999800902_2010_10_online

The Formwork Experts

10/2010

en-GB999800902

User informationMethod statement

Protection screen Xclimb 60

98009-240-01

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Introduction User information Protection screen Xclimb 60


Introduction

by Doka Industrie GmbH, A-3300 Amstetten

User information Protection screen Xclimb 60 Introduction

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Contents4 Introduction4 Elementary safety warnings7 Eurocodes at Doka8 Several utilisations one system

10 System description11 System overview12 Functional principle14 System dimensions

15 Structural design15 Loading data16 Structural design

18 Anchoring on the structure

22 Assembly instructions30 Starting up

32 Repositioning32 Hydraulic system33 Hydraulic repositioning36 Resetting by crane

39 Dismantling

40 Additional areas of use41 Variable clearance between floor-slab and

vertical profile42 Imposed loads44 Inclined facades46 Varying inclinations48 Floor support Xclimb 60 / Floor support

Xclimb 60 adjustable

52 Loading platform52 Protection screen Xclimb 60 with integral loa-

ding platform56 Loading platform Xclimb 60 for constant

storey heights60 Loading platform Xclimb 60 for non-constant

storey heights

66 General remarks66 Design variants74 Using the Protection screen Xclimb 60 in con-

junction with . . .75 Fall-arrest systems on the structure76 Transporting, stacking and storing77 Doka service offerings

78 Component overview

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IntroductionElementary safety warnings

User target groups This User Information booklet (Method Statement) is

aimed at everyone who will be working with the Doka product or system it describes. It contains informa-tion on the standard design for setting up this sys-tem, and on correct, compliant utilisation of the sys-tem.

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 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.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 User Information booklet!

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.

Instruction as required by EN 13374: If a person or object falls against, or into, the edge

protection system and/or any of its accessories, the edge protection 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. 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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Important note:The first time of putting into service and the first typical sequence of a hydraulic raising oper-ation must all be supervised by a Doka Form-work Instructor or other authorised technician.

All persons who are going to put the Doka automatic climbing formwork Xclimb 60 into operation need special knowledge which can only be passed on by skilled Doka per-sonnel in a special instruction and training programme.

As proof that they have received such spe-cial instruction, an "OPERATION LICENCE" is issued to persons who have undergone this training course.

Persons who have not obtained this "OPER-ATION LICENCE" are not allowed to perform hydraulic repositioning on the Doka auto-matic climbing formwork Xclimb 60.


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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 resistance e.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, wind Values from EN 12812

M Partial 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

Ed

Rd

Permissible stress design EC/DIN concept

Factual Fpermissible Ed RdA Utilisation factor

60 [kN]

60

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Several utilisations one systemAll the utilisations set out here are based on the same functional principle and use the same key components.

Protection screen Xclimb 60Full-area enclosure for safeguarding work on the floor-slab formwork.Loading platforms can be integrated in the protection screen, for inbound/outbound loading of equipment.

Loading platform Xclimb 60An easy-to-reposition loading platform for constant or non-constant storey heights.

98009-240-01

This manual deals with the Protection screen Xlimb 60 and the Loading platforms Xclimb 60 only.

98009-241-01


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Automatic climbing formwork Xclimb 60Innovative self-climbing formwork for safe, fast reposi-tioning.

Guided climbing formwork Xclimb 60Innovative climbing formwork for safe, fast reposition-ing by crane.

Follow the directions in the Automatic climbing formwork Xclimb 60 User Information booklet!

98010-252-01

Follow the directions in the "Guided climbing formwork Xclimb 60" User Information booklet!

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System description User information Protection screen Xclimb 60


System descriptionSystem description

Protection screen Xclimb 60 guided repositioning, either by crane or hydraulicallyThe Doka protection screen Xclimb 60 is a system in which the entire unit is structure-guided at all times, even while being repositioned.

Resetting by craneEven in windy conditions, an entire unit is repositioned safely and easily in one single lift.

