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Article n°

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999771002 - 08/2008 Ü

User information Doka forming wagon T

The Formwork Experts

Component overview

Bogie for forming wagon TS

936.0 584336000

Grundgestell Schalwagen TS
consisting of:

(A)

Horizontal frame for forming wagon T

505.0 584337000

(B)

Vertical frame for forming wagon T

177.0 584338000

(C)

Frame strut for forming wagon T

13.5 584339000

2 pcs.

(D)

Spindle strut GS T6 95/140cm

10.3 584340000

2 pcs.
Galvanised

(E)

Flanged wheel T

51.0 584341000

4 pcs.

Double jib for forming wagon T

357.0 584342000

Ausleger Schalwagen T
consisting of:

(A)

Jib frame for forming wagon T

294.0 584343000

(B)

Jib slide for forming wagon T

63.0 584344000

Galvanised
Length: 64.4-102.2 cm

Spindle strut T6 73/110cm

10.2 584355000

Spindelstrebe T6 73/110cm

Spindle strut T6 100/150cm

12.5 584323000

Spindelstrebe T6 100/150cm

Spindle strut T7 150/200cm

21.6 584324000

Spindelstrebe T7 150/200cm

Spindle strut GS T7 109/166cm

21.6 584345000

Spindelstrebe GS T7 109/166cm

Pressure prop T

37.7 584349000

Druckstütze T

Suspension beam for forming wagon T

175.0 584346000

Hängeträger Schalwagen T

Longitudinal beam for forming wagon T

36.0 584351000

Längsträger Schalwagen T

Galvanised
Length: 330 cm
Width: 229 cm
Height: 214 cm
Delivery condition: folded closed

Galvanised
Length: 580 cm
Height: 127 cm

Galvanised

Painted blue

Galvanised

Galvanised
Height: 194 cm

Galvanised
Height: 352 cm

Galvanised
Length: 301 cm

Summary of Contents for T

Page 1: ...The Formwork Experts 08 2008 Ü GB 999771002 User information Method statement Doka forming wagon T 9730 235 01 ...

Page 2: ...2 999771002 08 2008 Ü User information Doka forming wagon T The Formwork Experts Introduction by Doka Industrie GmbH A 3300 Amstetten ...

Page 3: ...Ready to use platform for Forming wagon T 12 Examples of the system in action 14 Dimensioning of the ballast 16 Assembly instructions 18 Pouring 24 Striking 25 Repositioning the forming carriage units 26 Safety on the structure 28 Weatherproofing 30 Flexible adaptation to the requirements of the structure 31 Adjusting the forming wagons 32 Multifunctional utilisation 33 Transporting stacking and s...

Page 4: ...supplementary assembly instructions Rules applying during all phases of the assignment The customer must ensure that this product is erected and dismantled reset and generally used for its intended purpose under the direction and supervision of suitably skilled persons with the authority to issue instructions Doka products are ONLY to be used in accord ance with the Doka User Information booklets ...

Page 5: ...All components must be stored safely following all the special Doka instructions given in the rele vant sections of this User Information booklet Regulations industrial safety Always observe all industrial safety regulations and other safety rules applying to the application and utilisation of our products in the country and or region in which you are operating Instruction as required by EN 13374 ...

Page 6: ...n VRd NRd MRd Fd Design value of an action Steel Rd Rk Timber Rd kmod Rk Fd γF Fk γM γM F force Fk Characteristic value of an action actual load service load k characteristic e g dead weight live load concrete pres sure wind Rk Characteristic value of the resistance e g moment resistance to yield stress γF Partial factor for actions in terms of load F force e g for dead weight live load concrete p...

Page 7: ...ridges with large radii The many plus points of the Doka forming wagon T high flexibility in terms of different formwork configurations unlimited options regarding adjustability quick to erect and dismantle thanks to high degree of pre assembly also means that less storage space is needed easy to handle permitting a rapid pace of work daily rhythm multifunctional useage forming wagon demolition wa...

Page 8: ...on T K Spindle strut GS T7 109 166cm M Suspension beam for Forming wagon T N Spindle strut T6 100 150cm P Longitudinal beam for Forming wagon T Q Railing strut for Forming wagon T R Ready to use platform for Forming wagon T S Spindle strut T6 73 110cm T Handrail post T 0 70m X Pressure prop T Y Spindle strut GS T6 95 140cm included with Item B 9730 235 01 B Y N R T S F G P M X Q A K ...

