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Variant Vertex 60, User Manual

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Variant Vertex 60 User Manual Download Page 3

MODULAR SUPPORTING FRAMES

3

www.variant-factory.eu

Contents

GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WARNING NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SUPPORTING MODULAR FRAME UNITS (SM- FRAME UNITS) . . . . . . . . . . . . . . . . . . . 8
COMBINING WITH LARGE-AREA FORMWORK VERTEX 60 . . . . . . . . . . . . . . . . . . . . . . . . . 11
STRUCTURAL DESIGN − LARGE-AREA FORMWORK VERTEX 60 . . . . . . . . . . . . . . . . . . 13
COMBINING WITH FRAMED FORMWORK VARIMAX . . . . . . . . . . . . . . . . . . . . . . . . . . 15
STRUCTURAL DESIGN − FRAMED FORMWORK VARIMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSIDE CORNER CONFIGURATIONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
POURING PLATFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SHIFTING BY CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SHIFTING BY WHEEL UNITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRANSPORTING, STACKING AND STORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ANCHORING SOLUTIONS FOR THE SUPPORTING FRAMES. . . . . . . . . . . . . . . . . . . . . . . . . . 33

Option of using anchoring system 15.0  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Option of using anchoring system 20.0  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Option of using anchoring system 26.5   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FITTING DIAGONAL ANCHORS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
COMPONENT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Summary of Contents for Vertex 60

Page 1: ...1 www variant factory eu ...

Page 2: ...2 VARIANT FACTORY LTD ...

Page 3: ...ERTEX 60 13 COMBINING WITH FRAMED FORMWORK VARIMAX 15 STRUCTURAL DESIGN FRAMED FORMWORKVARIMAX 18 INSIDE CORNER CONFIGURATIONS 20 POURING PLATFORMS 26 SHIFTING BY CRANE 27 SHIFTING BY WHEEL UNITS 28 ASSEMBLY 29 TRANSPORTING STACKING AND STORING 32 ANCHORING SOLUTIONS FORTHE SUPPORTING FRAMES 33 Optionofusinganchoringsystem15 0 34 Optionofusinganchoringsystem20 0 35 Optionofusinganchoringsystem26 5...

Page 4: ...nt serves as the basis for the site specific hazard assessment and for the instructions given to users on how to prepare and use the system It does not substitute for these however This manual can also be used as a generic method statement or incorporated with a site specific method statement The equipment system must be inspected by the customer before use to ensure that it is in suitable conditi...

Page 5: ...o be welded are those for which the VARIANT literature expressly points out that welding is permitted If a person or object falls against or into the side guard component and or any of its accessories the component affected may only continue in use after it has been inspected and passed by an expert Provide safe workplaces for those using the formwork e g for when it is being erected dismantled mo...

Page 6: ...th large thickness Walls which are casted against rock faces or sheet piling walls Walls of great thickness in this case single sided system is to be installed on both sides Walls where there is no place for installation of opposite formwork shutter double sided system The single sided modular formwork system consists of two main parts 1 Wall formwork shutters can be used either of Framed formwork...

Page 7: ...MODULAR SUPPORTING FRAMES 7 www variant factory eu Permitted load of fresh concrete up to 50 kN m2 With Varimax height 8 00 m With Vertex 60 height 8 00 m ...

Page 8: ...etween the support frames is to be determined depending on the actual pressure of the concrete mixture The supporting modular frame units are formed by combining of supporting or attachable frames in one block by means of bracing The modular units shall be correctly braced with scaffold tubes to attain the stated capacity Adaptability of the supporting modular frame units allows to form single sid...

Page 9: ...mes come with ready mounted screw on couplers making it possible to attach the bracing tubes very quickly on a construction site 2 parallel frames Vertex 60 Centre to centre a m A Supporting frame 4 50 m B Vertical stacking with Attachable frame 1 50 m C Vertical stacking with Attachable frame 2 00 m 1 00 m to 1 25 m 1 00 m 1 35 m 0 90 m Vertex 60 Varimax Varimax 3 parallel frames ...

