Doka Top50

The Formwork Experts

10/2012

en-GB999732002

User informationMethod statement

Large-area formwork Top 50

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Introduction User information Large-area formwork Top 50


Introduction

by Doka Industrie GmbH, A-3300 Amstetten

User information Large-area formwork Top 50 Introduction

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Contents4 Introduction4 Elementary safety warnings6 Eurocodes at Doka8 Doka services

10 System overview

11 Wall formwork11 Instructions for assembly and use14 Top 50 element in detail15 Flexibility16 Tie-rod system18 Inter-panel connections19 Examples of the system in action20 Length adjustment using closures25 Height adjustment26 90 degree corners30 Acute & obtuse-angled corners32 Stop-end formwork33 Vertical stacking of elements34 Shaft formwork39 Circular formwork40 Plumbing accessories44 Pouring platforms with single brackets46 Pouring platforms49 Guard rails50 Ladder system54 Combining different formwork systems55 Resetting by crane56 Enhanced requirements for fair-faced con-

crete

58 Wall formwork with Platform system Xsafe plus

59 Instructions for assembly and use62 Platform system64 Xsafe plus platform67 Xsafe plus platform accessories73 Mounting the Xsafe plus platform onto the

formwork76 Ladder system78 Plumbing accessories82 Examples of Top 50 elements with Xsafe plus85 Stop-end formwork86 Resetting by crane90 Transporting, stacking and storing

92 Column formwork93 Design of column formwork96 Column formwork with Multipurpose walings

WS10 Top5098 Column formwork with Multi-purpose walings

WU12 Top50101 Ladder system102 Instructions for assembly and use

105 Other possible areas of use105 Top 50 as a superstructure and tunnel form-

work108 Extra functions provided by the Multi-purpose

waling WS10 Top50109 Utilising self-compacting concrete110 Top 50 combined with . . .

112 Element assembly119 Doka "Ready-to-Use" Service

120 Structural design120 Deflection diagrams122 Top 50 elements126 Struts

127 General remarks127 Fall-arrest systems on the structure128 Doka multi-trip packaging132 Cleaning

134 Component overview

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IntroductionElementary safety warnings

User target groups This manual is aimed at all persons who will be work-

ing with the Doka product or system that it describes. It contains information on the standard design for setting up this system, and on correct, compliant uti-lisation of the system.

All persons working with the product described herein 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, Operating Instruction manuals, plans etc.) are available to all users, and that they have been made aware of them and have easy access to them at the usage location.

In the relevant technical documentation and form-work utilisation plans, Doka shows the workplace safety precautions that are necessary in order to use the Doka products safely in the usage situations shown. In all cases, users are obliged to ensure compliance with 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 a hazard assessment at every job-site.This document serves as the basis for the site-spe-cific hazard assessment, and for the instructions given to users on how to prepare and utilise the sys-tem. It does not substitute for these, however.

Remarks on this document This manual can also be used as a generic method

statement or incorporated with a site-specific method statement.

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.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 this document!

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 to get to and from these workplaces via safe access routes!

If you are considering any deviation from the details and instructions given in this booklet, or any application which goes beyond those described in the booklet, then revised static cal-culations must be produced for checking, as well as 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 super-vision of suitably skilled persons with the authority to issue instructions.These persons' mental and physical capacity must not in any way be impaired by alcohol, medicines or drugs.

Doka products are technical working appliances which are intended for industrial/commercial use only, always in accordance with the respective Doka User Information booklets or other technical docu-mentation authored by Doka.

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

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

Fire-sources are not permitted anywhere near the formwork. Heating appliances are only allowed if properly 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 the equipment, and the immediate vicinity of the equip-ment, and to protect employees.

All connections must be checked regularly to ensure that 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 if necessary.


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Assembly The equipment/system must be inspected by the

customer before use, to ensure that it is in suitable condition. Steps must be taken to rule out the use of any components that are damaged, deformed, or weakened due to wear, corrosion or rot.

Combining our formwork systems with those of other manufacturers could be dangerous, risking damage to both health and property. If you intend to combine different systems, please contact Doka for advice first.

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

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

Erecting the formwork Doka products and systems must be set up in such

a way that all loads acting upon them are safely transferred!

Pouring Do not exceed the permitted fresh-concrete pres-

sures. Excessively high pouring rates lead to form-work overload, cause greater deflection and risk causing breakage.

Striking the formwork 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!

When striking the formwork, never use the crane to break concrete cohesion. Use suitable tools such as timber wedges, special pry-bars or system features such as Framax stripping corners.

When striking the formwork, do not endanger the stability 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 of

formwork and scaffolding. In addition, the Doka slinging means must be used - this is a mandatory requirement.

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

All components must be stored safely, following all the special Doka instructions given in the relevant sections of this manual!

Regulations; industrial safety Always observe all industrial safety regulations and

other safety rules applying to the application and uti-lisation of our products in the country and/or region in which you are operating.

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.

Maintenance Only original Doka components may be used as

spare parts. Repairs may only be carried out by the manufacturer or authorised facilities.

Symbols usedThe following symbols are used in this booklet:

MiscellaneousWe reserve the right to make alterations in the interests of technical progress.

Important noteFailure to observe this may lead to malfunc-tion or damage.

CAUTION / WARNING / DANGERFailure to observe this may lead to material damage, and to injury to health which may range up to the severe or even life-threaten-ing.

InstructionThis symbol indicates that actions need to be taken by the user.

Sight-checkIndicates that you need to do a sight-check to make sure that necessary actions have been carried out.

TipPoints out useful practical tips.

ReferenceRefers to other documents and materials.

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Eurocodes at DokaIn Europe, a uniform series of Standards known as Eurocodes (EC) was developed for the construction field by the end of 2007. These are intended to provide a uniform basis, valid throughout Europe, for product specifications, 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 standard from the end of 2008. They will thus supersede the DIN norms 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 the EC.The EC contrast the actions (loads) with the resistance (capacity). The previous safety factor in the permissible stresses is now divided into several partial factors. The safety 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 take account of the moisture and the duration of load action)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 RdA Utilisation factor

60 [kN]60


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Doka services

Support in every stage of the projectDoka 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 one thing that all construction projects have in common and that is a basic structure with five stages. We at Doka know our clients' varying requirements. With our consulting, planning and other services, we help you achieve effective implementation of your formwork assignment using our formwork products in every one of these stages.

Project Development Stage Bidding Stage Project Management Planning Stage

Taking well-founded decisionsthanks to professional advice and consulting

Optimising the preliminary workwith Doka as an experienced part-ner

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

Find precisely the right formwork solutions, 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 formwork

choices having an optimum time-calcula-

tion basis

Plan cost-effectively right from the outset, thanks to detailed offers determination of the commission-

ing quantities co-ordination of lead-times and

handover deadlines

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The advantages for youthanks to professional advice and consulting Cost savings and time gains

When we advise and support you right from the word "go", we can make sure that the right formwork systems are chosen and then used as planned. This lets you achieve optimum utilisation of the formwork equipment, and effec-tive forming operations because your workflows will be correct.

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

TransparencyBecause our services and costs are completely transparent, there is 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 the selection, quality and correct use of the equipment helps you avoid damage, and minimise wear-and-tear.

Concrete Construction Stage Project Close-out Stage

Optimum resource utilisationwith assistance from the Doka Formwork Experts

Seeing things through to a posi-tive conclusionwith professional support

Workflow optimisation, thanks to thorough utilisation planning internationally experienced pro-

ject technicians appropriate transport logistics on-site support

Doka Services are a byword for transparency and efficiency here, offering jointly handled return of rented

formwork professional dismantling efficient cleaning and recondition-

ing using special equipment

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System overview

Doka large-area formwork Top 50 - for any shape and any loadThe Doka large-area formwork Top 50 is designed to be tailored to many very diverse types of task - so it gives you ideal scope for adapting the shapes and sizes of the elements to suit your structure.The element size-grid and tie-hole pattern provide the adaptability needed to accommodate architectural

demands. The large-area elements and exact connec-tions make for a perfect joint pattern.You can choose whichever form-face material best meets your requirements - e.g. for smooth fair-faced concrete, wood-textured surfaces, intensive re-use etc.A range of practical accessories makes work on the site a lot easier and does away with the need for costly in-situ improvisations.Doka will plan the most economical solution for you. Also, having your formwork pre-assembled by the Doka "Ready-to-Use Service" saves time and space on site.

A Tie-rod system (Page 16)B Inter-element connections (Page 18)C Length adjustment (Page 20)D 90 degree corners (Page 23)E Acute and obtuse-angled corners (Page 26)F Stop-end formwork (Page 28)G Plumbing accessories (Page 36)H Pouring platforms (Page 40)I Resetting by crane (Page 51)J Element assembly (Page 108)K Ladder system (Page 46)

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User information Large-area formwork Top 50 Wall formwork

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Wall formwork

Instructions for assembly and useThe sequence shown here is based on a straight wall. However, you should always start to form from the cor-ner outwards.Ladders must be located so as to create viable "traffic routes" in the horizontal. (On a straight wall, for exam-ple, one ladder on the first element and another on the last).

