High-performance safety slab formwork. French design

Transcription

1 High-performance safety slab formwork French design

2 High-performance safety slab formwork The versatile TopDalle system suits every type of building: offices, homes, retirement residences, hospitals, prisons, etc. Simple and quick to install, the TopDalle system offers productivity of 30 m 2 /person/ day at a height of 2.50 m and up to 1.50 m 2 formwork per C4+ frame. Designed by the Alphi Design Office in collaboration with CARSAT Rhône-Alpes, TopDalle formwork is compliant with the french decree of September 2004 on falls from height due to its anti-overturning system for the secondary frames and controlled spacing of 13 cm between frames. BV Cert

3 3 simple components Technical support Integral drop-head for fast removal (patented system) Reinforcement of the base Hot-dip galvanized Cast iron sleeve Primary beam Available in 4 different lenghts. Theft protection Can be mounted in a drawer. Wooden inserts allowing plywood to be nailed on. Secondary frames C2+ and C4+ Theft protection Wooden inserts Like the primary beams, the secondary beams contain a wooden insert allowing plywood to be nailed on using 40 mm nails. Anti-overturning system i n n o v a t i o n i n n o v a t i o n Extendable primary beam From 90 to 110 cm, the extendable primary beam suits all cell sizes. Can be mounted in a drawer. Continuous resting of secondary beams on primary beam. Angulary extendable secondary beam Combined with the primary beam, allows working close to the edges of the cell. Adjustable length. Wooden inserts allowing plywood to be nailed on. Modular orientation as close as possible to the concrete skin by rotating the tip. TopDalle Formwork - January

4 High-performance safety slab formwork Safety Safety of personnel Protection against falling at ground level and falling from height by an anti-tipping system for the secondary frames and controlled spacing of 13 cm. Frames are installed and removed from floor level. With the Top Perche pole, formwork is installed and removed from ground level (no need for the mobile safety ladder). Freestanding system The unique design of the TopDalle system guarantees optimum stability. Theft protection The chemical process developed by Alphi prevents fraudulent recycling of aluminium beams. Compliant with the Decree dated September 2004 concerning falls from height Fall from ground level NF E Fall from height NF E Physical positions causing strain The installation (and removal) of C2+ frames using the Top Perche provides a dual safety advantage: > The installer is working from floor level; there is no more risk of falling from height, > controlled 13-cm spacing. Falling objects NF E Mediocre Manual load handling NF X Excellent Safety and ergonomic performance TopDalle is the best-performing framework of its generation in terms of the requirements of standards NF E and NF X

5 Ergonomics Productivity Quality The lightest weight per m 2 framework on the market. Made of aluminium, the frames and beams contribute to the lightness of the TopDalle portable formwork system. Less repetitive strain injury Better weight distribution. Ergonomic handles on the C2+ and C4+. Accommodates 15 mm plywood. Less noise pollution Complies with the European noise directive (2003/10/EC dated 6 February 2003). Easier identification The beams are colour-coded in compliance with the layout drawings provided. 30 m 2 / person / day at a height of 2.50 m (formwork / formwork removal / cladding / adjustment) Up to 1.50 m 2 formwork per C4+ frame. Easy removal The drop-head for fast removal integral with the technical support (Alphi patented system) keeps the slab supported during formwork removal. The rotation of the aluminium structure takes less time. Flexible use to satisfy all technical requirements "Primary on primary" assembly allows the TopDalle system to adapt to the exact dimensions of the cells. The C2+ and C4+ frames are adaptable to all modular slab formwork including primary beams, secondary beams, and drop-heads Cast concrete thickness up to 82 cm. Higher quality of concrete soffits Quality exceeding conforms to the DTU 21 recommendation for concrete floors. Nailing on wooden insert Plywood (15 mm authorised) secured using nails. Regulations Beams are designed in accordance with standard NF concerning formwork. The drop-head integral with the prop allows fast formwork removal without releasing pressure on the slab. TopDalle Formwork - January

