and to avoid placing other people atrisk. Such as those who work with you andmembers of the public.

• If in doubt about your job, ask yourimmediate supervisor for guidance.

• Your co-operation in discouraging childrenfrom entering the site will help to reducethe risk of accidents to them and others.

• Remember that entering an unsafe areacould render you liable to prosecution. If itlooks or feels unsafe, report it. If you areunsure, ask site supervision for advice.

Personal protectiveequipment

For your protection, always use the safetyhelmets, ear protectors, face masks,goggles, gloves, safety harnesses and otheritems of personal protective equipmentappropriate to the tasks you are undertaking.

When protective clothing and/or equipment isissued to you:-

• Wear or use the equipment when requiredand when there is any possibility ofpersonal injury in the course of your work.

• Look after the equipment.• If the equipment is on personal issue, store

it carefully and ensure that it is available foruse when needed.

• Make sure that equipment is properlymaintained.

• Replace defective equipment immediately.• If you have any doubts about the correct

use, adjustment or maintenance of theequipment, ask your supervisor.

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1 The wedge jacks and their use

The TITAN 500 and TITAN 1000 wedge jacksfrom Ishcbeck Titan have been tested for useas jacks in heavy falsework applications.

The wedge jacks are generally used for thesupport of beams and beam falsework orsingle rolled steel props or heavyduty falsework props. The item to besupported may be fastened to the wedgejack by means of connecting brackets.The wedge jack is to be placed on a surfaceas solid and flat as possible, such as aconcrete foundation, a foundation beamor a steel bracket.

The wedge jack may be subjected to bothcentric and eccentric vertical forces and alsoto a lesser extent horizontal forces.

The load-bearing capacity of the wedge jackis depending on the surface it has beenplaced on and how it has been placedthere.

Figures 1-3 show the TITAN 500 wedge jack.The TITAN 1000 wedge jack is similar.

In this document, permitted maximum loadsare indicated for the TITAN 500 and TITAN1000 wedge jacks for specific caseswith given conditions.

Figure 1: View 1 - Front viewTie rod in parallel with the picture surface

Figure 2: View 2 - Side viewTie rod pointing into the picture

Figure 3:Isometric view

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2 Design and function

The wedge jack consists of four identicalwedges arranged at an angle of 90° to eachother.

The wedges are held together by a tie rod(TITAN 500) or an anchor bolt (TITAN 1000)and by vertical bolts that limit the maximumheight (see figures 4-7).

A layer of synthetic resin protects the wedgejack against corrosion.

Angularheadplate

Special nut forthe tie rod

Tie rod,ø 26,5 mm

Side wedge

Base plate weldedto wedge

Base plate 200 x 200 mmHeight H 168 – 268 mmAdjustment range 100 mm

Figure 5: The TITAN 500 Wedge JackTop: Maximum height (268 mm)Bottom: Minimum height (168 mm)

Figure 4: The TITAN 500 Wedge Jack

The TITAN 500 Wedge JackThe bottom wedge of the TITAN 500 has awelded-on base plate (200x200x10 mm),while angular headplates have beenwelded to both sides of the top wedge (seefigures 4 and 5).The side wedges are positioned verticallybetween the top and bottom wedges andheld together by means of a threadedtie rod (ø 26,5 mm) and nuts. One of thenuts has been tack welded to one of the sidewedges.

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The TITAN 1000 Wedge Jack

On the TITAN 1000 wedge jack, plates(300x300x10 mm) have been welded to boththe top and bottom wedgesrespectively (head plate and base plate, seefigures 6 and 7).

The side wedges are positioned verticallybetween the top and bottom wedges andheld together by means of ananchor bolt Tr 53 x 13 mm and nut.

FunctionTightening the adjustment nut will pull theside wedges together, thereby lifting the topwedge and increasing the total height of thewedge jack. Loosening the adjustment nutwill make the side wedges move away fromeach other, letting the top wedge sink. Inboth cases, the wedges will slide along their45° surfaces.The adjustment range is 100 mm for theTITAN 500 and 90 mm for the TITAN 1000.Due to a large pitch thread, adjustmentis fast and requires little force.