Page 10: ... 3 2 3 2 3 STANDARD UNITS FIXING THE ANCHOR WALING TogetherwiththeSuperplate theAnchorwalingpositionersecures the Anchor waling so that it cannot tilt or slip out of position ANCHOR POSITIONING The loads from the diagonal anchors are transferred via anchor walings For each supporting frame an anchor is placed 15 cm either side of the vertical axis of the supporting frame i e 2 in all For more deta...

Page 11: ...older The supporting frames and attachable frames are designed so that the walings of the elements can be fixed anywhere onto the frame COMBININGWITHLARGE AREAFORMWORKVERTEX60 O Waling to bracket holder P Waling 10 or 12 Q Flange clamp Formwork height 2 parallel frames 3 parallel frames up to 4 50 m 4 6 up to 6 00 m 6 9 up to 8 00 m 8 12 Minimum q ty of waling to bracket holder ...

Page 12: ...height 4 50 m Centre to centre distance a 1 00 m Influence width 1 00 m Supporting module type A Example Formwork height 8 00 m Centre to centre distance a 1 00 m Influence width 1 00 m Supporting module type C a 1 0 m b 2 0 m a 1 0 m b 3 0 m ...

Page 13: ...ncrete Pour height H m Anchor force Z kN Spindle force V kN Deformation at top mm Anchor force Z kN Spindle force V kN Deformation at top mm 40kN m2 3 00 124 55 1 156 68 2 3 50 153 81 2 191 101 2 4 00 181 113 3 226 141 4 4 50 209 150 10 262 188 12 50kN m2 3 00 141 59 1 177 73 2 3 50 177 89 2 221 111 2 4 00 212 126 4 265 158 4 4 50 247 170 10 309 213 12 STRUCTURAL DESIGN LARGE AREA FORMWORKVERTEX 6...

Page 14: ...m Anchor force Z kN Spindle force V kN Deformation at top mm 40kN m2 6 00 294 145 5 368 182 6 6 50 322 174 6 403 218 7 7 00 351 206 7 438 258 9 7 50 379 241 9 474 301 12 8 00 407 278 15 50kN m2 6 00 354 169 6 442 211 7 6 50 389 204 7 486 255 8 7 00 424 242 8 7 50 460 284 10 8 00 495 329 16 POUR HEIGHTS FROM 6 00 m TO 8 00 m Fields containing no data are not permissible Supporting module would be o...

Page 15: ...g module are designed so that the walings of the elements can be fixed anywhere onto the frame To be able to fix Varimax panels to the modular supporting frames waling 10 or 12 are used which are fiixed to the framed formwork by means of connection screw 10 16 and super plate Then the panels is fixed to the modular supporting frames using the waling to bracket holder O Waling to bracket holder P W...

Page 16: ...k height 4 50 m Centre to centre distance a 1 35 m Influence width 1 35 m Supporting module type A Example Formwork height 8 00 m Centre to centre distance a 0 90 m Influence width 0 90 m Supporting module type C a 1 35 m b 2 70 m b 2 70 m ...

Page 17: ...op panels can only be upright 1 35 m panels 4 50 m Supporting frame 4 5 m 6 00 m Supporting frame 4 5 m Attachable frame 1 50 m 8 10m Supportingframe4 5m Attachableframe1 50m Attachable frame F 2 00 m OneachparallelSupportingframe anadjustingspindlemustbeattachedunderawaling ANCHOR POSITIONING b c a J She bolt K Pigtail anchor x 19 0 cm where waling 10 anchor is angled at 450 and h 18 0 cm α 45 Th...

Page 18: ...WORK VARIMAX The values given in the table are only applicable to forming situations where there is no kicker In cases with large kickers the overall stability of the supporting frame must be reviewed The loading data is per parallel frame with an anchor inclination of 45 POUR HEIGHTS OF UP TO 4 50 m Supporting module type Influence width 0 90 m Influence width 1 35m A Permitted pressure offresh c...