Page 9: ...ns a max 596 0 cm b max 60 cm c Track gauge 197 5 cm d 213 0 cm e 200 0 cm f Adjusting range 4x30 0 cm 120 0 cm g max sidewalk space 200 0 cm h max 80 cm i 18 0 cm Where forming carriages are erected over traffic routes roads navigated waterways railways then in order to prevent objects being dropped and endangering passing traffic the platform decking must be tightly laid and the railings must be...

Page 10: ...0 0 cm m Standard formwork length 500 0 cm Travel gear Centre to centre spacing of rails 197 5 cm Parking wedges A on the double flanged wheels secure the Forming wagons T in their duty position Clamping jaws can be used to provide additional fixing on adaptation to the rail profile Tools needed Fork spanner 13 17 9730 259 01 k l m a 25 0 cm b max 8 0 cm 9730 244 01 a A 9730 245 01 b ...

Page 11: ... waling or Steel waling WS10 Top50 D Doka beam H20 E Tie rod 15 0 length 45 cm F Super plate 15 0 G Flange clamp H20 H Connecting pin 10cm Spring cotter 6mm I Façade pre cast member clamp V Optimum accommodation of the stop ends on the side facing the bridge is obtained by bracing the bottom steel waling C with squared timbers and wedges or with the Façade pre cast member clamp V I 9730 240 01 A B...

Page 12: ...n the formwork on the cantilevering zones of the superstructure during inspection and site erection work Slide off protection can be provided using e g the Handrail clamp T F or the Handrail post 1 80m The Handrail lengthening piece T 1 00m G pro vides effective fall arrest protection for work carried out on the top of the superstructure For this additional support the following items are needed f...

Page 13: ...r end of the forming wagon train Easy to assemble using parts from the Doka stand ard range A Multi purpose waling or Steel waling WS10 Top50 B Connecting pin 10cm Spring cotter 6mm C e g Handrail clamp S or Handrail post T 1 80m D Extra platform planking unit E Guard rail boards F Extra long guard rail boards of the Forming wagon T 9730 314 01 A C D E F G B ...

Page 14: ...The Formwork Experts 14 999771002 08 2008 Ü User information Doka forming wagon T Examples of the system in action ...

Page 15: ...User information Doka forming wagon T 15 999771002 08 2008 Ü The Formwork Experts ...

Page 16: ...2 120 cm standard ex factory setting a3 257 0 cm for special applications Note Where distance a1 50 cm and a3 257 cm the standard Spindle strut GS T6 95 140cm C cannot be used On site fixing is needed in this case Position of formwork unit as a whole The position of the suspension beam together with the platform and the formwork can be continu ously adjusted within the range indicated b as require...

Page 17: ... Standard 120 cm b 220 0 to 375 0 cm c min 130 0 cm d max 220 0 cm Diagram for determining the ballast weight Length of ballast A Pressure prop T B Centre of gravity of ballast C Spindle strut GS T6 95 140cm X Cross section of the edge kerb having an effect on the load Risk of tipping over Dimension c for the centre of gravity of the ballast MUST be strictly observed Sufficient ballast must be pro...

Page 18: ... part lifting tackle to Bogie for Form ing wagon TS B Spreading angle of lifting tackle max 60 Close ups of crane hoisting points Lower the Bogie for Forming wagon TS onto the rails a Centre to centre spacing of rails 197 5 cm x Distance from edge of bridge superstructure as per shop drawing Rear crane hoisting point Front crane hoisting point and parking wedge to immobilise the bogie Warning abou...

Page 19: ...verti cal Close up of crane hoisting point Take the frame strut E out of the Parked posi tion in the horizontal and bolt it into the verti cal frame of the Bogie for Forming wagon TS securing it with a spring cotter View Z Place the ballast on the bogie For details on the dimensioning and position of the ballast F see the shop drawing and or Dimension ing of the ballast 9730 205 01 Z D 9730 206 01...