6 High-performance safety slab formwork Equipment Technical supports (TS) with integrated drop-head Hot-dip galvanised - Identified by sleeve colour. Designation Colour Setting (cm) Unit weight (kg) TS TS TS According to Eurocode 0 and 3 safety coefficients Primary beams Designation Colour Unit weight (kg) PPE PP PP PP PP cm Secondary frames L (cm) Colour Unit weight (kg) C2+ frames C4+ frames Compatible with other formwork solutions. Please contact us. 61 cm Angulary extendable secondary beam Designation Colour Angles of use Unit weight (kg) PSE ang 110 from 0 to PSE ang 150 from 0 to PSE ang 180 from 0 to

7 Equipment TopPerche Lenght (cm) Unit weight (kg) Compatibility C2+ frames Insulated head option Zinc-electroplated insulated head. Holes (mm) Height (cm) Unit weight (kg) Maximum permissible load (kn) 4 x Ø 12 x Vertical storage trolley (for beams only) Dimensions L x W x H (cm) Maximum load (kg) 100 x 82 x Galvanised rack on wheels Dimensions L x W x H (cm) Maximum load (kg) 100 x 82 x Galvanised handling rack Dimensions L x W x H (cm) Maximum load (kg) 135 x 90 x Accessories i n n o v a t i o n TransÉtais housing Prop sizes Maximum number <3 m 12 props >3 m 8 props The new Alphi TransÉtais makes prop handling easy and facilitates passing through doorways. TopDalle Formwork - January

8 High-performance safety slab formwork Abacus for use of the beams Value given for a superior quality conform to Unified Technical Document 21 (DTU) for concrete floors, taking into account the workload (2,5 kn/m 2 ) Thickness of concrete (m) PP 180 PP 150 PP 110 PP C2+ frame 180 C2+ frame 150 C2+ frame 110 C2+ frame 180 C2+ frame 150 C2+ frame 110 C2+ frame 180 C2+ frame 150 C2+ frame C2+ frame C2+ frame C2+ frame TS (32 kn) and beam limit load on prop greater than 32 kn (zone requiring special study by the Alphi design office) CP: plywood (provided by the customer) PP: primary beam C2+ / C4+: secondary frames Abacus for use of the technical supports Technical supports TS with integrated formwork head Hot-dip galvanized - Identified by the color of the sleeve - According to the coefficients of security Eurocodes 0 and 3. Designation Colors Setting (cm) Weight (kg) Height of shoring (m) / Load for use (kn) min.-max TS TS TS

9 Operating procedure Recommandation distributes As a part of its approach to fight against pain, Alphi precognizes the use of special adapted tools for the assembling and disassembling of the formwork systems. The range nanovib, elaborated by Leborgne, includes all our requirements concerning security, vibration reduction and noise. Mitigate mechanical vibrations Designation Common features Product advantages Claw Hammer Nanovib Rounded angles of the claws Carpenter hammer 1 tooth nanovib Hammer for Wooden House Builders nanovib 40 % less vibrations Steel rod high resistance to false strokes Ergonomic handle Anti-slip grip Flared end of the handle for anti-loosely Nail holder magnet Side impact surface Sharp upper edges Ergot for redressing Surface for striking with two rounded angles Anti fall Designation Common features Product advantages Hammer holder Carpenter pencil 100 % graphite integrated Universal hammer holder For right and left handers Its 45 angle avoids the hammer to fall when the worker crouches Reduce the noise Designation Common features Product advantages Key for props Universal key to tight the nuts of the props, the shoring towers and the scaffoldings Extends the life of the nuts for props Angled and sheathed handle Eliminates 100 % of the noise occured by the striking of the hammer on the nuts of props TopDalle Formwork - January

10 The safety AlphiSafe is a collective protection system for formwork and slab edges. The system s technical innovations make it possible, in particular, to have a safe installation and automatic locking. Robust AlphiSafe is Ginger CEBTP certified, EN standard from july 2013, Class A and B for certain elements. AlphiSafe is distinguished by its height of 1.30 m, which is above the minimum height of one metre set by the standard, and protects traditional slab formwork up to 30 cm thick. The grid is locked at the top by the anti-lifting pin and its rotation is locked at the base. Equipment 2.50 m Grid Dimensions (m) Weight (kg) Characteristic 1.25 x The grid wires are galvanised, with 2.50 x a polyester powder coating m Galvanised post Section (cm) Height (m) Weight (kg) 3.5 x Adapters for Alphi formwork Designation Height (m) Primary adaptator 2.3 Prop adaptator