Pre-assembly Pre-assemble the elements face-down on an

assembly bench (see "Element assembly").

Mount the platforms to the face-down element (see "Pouring-platforms with single brackets").

Mount the ladder system to the face-down element (see "Ladder system").

Mount panel struts to the face-down element (see "Plumbing accessories").

Erecting the formwork Attach the crane suspension tackle to the lifting-

brackets (see "Lifting by crane").

Pick up the element by crane. Spray the ply with release agent (see "Cleaning and

care").

Fly the element to its new location.

Fix the panel struts firmly to the ground (see "Plumb-ing accessories").

Mount the top guard-rail board.

The element is now stable and can be plumbed and aligned exactly, with no need for the crane.

Detach the element from the crane. Continue lining up elements in this way, and link

them together (see "Inter-element connections").

Wall formwork

Preconditions for use:

Platforms and all accessories must only be mounted to the element when this is face-down on the ground.

It must be possible for all formwork set-up, pouring and stripping operations to be carried out from safe workplaces.

The professionals from the Doka "Ready-to-Use Service" plan and assemble site-ready and custom formworks exactly to your speci-fications.

A PlatformB Ladder systemC Panel strut

Max. load:1300 kg per lifting-bracket

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CAUTIONNever use a sledge-hammer to plumb and align the elements!This would damage the elements. Use only proper plumbing tools (e.g. a spe-

cial pry-bar) that cannot cause any damage.

WARNINGThere is not yet an opposing guard-rail on the formwork!Danger to life from fatal falls! Either use personal protective equipment to

protect against falls (e.g. Doka safety har-ness)ormount an opposing guard-rail to the element while this is still being pre-assembled in a flat position.

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Wall formwork User information Large-area formwork Top 50


Erecting the opposing formwork:Once the reinforcement has been placed, the form-work can be closed. Spray the ply with release agent (see "Cleaning and

care"). Lift the opposing formwork by crane to its next loca-

tion.

Working from the ground, insert the bottom rows of form-ties (see "Form-tie system").

Detach the element from the crane. Insert the remaining form-ties. These form-tie loca-

tions can be reached from the platforms. Continue lining up elements in this way, and link

them together (see "Inter-element connections").

Pouring

Pour the concrete. Make only moderate use of vibrators, carefully co-

ordinating the times and locations of vibrator use.

WARNINGThere is not yet an opposing guard-rail on the formwork!Danger to life from fatal falls! Use personal fall arrest systems to protect

against falls (e.g. Doka safety harness).

Before disconnecting from the crane: If there are no panel struts on the opposing

formwork, do not disconnect the element from the crane until a large enough number of form-ties have been installed to keep it safely in the upright.

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Do not exceed the maximum permissible rate of placing. See also "Concrete pressure on perpendicu-

lar formwork to DIN 18218" in the Doka Cal-culation Guide.

Max. pressure of the fresh concrete: Depends on structural design of elements - see also project plan

Concrete compaction by vibration must com-ply with DIN 4235 Part 2.

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Striking

Remove any loose items from the formwork and plat-forms, or secure them firmly.

Begin work on striking the formwork on the oppos-ing formwork: Undo the connectors to the adjacent elements.

Take out the form-ties from the top rows of ties. These form-tie locations can be reached from the platforms.

Attach the element (incl. platforms) to the crane. Working from the ground, take out the bottom rows

of form-ties.

Lift the element away and to its next location, or place it face-down for intermediate storage.

Clean residual concrete off the formwork sheet (see "Cleaning and care").

Where the element has panel struts attached to it, first attach this element to the crane, and only then detach the floor anchorages of the panel struts.

Observe the stipulated striking times.

WARNING There must be at least as many form-ties left

in place as are needed to keep the element safely in the upright.

WARNINGThe formwork tends to adhere to the concrete. When stripping the formwork, do not try to break concrete cohesion using the crane!Risk of crane overload. Use suitable tools such as timber wedges or

a special pry-bar to detach the formwork from the concrete.

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WARNINGThere is not yet an opposing guard-rail on the formwork!Danger to life from fatal falls! Use personal fall arrest systems to protect

against falls (e.g. Doka safety harness).

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Top 50 element in detail

Form-ply No restrictions on what form-ply you choose - e.g. for

smooth fair-faced concrete, wood-textured surfaces, repetitive re-use etc.

The sheets are quick and easy to change Custom versions possible with profiled timber form-

ers, open formwork and tongue-and-groove form-work

Steel walings (multipurpose wal-ings) hold the Doka H 20 beams in place and give the ele-

ment rigidity sustain the forces from the form-ties make the elements easy to join, using plates and

connecting pins

Doka beam H20 topInnovative end-reinforcement: reduces damage to the ends of the beams greatly lengthens the service life

Fastening the beams

See "Element assembly" for alternative ways of fixing the Doka beams.

Crane slinging by mounting a lifting-bracket and a top plank (pres-

sure bracing); see the section headed 'Element assembly'.

Tie-holes can be located anywhere along the middle of the

waling between the Doka beams

Follow the directions in the "Formwork sheet-ing" User Information booklet!

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a ... 8 cmb ... 20 cm

Follow the directions in the "Timber formwork beams" User Information booklet!

Flange-clamp H20 Beam screw

Where more frequent alterations are needed

Can be mounted any-where on the waling

For bolting the Doka beams directly onto the waling

Can be mounted any-where on the waling

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Flexibility

SizeTop 50 elements can be assembled in widths of up to 6 m and in heights of up to 12 m.

Pressure of fresh concreteDepending on the concrete pressure required, the Doka beams and the walings are spaced closer together or further apart. This ensures optimum form-work design and the greatest economy of materials.For more information on structural design of Top 50 elements, see "Structural design".

SurfaceAny type of form-face can be used, as required: Doka formwork sheets 3-SO Dokaplex formwork sheets Doka textured formwork sheets Xlife sheets Tongue-and-groove board formwork etc.The tie-hole pattern and the element size-grid are eas-ily adapted to suit architectural demands. The large-area elements and exact connections deliver perfect joint patterns.

ShapeCreating complex concrete shapes demands a high degree of formwork flexibility. On the large-area form-work Top 50, this is achieved by the use of profiled tim-ber formers.

e.g. concrete pressure 40 kN/m2

e.g. concrete pressure 90 kN/m2

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Tie-rod system

For correct positioning of the form-ties, see "Top 50 elements" and/or the relevant project plan.Doka also offers economical solutions for creating watertight wall-ties.

Form-tie system 15.0

As an alternative to the plastic tube with universal cone, there is also a distance piece designed as an all-in-one form-tie distance tube.

The plugs for sealing the ends of each distance piece are supplied along with it.

WARNINGSensitive rod steel! Never weld or heat tie-rods. Tie rods that are damaged or have been

weakened by corrosion or wear must be withdrawn from use.

Only use approved tie-rods.

Allow for elongation of long or coupled tie-rods (see the Calculation Guide 'Doka formwork engineering')!

Spanner for tie-rod 15.0/20.0For turning and holding the tie-rods.

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A Top 50 elementB Tie-rod 15.0C Super-plate 15.0D Plastic tube 22mmE Universal cone 22mm

The "Plastic tubes 22mm" left behind in the concrete are sealed off with Plugs 22mm.

A Top 50 elementB Tie-rod 15.0C Super-plate 15.0D Distance piece (ready-to-use for certain wall thicknesses)

Tie-rod 15.0mm:Permitted capacity, allowing a 1.6 : 1 factor of safety against failure: 120 kNPermitted capacity to DIN 18216: 90 kN

The friction-type ratchet SW27 or Box spanner 27 0.65m can be used for low-noise releasing and tightening of the following anchoring com-ponents: Super-plates 15.0 Wing nuts 15.0 Star grip nuts 15.0

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Form-ply protectionThe Form-ply protector 22mm protects the form-ply from damage at form-tie points. This is a particular advantage for formwork with high numbers of repeat uses.Possible thicknesses of form-ply: 18 - 27 mmIn order to fit the form-ply protector, a 30 mm diameter hole must be drilled in the form-ply first.If necessary, the form-ply protector fitted into the form-ply can be closed off with the Framax plug R20/25.

Form-tie system 20.0

Operating the form-tie from one sideThe Top50 form-tie nut 15.0 or Top100 tec form-tie nut 20.0 makes it possible to operate the form-tie from one end of the tie (e.g. where space is tight).Suitable for U100, U120 and U140 walings with a 50 mm waling-gap.The form-tie nut has an integrated stopper plate for the tie-rod.

b ... 10 cm

How to mount: Hook the form-tie nut onto the waling and clamp it on

firmly with the integrated star-grip nut. Screw in the tie-rod of the opposing formwork as far

as the stopper plate. Fix the form-tie with the super-plate.