Page 19: ...e V kN Deformation at top mm 40kN m2 6 00 265 131 4 397 196 7 6 45 288 154 5 431 231 8 6 90 311 180 6 466 269 9 7 20 326 198 7 489 296 11 7 65 349 226 9 8 10 372 257 15 50kN m2 6 00 318 152 5 477 228 8 6 45 347 180 6 6 90 375 211 7 7 20 395 233 8 7 65 423 267 10 8 10 452 304 17 POUR HEIGHTS FROM 6 00 m TO 8 00 m Fields containing no data are not permissible Supporting module would be overloaded ...

Page 20: ... have the construction joint in the corner instead to avoid time consuming planning and If corners still need to be constructed in a single pour two standard components are available for this Corner plate for supporting frame Anchor waling 0 70 m Up to a formwork height of 2 75 m only 1 supporting frame 4 50 m is needed in the corner zone Plywod thickness 21mm 18mm Corner zone Dimension a Walling ...

Page 21: ...CORNER ZONE a A Corner plate for supporting frame B Anchor waling 0 70 m C Supporting frame 4 50 m D Waling to bracket holder E Framed tube 1 00 m F Swivel coupler G Connecting pin H Spring cotter Article 4025 4001 4005 9412 9417 3022 3023 up to 2 75 m 2 3 3 4 5 4 20 12 up to 4 10 m 3 3 4 6 7 4 30 18 Concrete height ...

Page 22: ... ANCHORING POINTS The dimensions given here apply to H20 timber beam formwork with a 21 mm or 18 mm thick form ply where h 18 0 cm anchor inclination α 45 a 236 0 cm b 88 0 cm c 49 0 cm d 15 0 cm X 29 0 cm with waling 10 Plan view View ...

Page 23: ...w variant factory eu EXAMPLE WITH FRAMED FORMWORK VARIMAX Max formwork height 4 05 m Permitted pressure of fresh concrete 50 kN m Up to a formwork height of 2 70 m only 1 Supporting frame 4 50 m is needed in the corner zone a 3 00 m ...

Page 24: ...waling 0 70 m C Supporting frame 4 50 m D Waling to bracket holder H Waling 10 2 50 m I Connecting pin J Spring cotter K Connection screw 10 16 L Superplate M Framed tube 1 00 m N Swivel coupler Article 4025 4001 4005 3060 3022 3023 2033 2034 9412 9417 up to 2 75 m 3 3 3 4 6 12 12 12 12 5 4 up to 4 05 m 5 3 4 6 10 20 20 20 20 7 4 Concrete height ...

Page 25: ...NG FRAMES 25 www variant factory eu LOCATION OF ANCHORING POINTS The dimensions given here apply to framed formwork Varimaxwhere h 18 0 cm anchor inclination α 45 a 226 0 cm b 78 0 cm c 39 0 cm d 15 0 cm Plan view View ...

Page 26: ... kN m 150 kg m Max influence width 2 00 m FLOOR DECKING FOR SUPPORT CENTRES OF UP TO 2 50 M Deck boards min 20x5 cm Guard rail boards min 20x3 cm Deck boards fix with 4 square bolts M10x70 and 1 square bolt M 10x120 per bracket not included in supportingope of supply GUIDE RAIL CLAMP Attached with integral clamp on the timber beam on the floor slab Guard rail boards or scaffold tubes can be used a...

Page 27: ...e are platforms in the way there are 2 possible solutions SHIFTING BY CRANE The Supporting frame is equipped with 3 crane hoisting points In this way it is always possible to find an optimum centre of gravity position for the whole unit despite the many different possible configurations of the formwork and the Supporting frames e g vertically stacked configurations using attachable frames IMPORTAN...

Page 28: ...e supporting frame units in situations where no crane assistance is available e g in tunnels Wherever crane time is in short supply CAN BE MOUNTED ON Supporting frame 4 50 m Attachable frame 1 50 m MAX LOAD Attachable roller 250 1400 kg Attachable roller 200 1000 kg a 27 cm A Winch with transport device B Attachable roller 250 C Attachable roller 200 D Ballast ...

