Peri CB 240 Operator's manual

Edition 11 | 2014
CB 240
Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
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B3 Formwork Utilisation
CB Carriage Operations 50
Formwork Alignment 51
Inclination Adjustment 52
Horizontal Movement – VARIO 52
B4 Crane-Assisted Climbing
Preparation 53
Moving procedure 55
C1 Planning and Work Preparation
Static System 56
Platform Dimensioning 57
Platform Decking 58
Handrails and Guardrails 61
Connecting VARIO GT 24 Formwork 62
Connecting TRIO Formwork 64
Moving the Units 66
Drawings and Plans 67
Use on Circular Structures 68
Corner Platforms 69
Components
Components 70
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Content
Introduction
Overview, Main Components 1
Key 4
Intended Use 5
Instructions for Use 5
General Safety Instructions 6
Storage and Transportation 6
System-Specific Safety Instructions 7
Additional Technical Documentation 7
Load Models 8
Standard Work Flow 10
A1 Assembly of the CB 240 Platform
Required Resources 12
Assembly of CB 240 Brackets 13
Girder Assembly 14
Assembly of CB 240 Carriage 16
Assembly of Decking for the
Working Platform 18
Assembly of Guardrails 20
A2 Other Assembly Work
Assembly of End Guardrail Posts 22
Assembly of Foldable Hatch 23
Assembly of Finishing Platform 24
Assembly of Finishing Tasks 25
B1 Work on the Construction Site
Anchoring 26
Mounting the Platform Unit 32
Mounting the Finishing Platform 34
Assembly of Wind Bracing 37
Removal of Climbing Cones 39
Dismantling of the Climbing Unit 39
Ladder Assembly 40
B2 Assembly of the Formwork Elements
VARIO GT 24 Element 42
TRIO Element 46
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1
Overview, Main Components
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Introduction
Concreting platform
Concreting height hB
Formwork height hs
Intermediate platform
Working platform
Finishing platform
9
7
6
11
1
8
3
4
10
5
5
2
Climbing Formwork CB 240 with
VARIO GT 24 Girder Wall Formwork
– Concreting height 5.40 m.
– Extended suspension of finishing
platform.
– Tension Anchor CB with DW 15 as
wind bracing.
– Intermediate platform on formwork.
*Formwork height =
concreting height + formwork projection
(max. 5.40 m)
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2
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Introduction
Overview, Main Components
1 Working platform with Climbing Bracket CB 240
2 Carriage CB 240 with Rack CB 240
3 Adjustable Brace CB 164-224
4 Strongback CB 270 or CB 380
5 Anchoring and Leading Anchor
6 Bracing Shoe Wall CB M24
7 Wind bracing with tension belt or tie rod
8 Finishing Platform with Platform Beam CB
9 Suspension of finishing platform
10 VARIO GT 24 or TRIO formwork with concreting scaffold
11 Bracing with scaffold tubes
Climbing Formwork CB 240 with TRIO
Panel Formwork
– Concreting height 3.60 m.
– Suspension of finishing platform,
single.
– Tension Belt CB as wind bracing.
*Formwork height =
concreting height + formwork projection
(max. 5.40 m)
Concreting height hB
Formwork height hs
Finishing platform
Concreting platform
Working platform
3
4
10
5
9
8
7
6
11
21
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3
L1
L2
5.2 5.1 5.75.6
5.4 5.5 5.65.3 5.7
5.8
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Introduction
Anchoring to the building structure
Version 1
5.4 Threaded Anchor Plate DW 15*
5.5 Tie Rod DW 15*, Z-12.4-70
L1= h – 8 cm or Tie Rod B15*, Z-12.5-82
5.3 Climbing Cone 2 M24/DW 15
5.6 Scaffold Mounting Ring M24, galv.
5.7 Hex. Bolt M24 x 120 ISO 4014-10.9
5.8 Spacer Tube DR 22* (optional)
L2= h – 18.5 cm (tolerance 0 to +5 mm)
Anchoring depth h ≥ 18.5 cm (variable).
* “Not re-usable”
When using the PVC Spacer Tube, the
tie rod (5.5) can be re-used.
Version 2
5.2 Threaded Anchor Plate DW 20*
5.1 Screw-On Cone 2 M24/DW 20
5.6 Scaffold Mounting Ring M24, galv.
5.7 Hex. Bolt M24 x 120 ISO 4014-10.9
Anchoring depth h = 15.5 cm (fix).
* “Not re-usable”
Overview, Main Components
15,5 cm
Ø 10 cm
h
Ø 8 cm
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4
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Introduction
Dimension Specifications
Dimensions are usually given in mm and
m. Other measurement units, e.g. cm,
are shown in the drawings.