11 Assembly of AlphiSafe security system In cantilever TopDalle Formwork - January

12 Assembly of AlphiSafe security system 1 In technical support (to advancement)

13 Operating procedure WARNING To use our products safely, please observe the regulations applicable in each country. The elements and setups presented in this brochure match the characteristics of the equipment on the date of issue of the document. Some changes may have been incorporated since the document was issued. The use of our systems in combination with systems from other manufacturers may involve some risk, and would require special inspection. Before starting to set up, remember to secure the area. Preparatory stage Note: TopDalle formwork is set up by two formwork engineers, even though they are not always shown in the images. - Reception of equipment on the worksite: check quantities and validate delivery note. - Precise distribution of the equipment according to the first phases of formwork defined by the layout drawing. - Height adjustment of props and setting of drop-heads in forming position: locking in position with hammer. distributes Do not place the props against the wall. Warning: It is essential to lock the head. Click here or flash the code to acceed to the video of operating procedure TopDalle Formwork - January

14 Operating procedure 1 WARNING: Insert the primary beams in the large bushings of the technical support prop + tripod - Starting from a corner of the room, set up a primary beam on two technical supports (TS) stabilised by tripods. - Mount a second primary beam on two TSs stabilised by tripods. - Use of lightweight mobile safety ladder in accordance with regulations. ÎÎRefer to the layout drawing. 2 - Setting up C2+ secondary frames using the TopPerche. ÎÎObserve the layout plan. 14

15 3 Î ÎFor the C4+, use a mobile safety ladder. - Start installing a C2+ or C4+ secondary frame. - The installer lifts the frame between the two primary beams and then lowers the Top Perche, ensuring that the ends of the frame are properly engaged in the primary beams. 4 Gap = 13 cm Î ÎFor the C4+, use a template to control the spacing. - Install the C2+ frames from one to the next using the Top Perche. - Do not leave gaps greater than 13 cm between frames. TopDalle Formwork - January

16 Operating procedure 5 - Mounting a primary beam on a TS stabilised by tripods. 6 - The installer uses the prop to position the primary beam. 16

17 7 - Continue installing the C2+ or C4+ secondary frames. 8 - Finish installing the C2+ or C4+ secondary frames. TopDalle Formwork - January

18 Operating procedure Installing the extendable beam - Unlock the beam by loosening the wing nut. - Adjust the beam to the desired length. - Lock the beam by tightening the wing nut. 18

19 9 Note: The extendable primary beam must be adjusted and locked before assembly. - After the length has been adjusted and locked, the extendable primary beam is positioned on stabilised props The installer uses the prop to position the second extendable primary beam. TopDalle Formwork - January

20 Operating procedure Installing the angulary extendable secondary beam C2+ or C4+ frames Angulary extendable secondary beam Colours 110 PSE ang PSE ang PSE ang An angulary extendable secondary beam is associated to a type of C2+ or C4+ frames. - The color code of the angulary extendable secondary beam corresponds to the one of the panel for an easier recognition. - A symmetrical length for extensions output will be privileged. - The large tip, with 4 zones for support, allows the stability. - The implementation must be done by assembling the large tips in order to have a gap of 19 cm. 20

21 11 - Position the angulary extendable secondary beam The articulated heads of the angulary extendable secondary beam allow it to be adjusted to any configuration. TopDalle Formwork - January

22 Operating procedure 13 - Continue installing the C2+ or C4+ secondary frames Continuer fitting the C2+ frames using the TopPerche, or C4+ from one to the next. 22

23 15 - Repeat Step 6 and finish installing the C2+ or C4+ secondary frames. Make a final check to ensure the heads are locked at this stage Fine-tune the level using a laser level, TS by TS. - A gauge stick hanging from the formwork allows laser adjustment to be performed by one person. TopDalle Formwork - January

24 Operating procedure 17 distributes distributes - When the structure is finished and the height has been adjusted: laying the plywood. - Use of plywood cutting support to cut plywood (see Accessories, p. 6). ÎÎPeripheral safety (web, beam) completed previously. ÎÎUse of plywood cutting support to cut plywood. 18 No walking on the plywood panels, except for personnel trained and qualified to install plywood panels. distributes - Nail using 40 mm (max.) nails. - Ensure that a load-bearing member is present under the plywood sheet joins. - Check the sealing of the formwork between plywood sheets and at the edges. 24

