Doka T Operation manual

The Formwork Experts
08/2008 Ü
GB
999771002
User information
Method statement
Doka forming wagon T
9730-235-01

2999771002 - 08/2008 Ü
User information Doka forming wagon T
The Formwork Experts
Introduction
© by Doka Industrie GmbH, A-3300 Amstetten

3999771002 - 08/2008 Ü
Contents Page
User information Doka forming wagon T Introduction
The Formwork Experts
Introduction ..................................................................................................2
Elementary safety warnings ........................................................................4
Eurocodes at Doka........................................................................................6
System overview ..........................................................................................7
Areas of use ..................................................................................................9
Formwork configuration ............................................................................11
Enlarging the Ready-to-use platform for Forming wagon T...................12
Examples of the system in action .............................................................14
Dimensioning of the ballast.......................................................................16
Assembly instructions................................................................................18
Pouring ........................................................................................................24
Striking ........................................................................................................25
Repositioning the forming-carriage units.................................................26
Safety on the structure...............................................................................28
Weatherproofing.........................................................................................30
Flexible adaptation to the requirements of the structure........................31
Adjusting the forming wagons..................................................................32
Multifunctional utilisation..........................................................................33
Transporting, stacking and storing ...........................................................34
Items needed...............................................................................................35
Component overview.................................................................................36

The Formwork Experts
4999771002 - 08/2008 Ü
Introduction User information Doka forming wagon T
Elementary safety warnings
User target groups
●This User Information booklet (Method State-
ment) is aimed at everyone who will be working
with the Doka product or system it describes. It
contains information on how to set up this sys-
tem, and on correct, compliant utilisation of the
system.
●All persons working with the product described
herein must be familiar with the contents of this
manual and with all the safety instructions it con-
tains.
●Persons who are incapable of reading and under-
standing this booklet, or who can do so only with
difficulty, must be instructed and trained by the
customer.
●The customer is to ensure that the information
materials provided by Doka (e.g. User Informa-
tion booklets, 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.
Remarks on this document
●This User Information booklet 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.
●Further safety instructions, especially warnings,
will be found in the individual sections of this
document!
Planning
●Provide safe workplaces for those using the
formwork (e.g. for when it is being erected/dis-
mantled, 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
supervision of suitably skilled persons with the
authority to issue instructions.
●Doka products are ONLY to be used in accord-
ance with the Doka User Information booklets or
other technical documentation provided by
Doka.
●The stability of all components and units must be
ensured during all phases of the construction
work!
●The functional/technical instructions, safety
warnings and loading data must all be strictly
observed and complied with. Failure to do so can
cause accidents and severe (even life-threaten-
ing) 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 distance away from the formwork.
●The work must take account of the weather con-
ditions (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
equipment, and to protect employees.
●All connections must be checked regularly to
ensure that they still fit properly and are function-
ing correctly.
It is very important to check all screw-type con-
nections and wedge-clamped joins whenever the
construction operations require (particularly
after exceptional events such as storms), and to
tighten them if necessary.
Assembly
●The equipment/system must be inspected by the
customer before use, to ensure that it is in suita-
ble 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 con-
tact Doka for advice first.
●The assembly work must be carried out by suita-
bly qualified employees of the client's.

User information Doka forming wagon T Introduction
5999771002 - 08/2008 Ü The Formwork Experts
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
formwork 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 sys-
tem features such as Framax stripping corners.
●When striking the formwork, do not endanger the
stability of any part of the structure, or of any
scaffolding, 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 rele-
vant sections of this User Information booklet!
Regulations; industrial safety
●Always observe all industrial safety regulations
and other safety rules applying to the application
and utilisation of our products in the country and/
or region in which you are operating.
Instruction as required by EN 13374:
●If a person or object falls against, or into, the
sideguard system and/or any of its accessories,
the sideguard component affected may only con-
tinue in use after it has been inspected and
passed by an expert.
Maintenance
●Only original Doka components may be used as
spare parts.
Symbols used
The following symbols are used in this booklet:
Miscellaneous
We reserve the right to make alterations in the inter-
ests of technical progress.
Unless otherwise stated, all dimensions are given
in cm.
Important note
Failure to observe this may lead to mal-
function or damage.
Caution / warning / danger
Failure to observe this may lead to mate-
rial damage, and to injury to health which
may range up to the severe or even life-
threatening.
Instruction
This symbol indicates that actions need to
be taken by the user.
Sight-check
Indicates that you need to do a sight-
check to make sure that necessary actions
have been carried out.
Tip
Points out useful practical tips.
Reference
Refers to other documents and materials.
☞