Conventions
– Instructions are numbered
(1. ....., 2. ....., 3. .....)
Multiple position numbers, i.e. alternative
components, are represented with a
slash: 1 / 2.
Arrows
Actions
Forces
Key
General
The illustration on the front cover of
these instructions is understood to be a
system representation only. The assem-
bly steps presented in these Instructions
for Assembly and Use are shown in the
form of examples with only one compo-
nent size. They are valid for all component
sizes contained in the standard configu-
ration accordingly.
In order to ensure better understandibility,
detailed descriptions are partly incom-
plete. The safety installations which have
possibly not been shown in these de-
tailed descriptions must nevertheless be
available. Preceding working steps must
be complied with.
Safety Instructions
Visual Check
Load-bearing point
Personal protective equipment
to prevent falling from a height
(PPE)
Warning of suspended load
Note
Tip
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5
General
The use in a way not intended, deviating
from the standard configuration or the
intended use according to the Instruc-
tions for Assembly and Use, represents
a misapplication with a potential safety
risk, e.g. risk of falling.
Only PERI original components may be
used. The use of other products and
spare parts is not allowed.
Changes to PERI components are not
permitted.
The working platform can be supple-
mented with:
– formwork carriage, strongbacks and
adjustable braces for accommodating
the VARIO and TRIO formwork sys-
tems.
– a height-adjustable finishing platform
complete with access ladder which is
attached to posts.
– end-to-end guardrails on the working
and finishing platforms in accordance
with respective national guidelines.
– a tension anchor which prevents tip-
ping inwards.
Technical Data
– width of bracket: 2.40 m
– static height: 1.80 m
– retraction distance: 75 cm
– max. formwork height: 5.40 m
Product Description
PERI products have been exclusively
designed for use in the industrial and
commercial sectors by suitably trained
personnel.
The CB 240 climbing formwork system
is normally used as shoring in order to
support anchored wall formwork in ac-
cordance with EN 12812. The formwork
is firmly connected with the climbing
bracket and is moved as a single unit
suspended on a crane. The climbing
formwork can also be used as a working
platform. The working platform for ope-
rating the formwork consists of plan-
king, platform beams and two fixed
climbing brackets. These transfer the
loads deriving from the dead weight, live
loads and prevailing wind loads via the
anchorage and bottom pressure point
into the structure.
Intended Use
Instructions for Use
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Introduction
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6
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Introduction
General
These assembly instructions serve as
basis for the project-related risk assess-
ment and the instructions for the provisi-
on and use of the system by the con-
tractor.
However, they do not replace them.
The contractor must ensure that the
Instructions for Assembly and Use provi-
ded by PERI are available at all times for
the users and that they are also fully un-
derstood.
Safety instructions and permissible
loads must be observed at all times.
For the application and inspection of our
products, the current safety regulations
and guidelines in the respective coun-
tries where they are being used must be
observed at all times.
In order to guarantee the safety against
falling, the contractor must carry out a
site-specific risk assessment based on
these Instructions for Assembly and Use
and the included safety and warning in-
formation during each respective assem-
bly, modification and dismantling proce-
dure, as well as every time the system
is used! Based on the risk assessment,
appropriate measures regarding safety
against falling are to be implemented on
site.
The contractor must ensure that the
required personal protective equipment
required for the assembly, modification
or dismantling is available and used as
intended.
Storage and Transportation
Store and transport components ensu-
ring that no unintentional change in their
position is possible. Detach lifting gear
from the lowered components only if
they are in a stable position and no unin-
tentional change is possible.
Do not drop the components.
Safety Instructions
Safety Instructions
Materials and working areas are to be in-
spected on a regular basis especially be-
fore each use and assembly, and che-
cked for signs of damage as well as sta-
bility and functionality. Damaged
components must be exchanged imme-
diately on site and may no longer be
used.
The contractor has to provide safe wor-
king areas for site personnel which are
to be reached through the provision of
safe access ways. Areas of risk must be
cordoned off and clearly marked.
Safety components are removed only
when they are no longer required.
The contractor must guarantee the sta-
bility during all stages of construction
especially during assembly, modification
and dismantling. He must ensure and
prove that all loads can be safely trans-
ferred.
Any deviations from the standard confi-
guration may only be carried out after a
separate risk assessment has been
done by the contractor (user).
On this basis, appropriate measures for
the working and operational safety as
well as the stability are to be implemen-
ted. Appropriate proof of stability can be
provided by PERI if the risk assessment
and measures deriving from this are
readily available.
Use only suitable load-carrying equip-
ment to move the components as well
as the designated load-bearing points.