Hydraulic repositioningPortable hydraulic components can be added to make the Protection screen Xclimb 60 independent of the crane.

High safety in every phase of the work The system is guided up, and secured to, the struc-

ture during lifting. operators are protected from all climatic influences safe repositioning also possible in high winds

High flexibility variable influence widths, for ideal adaptation to

structure geometry working platforms can be attached anywhere on

scaffold suitable for storey heights of between 2.70 and

4.50 m

User information Protection screen Xclimb 60 System description

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System overview

Suspension point Floor support Xclimb 60 rigid

- For anchoring the protection screen to the floor-slab. The "Guiding shoe" is fastened to the "Floor support", with a Cone screw B 7cm.

Guiding shoe Xclimb 60 rigid- Provides guidance during repositioning, and load-

transfer.

Vertical profile Xclimb 60 Vertical profile Xclimb 60 10.75m

- For guiding the screen unit through the "Guiding shoes". Climbing cams on this vertical profile give it a safe, firm hold in the "Guiding shoe".

Shackle Xclimb 60 6.5to- Attachment point for fixing the screen unit to the

structure at the start of operations.- Attachment point for lifting the screen unit by

crane. Strengthening profile Xclimb 60 2.00m

- To increase the influence width, a Strengthening profile Xclimb 60 2.00m can be bolted onto the vertical profile.

Working platformThis facilitates work on slab stop-ends and pre-stressed floor-slabs.Consisting of: Connector WS10 Xclimb 60 Multi-purpose waling WS10 Top50 0.50m Corner connecting plate SK Multi-purpose waling WU12 Top50 3.00m Pressure strut Xclimb 60 0.67mThe individual components are joined together with Connecting pins 10cm and Spring cotters 5mm.

Hydraulic system Hydraulic cylinder Xclimb 60

- Is fixed onto the "Guiding shoe" to perform hydraulic raising. The screen unit is raised in 300 mm steps.

Lifting mechanism Xclimb 60- This is bolted onto the hydraulic cylinder when the

system is first assembled. In the hydraulic raising operation, the lifting mechanism meshes with the climbing cams of the vertical profile and pushes the entire unit upward.

A Floor support Xclimb 60 rigidB Cone screw B 7cmC Guiding shoe Xclimb 60 rigidD Shackle Xclimb 60 6.5toE Vertical profile Xclimb 60 10.75mF Strengthening profile Xclimb 60 2.00mG Screw-set for Strengthening-profile Xclimb 60H Connector WS10 Xclimb 60I Multi-purpose waling WS10 Top50 0.50mJ Multi-purpose waling WU12 Top50 3.00mK Corner connecting plate SKL Pressure strut Xclimb 60 0.67mM Hydraulic cylinder Xclimb 60N Lifting mechanism Xclimb 60

9800

9-20

2-01

A CB

I

K

H

L

E

J

F

G

M

N

D

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Functional principle

Resetting by crane

Unit for repositioningis in starting position.

Crane-lift the unit for repositioning into the

desired position.The vertical profile is safely

guided in at least 2 "Guiding shoes".

Lower the screen unit until the climbing cams are

resting on the pressure bolts.

The repositioned unit isin its new position.

98009-203-01

98010-254-01

9800

9-20

4-04

98010-253-01

9800

9-23

4-04

98009-205-01

User information Protection screen Xclimb 60 System description

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Hydraulic repositioning

Unit for repositioningis in starting position.

The unit for repositioning is raised by repeated extension and retraction of the hydraulic cylinders.

The repositioned unit isin its new position.

Lifting mechanisms mesh with the climbing cams and

push the unit upward.The vertical profile is safely

guided in at least 2 "Guiding shoes".

Lower the unit until the climbing cams are resting

on the pressure bolts.Continue retracting the

hydraulic cylinders until the lifting mechanism can

mesh with the next climb-ing cam.