The Formwork Experts
6999771002 - 08/2008 Ü
Introduction User information Doka forming wagon T
Eurocodes at Doka
In 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 pro-
vide a uniform basis, valid throughout Europe, for
product specifications, tenders and mathematical
verification.
The EC are the world's most highly developed
Standards in the construction field.
In the Doka Group, the EC are to be used as stand-
ard 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" (com-
paring the actual stresses with the permissible
stresses) has been superseded by a new safety con-
cept in the EC.
The EC contrast the actions (loads) with the resist-
ance (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)
EdDesign value of effect of actions
(E ... effect; d ... design)
Internal forces from action Fd
(VEd, NEd, MEd)
RdDesign value of the resistance
(R ... resistance; d ... design)
Design capacity of cross-section
(VRd, NRd, MRd)
FdDesign value of an action Steel: Rd= RkTimber: Rd= kmod · Rk
Fd= γF· FkγMγM
(F ... force)
FkCharacteristic value of an action
"actual load", service load
(k ... characteristic)
e.g. dead weight, live load, concrete pres-
sure, wind
RkCharacteristic value of the resistance
e.g. moment resistance to yield stress
γFPartial factor for actions
(in terms of load; F ... force)
e.g. for dead weight, live load, concrete pres-
sure, wind
Values from EN 12812
γMPartial factor for a material property
(in terms of material; M...material)
e.g. for steel or timber
Values 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 H20
Values as given in EN 1995-1-1 and EN 13377
EdRd
Permissible stress design EC/DIN concept
Factual≤Fpermissible Ed≤Rd
ALoad factor
60 [kN]
60<70 [kN]
115.5 [kN]
n~ 1.65
Fyield
Fpermissible
Factual
98013-100
A
90 [kN]
115.5 [kN]
90<105 [kN]
Rk
Rd
Ed
gM= 1.1
gF= 1.5
98013-102
A
The "permissible values" communicated in
Doka documents (e.g.: Qpermissible = 70 kN) do
not correspond to the design values (e.g.:
VRd = 105 kN)!
➤Avoid any confusion between the two!
➤Our documents will continue to state the
permissible values.
Allowance has been made for the following
partial factors:
γF= 1.5
γM, timber = 1.3
γM, steel = 1.1
kmod = 0.9
In this way, all the design values needed in
an EC design calculation can be ascertained
from the permissible values.

User information Doka forming wagon T
7999771002 - 08/2008 Ü The Formwork Experts
System overview
Doka forming wagon T – the site-
ready, travelling bridge-edge beam
formwork
The travelling Forming wagon T carries a large area
of pre-assembled, repositionable bridge edge beam
formwork that can be cycled with no need for dis-
mantling. It stands out for its high carrying capacity.
Cost-effective areas of utilisation include the cast-
ing of edge kerbs in the following cases:
●longer bridge superstructures
●high number of re-use cycles
●"section-at-a-time" repositioning cycles
●rehabilitation of existing bridge superstructures
The system is also suitable for curved bridges with
large radii.
The many plus-points of the Doka forming
wagon T:
●high flexibility in terms of different formwork
configurations
●unlimited options regarding adjustability
●quick to erect and dismantle, thanks to high
degree of pre-assembly (also means that less
storage space is needed)
●easy to handle, permitting a rapid pace of work –
daily rhythm
●multifunctional useage:
- forming wagon
- demolition wagon
- basic construction for travelling of wall form-
work
●galvanised, long-life constructional design
Example using Doka bridge edge beam
formwork T:
For shorter bridge superstructures and
bridges of medium length needing only a
small number of repositioning cycles, the
Doka bridge edge beam formwork T is ideal.
This system can quickly be erected by hand.
Please follow the directions in the "Doka-
bridge edge beam formwork T" User Infor-
mation booklet.
9770-200-01

The Formwork Experts
8999771002 - 08/2008 Ü
User information Doka forming wagon T
The main system components
ARails
BBogie for Forming wagon TS
FBallast
GDouble jib for Forming wagon T
KSpindle strut GS T7 109/166cm
MSuspension beam for Forming wagon T
NSpindle strut T6 100/150cm
PLongitudinal beam for Forming wagon T
QRailing strut for Forming wagon T
RReady-to-use platform for Forming wagon T
SSpindle strut T6 73/110cm
THandrail post T 0.70m
XPressure prop T
YSpindle strut GS T6 95/140cm
(included with Item B)
9730-235-01
B
Y
N
R
TS
F
G
PM
X
Q
AK