During the moving procedure, ensure
that components are picked up and set
down so that unintentional falling over,
falling apart, sliding or rolling is avoided.
When moving pre-assembled units by
crane, always use ropes to guide the
load.
Components provided by the contractor
must conform with the characteristics
required in these Instructions for Assem-
bly and Use as well as with all valid
construction guidelines and standards.
In particular, the following applies if
nothing else is specified:
– Timber components: Strength Class
C24 for Solid Wood according to
EN338.
– Scaffold tubes: galvanised steel tubes
with minimum dimensions of
Ø48.3x 3.2 mm according to
EN12811-1:2003 4.2.1.2.
– Scaffold tube couplings according to
EN 74.
In the event of unfavourable weather
conditions, e.g.
– poor visibility (fog),
– strong winds,
– snow,
suitable precautions and measures are
to be taken in order to ensure both work
and operational safety as well as stability.
In case of extraordinary events which
could compromise safety, e.g.
– storms,
– earthquakes,
– accidents,
– longer downtimes,
the system must be comprehensively
checked by a qualified person on behalf
of the contractor regarding the working
and operational safety as well as the sta-
bility. The results of the inspection are to
be documented.
The access areas on the jobsite must be
free of obstacles and tripping hazards as
well as being slip-resistant.
For transportation, the surface must
have sufficient load-bearing capacity.
Use original PERI storage and transport
systems, e.g. crate pallets, pallets or
stacking devices.
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7
System-Specific
Retract components only when the con-
crete has sufficiently hardened and the
person in charge has given the go-ahead
for striking to take place.
Anchoring is to take place only if the an-
chorage has sufficient concrete
strength.
Inspection of the anchoring and associa-
ted components must be carried out by
the contractor (user).
Enclosure of the platform or mounting
of additional surfaces which are exposed
to the influences of the wind changes
the stability and must therefore be che-
cked. If necessary, additional measures
must be implemented.
The platforms are to be inspected for
signs of damage by authorised person-
nel at regular intervals.
During operating conditions, working
areas at great heights are always to be
secured against falling objects through
the use of suitable construction
measures.
Hatches and openings on accessible
working areas must be kept closed
during working operations.
Concrete residue and other soiling that
could impair or cause the function to fail
must be removed. The platforms are to
be kept clean at all times.
As a result of the moving procedure,
falling edges are formed between the
platforms. Corresponding areas of risk
are to be secured.
In case the access hatches are blocked
when retracting the formwork as well as
during the entire moving procedure,
ensure that site personnel can still use
the emergency escape route.
Site personnel, construction materials or
tools may not be transported with the
crane during moving operations. Excep-
tions to this can be determined through
the operational working and assembly
instructions.
Safety Instructions
Introduction
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
– CB 240 Dimensioning Information
– CB 240 Climbing scaffold type test
– CB 240 and CB 160 Climbing System Brochures
– Instructions for Use for the Crane Splice 24
– Instructions for Use: MAXIMO Lifting Hook
– PERI design tables
Additional Technical Documentation
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8
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Introduction
Load Models
Working Position
The area-related loads correspond to
EN12811.
Concreting platform
150 kg/m²
LoadClass 2
Working platform
200 kg/m²
LoadClass 3
Finishing platform
75 kg/m²
LoadClass 1
300 kg/m2
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9
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Introduction
Finishing platform
75 kg/m²
LoadClass 1
Concreting platform
150 kg/m²
LoadClass 2
Working platform
200 kg/m²
LoadClass 3
Load Models
Concreting Position
The area-related loads correspond to
EN12811.
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Introduction
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
Preparation
1. Assemble wall formwork.
2.Assemble platforms.
3.Assemble finishing platform.
Standard Work Flow
10. Place formwork on platform unit and
secure.
11. Clean formwork and adjust if
necessary.
12. Reinforce second wall section.
13. Mount leading anchor and close
formwork.
14. Place formwork anchor.
15. Pour second wall section.
16. Remove advancing bolts and retract
formwork.
17. Mount scaffold mounting rings.
Initial use
1. Position wall formwork for first wall
section.
2.Add reinforcement to first wall
section.
3.Mount leading anchor and close
formwork.
4.Place formwork anchor.
5.Pour first wall section.
6.Remove advancing bolts and strike.
7. Mount scaffold mounting rings.
8.Attach platform unit.
9.Mount wind bracing if required.
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11
Introduction
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
28. Remove advancing bolts and retract
formwork.
29. Mount scaffold mounting rings.
30. Remove the following anchor from
the previous casting step.
31. Move climbing unit to next wall
section. Continue with standard
cycle.