A Form-ply protector 22mm (width-across 46 mm)B Universal cone 22mmC Plastic tube 22mmD Form-plyE Tie-rod 15.0mm

A Top 50 elementB Tie-rod 20.0C Super-plate 20.0 BD Plastic tube 26mmE Universal cone 26mm

Tie-rod 20.0mm:Permitted capacity, allowing a 1.6 : 1 factor of safety against failure: 220 kNPermitted capacity to DIN 18216: 150 kN

The "Plastic tubes 26mm" left behind in the concrete are sealed off with "Plugs 26mm".

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D

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K Notch for aligning the form-tie nutL Stopper plate for tie-rod

A Form-tie nutB Multipurpose walingC Tie-rodD Super-plateE Universal coneF Plastic tube

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Inter-panel connections

The elements are linked and aligned horizontally using Formwork element connectors FF20/50 Z and Con-necting pins 10cm: fast, tension-proof joints between elements additionally, the inter-element joint can be pulled

tight in 2 stages insensitive to soiling only tool needed is a hammer

The 3 zones of the Connecting pin 10cm:

To fit normally

To pull tight half the way

To pull tight all the way

Note:Only pull tight where there actually is a gap to close!

Other possible types of inter-ele-ment connection Splice plate Top50 Z - with pull-tight function Formwork element connector FF20/50 - without pull-

tight function Anchoring plate FF20/50 - without pull-tight function

(for details of how to use on inside corners, see "90 degree corners")

Splice plate with join adjustment - with pull-tight function (5 mm and 1.5 mm)

For more information, please contact your Doka techni-cian.

Section modulus: 21.6 cm3Moment of inertia: 97.2 cm4

A Head: (hammer)B Shank: (hold)C Cone: (pull tight)

When the connecting pin is used in a horizontal position, secure it with a Spring cotter 5mm.

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Examples of the system in action

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Length adjustment using closures

Adjustable waling extensions are used for obtaining tension-proof and slippage-free links between the Top 50 elements.

For closures of up to 50 cm

with Adjustable waling extension FF20/50 and formwork sheeting in the infill zone

Up to 23 cm

23 - 50 cm

When connecting short elements to the clo-sure zone, watch out for possible collisions between the Adjustable waling extensions and the Formwork element connectors.

Adjustable waling extension FF20/50 and 1.40m Top50:Section modulus: 21.6 cm3Moment of inertia: 97.2 cm4

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A Doka beam H20B Doka formwork sheetC Nailed-on timber stud to add support to the infillD Adjustable waling extension FF20/50E Beam clamp Top50F Connecting pin 10cm

A Adjustable waling extension FF20/50B Where statically necessary - place a tie through the closure.

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Determining the pin-fixing positions

Note:Only the pin-fixing position on the 1st element needs to be determined. After the 2nd element has been aligned, all the other pin-fixing positions will automatically be apparent.

Example: Closure needed: 264 mmResult: - pin-holes in waling: D and E or E and F- pin-holes in Adjustable waling extension: 3 and 6

Closure Pin-holes in walings [mm] A B C D E F

0 2 8

73 6

3 6

141 7

1 721 2 8

293 6

3 636 1 7

432 8

2 8

503 6

3 657 1 764 2 871 3 6

791 7

1 7

862 8

2 893 3 6

100 1 7107 2 5

1143 6

3 6

1211 7

1 7128 2 5136 3 6143 1 4

1502 5

2 8

1573 6

3 6164 1 4171 2 5178 3 6

1861 4

1 7

1932 5

2 8200 3 6207 1 4214 2 5

2213 6

3 6

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A B C D E F

6 7 812 34 5

2281 4

1 7235 2 5243 3 6250 1 4257 2 8

2643 6

3 6271 1 4278 2 5285 3 6293 1 7300 2 8314 1 4321 2 5328 3 6335 1 7357 1 4364 2 5371 3 6400 1 4407 2 5442 1 4

Closure Pin-holes in walings [mm] A B C D E F

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For closures of 50 - 64 cm

with Adjustable waling extension 1.40m Top50 and formwork sheeting in the infill zone

Beam clamp Top50For fastening the Doka beams H20 to the Adjustable waling extensions. The beam clamp is held in place by a Connecting pin 10cm.

Determining the pin-fixing positions

Note:Only the pin-fixing position on the 1st element needs to be determined. After the 2nd element has been aligned, all the other pin-fixing positions will automatically be apparent.

A Adjustable waling extension 1.40m Top50B Where statically necessary - place a tie through the closure.

A Beam clamp Top50B Connecting pin 10cmC Adjustable waling extension

9732-255-01

A B

9732

-215

-01

C

A

B

Closure Pin-holes in waling Closure Pin-holes in walings [mm] A B C s [mm] A B C

0 5 210 22 4 212 13 4 213 55 3 216 49 2 219 3

12 1 220 313 1 223 216 4 225 519 3 229 422 2 230 423 2 233 325 1 236 229 4 239 130 4 240 532 3 243 433 3 246 336 2 249 239 5 250 240 5 253 542 4 256 443 4 259 346 3 260 349 2 263 252 5 265 553 5 270 456 4 273 359 3 276 260 3 279 162 2 280 563 2 283 466 5 285 369 4 289 270 4 290 272 3 293 573 3 296 476 2 300 379 5 303 280 5 306 582 4 310 483 4 313 385 3 316 289 2 319 190 2 320 592 5 323 493 5 325 396 4 330 2

9732-565-01

s

A B C A B C

12345 12345


23999732002 - 10/2012


Example: Closure needed: 433 mmResult: - Pin-holes in waling: 2x 'C'- pin-holes in Adjustable waling extension: 2x '3'

99 3 333 5100 3 336 4102 2 340 3103 2 343 2106 5 345 1109 4 350 4110 4 353 3112 3 356 2113 3 360 5116 2 363 4119 5 366 3120 5 370 2122 4 373 5123 4 380 3126 3 383 2129 2 386 1130 2 390 4132 1 393 3133 5 396 2136 4 400 5139 3 403 4140 3 410 2142 2 415 5143 2 420 3146 5 423 2149 4 426 1150 4 430 4152 3 433 3153 3 440 4156 2 443 4159 5 450 2160 5 453 1163 4 460 3166 3 463 2169 2 470 4170 2 473 3172 1 480 5173 5 490 2176 4 493 1179 3 500 3180 3 503 2182 2 510 4183 2 520 5185 5 530 2189 4 533 1190 4 540 3193 3 550 4196 2 560 1199 5 570 2200 5 580 3203 4 600 1206 3 610 2209 2 640 1

Closure Pin-holes in waling Closure Pin-holes in walings [mm] A B C s [mm] A B C

9732-565-02

A B C A B C

1 2 3 4 5 1 2 3 4 5

24 999732002 - 10/2012



For closures of 3 - 11 cm

with Adjustable waling extension FF20/50 and Joint plate in the infill zoneAvailable in heights of 3.0 and 4.0 m, the Joint plates can be placed on top of one another where needed.

To make the formwork easier to strip: Approx. 2 hours after pouring, loosen the Joint plate and pull it out a short way by crane.

A Joint plateB Adjustable waling extension FF20/50

9732

-216

-01

9732-256-01

B

A


25999732002 - 10/2012


Height adjustment

using "Height adjuster for formwork beams"The "Height adjuster for formwork beams" is used for vertical adjustment of upright Top 50 elements, e.g. on shafts.

Adjusting range a: max. 24.5 cm

Ways of operating: Box nut 50 3/4" and Reversible ratchet 3/4" (with

lengthening-piece if needed) Tie-rod 15.0mm or round steel bar (max. diam.

17 mm)There are holes in the hexagonal nut of the spindle for inserting a tie-rod.

For custom applications, the footplate can also be fixed on e.g multipurpose walings.

using Height adjuster WS10-WU16The Height adjuster WS10-WU16 is used for vertical adjustment of timber-beam formwork elements used in the horizontal.

Adjusting range a: max. 24.5 cm

Ways of operating: Box nut 50 3/4" and Reversible ratchet 3/4" (with

lengthening-piece if needed) Tie-rod 15.0mm or round steel bar (max. diam.

17 mm)There are holes in the hexagonal nut of the spindle for inserting a tie-rod.

using Adjusting spindle M36The Adjusting spindle M36 is used for vertical adjust-ment of horizontal Top 50 elements.

Adjusting range a: max. 22 cm

Ways of operating: Box nut 24 and Reversible ratchet 1/2"

A Height adjuster for formwork beams (incl. nuts & bolts etc.)