User information Doka forming wagon T
9999771002 - 08/2008 Ü The Formwork Experts
Areas of use
Wide setting ranges and versatile scope for adjust-
ments – leading to high flexibility and adaptability
to just about any site situation. The system's ease of
handling permits rapid working.
System dimensions:
a ... max. 596.0 cm
b ...max. 60 cm
c ... Track gauge 197.5 cm
d ... 213.0 cm
e ... 200.0 cm
f ... Adjusting range 4x30.0 cm = 120.0 cm
g ... max. sidewalk space 200.0 cm
h ... max. 80 cm
i ... 18.0 cm
☞
Where forming carriages are erected over
traffic routes (roads, navigated waterways,
railways), then – in order to prevent objects
being dropped and endangering passing
traffic – the platform decking must be tightly
laid and the railings must be fitted with
screens as required by regulations.
ABallast
±5°
±15°
±10°
9730-239-01
c
i
e
f
a
b
g
h
d
A

The Formwork Experts
10 999771002 - 08/2008 Ü
User information Doka forming wagon T
Plan view: (simplified drawing not showing bridge superstructure)
k ... 280.0 cm
l ... Standard platform length 490.0 cm
m ... Standard formwork length 500.0 cm
Travel gear
Centre-to-centre spacing of rails 197.5 cm.
Parking wedges (A) on the double flanged wheels
secure the Forming wagons T in their duty position.
Clamping jaws can be used to provide additional
fixing on / adaptation to the rail profile.
Tools needed:
●Fork spanner 13/17
9730-259-01
k
l
m
a ... 25.0 cm b ... max. 8.0 cm
9730-244-01
a
A
9730-245-01
b

User information Doka forming wagon T
11999771002 - 08/2008 Ü The Formwork Experts
Formwork configuration
The forming wagons are designed for a formwork
length of 5 m. Thanks to the flexible connection
possibilities provided by the hole grid in the sus-
pension beam, almost any formwork configuration
is possible. The formwork elements can also be pre-
assembled.
Example:
Example: Formwork adjustable with Adjusting
spindle T
ALocation plate, adjustable in 5.3 cm increments
(included with Suspension beam)
BSuspension beam for Forming wagon T
CMulti-purpose waling or Steel waling WS10 Top50
DDoka beam H20
ETie-rod 15.0 (length = 45 cm)
FSuper-plate 15.0
GFlange-clamp H20
HConnecting pin 10cm + Spring cotter 6mm
IFaçade pre-cast member clamp V
Optimum accommodation of the stop-ends
on the side facing the bridge is obtained by
bracing the bottom steel waling (C) with
squared timbers and wedges, or with the
Façade pre-cast member clamp V (I) .
9730-240-01
A
B
C
C
D
E
F
G
H
I
AAdjusting spindle T
BSuspension beam for Forming wagon T
CMulti-purpose waling or Steel waling WS10 Top50
DDoka beam H20
ETie-rod 15.0
FSuper-plate 15.0
GFlange-clamp H20
HConnectin pin 10cm + Spring cotter 6mm
IFaçade pre-cast member clamp V
Je.g. Spindle strut T6 100/150cm
KFlange claw
9730-315-01
A
B
C
C
D
E
FG
K
H
C
J
I

The Formwork Experts
12 999771002 - 08/2008 Ü
User information Doka forming wagon T
Enlarging the Ready-to-use platform for Forming wagon T
Lowering and widening the work
deck
Where there are high edge-beams, the work deck
(i.e. the "Ready-to-use platform for Forming wagon
T") (B) can be hung 1 metre lower using the Sus-
pension beam extension T 1.00m (A) .
When combined with:
●Platform extension plate T (C) (incl. cable + turn-
buckle)
●Multipurpose or standard steel waling
WS10 Top50 1.00m (D)
●squared timbers and deck-boards (E)
the existing ready-to-use platform can be enlarged
into an up to 2.50 m wide working platform.
This makes for safe, convenient working:
●on the formwork
●on the cantilevering zones of the superstructure
(during inspection and site-erection work)
Slide-off protection can be provided using e.g. the
Handrail clamp T (F) or the Handrail post 1.80m.
The Handrail lengthening piece T 1.00m (G) pro-
vides effective fall-arrest protection for work carried
out on the top of the superstructure.
For this additional support, the following items are
needed for each Forming wagon T:
9730-301-01
A
BCD
E
F
G
H
I
☞Important note:
Where weatherproofing tarpaulins (H) are
hung over the outside, the Handrail length-
ening piece (G) must be given extra support
using a Railing profile 740 (I) .
N° of
items Name Part n°s
2 Railing profile 740 504348010
2Hexagon screw M16x90, galv.
DIN 601 019005
4Hexagon screw M16x140, galv.
DIN 931 019008
6 Spring washer A16, galv. DIN 127 019900
6 Hexagon nut M16, galv. DIN 934 019303

