Peri SKYMAX Operator's manual

Instructions for Assembly and Use – Standard Configuration – Version 2.0
SKYMAX
LargePanelSlabFormwork

2
SKYMAXPanelSlabFormwork
Instructions for Assembly and Use – Standard Configuration
Content
B Shuttering
B1 Shuttering – General 42
Explanation of terminology 42
B2 Starter beam 43
Fitting the starter beam 43
B3 Control range 46
Shuttering without wall 46
Panels (aluminium and
polymer versions) 48
Forming above 3.80m 52
Arrangement of LoweringHeads
SXPLT2 52
Arrangement of PropHeadsSXPS 53
Assembly without a starter beam 54
B4 Change of direction 55
B5 Filler areas 56
General 56
Width compensation 57
Longitudinal infill 58
Component overview 59
Filler panels 59
Residual gap 60
Filler designs 62
Corner areas 65
Shuttering procedure 67
B6 Shuttering around columns 68
General 68
Preparation 68
Columns within the panel grid 69
Columns outside the panelgrid 70
B7 Cantilevers, guardrails 73
General 73
Cantilever at edge of building 74
Guardrail with GuardrailUnit
SXPGU100 74
Guardrail with GuardrailPost
HolderSXPGPRT2 and GPLT2
(foraluminium version) 80
Guardrail with Guardrail Post
HolderSXPGPRT2
and GPLT2 (for polymer version) 82
B8 Shuttering, concreting section 87
Guardrail at the concreting section 87
B9 Bracing 88
Applications of the
TensioningUnitSXPTU15
and BracingSXPTU3T2 88
C Striking
C1 Striking – General 94
C2 Compensations 95
General 95
Corner areas 96
Longitudinal infill 97
Width compensation 101
C3 Control range 102
General 102
Lowering head system 103
Backpropping 105
Prop head system 106
Overview
Main components 4
Key 5
Introduction
Target groups 6
Additional technical documentation 6
Intended use 7
Instructions for Use 7
Cleaning and maintenance instructions 8
Safety instructions
Cross-system 9
System-specific 10
Storage and transportation 10
A System components
A1 Prop heads 11
LoweringHeadSXPLT2 11
LoweringHeadSXPLQ 13
PropHeadSXPS 15
PropHeadSXPSPOLY 17
A2 Panels 18
Panel SXP P 18
PanelSXPPPOLY 20
A3 Starter beam 21
Starter beam SXP SB 21
A4 Shuttering aid 22
ShutteringAidSXPA 22
ShutteringAidSXPA530 23
PropGuideSXPPG 24
StrippingHammerSXPSH 25
A5 Wall holder 26
WallHolderSXPW 26
A6 Column frame 28
ColumnFrameSXPCFT2 28
A7 Guardrail unit 29
GuardrailUnitSXPGU100 29
A8 Guardrail post holder 30
GuardrailPostHolder
SXP GPRT2/GPLT2 30
A9 Tensioning unit 31
BracingSXPTU3100T2
(for use in aluminium panel) 31
BracingSXPTU3100T2
(for use in polymer panel) 33
BracingSXPTU366.5T2 34
TensioningUnitSXPTU15 34
TransverseTensionUnit SXPTUT 36
A10 Additional components 37
CompensationBeam SXPAB200T2 37
Double compensation beam 37
TelescopicGirderSXP TBR200-300
and TelescopicGirderSXP TBL200-300 38
Double telescopic girder 39
PanelClipsSXPC and
AssemblyAidSXPMA 40
A11 Component compatibility 41
Component compatibility in the
aluminiumand polymer versions 41

3SKYMAXPanelSlabFormwork Instructions for Assembly and Use – Standard Configuration
Content
C4 Starter beam 107
Lowering head system 107
Prop head system without
starter beam 108
C5 Cantilevers 110
Lowering head system 110
GuardrailUnitSXPGU100 110
Prop head system 113
GuardrailUnitSXPGU100 113
GuardrailPostHolderSXP
GPRT2/GPLT2 114
C6 Concreting section 115
Lowering head system 115
Prop head system 117
C7 Column frame 119
Column frame 119
C8 Change of direction 122
General 122
Lowering head system 122
Prop head system 124
D Logistics
D1 Storage and transportation 125
TransportPalletSXPTP 200x200 125
Single-usePalletSXPTPO 200x100 127
Crate Pallet 80 x 120 129
TransportPalletSXPTPF 200x100 130
TransportPalletSXPTPF 200x66.5 132
D2 RFID 134
RFID in the SKYMAX system 134
Application 134
Installing RFID in polymer panels 136
D3 Cleaning and maintenance 137
E Static design
E1 Design information 140
Notes on structural design 140
E2 Implementation log 141
E3 Prop loads 142
System with PropHeadSXPS 142
System with LoweringHeadSXPLT2 143
System with LoweringHeadSXP L T2 –
partial early striking with backpropping 144
Selection of suitable props when
usingLoweringHeadSXPLT2
and SXPLQ 146
Calculation of the fictitious prop height 147
Required number of screws in
system with LoweringHeadSXPLT2
andSXPLQ 148
E4 Slab props 149
PEP Ergo B 149
PEPErgoD 150
PEP Ergo E 153
PEPAlpha-2B 154
PEPAlpha-2D 155
PEP20 156
PEP30 158
Program overview