B Doka beamC Stiffening board between 2 adjacent beams (site-provided)D Sliding plate (site-provided)

Max. load: 1000 kg

When using the height adjuster on shaft form-work, ensure that the platform decking is ade-quately dimensioned, as the loads act on the decking in a concentrated manner via the spin-dles!Elements can be moved and relocated more easily using sliding plates.

Tr62

0-20

0-06

A

B

C

D

a

A Height adjuster WS10-WU16B Connecting pin 10cm and Spring cotter 5mmC Multipurpose waling

Max. load: 3000 kg

A Adjusting spindle M36 (incl. nuts & bolts etc)B Multi-purpose walingC Steel plate (site-provided), e.g. 150x100x10 mm

Max. load: 1000 kg

a

C

A

Tr69

7-20

0-01

B

Tr69

7-20

1-01

C

A

B

a

26 999732002 - 10/2012



90 degree corners

Outside cornersThe elements are clamped together with the Universal angle tie bracket and Tie-rods 15.0.

a ... 23 - 64

The flange reinforcement prevents the flange of the beam breaking when exposed to high oblique pull from the tie-rod.

9732

-217

-01

A Universal angle tie bracketB Tie-rod 15.0C Wing nut 15.0D Connecting pin 10cmE Flange reinforcementF Plank

CAUTIONRisk of tie overload if not correctly positioned! Make sure that the Universal angle tie

bracket is bolted into the right holes for the Multipurpose waling WS10 Top50 or WU12 Top50, depending on which type of waling is being used!

Bolting holes for Multi-purpose waling WS10 Top50

Bolting holes for Multi-purpose waling WU12 Top50

E Fit 2 flange reinforcements (strips of formwork sheeting) between the flanges of the outside beam, so that the form-ply of the second corner element is supported.

9732-257-01

E

A

C

B

D

9732-258-01

F

A

C

B

D

9732-381-02 9732-381-01

9732

-299

-01

E


27999732002 - 10/2012


Inside corners

with Corner waling 20With the Corner waling 20, it is possible to make a gen-uine inside-corner element. The Doka beams give the element the necessary rigidity, and also ensure dimen-sional accuracy.The adjacent Top 50 elements are fastened with the normal connector components.

Tying in the Corner waling 20Corner walings 20 manufactured from 2010 onwards can also be tied using the Eye-lug tie rod 15.0.

with Internal angle plate H20 Top50An economical way of making inside corners with a closure function. (For closures of up to 32 cm in 1 cm increments)By nailing a form-ply to the end face of standard ele-ments, these are turned into corner elements. The con-crete pressure on the end face is transferred by means of reinforcements (e.g. Fastening plate) on the edge beam.

See "Element assembly" for more information on how to mount the inside corner.

Formwork sheet Corner dimension [A]21mm 54.9 cm27mm 55.5 cm

A Where statically necessary - place a tie through the Corner wal-ing 20.

B Anchoring plate FF20/50C Formwork element connector FF20/50 ZD Eye-lug tie rod 15.0E Tie-rod 15.0

Max. load on tie-rod: 70 kN

9732

-263

-01

A

A

A

9732-409-02

B C

D

E

When connecting the Corner waling 20 to adjacent elements, please remember:If the Adjustable waling extension (A) reaches a long way into the Corner waling 20, no Form-work element connector FF20 Z may be used on the 2nd leg. Because of the "pull-tight function hole-grid", it is not possible to mount the Formwork element connector FF20 Z one hole-grid further along.In this case, use an Anchoring plate FF20/50 instead.

A Adjustable waling extensionB Anchoring plate FF20/50

9732-261-01

B

A

9732

-259

-01

28 999732002 - 10/2012



with Corner plate H20/H36 Top50Same function as Internal angle plate H20 Top50, but without the closure function.

with Shaft corner waling WS10 Top50The Shaft corner waling WS10 Top50 is a 90-welded steel waling used for making sturdy corner elements. This special waling is custom-built on a project-specific basis.The Shaft corner waling is often used for shaft form-work (see "Shaft formwork").

T-junction

with Corner waling 20The Corner waling 20 allows the form-ties to cross over in the corner zone. This avoids an excessively wide spacing a between the form-ties on the opposing ele-ment.

The Offset plate FF20/50 makes it possible to arrange Multipurpose walings WS10 Top50 in parallel, as a means of reinforcing T-junctions.

9732

-408

-01

9732

-260

-01

A Corner waling 20

A Offset plate FF20/50B Connecting pin 10cmC Multi-purpose waling

9732

-264

-01

A A

a

TR594-201-01

ABC


29999732002 - 10/2012


Corner connections Rounded surfaces in corner zones

using Offset plate FF20/50The Offset plate FF20/50 makes it possible to arrange Multipurpose walings WS10 Top50 in parallel, for form-ing large rounded surfaces in corner zones.

a ... 10.2 cm

A In-situ support

On short walls (with high horizontal forces), shoring/tension anchoring is required to restrain the formwork.

9732-262-01

A

A Offset plate FF20/50B Connecting pin 10cmC Multi-purpose waling

9732

-390

-01

a

A

B

A

C

30 999732002 - 10/2012



Acute & obtuse-angled cornersFor non-right-angled corners, too, the standard compo-nents of the Large-area formwork Top 50 will always provide an optimum solution.

Outside cornersIn a similar way to the right-angled corners, on outside corners the elements are also mainly connected using Universal angle tie brackets.

Inside corners

with Articulated connecting plate A Top50 ..... Can be used on walings of 0.75 m and longer Makes it possible to set two steel walings at any

angle (in a range between 61 and 299) Can be used over and over again

If there are no planned moments that need to be trans-ferred by the connecting plate (i.e. if it is being used as an ordinary user-adjustable form connector), it is suffi-cient to tighten the threaded joint using ordinary tools such as the Reversible ratchet 3/4".In order to achieve the stability required when the form-work is being lifted, a force of approx. 400 N should be applied to the approx. 75 cm long lever arm of a "Reversible ratchet 3/4" (to give a tightening torque of approx. 300 Nm).When used in this way as an ordinary user-adjustable form connector, it is not necessary to insert a new alu-minium locking ring. The hexagonal bolt M30x90 and the nut of the connection must always be greased before being tightened.

with Half splice plateHalf splice plates are used for fabricating low-cost cor-ner plates, with any angle, directly on the site.To make a corner plate in this way, two Half splice plates are needed. After the formwork has been plumbed at the prescribed angle, these two plates must be welded firmly together.

A Articulated connecting plate A Top50 ..... B Connecting pin 10cmC Multi-purpose walingD Universal angle tie bracket

Permitted load:The Articulated connecting plate A Top50 ..... is designed to transfer a permitted bending moment of 9 kNm. If tensile forces (e.g. ring tensile forces) are to be transferred at the same time, the moment load must be reduced accordingly.

Per

mitt

ed b

endi

ng m

omen

t [kN

m]

Permitted normal force [kN]

9732-266-01

A

B

C

D

9732-100

10

8

6

4

2

00 20 40 60 80 100 120

Important note: When the angle is re-set, a new Aluminium locking ring (art.n 50 0208 020) has to be fitted.

The angle can only be set at the Doka Cen-tral Plant in Amstetten, Austria.

The user is responsible for the integrity of the welded joint!

A Half splice plateB Connecting pin 10cmC Multi-purpose walingD Universal angle tie bracketE Weld-seam

9732-265-01

A

E

D

B

C


31999732002 - 10/2012


with Swivel joint plateThe Swivel joint plate is an alternative to using two Half splice plates welded onto one another. Angles of between 45 and 180 are possible. Rough adjustment is carried out in 35.7 mm incre-

ments (= 1/3 of the hole-grid of the Multipurpose wal-ing).

Fine adjustment is carried out using the integral adjusting thread, with a max. theoretical formwork deviation of 2.5 mm.

Use suitable sealing tapes on any gaps which occur at joints.

Dimensioning diagram

Angular waling WS10 Top50The Angular waling is a welded steel waling used for making strong corner elements. The legs are rigidly fixed at any desired angle other than 90.This special waling is custom-built on a project-specific basis.

A Swivel joint plateB Connecting pin 10cmC Multi-purpose walingD Universal angle tie bracket

Per

mitt

ed fo

rce

N [k

N]

Angle

A

98005-226-01

B

C

D

N

N

45

40

35

30

25

20

15

10

5

00 20 40 60 80 100 120 140 160 180 200

Tr74

4-10

0-01

45 90 135

155

180

A Angular waling WS10 Top50B Connecting pin 10cmC Multi-purpose walingD Universal angle tie bracketE Splice plate

9732-267-01

ABC E

9732-268-01D

ABC E

32 999732002 - 10/2012



Stop-end formwork

The Large-area formwork Top 50 is a complete form-work system. As such, it also offers practical solutions for e.g. the stop-end formwork.