Head plate welded totop wedge

Side wedge

Base plate welded tobottom wedge

Anchor boltTr 53x13

Anchor bolt53x13

Base plate 300 x 300 mmHeight H 182 – 272 mmAdjustment range 90 mm

Figure 7:The TITAN 1000 Wedge JackTop: Maximum height (272 mm)Bottom: Minimum height (182 mm)

Figure 6: The TITAN 1000 Wedge Jack

max

.272

300 x 300

min

.182

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Below maximum load, the wedge jack can beloosened by means of a ring spanner and a 2kg hammer. For safety reasons, a wrenchwith a torque multiplier (preferably 1:15) isrecommended when working on thefalsework. The respective beams may beused for supporting torque multiplier lever.

The wedge jacks can lift and adjust loads upto 40 kN.

The TITAN wedge jacks have beendeveloped from the traditional sand support,in comparison with which it has the followingadvantages:

- exact height adjustment- data on load deformation properties- insensitive to water

In comparison with spindle designs andhydraulic cylinders, the wedge jack is alsocapable of handling eccentric loads andhorizontal forces within a certain limit. The

Figure 8: Wedge jack with a ring spanner

Technical data

Figure 9:Indication of loads

Wedge jack TITAN 500 TITAN 1000

Maximum loadaccording toDIN 4421 andDIN 18800

See Section 5:Maximum load for the wedge jack

Vertical loadFz maxHorizontal loadFx max, Fy maxEccentricityex max, ey maxSettlement 1 mm / 100 kN 1 mm / 100 kN

Adjustmentrange

168 – 268 mm 182 – 272 mm

Base plate area 200 x 200 mm 300 x 300 mm

Weight 29.5 kg 53.3 kg

For safety: The sliding surfaces of the wedges mustnot be lubricated.

wedge jacks are less expensive yet moresolid than hydraulic equipment with the sameload capacity.

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3 Verification of stability based onstructural analysis

For real applications, the stability of thewedge jack may be calculated and verifiedbased on static calculation models of thewedge jack alone. In these calculationmodels, impact and load-bearingcapacity are taken into consideration.

The calculation models that form the basis ofthe test type are described in detail inChapter 4. Support conditions are governedby the foundation conditions and theconnected elements or with the aid oftechnical applications.

In Chapter 8, various applications are shownwith the appropriate static calculation model.

In the design of falsework it must beremembered that the wedge jack provides avery low degree of restraint for thesurroundings. Because of its low torsionalstiffness, the wedge jack will therefore notadd to stability.

4 Description of load cases and staticcalculation models

The following examples are cases wherewedge jacks may be used:

1. In the case of torque transfer with nohorizontal loads, if one of the end plates(head and/or base plate) is not fixed so thatit cannot rotate, it must be ensured that theend plates cannot shift in relation to eachother in any direction.

At pure eccentric vertical loads, the followingcalculation models are to be used (staticcalculation models A):

Figure 10:Static calculation model A-1 for view 1(see figure 1) of the wedge jack

Sliding stiffness from friction


The degree of restraint of the wedge jack islow. The end plates will rotate by more than1° from the horizontal plane even at a verylow load eccentricy without impeding theload-bearing capacity of the wedge jack.

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2. If both end plates are fixed, the wedgejack can also transfer horizontal loads.

For the transfer of horizontal loads whenthere is a centric vertical load, the followingstatic calculation models are to beused (static calculation models B):

Figure 12;Static calculation model B-1 for view 1(see figure 1) of the wedge jack

Sliding stiffness from frictionFigure 13:Static calculation model B-2 for view 2(see figure 2) of the wedge jack

Figure 14;Static calculation model A-1 for view 1(see figure 1) of the wedge jack



tested to verify the load-bearing behaviour.As long as the conditions mentioned inChapter 4 are met, the wedge jack will meetthe requirements of"Traggerüstgruppe III" (Framework Class III)of DIN 4421.

5.1 Maximum permissible centric load

a) End plates not fixed rotationwiseStatic calculation models A-1 and A-2

Note:The wedge jack may not be used for takingup eccentric vertical loads and horizontalloads at the same time.