User information Doka forming wagon T
13999771002 - 08/2008 Ü The Formwork Experts
Lengthening the work deck
e.g. to facilitate mounting of the stop-end at either
end of the forming-wagon train.
Easy to assemble, using parts from the Doka stand-
ard range.
AMulti-purpose waling or Steel waling WS10 Top50
BConnecting pin 10cm + Spring cotter 6mm
Ce.g. Handrail clamp S or
Handrail post T 1.80m
DExtra platform planking unit
EGuard-rail boards
FExtra-long guard-rail boards of the Forming wagon T
9730-314-01
A
C
D
E
FG
B

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

User information Doka forming wagon T
15999771002 - 08/2008 Ü The Formwork Experts

The Formwork Experts
16 999771002 - 08/2008 Ü
User information Doka forming wagon T
Dimensioning of the ballast
As well as by the weights of the components
involved and by the live loads, the dimensioning of
the ballast will also be influenced by the following
factors:
●position of Pressure prop T
●position of formwork unit as a whole
●position of ballast
●repositioning operation (no Pressure prop T)
Position of Pressure prop T
The Pressure prop T (A) can be attached to several
possible positions on the double jib. This permits
additional project-specific optimisation.
a1 ... 50.0 cm
a2 ... 120 cm (standard ex-factory setting)
a3 ... 257.0 cm (for special applications)
Note:
Where distance a1=50 cm and a3=257 cm, the
standard Spindle strut GS T6 95/140cm (C) cannot
be used. On-site fixing is needed in this case.
Position of formwork unit as a
whole
The position of the suspension beam, together with
the platform and the formwork, can be continu-
ously adjusted within the range indicated b, as
required.
The position set here will also have an influence on
the size of the ballast (B) (see diagram on next
page).
b ... 220.0 to 375.0 cm
☞Important note:
The weight calculated for the ballast must
be sufficient to permit all the forces to be
sustained with an adequate margin of
safety!
APressure prop T
BBallast
CSpindle strut GS T6 95/140cm
9730-302-01a
a1
a2
a3
A
C
B
9730-303-01
b
B

User information Doka forming wagon T
17999771002 - 08/2008 Ü The Formwork Experts
Determining ballast weight
The diagram for determining ballast weight makes
it easier to find which weight of ballast is required
on a standard version of forming wagon. It makes
the following design assumptions:
●Length of formwork 5 m
●Ballast position: dimension c=130 cm
●Dimensions a and b: see diagram lines
●Weight of formwork per unit: 400 kg
●Dead weights incl. lowered platform (Suspension
beam extension 1.00m and 1.00 m extra width)
●Pouring platform at same height as formwork
●Live loads per unit:
- when Pressure prop T is in place
Permitted service load: 1.5kN/m2(150 kg/m2)
Load Class 2 to EN 12811-1:2003
- when Pressure prop T is removed
(situation during travel - 4 kN)
For project-specific deviations (e.g. deviations in
the centre-of-gravity position), separate calcula-
tions must be performed.
a ... Standard 120 cm
b ...220.0 to 375.0 cm
c ... min. 130.0 cm
d ... max. 220.0 cm
Diagram for determining the ballast weight
Length of ballast
APressure prop T
BCentre of gravity of ballast
CSpindle strut GS T6 95/140cm
XCross-section of the edge kerb having an effect on the load
Risk of tipping over!
➤Dimension "c" for the centre of gravity of
the ballast MUST be strictly observed!
Sufficient ballast must be provided to
ensure stability at all times, including during
the erection and dismantling phases.
9730-258-01
a
d
c
b
B
A
CX
Ballast [kN] (w/o weatherproofing tarp.)
Cross-section (X) of the edge kerb [m2]
Curve Dimension a [cm] Dimension b [cm]
A 120 220
B 120 295
C50 220
D 120 375
E50 295
F w/o pressure prop 220
G50 375
Dimension e [cm]
max. 240.0
If the ballast is longer than this,
the rear spindle struts can no
longer be turned.
min. 220.0
Where the ballast is shorter
than this, a revised static calcu-
lation must be produced for
the supporting profiles
9730-101
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50
A
C
E
G
B
D
F
9730-300-01
e