4SKYMAXPanelSlabFormwork Instructions for Assembly and Use – Standard Configuration
Main components
Overview
A1 A2 A6
A3
A5 A8
A9
A1 Panels
A2 Starter beam
A3 Prop heads
A4 Shuttering aid (not shown)
A5 Wall holder
A6 Column frame
A7 Guardrail post holder (not shown)
A8 Guardrail unit
A9 Bracing (not shown)

5
SKYMAXPanelSlabFormwork
Instructions for Assembly and Use – Standard Configuration
Overview
Key
Pictogram | Definition Dimensions
Dimensions are usually given incm.
Other measurement units, e.g.m,
areshown in the illustrations.
Conventions
■Instructions are numbered with:
1......, 2. ....., 3. ......
■The result of an instruction is
shownby: →
■Position numbers are clearly provided
for the individual components and
are given in the drawing, e.g.1, in
the text in brackets, for example (1).
■Multiple position numbers, i.e.
alternative components, are
represented with a slash: e.g. 1/2.
Notes on illustrations
The illustration on the front cover of
these instructions is understood to be
asystem representation only. The
assembly steps presented in these
Instructions for Assembly and Use are
shown in the form of examples with
only one component size. They are valid
for all component sizes contained in the
standard configuration.
To facilitate understanding, detailed
illustrations are sometimes incomplete.
The safety equipment which has
possibly not been shown in these
detailed illustrations must nevertheless
be available.
* If not identical to the action arrow.
Arrows
Arrow representing an action
Arrow representing a reaction
of an action*
Arrow representing forces
Safety instruction categories
The safety instructions alert site
personnel to the risks involved and
provide information on how to avoid
these risks. Safety instructions can be
found at the beginning of the section or
before instructions for action and are
highlighted as follows:
Danger
This sign indicates an extremely
hazardous situation which could result
in death or serious, irreversible injury, if
the safety instructions are not followed.
Warning
This sign indicates a hazardous
situation which could result in death or
serious, irreversible injury, if the safety
instructions are not followed.
Caution
This sign indicates a hazardous
situation which could result in minor or
moderate injury, if the safety
instructions are not followed.
Note
This sign indicates situations in which
failure to observe the information can
result in material damage.
Format of the safety instructions
Signal word
Type and source of hazard!
Consequences of non-compliance.
⇒Preventative measures.
Visual inspection
Tip
Incorrect use
Safety helmet
Safety shoes
Safety gloves
Safety goggles
Personal protective equipment
to prevent falling from a height
(PPE)
Danger/Warning/Caution
To be complied with
Note
Load-bearing point