Walls up to approx. 20 cm thickPlanks are simply nailed onto the Top 50 element and a strip of formwork sheeting is inserted.

Walls thicker than approx. 20 cmThe Anchoring plate FF 20/50 ensures that the loads are safely transferred into the waling system of the Top 50 elements.

The tie rods are screwed into the Anchoring plate, and the correct spacing of the stop-end element is adjusted using the Super plate 15.0.

A PlanksB Strip of formwork sheeting

9732

-218

-01

9732-270-01

B

A

Maximum permitted load where 2 Connecting pins 10cm are used: 56 kNSection modulus: 21.6 cm3Moment of inertia: 97.2 cm4

A Anchoring plate FF20/50B Connecting pin 10cmC Super-plate 15.0D Tie-rod 15.0E Doka beamF Nailed-on plankG Multi-purpose walingH Strip of formwork sheeting

The Anchoring plate FF20/50 can also be used as a normal element connector (no pull-tight function).

Combining a Corner connecting plate 90/50 with an Anchoring plate makes it possible to lift the stop-end element jointly with the wall ele-ment.Anchoring plates are used on one side, and Corner connecting plates on the other.

9732-269-01

AC

B

E

D

F

G

H


33999732002 - 10/2012


Vertical stacking of elementsThe vertical-stacking methods shown here are only suitable for: lifting setting down and crane-handlingthe formwork.

with Stacking plate H20The Stacking plate H20 serves as a bolt-on longitudinal connector for Doka beams, and is used for vertical stacking of formwork elements. The plate is bolted onto the beams through the pre-drilled holes at either end of the beam.

a ... min. 40 cm

The number of Stacking plates H20 needed will depend on the overall height of the gang-form: Up to an overall height of 6.0m: A Stacking plate

H20 must be fastened to every other beam. Up to an overall height of 8.0m: A Stacking plate

H20 must be fastened to every beam.In addition, it is advisable to place extra multipurpose walings across the horizontal joins, in order to achieve greater stability.

Over 8.0 m, up to a max. overall height of 14.0 m: A Stacking plate H20 must be fastened to every beam.In addition, it is absolutely essential to place extra multipurpose walings across the horizontal joins, in order to achieve sufficient stability.

Included in scope of supply: 4 hexagonal bolts M20x70 (width-across 30 mm) 4 hexagon nuts M20 4 spring washers A20

Note:Make sure that the bolted connections are tightened firmly!

with board-platesAn in-situ solution that often works well in practice. The existing holes at the end of the beam can be used for making the bolted connections.

Items needed for each beam join:

*) It is also possible to use strips of 3-SO 21 or 27 mm formwork sheet instead of the planks.

Important note:The vertical stacking joint must not be exposed to loads from concrete pressure or concrete weight. This means: that the cantilever arms at the beam-joints

must be as short and symmetrical as possi-ble,

or that users must take all statically required measures (e.g. extra waling level).

Permitted moment: where outermost hole is 9 cm from edge of beam:

2.0 kNm where outermost hole is 5 cm from edge of beam:

1.5 kNm

9772

-201

-01

a

a ... 22.4 cm b ... 18.0 cm c ... 11.5 cm

d ... min. 80.0 cm

Permitted moment: 0.7 kNm

Plank*) 115/25, lmin = 80.0 cm 2 pcs.Hexagonal bolt M20x110 4 pcs.Hexagon nut M20 4 pcs.Washer 22 4 pcs.

9732

-273

-01

d

aa

b

c

9732

-274

-01

34 999732002 - 10/2012



Shaft formwork

Shaft formwork with Stripping cor-ner I and Transition plateWith the Stripping corner I, the entire shaft formwork unit is detached from the wall, in one piece, before being lifted and reset by crane.Product features: No negative impression in the concrete. Formwork set-up and stripping function integrated in

the inside corner (no need for crane uses stripping spindles).

Entire shaft formwork unit is lifted and reset in one piece (with lifting-brackets and four-part lifting chain).

Two different types of stripping spindle can be used for setting up and stripping the formwork: Framax stripping spindle I with ratchet Framax stripping spindle IThe Transition plate makes it possible to use the Framax stripping corner I with Large-area formwork Top 50.

Vertical stacking of Framax stripping corners I1) Pull out the coupling bolt.2) Manoeuvre the Stripping corner I into place so that

it is flush with the one below it.3) Push the coupling bolt back in.4) Bolt the Stripping corners I together with 2 hexago-

nal bolts M16x45.

Mounting the Framax stripping spindles IThese mounting instructions apply to both Stripping spindles I and Stripping spindles I with ratchet.1) Pull out the U-bolt from the stripping spindle.2) Place the stripping spindle on the centering stud of

the stripping corner.3) Twist the stripping spindle clockwise until fully

engaged.4) Position the ratchet or spindle nut between the

holes in the push-rod.5) Fix the stripping spindle with the U-bolt.

Operating the Framax stripping spindle I with ratchet Screw a Tie-rod 15.0mm into the Weldable coupler

15.0 of the ratchet. Setting up:

- shift the change-over lever into the "L" position- turn the ratchet clockwise

Stripping: - shift the change-over lever into the "R" position- turn the ratchet anti-clockwise.

A Coupling boltB Stripping corner IC Hexagonal bolt M16x45

9764

-281

-01

A

B

C

A Framax stripping spindle I or Framax stripping spindle I with ratchet

B U-boltC Centering stud of stripping cornerD Ratchet or spindle nutE Push-rod

A Tie-rod 15.0mmB Weldable coupler 15.0C RatchetD Change-over lever

Tr750-202-01

A

C

B

E

1

2

Tr750-203-01

D

5

3

Tr750-203-02

B

Tr70

6-20

2-01

A

D

C


35999732002 - 10/2012


Operating the Framax stripping spindle I Push a Tie-rod 15.0mm through one of the holes in

the spindle nut. Setting up: Twist the spindle nut clockwise. Stripping: Twist the spindle nut anti-clockwise.

Adjustment range of Transition plate

a ... 42.5 - 55.0 cmb ... Adjusting range 12.5 cm, in 2.5 cm increments

Possible sizes of shaft

Connections

Supporting the plywood face

Max. spacing c [cm] between 2 transition plates (form-ply not supported by Framax moulded timber or squared timber)

Number of quick-acting clamps RU needed (form-ply supported by Framax moulded timber or squared timber)

A Tie-rod 15.0mmB Spindle nut

A Multi-purpose walingB Transition plate 18mm or 21mmC Connecting pin 10cm and Spring cotter 5mmD Framax stripping corner IE Quick-acting clamp RU

Length of WS10 Top50 waling [cm]

Width of shaftmin. [cm] max. [cm]

75 160 185100 185 210125 210 235150 235 260175 260 285200 285 310225 310 335250 335 360275 360 385300 385 410

Tr75

0-20

4-01

BA

Tr709-201-01

b

a

E

DBA C

D Framax quick-acting clamp RUE Connecting pin 10 cm with spring cotterF Framax screws (not included in scope of supply)

In order to obtain the full available stripping-play, make sure that the Framax quick-acting clamps RU are mounted at staggered heights (i.e. not opposite one another).

Permitted formwork pressure[kN/m2]

Formwork sheet 30 40 50 60 703-ply sheet 21mm 15 10 10 -- --Multi-ply sheet 18mm 40 30 25 20 15Multi-ply sheet 21mm 50 40 35 30 25

Spacing c [cm] N of quick-acting clamps RUMax. 30 1Max. 60 2Max. 90 3

A Transition plateB Framax quick-acting clamp RUC Moulded timber or squared timber

D

E

F

Tr70

9-20

1-04

Tr70

9-20

1-02

c

A

C

B

36 999732002 - 10/2012



Shaft formwork closed ready for pour

Form-tie zones:

x ... 16.5 - 22.0 cm

Shaft formwork stripped ready for lifting

Stripping play:

a ... 3.0 cmb ... 6.0 cm

Important note: Only tie through the waling.It is not permitted to tie through the Transition plate.

The outside and inside formwork must be dimensioned in line with the structural-design requirements for the Large-area formwork Top 50 and a permitted waling load of 90 kN/m!

9732-391-01

9732-391-02

x

9732-392-01

9732

-392

-02

a

b


37999732002 - 10/2012


Resetting by crane

... max. 15

Shaft formwork with Corner spindle, Shaft waling squaring plate and Inside corner plate

For inside formwork in narrow cross-sections (e.g. lift shafts, stairwells etc.), the Corner spindle, Shaft waling squaring plate and Inside corner platecan be used to enable rapid striking of the formwork and lifting of the complete shaft formwork, in one piece.

a ... 6 cm b ... 10 cm

The elements of the inside formwork incorporate: Shaft corner walings or Multipurpose walings with Corner walings 20

A Lifting-bracketB Four-part lifting chain

The crane hook on the Stripping corner I is not allowed to be used for lifting the shaft form-work. The shaft formwork must only be lifted

using lifting-brackets, or in one piece with the shaft platform.