Page 20: ...ogie for Forming wagon TS Lift the assembled double jib G into the Bogie for Forming wagon TS bolt it into the vertical frame D with a peg in unit O and secure it Close up of peg in unit O Bolt in the Spindle strut T6 N between the jib G and the Bogie for Forming wagon TS B and secure it with a spring cotter G Double jib for Forming wagon T H Scaffolding tube 48 3mm 4 50m I Scaffolding tube 48 3 m...

Page 21: ... Connect the suspension beam unit to the platform Lower the ready to use platform R by crane onto an approx 20 cm high base U e g Doka beams H20 Lower the suspension beam unit by crane into the ready to use platform Attach Scaffolding tube 48 3mm 4 50m H and Swivel coupler 48mm J This stiffening is no longer necessary if the out side railings are erected using Railings T Insert the Handrail posts ...

Page 22: ...xagon nuts M10 On the inside Insert guard rail boards min 20x4 cm into the Handrail posts T 0 70m and fix them in place The platform stop V protects the ready to use platform R against slipping out at all times even when it is being lifted When dismantling always remove the platform stop V first The ready to use platform cannot be disman tled until the platform stop has been removed After dismantl...

Page 23: ...T is in the vertical Take the Spindle struts GS T6 95 140cm Y out of their Parked position and bolt them in place and secure them so as to fix the Pressure prop T X onto the Bogie for Forming wagon TS B Lift the platform unit into position by crane guid ing with tag lines if necessary Insert and secure the safety pins Z Bolt the Spindle struts GS T7 109 166cm K into the suspension beam M and secur...

Page 24: ... formwork Extra working platform A working platform can easily be made for striking off the surface of the concrete Close up A Tools needed Fork spanner 13 17 Before pouring Check that there is no play in the spindle set tings A 9730 253 01 A Attachable platform support T can be attached to the railing strut in 5 cm increments B Doka beam H20 C Platform planking secure against slipping 9730 200 01...

Page 25: ... T C by approx 5 cm 4 Unbolt the Spindle struts GS T6 95 140cm D from the Bogie for Forming wagon TS and tie them to the Pressure props T C by cable 5 Once the Spindle strut and Pressure prop are tied together tilt them away together and tie them to the Bogie for Forming wagon TS E with a cable After the parking wedges have been removed the Forming wagon is ready to be repositioned Warning Do not ...

Page 26: ... section Only attach slinging chains to the Slinging plate T F provided for this purpose and to the towing machine Remove the parking wedges wagon immobi lisers Tow the Forming wagons to their new operating position Before removing the towing machines Replace the parking wedges to immobilise the wagons Max speed 4 km h walking pace Avoid any jerking jolting movements Passenger transportation is fo...

Page 27: ...nded formwork construction With multipurpose or WS10 Top50 steel walings J that are interlinked using splice plates in such a way as to resist tensile and compressive forces Lay the rails U profiles for the next section Only attach slinging chains to the Slinging plate T F provided for this purpose and to the towing machine Remove the parking wedges wagon immobi lisers Tow the Forming wagons to th...

Page 28: ...reinforcement hoops min 13 0 cm b min 5 5 cm max 35 0 cm c min 12 cm d min 1 0 cm Variant 2 Fastened to end face In cases where there are no reinforcement hoops Variant 3 Floor mounted to the already completed edge kerb A Handrail clamp T B Guard rail board C Reinforcement hoop 9755 207 01 1 0 m a A B C 9755 207 02 b d c A B C A Handrail clamp T B Guard rail board C Anchorage Bridge edge beam anch...

Page 29: ... Fixed in an Attachable sleeve 24mm c Distance from edge min 10cm Variant 2 Fixed in a Screw sleeve 20 0 c Distance from edge min 10cm Variant 3 Fixed in a hole subsequently drilled in the con crete c Distance from edge min 10cm Drilled hole Diameter 25 mm A Guard rail 1 10m B Guard rail board Follow the directions in the Handrail post 1 10m User Information A Guard rail 1 10m B Attachable sleeve ...

Page 30: ...equired items see the section headed Items needed Tools needed Reversible ratchet 1 2 Nut for box spanner 19 Extension piece 22 cm Important note The ballast must be increased by the follow ing loads over and above the values deter mined under the heading Dimensioning of the ballast 15 kN bogie to pressure prop distance 120 cm 20 kN bogie to pressure prop distance 50 cm 28 kN no pressure prop A Ta...