5 Maximum permissible loads for thewedge jack

The wedge jack load-bearing capacity andmaximum permissible load eccentricity havebeen calculated analyticallyaccording to DIN 4421. Each case has been

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b) End plates fixed rotationwiseStatic calculation models B-1 and B-2

Maximum permissible load (Fz ) regardlessof the total height (H) and eccentricity (e):TITAN 500 Fz max = 420 kNTITAN 1000 Fz max = 1000 kN

5.2 Maximum permissible eccentric load

The maximum permissible eccentricity (e) isreduced with increasing total height (H) ofthe wedge jack (see diagram 1-1 and table1-1 for TITAN 500 and diagram 1-2 and table1-2 for TITAN 1000).

Sliding stiffness from frictionFigure 16;Static calculation model B-1 for view 1(see figure 1) of the wedge jack

Figure 17:Static calculation model B-2 for view 2(see figure 2) of the wedge jack


Figure 18;Static calculation model A-1 for view 1(see figure 1) of the wedge jack


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Permissible load eccentricity TITAN 500 wedge jack

Permissible load eccentricity TITAN 1000 wedge jack

Diagram 1-1:Maximum permissible eccentricityfor the TITAN 500 wedge jack

Table 1-1:Maximum permissible eccentricityfor the TITAN 500 wedge jack

Diagram 1-2:Maximum permissible eccentricityfor the TITAN 1000 wedge jack

Hmm

ex max = ey maxmm

168 30178 30188 30208 30218 30228 26238 23248 19258 16268 12

Table 1-2:Maximum permissible eccentricityfor the TITAN 1000 wedge jack

Hmm

ex max = ey maxmm

182 26192 26202 26212 26222 26232 24242 21252 17262 14272 10

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5.3 Maximum permissible loads withsimultaneous horizontal (Fx or Fy )and centric vertical (Fz) loadsIf the end plates cannot rotate in relation toeach other, the wedge jack can also take uphorizontal loads.

Sliding stiffness from frictionFigure 20:Static calculation model B-1 for view 1(see figure 1) of the wedge jack

Figure 21:Static calculation model B-2 for view 2(see figure 2) of the wedge jack

a) Maximum permissible horizontal loads Fxmax or Fy max with a centric load Fz existThe maximum permissible horizontal loadsFx max or Fy max are determined by thevertical load (Fz exist) and the total

Maximum permissible load TITAN 500 wedge jack

Diagram 2-1:Maximum permissible horizontal loadfor the TITAN 500 wedge jack

Table 2-1:Maximum permissible horizontalload for the TITAN 500 wedge jack

Hmm

Fx max / Fz exist,Fy max / Fz exist,

resp.[kN]

168 0.142178 0.142188 0.142208 0.142218 0.142228 0.136238 0.129248 0.123258 0.116268 0.110

height of the wedge jack (H) (see diagram 2-1 and table 2-1 for TITAN 500 and diagram2-2 and table 2-2 for TITAN 1000).

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Maximum permissible horizontal load TITAN 1000 Wedge jack

Diagram 2-2:Maximum permissible horizontal loadfor the TITAN 1000 wedge jack

Table 2-2:Maximum permissible horizontalload for the TITAN 1000 wedge jack

Hmm

Fx max / Fz exist,Fy max / Fz exist,

resp.[kN]

182 0.152192 0.152202 0.152212 0.152222 0.152232 0.149242 0.142252 0.135262 0.128272 0.122

b) Maximum permissible vertical load (Fz max)at an existing horizontal load (Fx) or (Fy)

View 1 – Fx exist: The maximum vertical load(Fz max) is calculated taking the horizontal load(Fx exist) into consideration

TITAN 500 Fz max = 420 kN – 1,4 x Fx existTITAN 1000 Fz max = 1000 kN – 1,4 x Fx exist

View 2 – Fy exist: The maximum vertical load(Fz max) is independent of the horizontal load(Fy exist) and does not have to be reduced

TITAN 500 Fz max = 420 kNTITAN 1000 Fz max = 1000 kN

The conditions a) Fx ≤ Fx max, Fy ≤ Fy maxand b) Fz ≤ Fz max must be met at the sametime.