Permitted weight of the shaft formwork:4000 kg with 4 lifting-bracketsReason: 15 oblique pull in both directions

9785-202-01

A

B

A Corner spindleB Shaft waling squaring plateC Connecting pin 10cmD Inside corner plateE Form-tie

9732-291-01

9732-293-01E

D

A

a

b

B

C

38 999732002 - 10/2012



Striking the formwork

Loosen the form-ties on one half of the formwork. Remove the form-ties from the other half of the form-

work. Remove all 4 connecting pins from the Shaft waling

squaring plates. Loosen the Corner spindles and Inside corner plates. Pull out the Inside corner plates by crane. Use the Corner spindles to pull the Inside formwork

approx. 2 - 3 cm together. Remove the remaining form-ties. Use the Corner spindles to pull the Inside formwork

approx. 2 - 3 cm further together. Lift and reposition the entire inside formwork.

Resetting by craneUse suitably long lifting-chains or 3 two-part lifting chains in order to avoid oblique pull (depending on the size of the shaft).

If there is too much oblique pull, a stiffening reinforce-ment will be needed.For further information, see the section headed "Reset-ting by crane".

Doka shaft platformWith its telescopic shaft beams, this platform can accommodate any dimension of structure. The inside formwork can be "parked" on the platform and reposi-tioned together with the platform.

To make the formwork easier to strip: Approx. 2 hours after pouring, loosen the Inside corner plate and pull it out a short way by crane.

9732-292-01

9732-294-01

9727

-358

-01

Follow the directions in the "Doka shaft plat-form" User Information booklet.


39999732002 - 10/2012


Circular formworkCurved structures can be formed with Half splice plates or Swivel joint plates. For more detailed information on these plates, see the section headed "Acute and obtuse-angled corners".Profiled timber formers are placed between the Doka beams and the form-ply to provide the desired shape.

Minimum bending radii of Doka formwork sheets:

with Half splice plate

Example - formwork for a circular tank

with Swivel joint plate

Formwork sheet Grain direction of face layer Min. radius [m]

Dokaplex 9mmTransverse 2.0Longitudinal 3.5



Doka 3-SO 21mmTransverse 3.5Longitudinal 8.0

Doka 3-SO 27mmTransverse 5.0Longitudinal 10.0

Smaller radii can be achieved by cutting into the formwork sheets or by using strips of formwork sheeting.

A Half splice plateB Connecting pin 10cmC Profiled timber formerD Doka beamE Multi-purpose walingF Weld here after the formwork has been plumbed and aligned

9732-295-01

AB

CD

E

F

9732-296-01

A Swivel joint plateB Connecting pin 10cmC Profiled timber formerD Doka beamE Multi-purpose waling

A

98005-227-01

BE

C

D

40 999732002 - 10/2012



Plumbing accessories

Plumbing accessories brace the formwork against wind loads and make it easier to plumb and align.

Permitted spacings [m] of the plumbing accesso-ries:

The values apply where the wind pressure we = 0.65 kN/m2. This results in a dynamic pressure qp = 0.5 kN/m2 (102 km/h) where cp, net = 1.3. The greater wind loads encountered at exposed formwork-ends must be constructionally sustained by additional plumb-ing accessories (e.g. struts or pipe-braces). In cases where higher wind pressure is encountered, the num-ber of struts must be determined by statical calculation.

Note:Every gang-form must be supported by at least 2 plumbing accessories.

Example: Where the formwork height is 7.00 m, the fol-lowing are needed for every 8.00 m wide gang-form: 2 Panel struts 340 2 Eurex 60 550 / Adjustable plumbing struts

Possible ways of connecting to the multipurpose waling

Fixing to the ground Anchor the plumbing accessories in such a way as to

resist tensile and compressive forces!

Drilled holes in footplate

a ... diam. 26 mmb ... diam. 18 mmc ... diam. 28 mmd ... diam. 18 mme ... slotted hole diam. 18x38 mmf ... diam. 35 mm

Important note:The formwork panels must be held stable in every phase of the construction work!Please observe all applicable safety regula-tions!

CAUTIONThere is a risk of the formwork tipping over in high winds. If high wind speeds are likely, and when

work finishes for the day or before prolonged work-breaks, always take extra precautions to fix the formwork in place.

Suitable precautions:- set up the opposing formwork- place the formwork against a wall- anchor the formwork to the ground

Formwork height [m]Panel strut Eurex 60 550 /

Adjustable plumbing strut340 5403.00 4.004.00 3.005.00 3.006.00 2.007.00 4.00 4.008.00 3.00 4.00

9732

-219

-01

For more information, see the Calculation Guide "Wind loads to the Eurocodes" or ask your Doka technician!

Horizontal walingVertical waling

Option 1 Option 2

A Prop head EBB Connecting pin 10cm + Spring cotter 5mm

CAUTION Variant 1 is not allowed on Adjustable

plumbing struts!

Panel strut Eurex 60 550 Pipe brace

Anchor x2!

A

9729-280-01 9729-279-01

AB

9729-281-01

B A

a

9727-343-01

b

9745-214-01

cdd

9727-344-01

fe


41999732002 - 10/2012


Anchoring the footplateThe Doka Express anchor can be re-used many times over - the only tool needed for screwing it in is a ham-mer.

Panel struts

... approx. 60

A Doka Express anchor 16x125mmB Doka coil 16mm

Characteristic cube compressive strength of the con-crete (fck,cube): min. 25 N/mm2 or 250 kg/cm2 (C20/25 grade concrete)

Follow the Fitting Instructions!

Required safe working load of alternative anchors for foot-plates:Rd 20.3 kN (Fpermissible 13.5 kN)Follow the manufacturer's applicable fitting instruc-tions.

TR632-201-01

A

B

Product features: Can be telescoped in 8 cm increments Fine adjustment by screw-thread All parts are captively integrated - including the tel-

escopic tube (has safety stop to prevent dropout)

Panel strut 340 Panel strut 540

a ... 190.8 - 341.8 cmb ... 134.6 - 185.5 cm

a ... 310.5 - 549.2 cmb ... 228.1 - 277.2 cm

A Panel strut 340 IBB Panel strut 540 IBC Prop head EB

9732

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-01

a

b

A

C

C

9732

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-01

a

b

B

C

C

42 999732002 - 10/2012



Eurex 60 550 used as a shoring & plumbing accessoryAs the "Doka plumbing strut Eurex 60 550" - fitted with the appropriate accessories - this prop can also be used for shoring high wall formwork. Can be connected directly without modification to

Doka framed formwork and Doka timber-beam form-work

The "Adjusting strut 540 Eurex 60 IB" makes han-dling much easier, especially when the formwork is being transferred.

Can be telescoped in 10 cm increments, with contin-uous fine adjustment.

Example of a possible combination of Type 4

a ... 361.0 - 600.4 cm ... approx. 60

Follow the directions in the "Eurex 60 550" User Information!

Type

Ext

ensi

on le

ngth

L [m

]

Plu

mbi

ng s

trut E

urex

60

550

(A)

Ext

ensi

on E

urex

60

2.00

m (B

)

Cou

pler

Eur

ex 6

0 (C

)

Con

nect

or E

urex

60

IB (D

)

Plu

mbi

ng s

trut s

hoe

Eur

ex 6

0 EB

(E)

Adj

ustin

g st

rut 5

40 E

urex

60

IB (F

)

Pro

p he

ad E

B (G

)

Wei

ght [

kg]

1 3.79 - 5.89 1 1 1 1 2 91.12 5.79 - 7.89 1 1 1 1 1 2 112.43 7.79 - 9.89 1 2 1 1 1 2 133.74 7.22 - 11.42 2 1 1 1 1 2 142.55 9.22 - 13.42 2 1 1 1 1 1 2 163.8

9745-208-011 2 3 4 5

A Plumbing strut Eurex 60 550B Extension Eurex 60 2.00mC Coupler Eurex 60D Connector Eurex 60 IBE Plumbing strut shoe Eurex 60 EBF Adjusting strut 540 Eurex 60 IBG Prop head EB

A good rule of thumb here is:

The length of the shoring & plumbing accessory (i.e. the complete Eurex 60 550 plumbing-strut assembly) = the height of the element to be shored.

9732

-359

-01

a

G

D

A

C

A

E

FG


43999732002 - 10/2012


Adjustable plumbing strut

... approx. 60See table below for required numbers and types of intermediate pieces

Note:The Spindle head must be secured to the waling with a Connecting pin 10cm and Spring cotter 5mm!