Page 31: ...ably reduced although it must still be sufficient to allow safe travelling as well Must be dimensioned on a project specific basis Special shapes of edge kerb The system also offers complete flexibility when it comes to adapting the formwork to the shape of the edge kerb In this way even complex kerb cross sections can be formed economically Situation when formwork is in place Situation when formw...

Page 32: ... spindles using the Adjusting device so as to bring the bridge edge forming wagon into the new travelling position Close up Exact positioning To achieve exact positioning follow the instruc tions for executing major changes of direction Incidents In the rough and tumble of work on the site inci dents will always happen from time to time e g the rollers slipping off the rail profiles at the rail jo...

Page 33: ...s height adjust able working platform the Forming wagon T can also be used as a demolition wagon After the demolition work is completed the work ing platform can be lowered to its normal position by crane or by block and tackle The formwork for constructing the new edge beam can now start to be erected Horizontal repositioning of large area formwork The following parts can also be used for project...

Page 34: ...re designed to facilitate haulage by truck Example Stack of 3 Bogies for Forming wagon TS a 230 0 cm b 224 0 cm c 72 0 cm View Z d 330 0 cm Please secure the stacked bogies against accidental rolling as shown here also when dispatching return consignments Caution Secure the whole stack against accidental rolling e g with intermediate timber 8x8 cm and nailed on battens A Prevent the flanged wheels...

Page 35: ...m for Forming wagon T 1 Railing strut for Forming wagon T 2 Spindle strut T6 73 110cm 2 Ready to use platform for Forming wagon T 1 Handrail post T 0 70m 2 Pressure prop T 2 Swivel coupler 48mm 7 Scaffolding tube 48 3mm 3 00m 4 Scaffolding tube 48 3mm 4 50m 5 Square bolt M10x100 DIN 603 ID n 019190 18 Hexagon nut M10 DIN 934 ID n 019309 18 Name N of items Bogie for Forming wagon TS 1 Double jib fo...

Page 36: ...00 B Jib slide for forming wagon T 63 0 584344000 Galvanised Length 64 4 102 2 cm Spindle strut T6 73 110cm 10 2 584355000 Spindelstrebe T6 73 110cm Spindle strut T6 100 150cm 12 5 584323000 Spindelstrebe T6 100 150cm Spindle strut T7 150 200cm 21 6 584324000 Spindelstrebe T7 150 200cm Spindle strut GS T7 109 166cm 21 6 584345000 Spindelstrebe GS T7 109 166cm Pressure prop T 37 7 584349000 Druckst...

Page 37: ...Bühnenauflage T Connecting pin 10cm 0 34 580201000 Verbindungsbolzen 10cm Spring cotter 6mm 0 06 580204000 Federvorstecker 6mm Railing T top 86 0 584376000 Fertiggeländer T oben Railing T bottom 98 0 584377000 Fertiggeländer T unten Timber parts varnished yellow Steel parts galvanised Length 490 cm Width 170 cm Galvanised Height 300 cm Delivery condition folded closed Galvanised Length 86 6 cm Gal...

Page 38: ... 48 3mm 3 50m 14 0 682019000 Scaffold tube 48 3mm 4 00m 16 0 682021000 Scaffold tube 48 3mm 4 50m 18 0 682022000 Scaffold tube 48 3mm 5 00m 20 0 682023000 Scaffold tube 48 3mm 5 50m 22 0 682024000 Scaffold tube 48 3mm 6 00m 24 0 682025000 Scaffold tube 48 3mm m 4 0 682001000 Gerüstrohr 48 3mm Scaffold tube connection 0 27 584375000 Gerüstrohranschluss Swivel coupler 48mm 1 5 582560000 Drehkupplung...

Page 39: ... 580587000 D Fork wrench 30 32 0 80 580897000 E Ring spanner 17 19 0 27 580590000 F Extension 11cm 1 2 0 20 580581000 G Extension 22cm 1 2 0 31 580582000 H Universal joint coupling 0 16 580583000 I Nut for box spanner 19 1 2 L 0 16 580598000 J Box nut 13 1 2 0 06 580576000 K Box nut 24 1 2 0 12 580584000 L Box nut 30 1 2 0 20 580575000 Reversible ratchet 3 4 1 5 580894000 Umschaltknarre 3 4 Extens...

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