25 19 - Creation of concrete slab after reinforcement and embedding. ÎÎSpread the concrete on the formwork without overloading the beams and TSs cm distributes - Removing formwork from the slab: remove the supports from the TSs as you progress. - The primary beams and C2+ or C4+ frames drop by 19 cm. - The TSs remain in position. TopDalle Formwork - January

26 Operating procedure 21 - Removal of formwork from the slab: remove the C2+ or C4+ frames as you progress, and the primary ones last. - Place them in the mobile racks. 22 distributes - Removing formwork from the slab: remove the TSs placed at the edges of the cells. - Leave the other TSs in position for at least three days (according to concrete type and outside temperature). 26

27 23 - Lower the panel elevator to mid-height. - Remove the plywood sheet Install the first drying prop, allowing one prop per 5 m 2 (general case). TopDalle Formwork - January

28 Operating procedure 25 - Repeat steps 24 and Repeat the operations from Step 1 on a higher level. 28

29 Special Cases Reduced space Use of the fork under the primary (mounting without utilization of the fast release). 20 cm Fork The fork enables to place the TS under the primaries and not on the extremities, thus enabling an additional setting. Management of the overflowing of façade Use in cantilever with fork and bracon. ⅓ of the beam (max.) Bracket Fork TopDalle Formwork - January

30 Operating procedure Special applications Precise adaptability to the cell dimensions (system called in "drawer") C C C PP 110 PP 150 C C PP 150 C C C C PP 150 PP 150 PP 110 PP 110 C C C PP 110 PP 150 PP 150 PP 150 C C C C PP 150 PP 150 C PP 180 PP 150 PP 150 C C C PP 110 PP 110 PP 150 PP 110 PP 150 PP 180 PP 150 PP

31 Installing TopDalle formwork at height - Starting from a corner of the room, set up four technical supports (TS) stabilised by a prop frame. 1 - Setting up the first two primary beams. - Storage of plywood panels on floor or in the wheeled racks. - Use of lightweight mobile safety ladder in accordance with regulations. ÎÎRefer to the layout drawing. TopDalle Formwork - January

32 Operating procedure Installing TopDalle formwork at height - Start installing a secondary frame, and then proceed from one to the next. 2 - Do not leave gaps greater than 13 cm. - Use a template to observe the 13 cm spacing. ÎÎObserve the layout plan. 32

33 - Finish setting up the secondary frames. 3 TopDalle Formwork - January

34 Operating procedure - Set up two new primary beam on TS. 4 - Repeat the operation in the same way as for standard heights. ÎÎUse prop frames instead of tripods: one prop frame per 40 m 2 of casting. 34

35 Primary beams meshing The use of a tipping-prevention safety fork provides 15 cm of extra adjustment (see page 29). PRIMARY BEAMS MESHING FROM 0 TO 10 M P180 P150 P110 P90 lengths between walls P180 P150 P110 P90 lengths between walls TopDalle Formwork - January

36 Primary beams meshing P180 P150 P110 P90 lengths between walls P180 P150 P110 P90 lengths between walls

37 Primary beams meshing P180 P150 P110 P90 lengths between walls P180 P150 P110 P90 lengths between walls TopDalle Formwork - January

38 Primary beams meshing P180 P150 P110 P90 lengths between walls P180 P150 P110 P90 lengths between walls

39 Primary beams meshing P180 P150 P110 P90 lengths between walls P180 P150 P110 P90 lengths between walls TopDalle Formwork - January

40 C2+ and C4+ frames meshing C2+ AND C4+ FRAMES MESHING FROM 0 TO 10 M C+180 C+150 C+110 lengths between walls C+180 C+150 C+110 lengths between walls

41 Alphi, the French leader in slab formwork Savoie Hexapole, Actipole 5 - Rue Maurice Herzog Viviers-du-Lac - France Tel. +33 (0) Fax +33 (0) info@alphi.fr Design department: +33 (0) be@alphi.fr Logistics department: +33 (0) newaru - TopDalle GB - January Version PDF - Photos: Alphi, newaru, Optima Strasbourg, Manuel Moulin / Chantier GFC French design