32. Dismantle the climbing unit.
18. Attach finishing platform.
19. Move climbing unit to second wall
section.
20. Bolt on finishing platform and attach
guardrails.
21. If necessary, mount ladder.
Standard Cycle
22. Mount wind bracing if required.
23. Clean formwork and adjust.
24. Install reinforcement to wall.
25. Mount leading anchor and close
formwork.
26. Place formwork anchor.
2 7. Pour wall section.
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12
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
A1 Assembly of the CB 240 Platform
0.3
Fig. A1.03
83 mm 80 mm
240
2,398 m120 mm
82 mm 82 mm
CFig. A1.02
Fig. A1.01
0.5
0.2
0.2
Required Resources
Equipment and Tools
Hammer, wire pins, plumb line, 4 screw
clamps with 300 mm clamping length,
circular saw, electric drill, HSS drill
Ø6mm, Ø 8 mm, min. L = 180 mm
072180 Ratchet Wrench 1/2”
102784 Socket SW 24 – 1/2”
029620 Socket SW 19 – 1/2”
072170 Socket SW 13 – 1/2”
072150 Power Wrench M14, ASB 636
072210 Power Screwdriver SCU 7 – 9
072220 Bit Holder
072230 Magnetic Holder
072140 Bit Points TX 30
031480 Socket Wrench SW 36
027212 Allen Key SW 14
031080 Drill Bit Ø 25 mm
Assembly Surface
Width: approx. 3.50 m.
Length: maximum platform width + min.
2.0 m.
Attach stop bars and support.
(Fig.A1.01)
Aids
– Locating Block (0.1) 12 plywood
blocks 21 x 80 x 80 mm.
– Support (0.2) h = approx. 24 cm, e.g.
GT 24 L = max. bracket spacing + 1.0 m.
– Stop Bars (0.3) 1 plank 40 x 120 mm
1plank 80 x 80 mm L = max. bracket
spacing + 1.0 m.
– Gauge for bracket spacing (0.4) 1
plank 40 x 120 mm L = bracket spacing
+ max. 1.0 m Formlining blocks (4).
(Fig. A1.02)
– Diagonal bracing for securing bracket
(0.5) 1 plank 40 x 120 mm, L = 2.0 m.
(Fig. A1.03)
Are the stop bars and support mounted
parallel to each other?
82 mm 82 mm
1,0 m
2,0 m
3,5 m
62 mm 62 mm
C
ca. 50 cm
2 stop bars
Support
Centre line of bra-
cket
Centre line of bra-
cket
Wall side
Section A-A
Guardrail side
A
A
Fig. A1.01a
0.2
0.1
0.1
0.1 0.4
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13
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
A1 Assembly of the CB 240 Platform
6.Lift in second bracket and align using
bracket spacing gauge. Fix gauge
using screw clamps. Check bracket
spacing. (Fig. A1.07)
Fig. A1.04
Fig. A1.05
Fig. A1.06
Fig. A1.07
Fig. A1.08
Assembly of CB 240 Brackets
Assembly
1. Check centre-to-centre spacing of
brackets regarding the planned
measurement, or measure spacing of
climbing cones already cast in con-
crete.
2.Adjust centre-to-centre spacing of bra-
ckets to the support (0.2). (Fig. A1.04)
The bracket axes form a right-angle to
the stops and support.
3.Fix locating blocks (0.1). (Fig. A1.05)
For spacings: see Fig. A1.02.
4.Lift first bracket (1.1) vertically into the
stops and then align.
5.Fix together with the diagonal bracing
(0.5). (Fig. A1.06)
7. Fix two scaffold tubes (11.1) to screw
couplings (1.3) in a parallel position to
provide support.
8.Brace with diagonal scaffold tube
(11.2) and two swivel couplings (11.3).
(Fig. A1.08)
The brackets are now aligned.
0.2
0.1
0.5
1.1
1.3
11.1
11.3
11.2
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14
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
A1 Assembly of the CB 240 Platforms
Girder Assembly
When using PERI GT 24 girders,
strengthen them on both sides in the
area of the brackets with plywood
strips (13.2).
(Fig. A1.09)
Dimensions: thickness/width/height
27x120 x 300 mm.
Fixing: Torx TSS 6 x 60.
Assembly
1. Fix girder (13.1) by means of screw
clamps. (Fig. A1.10)
2.Fix diagonals to the fixing plates using
two hex. wood screws 6 x 80 DIN 571
(13.3) each. (Fig. A1.11)
Alternatively:
Round head bolts M6 x 100 DIN 603 and
washer, or M6 x 180 (13.4) for double
girders.