6SKYMAXPanelSlabFormwork Instructions for Assembly and Use – Standard Configuration
Introduction
■PERI Structural Design Information
– SKYMAXLargePanelSlabFormwork
■Instructions for Assembly and Use:
– PEPErgoSlabProps
– RS and RSSPush-PullProps
– PERIUPFlex core components
– PROKITEP110SafetySystems
– PEPAlpha-2SlabProps
– PEP20/30SlabProps
■Instructions for Use:
– Pallet lifting trolley
– Pallets and stacking devices
– StrippingCartASW465
– Aluminium stripping cart
■User information:
– PERIUPFlexMobile WorkingPlatform
■Technical Data Sheet for TieBoltPERI14/20x130
■Design Tables 2015 – Formwork and Shoring
Target groups
Additional technical documentation
* Valid in Germany: Regulations for Occupational
Health and Safety on Construction Sites30
(RAB30).
** Instructions are given by the contractor
themselves or a competent person selected
bythem.
Contractors
These Instructions for Assembly and
Use are designed for contractors who
either
■assemble, modify and dismantle, or
■use the formwork systems, e.g. for
concreting, or
■allow them to be used for other
operations, e.g. carpentry or
electrical work.
Competent person
(Construction Site Coordinator)
The Safety and Health Protection
Coordinator*
■is appointed by the client,
■must identify potential hazards
during the planning phase,
■determines measures that provide
protection against risks,
■creates a safety and health
protection plan,
■coordinates the protective measures
for the contractor and site personnel
so that they do not endanger each
other,
■monitors compliance with the
protective measures.
Competent persons qualified to carry
out inspections
Due to the specialist knowledge gained
from professional training, work
experience and recent professional
activity, the competent person qualified
to carry out inspections has a reliable
understanding of safety-related issues
and can carry out inspections correctly.
Depending on the complexity of the
inspection to be undertaken, e.g. scope
of testing, type of testing or the use of
certain measuring devices, a range of
specialist knowledge is necessary.
Qualified personnel
Formwork systems may only be
assembled, modified or dismantled by
personnel who are suitably qualified to
do so. Qualified personnel must have
completed a course of training** in the
work to be performed, covering the
following points at least:
■Explanation of the plan for the
assembly, modification or
dismantling of the formwork in an
understandable form and language.
■Description of the measures for
assembling, modifying or dismantling
the formwork.
■Naming of the preventive measures
to be taken to avoid the risk of
persons and objects falling.
■Naming of the safety precautions in
the event of changing weather
conditions which could adversely
affect the safety of the formwork
system as well as the persons
concerned.
■Details regarding permissible loads.
■Description of all other risks and
dangers associated with assembly,
conversion, modification, dismantling
operations and use.
■In other countries, ensure that the
relevant national guidelines and
regulations in the respective
current version are complied with!
■If no country-specific regulations
are available, it is recommended to
proceed according to German
guidelines and regulations.
■A competent person must be
present on site during formwork
operations.

7
SKYMAXPanelSlabFormwork
Instructions for Assembly and Use – Standard Configuration
Use in a way not intended, deviating
from the standard configuration or the
intended use according to the
Instructions 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 system described in these
Instructions for Assembly and Use may
contain patent-protected components.
Instructions for Use
Intended use
Introduction
Technical data
System dimensions
With PropHeadSXPS
■Prop grid 2 x 1m:
Slab thickness of max. 40cm for
aluminium version,
as a standard case presented in the
Instructions for Assembly and Use.
Slab thickness of max. 35cm for
polymer version.
■Prop grid 1 x 1m:
with centre support:
Slab thickness of max. 55cm for
aluminium version.
Slab thickness of max. 35cm for
polymer version
With lowering head SXP LT2
■Prop grid 2 x 1m:
Slab thickness of max. 40cm for
aluminium version,
as a standard case presented in the
Instructions for Assembly and Use.
Slab thickness of max. 35cm for
polymer version
Accessories for infill areas, shuttering
around columns and for the slab edges
are also available.
Due to partial early striking with a
lowering head and backpropping, the
panels can be used quickly for the next
concreting cycle.
For supporting the SKYMAXPanels,
the following PERISlabProps may be
used subject to slab thickness and
ceiling height in accordance with the
PERI prop load table for the SKYMAX
system:
– For aluminium version: PEPErgo,
PEPAlpha-2 and PEP20/30,
– for polymer version: PEPErgo.
Area of application
PERI products have been designed for
exclusive use in the industrial and
commercial sectors only by suitably
trained personnel.
Product description
PERISKYMAX (aluminium version) is
apanel slab formwork system used for
constructing slab thicknesses up to
40cm; with centre support up to 55cm.
PERISKYMAX (polymer version) is a
panel slab formwork system used for
constructing slab thicknesses up to
35cm; with or without centre support.
The slab formwork is assembled and
dismantled from the erection surface
below. Up to a ceiling height of 3.80m
without a ladder or platform system.
Two different versions of the panels are
available:
■powder-coated aluminium version
■technopolymer version
Flatness deviation acc. to DIN18202
System without
centre support
Slab thickness d ≤ 35cm Line 7
Slab thickness 35cm < d ≤ 40cm Line 6
System with
centre support Slab thickness d ≤ 55cm Line 7
Flatness deviation acc. to DIN18202
System without
centre support
Slab thickness d ≤ 30cm Line 7
Slab thickness 30cm < d ≤ 35cm Line 6
System with
centre support Slab thickness d ≤ 35cm Line 7
Aluminium version
Polymer version