Fx max/Fz exist = Fy max/Fz exist [kN]

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5.4 Maximum permissible loads at adouble eccentric offset load

Meeting the support conditions in thechapters 5.2 and 5.3, respectively, the giveneccentricities and load capacities areanalogously valid for the direction xy in thefigure below.

TITAN 500 Wedge jackexy max = ex max = ey maxFz max = 420 kN

Fxy max = Fx max = Fy maxFz max = 420 kN – 1,4 x Fxy exist

TITAN 1000 Wedge jackexy max = ex max = ey maxFz max = 1000 kN

Fxy max = Fx max = Fy maxFz max = 1000 kN – 1,4 x Fxy exist

Important:

The inner surfaces of the wedges (slidingsurfaces) must not be lubricated. Beforeusing the wedge, make sure to clean thesliding surfaces from any oil or grease.

Place the wedge jack on solid, flat and non-rotating surfaces, such as concretefoundations, raft foundations,foundation beams, steel brackets, etc.

The surface on which the wedge jack isplaced must be at least as large as its baseplate.

Figure 23:Correct assembly

Figure 24:Incorrect assembly

Figure 25:Incorrect assembly

Figure 22:Loads and eccentricities

6 Operating instructions and conditions

6.1 Positioning and placement of thewedge jack

The wedge jack is generally to be assembledin a vertical position. Make sure that the sidewedges are in parallel with each other. Thisis also valid for the aligning of the top andbottom wedges (see figure 23).

Make sure that the wedges are at 90° angleto one another. It is not permitted to create aparallelogram and/or to tilt any ofthe end plates (see figures 24 and 25).

NOT

PERMITTED

NOT

PERMITTED

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6.2 Structural members on wedge jacks

The load on the wedge jack is to bedistributed over the entire surface. Thereforethe structural members resting on the wedgejack, or on which the wedge jack rests, mustbe adequately stiffened.

Sectional beams need stiffeners at everywedge jack location.

6.3 Flexible beams on wedge jacks

If a wedge jack is used for the support of aflexible beam, the tie rod is to be aligned inparallel with the axis of the beam.In this position the wedge jack will adjust in acontrolledmanner to the beam inclination(�<1° or 0,0175 rad, see figure 28). Herebythe vertical load is automatically centered.

Wedge jacks may not be used as a supportfor structural beams where, due to loads, therotation in the point of support �>1°.

NOT

PERMITTED

Figure 26:Beam on wedge jack

Figure 28:Flexible beam on wedge jack

Figure 27:Not permitted:Centering bar on a wedge jack

The use of centering bars directlyon top or underneath the wedgejack is not permitted.

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6.4 Wedge jacks for the support ofinclined beams

In cases where inclined beams are to besupported, the careful use of semicircularsteel rods of different radii (see figure 29)may ensure that the wedge jacks may still beused as they can then still be positionedvertically. It is vital that the steel rods

are positioned exactly above the edges ofthe top wedge and that they extend over theentire width of the wedge jack.The use of the steel rods and the load of thebeam are to be verified by a suitablyqualified person on site.

Figure 29:Inclined beam on wedge jack

LOASteel prop withwelded-on headand base plate

AnchorConnectionbracket

Wedge jack

The wedge jack placed on aflat foundation with sufficient

load-bearing capacity

6.5 Wedge jacks for the supportof props

When used for the support of props,the wedge jack is to be positioned sothat the line of action goes throughthe centre of gravity of the prop and ofthe wedge jack.

If rolled sections are used as props,end plates must be welded onto thesections for the correct transfer of theload. The positioning should besecured by means of beam clamps(see also Chapter 8.4 – Example IV).

At the positioning of the prop section it mustbe assumed that the wedge jack offers nodegree of restraint. The idealrotation point may be assumed to be on topof the wedge jack for view 1 and in the tie

Figure 29: Prop on wedge jack

rod axis for view 2. See also theapplication example in chapter 8.4.

Note:For view 1, ensure that the top of the wedgejack is fixed horizontally.

Line of Action

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If heavy duty props are to be supportedwhich may rotate freely around one axis, therotation point must be in View 1.