98009-206-01

9801

0-25

6-01

98010-254-01

9800

9-20

7-04

9801

0-25

7-01

9800

9-20

9-04

98010-253-01

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System dimensions

Dimensions in mma ... storey height 2700 - 4500 mm

9800

9-20

1-01

920

11

00

a

30

0

2

45

20

00

6

50

0

2

50

0

a

1500

12

60

0

350480

User information Protection screen Xclimb 60 Structural design

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Structural designLoading data

Anchoring on the structure

Imposed loads

Anchoring forces per suspension point

Working platforms

V ... permitted vertical load max. 30 kNH ... permitted horizontal load: max. 60 kN

For higher imposed loads than these, the Floor supports Xclimb 60 described in the section headed "Additional areas of use" must be used.

Max. anchoring forces:FX, k = 60 kN (Ed = 90 kN)FZ(1),k = 65 kN (Ed = 97.5 kN)FZ(2),k = 106 kN (Ed = 159 kN)

V

H

98009-248-01

FZ(1)

FX

FZ(2)

98009-248-01

A Multi-purpose waling WU12

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

9800

9-20

1-02

A

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Structural design User information Protection screen Xclimb 60


Structural design

Wind pressure1) Determine the wind pressure as a function of the

wind speed, the building environment and the structure height.

2) Refer to the relevant curve (A) to (H) in the follow-ing diagrams.

Note:Intermediate values may be linearly interpolated.

Influence width

when Trapezoidal metal sheet 35x207mm 1.03x.....m is used Select the influence width as a function of the storey

height.

With no Strengthening profile Xclimb 60 2.00m

With Strengthening profile Xclimb 60 2.00m

Examples Basic data:

- curve (B) (wind pressure = 1.70 kN/m2)- enclosure with trapezoidal metal sheet- storey height: 3.50 m

With no Strengthening profile Xclimb 60 2.00m- influence width: 2.10 m

With Strengthening profile Xclimb 60 2.00m- influence width: 2.75 m

Wind pressure [kN/m2]we = cp, net x q(Ze)

2.21 1.70 1.43 1.36 1.30 1.10 1.04 0.88Curve (A) (B) (C) (D) (E) (F) (G) (H)

Follow the directions in the Calculation Guide "Wind loads to the Eurocodes" when determin-ing the wind pressure!

Important note: The diagrams apply to the following imposed

loads:- V ... permitted vertical load: max. 30 kN- H ... permitted horizontal load: max. 60 kN

The diagrams are only valid so long as the protection screen does not extend more than 2.0 m above the new floor-slab.

The structural design data given here apply only to standard assignments on straight walls.For assignments on e.g. inclined walls, sep-arate statical verification must be performed.

Take account of the available length of the squared timbers when planning the project.The squared timbers needed for the enclo-sure must be the same length as the overall width of the protection screen.

a ...

sto

rey

heig

ht [m

]

Influence width [m]

To increase the influence width, a Strengthen-ing profile Xclimb 60 2.00m can be bolted onto the vertical profile.For more information, see the section headed "Design variants".

a ...

sto

rey

heig

ht [m

]

Influence width [m]

9800

9-10

2

4.5

4.3

4.1

3.9

3.7

3.5

3.3

3.1

2.9

2.7

2.50.00 1.00 2.00 3.00 4.00 5.00 6.00

FB ECA D G H

9800

9-10

4

4.5

4.3

4.1

3.9

3.7

3.5

3.3

3.1

2.9

2.7

2.50.00 1.00 2.00 3.00 4.00 5.00 6.00

FB ECA D

G

H

User information Protection screen Xclimb 60 Structural design

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when Trapezoidal perforated sheet 35x207mm 1.03x.....m is used Select the influence width as a function of the storey

height.