1 ... Permitted axial load under tension = 40 kN2 ... On timber-beam formwork: Also allow for the Connecting pin 10cm and the Spring cotter 5mm3 ... Included in scope of supply

A Spindle headB Spindle element without hinged end-plateC Intermediate piece 2.40mD Intermediate piece 3.70mE Spindle element with hinged end-plate

9732

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-01

A

C

B

D

E

A Connecting pin 10cm + Spring cotter 5mm

Universal dismantling toolThe easy way to turn the spindle nuts.

A good rule of thumb here is:

The length of the Adjustable plumbing strut should be the same as the height of the formwork to be sup-ported.

9732

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-01

A

Type Length L [m]

Permitted axial load [kN]

under compression 1)Spindle ele-ment with

hinged end-plate

Intermediate pieces

Spindle ele-ment without hinged end-

plate

Spindle head 2)Hexagonal bolts

M16 x 60 8.8Nut M16 8

Spring washer A16 3)

Weight[kg]

min. L half L max. L short2.40 mlong

3.70 m1 6.0 - 7.4 40.0 40.0 27.8 1 1 1 1 8 153.92 7.1 - 8.5 40.0 38.2 24.3 1 2 1 1 12 183.73 8.4 - 9.8 40.0 35.6 21.7 1 1 1 1 1 12 209.14 9.7 - 11.1 40.0 31.7 19.0 1 2 1 1 12 234.55 10.8 - 12.2 40.0 27.8 16.1 1 2 1 1 1 16 264.36 12.1 - 13.5 34.2 24.1 13.4 1 1 2 1 1 16 289.77 13.4 - 14.8 27.1 21.5 12.2 1 3 1 1 20 315.78 14.5 - 15.9 20.8 17.5 9.5 1 2 2 1 1 20 344.9

44 999732002 - 10/2012



Pouring platforms with single brackets

Doka brackets can be used to make pouring platforms that can easily be assembled by hand.They can be attached to any point on the Doka beam. This also makes it possible to erect intermediate plat-forms.

Universal brackets

Possible ways of fixing


Observe all applicable safety regulations.

Only fix the pouring platform onto formwork construc-tions that are sufficiently stable to transfer the expected loads.

Ensure that the formwork gang has sufficient stiff-ness.

Shore the formwork in a windproof manner when erecting it and when it is temporarily placed in the standing position.

The brackets must be secured against acciden-tal lift-out

9732

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-01

Width b Height hUniversal bracket 90 87 160Universal bracket 60 57 106

Permitted service load: 1.5 kN/m2 (150 kg/m2)Load Class 2 to EN 12811-1:2003Max. influence width: 2.00 m

WARNINGRisk of accidental lift-out if the Universal bracket is fixed to a multipurpose waling! Fix the bottom strut of every bracket with

28x60 nails or a hexagon screw M10x140 and hexagon nut M10, on both sides of the strut.

In upper hole in beam In lower hole in beam In multipurpose wal-ing

a ... 9 cm

CAUTION In the case of H20 N and P Doka beams

where the first drilled hole is 5 cm from the end of the beam, it is not allowed to fix the bracket in the top hole in the beam!

9732

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-01

b

h

9732

-287

-01

a

9732

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-01

9732

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-01


45999732002 - 10/2012


Deck and guardrail boardsBoard thicknesses for support centres of up to 2.50 m: Deck-boards min. 20x5 cm Guard-rail boards min. 20x3 cm, otherwise detailed

dimensioning to EN 12811.

Note:The plank and board thicknesses given here comply with the C24 category of EN 338.Observe all national regulations applying to deck-boards and guard-rail boards.

Universal bracket 90Deck and guardrail boards: Per 1 metre length of platform, 0.9 m2 of floor decking and 0.8 m2 of guard-rail boards are needed (in-situ).Fastening the floor decking: with 5 square bolts M 10x70 and 1 square bolt M10x180 per bracket (included with product).Fastening the guard-rail boards: with 4 nails per bracket (not included with product).

Universal bracket 60Deck and guardrail boards: Per 1 metre length of platform, 0.6 m2 of floor decking and 0.6 m2 of guard-rail boards are needed (in-situ).Fastening the floor decking: with 3 square bolts M 10x120 per bracket (not included in scope of supply).Fastening the guard-rail boards: Use nails

Using scaffolding tubes

Tools: Fork spanner 22 for mounting the couplers and scaffolding tubes.

Top scaffold bracket L

b ... 62 cm h ... 115 cm

Possible ways of fixingSee "Universal brackets"

Deck and guardrail boardsBoard thicknesses for support centres of up to 2.50 m: Deck-boards min. 20x5 cm Guard-rail boards min. 20x3 cm, otherwise detailed

dimensioning to EN 12811.

Note:The plank and board thicknesses given here comply with the C24 category of EN 338.Observe all national regulations applying to deck-boards and guard-rail boards.

Deck and guardrail boards: Per 1 metre length of platform, 0.65 m2 of floor decking and 0.6 m2 of guard-rail boards are needed (in-situ).Fastening the floor decking: with 3 square bolts M 10x120 per bracket (not included with product).Fastening the guard-rail boards: Use nails

Using scaffolding tubes

Tools: Fork spanner 22 for mounting the couplers and scaffolding tubes.

A Screw-on couplers 48mm 95B Scaffolding tube 48.3mm

9705

-226

-01

A

B

Permitted service load: 1.5 kN/m2 (150 kg/m2)Load Class 2 to EN 12811-1:2003Max. influence width: 2.00 m

A Scaffold tube connectorB Scaffolding tube 48.3mmC Screw-on couplers 48mm 50D Hexagon screw M14x40 + hexagon nut M14 (not included with

product)

9732

-286

-01

b

h

9705-227-01

A

B

D

C

46 999732002 - 10/2012



Pouring platforms

Framax pouring platform U 1.25/2.70mPre-assembled, collapsible, ready-to-use platform with width of 1.25 m for convenient, safe working.

The guard rail can be locked in either of two posi-tions:

- vertical- tilted by 15

With the aid of the Top50 adapter for Framax pouring platform U, the Framax pouring platform U can be fixed in the waling of the Top 50 elements (2 adapt-ers per pouring platform).

Preparing the pouring platform: Tilt up the guard rails and lock them in position.

Put both side stops into position.

Close the decking with the tilt-back board.


Observe all applicable safety regulations.

Only fix the pouring platform onto formwork construc-tions that are sufficiently stable to transfer the expected loads.

Ensure that the formwork gang has sufficient stiff-ness.

Shore the formwork in a windproof manner when erecting it and when it is temporarily placed in the standing position.

If the formwork is lifted with the pouring plat-form still mounted to it, the platform must be secured so that it cannot slip to either side.

It is NOT allowed to place the formwork on its side while the pouring platform is still mounted!

For length adjustments, it may be necessary to place floor planking as a bridge (max. 50 cm) between two platforms. Minimum plank overlap: 25 cm.

Permitted service load: 1.5 kN/m2 (150 kg/m2)Load Class 2 to EN 12811-1:2003

Other possible areas of use for the Framax pouring platform U: Doka framed formwork Framax Xlife and

Alu-Framax Xlife Doka wall formwork FF 20 (with FF20

adapter for Framax pouring platform U)

9727-262-01

2.70 m

1.25 m

1.00 m

A Top50 adapter for Framax pouring platform UB Framax pouring platform U

A Side stop

9732

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-01

15

B

A

9727-394-01

9727-395-01

A


47999732002 - 10/2012


Mounting the adapter: Using a four-part lifting tackle, slightly raise the pour-

ing platform. Dismount the screw from the platform connector of

the adapter. Push the telescopic tube of the adapter into the bot-

tom tubular opening on the Pouring platform U. Replace and tighten the screw on the platform con-

nector of the adapter. An extra plank can be mounted where necessary

(leave recesses for the adapters). When you have mounted the adapters on the Pour-

ing platform U, lay it back on the ground.

Lifting the platform onto the formwork: Attach a four-part lifting chain to the hoisting points

of the adapters at the front, and to the lifting-brackets of the platform railings at the rear.

Raise the safety catches of the adapters and latch them into the rear position.

Move the supporting profiles into the horizontal and slot the Pouring platform U onto the adapters on the steel walings.

Secure the platform against accidental lift-out: Raise the safety catches and latch them into the front position (the claw grips behind the steel waling).

Detach the four-part lifting chain.Lifting the platform off the formwork: Attach a four-part lifting chain to the hoisting points

of the adapters at the front, and to the lifting-brackets of the platform railings at the rear.

Release the safety catch by hand. Lift the pouring platform out of the way.

A ScrewB Telescopic tubeC Extra plank

9732-358-02

A

CB

9732-358-05

A Safety catchesB Supporting profile

Check that the safety catches (A) are in the right position!

The safety catches on the adapters can be operated from ground level, using a plank.