8SKYMAXPanelSlabFormwork Instructions for Assembly and Use – Standard Configuration
Introduction
Cleaning and maintenance instructions
Warning
Splintering parts / concrete residue
could cause injuries to the eyes and
hands.
⇒Wear protective goggles.
⇒Wear safety gloves.
In order to maintain the value and
operational readiness of the formwork
materials over the long term, clean the
panels after each use.
Some repair work may also be
inevitable due to the tough working
conditions.
The following instructions should help
to keep cleaning and maintenance
costs as low as possible.
Spray the formwork on both sides with
concrete release agent before each
use; this facilitates easier and faster
cleaning of the formwork. Spray the
concrete release agent very thinly and
evenly.
For the polymer version, do not use
diesel or kerosene as concrete release
agents, as these negatively affect the
surface of the polymer formwork.
Spray the rear side of the formwork with
water immediately after concreting; this
avoids any time-consuming and costly
cleaning operations.
When used continuously, spray the
formlining elements with concrete
release agent immediately after
striking; then clean by means of a
scraper, brush or rubber lip scraper.
Important: do not clean formlining
made of plywood with high-pressure
equipment. This could result in the
formlining being damaged.
Fix recesses and built-in parts with
double-headed nails; as a result, the
nails can easily be removed later, and
damage to the formlining is largely
avoided.
When placing bundles of reinforcement
bars or other heavy objects on
horizontally stored formwork elements,
suitable support, e.g. square timbers, is
to be used: this prevents impressions
and damage to the formlining to a large
extent.
Internal concrete vibrators should be
fitted with rubber caps if possible; as a
result, any damage to the formlining is
reduced if the vibrator is accidentally
inserted between the reinforcement
and formlining.
Never clean powder-coated
components, e.g. elements and
accessories, with a steel brush or hard
metal scraper; this ensures that the
powder-coating remains intact.
Use spacers for reinforcement with
large-sized supports or extensive areas
of support; this largely avoids
impressions being formed in the
formlining when under load.
Recurring inspections and use
The system components must be
checked by the contractor and the
proper condition ascertained. During
this process, the period of usability
must be checked above all else.
The components must be free of
damage (especially cracks).
The components may only be used if
the material is in good condition.
Identification marking
(forpolymer version only)
The planned period of usability for the
polymer panels is 10years. The
technical characteristics are guaranteed
for the period of usability.
The period of usability is checked by
means of the engraved production
date. If the period of usability is
exceeded, it is advisable to replace the
component.
The production date is engraved on
both front sides of the panels.
Example
Produced in November 2020 –
component can be used until
October2030.

9
SKYMAXPanelSlabFormwork
Instructions for Assembly and Use – Standard Configuration
Safety instructions
Cross-system
General
The contractor must guarantee that
theInstructions for Assembly and Use
supplied by PERI are available at all
times and understood by the site
personnel.
These Instructions for Assembly and
Use can be used as the basis for
creating a risk assessment. The risk
assessment is compiled by the
contractor. However, these Instructions
for Assembly and Use do not replace
the risk assessment!
Observe and comply with the safety
instructions and permissible loads.
For the application and inspection of
PERIproducts, the current safety
regulations and guidelines valid in the
respective countries must be observed.
Materials and working areas are to be
inspected on a regular basis, especially
before each use and assembly, for:
■damage,
■stability and
■functional correctness.
Damaged components must be
exchanged immediately on site and
may no longer be used.
Safety components are to be removed
only when they are no longer required.
Components provided by the contractor
must comply with the characteristics
stipulated in these Instructions for
Assembly and Use and all applicable
laws and standards. Unless otherwise
indicated, the following applies in
particular:
■Timber components: strength class
C24 for solid wood according to
DINEN338.
■Scaffold tubes: Galvanised steel
tubes with minimum dimension
Ø 48.3 x 3.2mm
according to DINEN12811-1:2003
4.2.1.2.
■Scaffold tube couplings according to
DINEN74.
Deviations from the standard
configuration are only permitted after a
further risk assessment has been
carried out by the contractor.
Appropriate measures for working and
operational safety, as well as stability,
are defined on the basis of this risk
assessment.
Corresponding proof of stability can be
provided by PERI on request, if the risk
assessment and resulting measures to
be implemented are made available.
Before and after exceptional
occurrences that may have an adverse
effect on the safety of the formwork
system, the contractor must
immediately
■produce another risk assessment
and make use of its results to take
suitable steps to guarantee the
stability of the formwork system,
■arrange for an extraordinary
inspection to be carried out by a
competent person qualified to do so.
The aim of this inspection is to
identify and rectify any damage in
good time in order to guarantee safe
use of the formwork system.
Exceptional events could be:
■accidents,
■long periods of non-use,
■natural events, e.g. heavy rainfall,
icing, heavy snowfall, storms or
earthquakes.
Assembly, modification and
dismantling work
Assembly, modification or dismantling
of formwork systems may only be
carried out by qualified persons under
the supervision of a competent person.
The qualified personnel must have
received appropriate training for the
work to be carried out with regard to
specific risks and dangers.
On the basis of the risk assessment
and the Instructions for Assembly and
Use, the contractor must create
installation instructions to guarantee
safe assembly, modification and
dismantling of the formwork system.
The contractor must ensure that the
personal protective equipment required
for the assembly, modification or
dismantling of the formwork system,
e.g.
■safety helmet,
■safety shoes,
■safety gloves,
■safety goggles,
is available and used as intended.
If personal protective equipment
against falling from a height (PPE) is
required or specified in local
regulations, the contractor must
determine appropriate attachment
points on the basis of the risk
assessment.
The PPE against falling to be used is
determined by the contractor.
The contractor must
■provide safe working areas for site
personnel, which are to be reached
through the provision of safe access
ways. Danger zones must be
cordoned off and clearly marked.
■guarantee stability during all stages
of construction, in particular during
assembly, modification and
dismantling operations.
■ensure and demonstrate that all
loads that occur are safely
transferred.
Use
Every contractor who uses or allows
formwork systems or sections of the
formwork to be used, is responsible for
ensuring that the equipment is in good
condition.
If the formwork system is used
successively or at the same time by
several contractors, the health and
safety coordinator must point out any
possible mutual hazards and all work
must be then coordinated.