The Formwork Experts
18 999771002 - 08/2008 Ü
User information Doka forming wagon T
Assembly instructions
The assembly workflow outlined here is for the
standard set-up. In practice, attention must also be
paid to the relevant assembly plan or shop draw-
ing!
Tools needed:
●Reversible ratchet 1/2"
●Extension piece 11cm
●Box nut 24
●Fork spanner 22/24
●Fork spanner 13/17
Position the Bogie for Forming
wagon TS
➤Lay the rails (A) .
➤Attach four-part lifting tackle to Bogie for Form-
ing wagon TS (B) .
Spreading angle of lifting tackle: max. 60°.
Close-ups of crane hoisting points
➤Lower the "Bogie for Forming wagon TS" onto
the rails.
a ... Centre-to-centre spacing of rails = 197.5 cm
x ... Distance from edge of bridge superstructure, as per shop
drawing
Rear crane-hoisting point Front crane-hoisting point, and
parking wedge to immobilise
the bogie
Warning about accidental movement of
bogie!
➤Fit parking wedges (C) to the "Bogie for
Forming wagon TS" to immobilise it in
both directions during all stages of the
erection operation
9730-203-01
B
9730-204-01
B
9730-204-01
C
B
9730-202-01
ax
A
B

User information Doka forming wagon T
19999771002 - 08/2008 Ü The Formwork Experts
Tilt up the vertical frame, and bolt in
the frame strut
➤Use the crane to tilt up the vertical frame (D) of
the "Bogie for Forming wagon TS" into the verti-
cal.
Close-up of crane hoisting point:
➤Take the frame strut (E) out of the "Parked" posi-
tion – in the horizontal – and bolt it into the verti-
cal frame of the "Bogie for Forming wagon TS",
securing it with a spring cotter.
View Z:
Place the ballast on the bogie
For details on the dimensioning and position of the
ballast (F) see the shop drawing and/or "Dimension-
ing of the ballast".
9730-205-01
Z
D
9730-206-01
9730-208-01
E
9730-211-01
F

The Formwork Experts
20 999771002 - 08/2008 Ü
User information Doka forming wagon T
Assemble the double jib
➤Set down the jibs with a centre-to-centre spacing
of b = 280.0 cm and stiffen with scaffolding tubes.
Make sure that the horizontal scaffolding tubes
all extend the same distance to either side of the
jibs.
b ... 280.0 cm
➤Adjust the position of the Jib slide (L) as shown
in the assembly plan.
Note:
If the Jib slide (L) is positioned very far back, ensure
that the suspension beam (M) can still be fitted
through from above. This can be achieved by not
fitting the two front scaffolding tubes until later.
c ... No stiffening tubes in this zone
Lift the double jib into the Bogie for
Forming wagon TS
➤Lift the assembled double jib (G) into the Bogie
for Forming wagon TS, bolt it into the vertical
frame (D) with a peg-in unit (O) and secure it.
Close-up of peg-in unit (O)
➤Bolt in the Spindle strut T6 (N) between the jib (G)
and the Bogie for Forming wagon TS (B) , and
secure it with a spring cotter.
GDouble jib for Forming wagon T
HScaffolding tube 48.3mm 4.50m
IScaffolding tube 48.3,mm 3.00m
JSwivel coupler 48mm
KSpindle strut GS T7 109/166cm
GDouble jib for Forming wagon T
LJib slide (included in scope of supply of Item G)
MSuspension beam for Forming wagon T
Assembling the jib on an assembly bench
with stop-bars and sleepers makes it easier
to keep the double jib both parallel and the
correct distance apart.
9730-212-01
b
G
H
I
J
KL
9730-213-01
c
G
L
M
NSpindle strut T6 100/150cm
9730-214-01
N
O
G
9730-216-01
O
D
G
9730-215-01
N
B