The same applies for hinged props whichhave to be set up at an angle due to shifts inthe superstructure.

The perpendicular deviation angle (�) mustnot exceed 0,0175 rad (=1°).

Figure 31:Wrench with a torque multiplier for looseningthe wedge jack under load

7 Lowering of formwork with wedge jacks

Operating instructionsAfter the concrete has hardened sufficiently,the formwork may be lowered.If no particular instructions have beenissued by the erecting contractor,the following instructions should befollowed:

1. Measure the heights between the bottomof the primary beam and the bases for thewedge jacks and write them down, e.g.with chalk on each section of the primarybeam, for reference.

2. At the use of several wedge jacks in a row,loosen the adjustment nuts 1/4 turnbeginning at the ends and moving inwards(in the figure below, this would mean thefollowing order: 1, 8, 2, 7, 3, 6, 4 and 5).Repeat at all beams alternately until thebeams have all been lowered by approx.10mm. At this stage, the downward motionof the beams should not differ by morethan 3mm.

3. Now loosen the adjustment nuts one fullturn beginning at the outer ends andmoving inwards. Repeat at all beams until

the beams have all been lowered approx.50mm. The downward motion of thebeams should not differ by more than 10mm.

4. At this point, every second wedge jackmay be removed.Remove the wedge jacks that have beenlowered the most and are approaching theminimum height of 170mm. Otherwise,hydraulic equipment will be necessary forfurther lowering.

5. Lower the remaining wedge jacks until theformwork is clear. When applicable,remove extra steel plates underneath thewedge jacks before reaching the mininumheight.

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8 Suggestions for common applications

8.1 Example IUsing wedge jacks for falsework

Note:Verification of the wedge jack in accordancewith chapter 5.3

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8.2 Example IIWedge jacks for direct support of primarybeams


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Note:Verification of the wedge jack in accordancewith the chapters 5.1a and 5.2A centering profile on top of the primarybeam is not required if the end tangent angleunder full load = 1° from the horizontal plane.

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8.3 Example IIIWedge jacks on steel beam brackets

Note:Verification of the wedge jack in accordancewith 5.3

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Note:Verification of the wedge jack in accordancewith chapter 5.1a and 5.2A centering profile on top of the primarybeam is not required if the end tangent angleunder full load = 1° from the horizontal plane.

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8.4 Example IVWedge jacks for support of individualprops

Note:Verification of the wedge jack in accordancewith chapter 5.1a

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Note:Verification of the wedge jack in accordancewith chapter 5.1a or 5.2

HEAD OFFICEJohn Dean HouseWellington RoadBurton upon TrentStaffordshire DE14 2TGTel: 01283 515677 Fax: 01283 516126www.ischebeck-titan.co.ukE-mail: [email protected]

NORTHERN REGIONAL OFFICE& DESIGN OFFICEHollinwood Business CentreAlbert Mills Albert StreetHollinwood Oldham OL8 3QPTel: 0161 682 4732 Fax: 0161 684 3603E-mail: [email protected]

Since our policy is one of continuous improvement we reserve the right tochange without prior notice the specifications and methods of constructionmentioned in this document. No responsibility whatsoever can be accepted forany errors or omissions in, or misinterpretation of the contents. Products mustbe used in conformity with safe practices and applicable codes andregulations. Photos and details shown are for general guidance only and mayvary according to circumstances. For specific information refer to IschebeckTitan Limited. Copyright reserved.

Ischebeck Titan Group

Founded in Germany over 120 years ago Ischebeck isrenowned internationally for it’s aluminium formwork andfalse work systems, trench support systems and groundengineering products.

Ischebeck Titan Ltd

The company operates from headquarters centrally locatedin the heart of the UK.

Product Availability

Substantial stocks of equipment are available ex-stock fromthe company’s strategically located 4-acre distribution site,with most main product lines available nationwide on a 48-hour delivery. Products are available for both hire andoutright purchase.

Technical Support

We will participate in concept stage development. Providinginput on applications, production rates, budget design,programming and costings. Active for on site support andtraining. We can provide guidance on industry specialEuropean and national standards.

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WedgeJack Method Statement