Page 29: ...nscrew it into the appropriate Attachable frame width across 46 mm Bolt the Supporting frame 4 50 m onto the Attachable frame width across 30 mm Once the Supporting frame is bolted together stand it on its back and stabilize it so that it cannot fall over Stand the next Supporting frame on its back in the same way Space the two frames the required centre to centre distanceapartandbracethemwithfram...

Page 30: ...ng module unit Fix the formwork element to the supporting module unit the connectors used will depend on which formwork system is being used Detach the formwork element from the crane Lift the entire formwork unit by crane to its usage location see Shifting Adjust the unit with the spindles Anchor the unit A Adjusting spindle The Adjusting spindle fixes the formwork elements at the desired height ...

Page 31: ...d refitting the front spindle incl nut plate 24 Reversible ratchet 1 2 with Box nut 24 or Fork spanner 22 24 Supporting distancer 20 cm 30 24 Fork spanner 30 32 Reversible ratchet 1 2 with Box nut 24 or Fork spanner 22 24 Holding the Supporting frame bolt Spanner for tie rod 15 0 20 0 For Width across mm Tool Adjusting spindle 19 Reversible ratchet 1 2 with Nut for box spanner 19 and Extension pie...

Page 32: ...ted not only provides a high degree of adaptability to different heights of formwork but also means that they are transported by truck easily and thanks to the integral spacers safely SUPPORTING FRAME 4 50 m Stack of 8 weight approx 2500 kg ATTACHABLE FRAME 1 50 m Stack of 5 weight approx 1200 kg ATTACHABLE FRAME 2 00 m Stack of 5 weight approx 2300 kg TRANSPORTING STACKING AND STORING a 188 cm a ...

Page 33: ...and the depth mark on the stop anchor or pigtail anchor PERMITTED LOADS FOR ANCHOR WALINGS Anchoring system Permitted 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 26 5 250 kN 350 kN Standard situation 2 anchors per supporting frame Example Tensile force Zk shown in Table 266 kN Anchoring system to choose 266 2 133 kN i e choose A...

Page 34: ...le anchoring component 2 Only suitable for Adjustable supporting frames M The depth mark must always be at the end fitted into the she bolt D Superplate 1 Expendable anchoring component 2 Only suitable for Adjustable supporting frames Tools for removing she bolts Spanner for tie rod 15 0 20 0 or Fork spanner 24 Alternative solution Alternative solution Pigtail anchor protrudes from concrete Instea...

Page 35: ...M The depth mark must always be at the end D Superplate 20 0 1 Expendable anchoring component 2 Only suitable for Adjustable supporting frames Tools for removing she bolts Spanner for tie rod 15 0 20 0 or 20 0 26 5 or Fork spanner 36 41 Alternative solution Alternative solution Pigtail anchor protrudes from concrete Instead of the she bolt fasten a Tie rod 20 0 mm to the pigtail anchor using an An...

Page 36: ...ent depth A Pigtail anchor 26 51 A Tie rod 26 5 mm B Rod connector 26 5 B Rod connector 26 5 C Tie rod 26 5 mm C Anchor plate 26 5 D Anchor plate 26 5 D Hexagon nut 26 5 E Hexagon nut 26 5 1 Expendable anchoring component M The depth mark must always be at the end The combination of Tie rod 26 5 mm Anchor plate 26 5 Hexagon nut 26 5 together serves as a substitute for a stop anchor For this reason...

Page 37: ...rloading A Pigtail anchor or stop anchor B She bolt with sealing sleeve C Wooden template D B C A 1 1 0 30 32 30 32 C WOODEN TEMPLATE This method permits variable distribution of the positioning points and can therefore be reused in any situation Alternatively a clear fixed arrange ment of the positioning points can be made with naildown wedges of square sawn timber Many variations are possible on...

Page 38: ...The stop anchor or pigtail anchor can be fixed to the longitudinal reinforcements with the aid of an extra hoop A suitably wide spacer board makes it easier to achieve exact positioning A Pigtail anchor or stop anchor D Extra reinforcement rod E Extra hoop A Stop anchor 15 0 40 cm or 20 0 45 cm F Hoop with stop anchor fastened to reinforcement G Spacer board D B C A D B C A Inside line of wall ...