Pre-drill girders when using round head
bolts. Use round head bolts for longer
girder cantilevers.
Timbers must be fixed accordingly.
The girders are now assembled.
Fig. A1.09
Fig. A1.10
Fig. A1.11
13.2
13.1
13.1
13.2
13.3
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15
13.6
13.3
13.2
13.7
13.3
13.6
13.4
13.2
13.2
13.4
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
A1 Assembly of the CB 240 Platform
Fig. A1.12 Fig. A1.13
Fig. A1.14 Fig. A1.15
Double Girder Position
– plywood or 3-ply board (13.2)
– timber 8/16 (2x) or 16 x 16 (1x) (13.6)
– round head bolt M6 x 180 DIN 603
(13.4)
– GT 24 lattice girder (13.7)
(Fig. A1.14 + A1.15)
These drawings conform to Appendix
K15 of the type test issued by the State
Structural Inspectorate, Düsseldorf, test
certificate no. P31 – 95/91 and may only
be used in accordance with the afore-
mentioned type test.
Single Girder Position
– plywood or 3-ply board (13.2)
– hex. wood screw 6 x 80 DIN 571
(13.3)
– timber 8/16 (13.6)
– GT 24 lattice girder (13.7)
(Fig. A1.12 + A1.13)
GT 24 Girder Timber
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16
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
A1 Assembly of the CB 240 Platforms
2.2
2.4
2.4
2.4 2.3, 2.4
2.3, 2.4 2.3, 2.4
Assembly of CB 240
Carriage
Assembly
1. Retract the wedge (2.2).
2.Insert rack (2.7) into the carriage (2.1).
(Fig. A1.16)
3.Secure with wedge (2.2). (Fig. A1.17)
4.Remove lower-positioned bolts (2.4)
and roller (2.3) from the carriage.
(Fig.A1.16)
Fig. A1.16
Fig. A1.17
Fig. A1.18
5.Depending on the height of the gir-
ders (24 cm or 16 cm), mark out both
bolts (2.4) and roller (2.3) accordingly.
(Fig. A1.18)
24
16
(2.1) Carriage CB 240
(2.2) Wedge
(2.3) Rollers Ø 60 x 85
(2.4) Bolt Ø 25 x 180 with Cotter Pin 4/1
(2.5) Traction Screw SW 19
2.7
2.8
2.9
2.1
2.6
2.3
2.4
2.22.5
2.42.3, 2.4
(2.6) Bolt Ø 16 x 65/86 with Cotter Pin 4/1
(2.7) Rack
(2.8) Strongback Connection Ø 26
(2.9) Adjustable Brace Connection Ø 26
Girder h = 24 cm Girder h = 16 cm
2.3
2.4
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17
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
A1 Assembly of the CB 240 Platforms
Assembly of CB 240
Carriage
Assembly
6.Position carriage (2.1) on the bracket
(1.1). (Fig. A1.19)
The mounting for the Strongback is
facing the formwork side.
7. Push roller (2.3) on bolt (2.4). On
theguardrail side, insert and secure
underneath the bracket beam.
(Fig.A1.20)
8.Insert and secure second bolt on the
formwork side. (Fig. A1.16)
9.Assemble carriage on second bracket
in the same way.
Risk of crushing!
Hold carriage when detaching!
Check the position of the rollers!
(Fig. A1.21)
10. Remove wedges from carriage. Ex-
tend rack (2.7) and attach to bracket
with bolts Ø 16 x 65/86 and cotter
pins (2.6). (Fig. A1.22)
Push carriage upwards and secure
with the wedges to the rack.
Fig. A1.19
Fig. A1.20
Fig. A1.21
Fig. A1.22
2.1
1.1
2.4
2.72.6
2.3
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18
13.5 13.1
81 mm
CB 240 Climbing Formwork
Instructions for Assembly and Use – Standard Configuration
A1 Assembly of the CB 240 Platforms
Assembly of Decking for the
Working Platform
Assembly
1. Cut planking at right angles,
L = 2.326 m.
2.At platform ends, fix each plank flush
to the girders (13.1). (Fig. A1.23)
Planking is flush with bracket front edge
on the wall side.
Projecting length: 81 mm over girder on
the wall side. (Fig. A1.24)
Mounting: Torx TSS 6 x 80 (13.5) 2 x per
girder support.
Alternatively: nails 38 x 100.
3.For accurate positioning, use plumb
line. (Fig. A1.24)
4.Fix remaining planking. (Fig. A1.25)
– Assembly details for the sliding hatch
are to be found in A2.
– Joint width in planking max. 2 cm.
Fig. A1.23
Fig. A1.24
Fig. A1.25
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