10 SKYMAXPanelSlabFormwork Instructions for Assembly and Use – Standard Configuration
Strike components only when the
concrete has sufficiently hardened and
the person in charge has given the go-
ahead for striking to take place.
The load-bearing capacity of the slabs
that have been completed must be
activated so as to avoid overloading of
the slab props during vertical concreting
cycles. For this, free deflection capability
is required for these components.
Thiscan be done by releasing and re-
installing all slab props available.
This is also required for formwork
systems where the prop head is an
integral part of the slab formwork.
Permissible slab thickness (aluminium
version):
Max. 40cm.
With centre support:
Max. 55cm.
Permissible slab thickness (polymer
version):
Max. 35cm.
With centre support:
Max. 35cm.
The prevailing prop loads (see tables)
must be safely transferred by slab
props with a sufficient load-bearing
capacity.
When storing heavy items on the
formwork, the load-bearing capacity
must be taken into consideration.
Cantilevers may only be accessed after
bracing has been mounted.
Safety instructions
The horizontal fixed position of the slab
formwork must be guaranteed during
assembly and work operations at all
times. During assembly, this is
provided through the correct installation
of wall holders.
During work operations, this must be
guaranteed by peripheral walls and
beams cast in advance. This must be
inspected by the structural engineer.
Otherwise, transfer of the horizontal
loads has to be guaranteed by means
of other measures provided by the
contractor, e.g. bracing. Load
assumptions for horizontal loads in
accordance with DIN EN12812.
Do not climb on the formwork system,
only use the means of ascent and
descent provided.
Anchoring
Anchoring is to take place only if
theanchorage has sufficient concrete
strength.
Exceptional events
The following applies to the aluminium
and polymer versions: Larger panel
units are to be formed for wind speeds
of 28km/h and more. For this, connect
panels to each other and secure by
means of bracing or ballast.
The value given is valid for rectangular
buildings that are closed on all sides,
open on all sides or closed on one side.
For unfavourable structure geometries
or greater wind speeds, additional
securing measures are to be
implemented including the dismantling
of the formwork.
System-specific Storage and transportation
Store and transport components in
such a way that no unintentional
change in their position is possible.
Detach lifting accessories and slings
from the lowered components only if
they are in a stable position and no
unintentional change is possible.
Do not drop the components.
Also ensure that partial quantities are
secure at all times.
Use PERIliftingaccessories and slings
and only those load-bearing points
provided on the component.
During the relocation procedure
■ensure that components are picked up
and set down so that unintentional
falling over, falling apart, sliding, falling
down or rolling is avoided.
■no persons are allowed to remain
under the suspended load.
The access areas on the construction
site must be free of obstacles and
tripping hazards, as well as being slip-
resistant.
For transportation, the substrate must
have sufficient load-bearing capacity.
Use original PERI storage and transport
systems, e.g. crate pallets, pallets or
stacking devices