9732-358-03

A

B

9732

-358

-04

A

48 999732002 - 10/2012



Transporting, stacking and storing

a ... 268 cmb ... 295 cmc... 10 x 18.7 cmd... 31 cme... approx. 218 cmf... 142 cmg... 50 cm

Stack of 10 Framax pouring platforms U Single collapsed platform

b

a

cd

e

9727-398-01 9727-393-01

f

g


49999732002 - 10/2012


Guard rails

Sideguards on exposed platform-endsOn pouring platforms that do not completely encircle the structure, suitable sideguards must be placed across exposed end-of-platform zones.

Side handrail clamping unit T

The sideguard consists of: 1 side handrail clamping unit T 1 railing plank min. 15/3 cm (in situ)How to mount: Fasten the clamping component to the floor planking

of the pouring scaffold, using the wedge (clamping range 4 to 6 cm).

Slot in the railing. Extend the telescopic railing to the desired length

and secure it. Insert footguard (railing plank).

Handrail clamp S

The sideguard consists of: 2 Handrail clamps S 3 guardrail boards, min. 15 x 3 cm (in-situ)How to mount: Fasten the Handrail clamps tightly to the floor deck-

ing of the pouring platform (clamping range 2 cm - 43 cm).

Secure the guardrail boards to the loops on the Handrail clamp S with one 28 x 65 nail per loop.

Opposing guard-railIf there are work platforms mounted on one side of the formwork only, then a fall-protection barrier must be mounted to the opposing formwork.

A Integrated telescopic handrailB Guard-rail board min. 15/3 cm (in-situ)C Pouring platform

9732

-222

-01

C B

A

A Guard-rail board min. 15/3 cm (in-situ)B Handrail clamp SC Universal bracket 90

Follow the directions in the Handrail clamp S User information!

A Opposing guard-rail (provided at site)

9732

-223

-01

C

B

A

9732

-290

-01

A

50 999732002 - 10/2012



Ladder systemThe Ladder system XS permits safe vertical access to and from the intermediate platforms and pouring plat-forms: when attaching/detaching the formwork to/from the

crane tackle when opening/closing the formwork when placing the reinforcement during pouring

Note:The Ladder system XS must be implemented in such a way that all national regulations are complied with.

Assembly instructions

Preparing the formwork Pre-assemble elements face-down on an assembly

bench (see "Inter-element connections"). Only mount the platforms and panel struts to the ele-

ment when this is in the flat position (see "Pouring platforms" and "Plumbing accessories").

Attaching connectors to the formwork

Place the "Connector XS wall formwork" onto the Multi-purpose waling near the top of the formwork and place a squared timber under it (pressure point). Nail the squared timber to the Doka beams.

Fasten the "Connector XS wall formwork" to the wal-ing with a tie-rod and 2 super-plates.

WARNING The Ladders XS may only be used as part of

the XS system, and must NOT be used sep-arately (as "lean-to" ladders).

9732

-393

-01

Important note: The Ladder system XS is normally mounted inside an element (i.e. not to either side of it).

If this is not possible (e.g. because of a sup-porting construction frame), then a beam grille (consisting of min. 4 Doka beams) can be attached on one side of the element to make this possible. This also makes it possi-ble to change quickly to another position.

A Connector XS wall formworkB Tie-rod 15.0 (Length = 0.40 m)C Super-plate 15.0D Squared timber 10x10 cm (site-provided)

9732-394-01

A

BC

D

9732-394-03

A

B

C

C


51999732002 - 10/2012


Place the "Connector XS wall formwork" onto the Multi-purpose waling near the bottom of the form-work (no need for a squared timber).

Fasten the "Connector XS wall formwork" to the wal-ing with a tie-rod and 2 super-plates.

For formwork heights above 5.85 m, an extra "Con-nector XS wall formwork" must be attached in the same way near the middle of the formwork (i.e. approx. half-way up).This extra connector prevents the ladder swaying when site crew climb up or down it.

Fixing the ladderto the top "Connector XS wall formwork" Pull out the push-in bolt, and pivot the two safety

hooks out of the way. Place the System ladder XS 4.40m onto the Connec-

tor XS, with the hooking brackets facing downwards. Close the safety hooks. Insert the push-in bolt into whichever rung of the lad-

der is suitable for the height of the formwork, and secure it with a linch pin.

- in the front position (a)

to the bottom "Connector XS wall formwork" Pull out the push-in bolt, pivot both safety hooks out

of the way, and place the ladder onto the Connector XS.

Close the safety hooks, re-insert the push-in bolt and secure it with a linch pin.

in the front position (a) for one single ladder in the rear position (b) in the telescoping zone (for 2 ladders)

Mount the Securing barrier XS to the ladder, with fix-ing hooks and wing-nuts.

The components needed for mounting the Securing barrier XS are captively attached to it.

A Connector XS wall formworkB Tie-rod 15.0 (Length = 0.40 m)C Super-plate 15.0

A Push-in boltB Safety hooksC System ladder XS 4.40m

9732-394-02

A

C

B

9732

-395

-01

A

B

C

B Safety hooksC Ladder XS

D Securing barrier XS

9732-395-02

B

C

a

b

9764-256-01

D

52 999732002 - 10/2012



Ladder system XS for heights above 3.75 mTelescoping ladder extension (for adjusting to ground level) To telescope the ladders past one another, lift the

safety latch on the ladder and fix the Ladder exten-sion XS 2.30m onto the desired rung of the other lad-der.

Close-up

A telescoping join between two Ladder extensions XS 2.30m can be made in the same way.

Permanently fixed ladder extension Insert the Ladder extension XS 2.30m into the

uprights of the System ladder XS 4.40m, with its hooking brackets facing downwards, and fasten it.Tighten the screws only very slightly!

Screws (C) are included in the scope of supply of the System ladder XS 4.40m and the Ladder extension XS 2.30m.

Two Ladder extensions XS 2.30m can be fixed together in the same way.

Attach the Ladder cage exit XS (the bottom of the cage must always be at the same height as the plat-form). The safety latches prevent the cage from being accidentally lifted out.

A System ladder XS 4.40mB Ladder extension XS 2.30mC Safety latch

Tr625-201-04

CA

B

Tr625-201-03

CB

A System ladder XS 4.40mB Ladder extension XS 2.30mC Screws, width-across 17 mm

Important note: Always observe all relevant safety regula-tions applying to the use of the Ladder cage XS in the country in which you are operating (e.g. in Germany: BGV D 36).

D Ladder cage exit XSF Safety latch

Tr625-202-01

CA

B

9732-396-01

D

F


53999732002 - 10/2012


Attach further ladder cages, in each case to the next available rung.

Items needed

1 ) No allowance made here for intermediate exits.

Exit onto an intermediate platform

Mounting the Ladder cage XS 0.25m Hook the ladder cage into an empty rung and secure

it against accidental lift-out.

E Ladder cage XSF Safety latches (lift-out guard)

Connectors + ladderFormwork height

2.70-3.25 m

>3.25-6.00 m

>6.00-8.00 m

Connector XS wall formwork 2 2 3System ladder XS 4.40m 1 1 1Ladder extension XS 2.30m 0 1 2Tie-rod 15.0 galvanised ..... m(length: 0.40 m) 2 2 3

Super-plate 15.0 4 4 6Squared timber 10x10 cm 1 1 1

Ladder cageFormwork height

2.70-3.15 m

>3.15-4.05 m

>4.05-5.40 m

>5.40-6.60 m

>6.60-7.65 m

>7.65-8.00 m

Ladder cage exit XS 1) 1 1 1 1 1 1

Securing bar-rier XS 1) 1 1 1 1 1 1

Ladder cage XS 1.00m 1) 0 1 2 3 4 5

9732-393-03

E

F

In general:

The number of "Connectors XS wall formwork" and ladder components is shown in the "Items needed" table.

For each additional exit, one "Ladder cage exit XS" and one "Securing barrier XS" are required.

Any over-large openings above the intermediate exit must be reduced with a Ladder cage XS 0.25m.

9764-270-019764-269-01

1 2

9732-393-02

54 999732002 - 10/2012



Combining different formwork systemsTop 50 and FF 20 timber-beam formwork can be com-bined with the following formwork systems: Framax Xlife framed formwork Alu-Framax Xlife framed formwork Circular formwork H 20The Transition plate 18mm or 21mm is needed for this.

Example of combination with Framax Xlife framed formwork

Example of combination with Circular formwork H 20

Tr70

9-20

3-01

A B

C

E

F G

D

A Transition plate 18mm or 21mmB Framax quick-acting clamp RUC Connecting pin 10cmD Spring cotter 5mmE Moulded timber supportF Timber-beam formworkG Framax Xlife framed formworkH Circular formwork H 20

Can be combined with Doka wall formwork FF 20:If the spacing of the walings is suitably adjusted, Top 50 elements can be combined with FF 20 ready-assembled elements. This enables users to supplement the available formwork with existing FF 20 equipment

Documents

Doka Top50