Page 39: ... frame 1 50 m Attachable frame 2 00 m Supporting construct frame 4 5 338 00 kg САИН 1145 00 000 Attachble frame 1 5 m 254 00 kg САИН 1146 00 000 Attachble frame 2 0 m 478 00 kg САИН 1147 00 000 Waling 12 1 00m 21 00 21 100 000 2 00m 42 32 21 200 000 3 00m 63 53 21 300 000 263 67 31 002 200 350 87 31 001 200 497 04 31 003 200 ...

Page 40: ...m 45 65 kg САИН2205 00 000 0 70m 26 45 33 070 200 1 95m 72 40 33 195 200 2 95m 108 93 33 295 200 0 55m 47 39 33 055 200 0 63 32108100 Front spindle MSF Rear spindle MSF Adjusting spindle Front spindle 18 50 kg САИН 1145 04 000 Rear spindle 18 27 kg САИН 1145 05 000 Adjusting spindle 6 30 kg САИН 1145 06 000 Corner plate MSF Corner plate supporting construction frame 45 00 kg САИН 1168 00 000 47 25...

Page 41: ...0 kg САИН 1015 00 000 10 25 mm 0 75 kg САИН 1015 00 000 01 Connecting pin Connection pin 0 39 kg САИН 1094 00 000 Spring cotter 0 045 kg САИН 30 013 00 000 Spring cotter Screw on access bracket 16 66 kg САИН 1155 00 000 Screw on access bracket 10 16 0 63 11908 100 0 39 23 400 100 0 05 23 402 100 2 61 75 200 100 17 32 75 116 100 Swivel plate 3 9 kg САИН 2277 00 001 Swivel plate 4 10 75 118 100 ...

Page 42: ... 1145 17 00 000 Домкрат 30 45 kg Framed tube 48 mm Adjustable jack Tube 1 5 m 6 5 kg 2 0 m 8 7 kg 2 5 m 10 85 kg 3 0 m 13 00 kg Screw on coupler 1 21 kg САИН 1145 13 000 Swivel coupler Screw on coupler 48 mm Swivel coupler 1 16 kg 9 78 34 100 000 41 06 34 102 000 30 45 34 104 000 1 00m 4 60 94 100 200 1 50m 6 91 94 150 200 2 00m 9 21 94 200 200 2 50m 11 51 94 250 200 3 00m 13 81 94 300 200 30 1 21...

Page 43: ...connector 26 5 1 44 kg Hexagon nut Hexagon nut 26 5 0 76 kg 15 0 50 95 214 100 20 1 05 95 312 100 15 0 38 95 300 100 20 0 38 95 302 100 15 1 22 95 200 100 20 2 10 95 202 100 15 0mm 0 65m 1 83 95 304 100 15 0mm 1 20m 2 72 95 306 100 20 0mm 1 25m 5 94 95 308 100 15 0mm 1 50m 2 40 92 150 300 20 0mm 1 50m 3 60 93 150 300 26 5mm 1 50m 6 83 95 310 300 15 0 37 95 208 100 26 5 0 80 95 218 100 26 5 1 51 95...

Page 44: ... holder Anchor holder 0 43 kg Pigtail anchor Pigtail anchor 15 0 92 kg 20 1 90 kg 26 5 3 60 kg Sealing sleeve Sealing sleeve 15 0 008 kg 20 0 03 kg 15 0mm 0 16m 0 43 99 200 100 15 0mm 0 40m 1 07 99 202 100 20 0mm 0 22m 0 64 99 204 100 20 0mm 0 45m 1 30 99 206 100 15 0 92 99 208 300 20 1 90 99 210 300 26 5 3 60 99 212 300 15 0 008 99 104 400 20 0 03 99 106 400 15 0 34 99 214 300 20 0 42 99 216 300 ...

Page 45: ...MODULAR SUPPORTING FRAMES 45 www variant factory eu ...

Page 46: ...46 VARIANT FACTORY LTD ...

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