With no Strengthening profile Xclimb 60 2.00m

With Strengthening profile Xclimb 60 2.00m

Examples Basic data:

- curve (B) (wind pressure = 1.70 kN/m2)- enclosure with perforated trapezoidal sheet- storey height: 3.50 m

With no Strengthening profile Xclimb 60 2.00m- influence width: 2.80 m

With Strengthening profile Xclimb 60 2.00m- influence width: 3.60 m

a ...

sto

rey

heig

ht [m

]

Influence width [m]

To increase the influence width, a Strengthen-ing profile Xclimb 60 2.00m can be bolted onto the vertical profile.For more information, see the section headed "Design variants".

a ...

sto

rey

heig

ht [m

]

Influence width [m]

9800

9-10

8

4.5

4.3

4.1

3.9

3.7

3.5

3.3

3.1

2.9

2.7

2.50.00 1.00 2.00 3.00 4.00 5.00 6.00

F

B ECA D

G

H

9800

9-10

7

4.5

4.3

4.1

3.9

3.7

3.5

3.3

3.1

2.9

2.7

2.50.00 1.00 2.00 3.00 4.00 5.00 6.00

F

B

E

CA

D

G

H

A Strengthening profile Xclimb 60 2.00m98

009-

200-

08

A

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Anchoring on the structure User information Protection screen Xclimb 60


Anchoring on the structureAnchoring on the structureComponents:

Both the positioning points and the suspension points are prepared using one single type of cone, the Univer-sal climbing cone (A) .

Dimensioning the suspension point

Preparing the positioning point and suspension point

Prevent the vibrator from touching the positioning-point.

Tools needed: Reversible ratchet 3/4" Spanner for Universal climbing cone 15.0/20.0 Box nut 50 3/4" (for Cone screw B 7cm)

A Universal climbing cone 15.0B Sealing sleeve K (expendable anchoring component)C Cone screw B 7cmD Stop-anchor (expendable anchoring component)F Depth mark

Depth of concrete cover on "cone" side of wall: 5.5 cm

Depth of concrete cover on the "stop-anchor" side in a slab of minimum thickness: 2 cm

Minimum slab thicknessStop-anchor 15.0 11.5cm 19 cmStop-anchor 15.0 16cm 24 cmStop-anchor 15.0 40cm 48 cm

The required cube compressive strength of the con-crete at the time of loading must be specified sepa-rately for each project by the structural designer. It will depend on the following factors: load actually occurring length of the stop-anchor reinforcement / extra reinforcement steel distance from edgeThe introduction of the forces, the transfer of these forces into the structure, and the stability of the overall construction, must all be verified by the structural designer.The required cube compressive strength fck,cube,current must be at least 10 N/mm2, however.

9767-321-01

D

F

C

B

A WARNING Always screw the Stop-anchor into the Uni-

versal climbing cone until it fully engages (i.e. up to the depth mark). Not screwing the anchor sufficiently far into the cone may subsequently lead to reduced load-bearing capacity and to the failure of the suspension point resulting in injury and damage.

For the positioning point and suspension point, ONLY use Cone screws B 7 cm (head of screw is red, to indicate its high load-bear-ing capacity)!

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.

C Cone screw B 7cmG Floor support Xclimb 60 rigidH Guiding shoe Xclimb 60 rigid

98009-243-01

G

H

C

C

User information Protection screen Xclimb 60 Anchoring on the structure

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Positioning point Screw the Stop-anchor into the Universal climbing

cone, until it engages (up to the depth mark). Fasten the Universal climbing cone to the installation

template with a Cone screw B 7cm.

Fix the installation template to the stop-end form-work.

Tie the Stop-anchor tightly to the reinforcements with binding wire.

a ... Centre-to-centre spacing ( 20 mm) b ... 480 mm ( 10 mm)

Note:Universal climbing cones are supplied with Sealing sleeves K (B) . Every time the Universal climbing cones are used again, fit them with new sealing sleeves first!

The installation template ensures that the posi-tioning-point is correctly located.

Important note: The positioning-point must align with the suspension point beneath it ( 10 mm in the horizontal).

92841-222-02

92841-222-01

b

98009-242-01

b

a

The axis of the universal climbing cone must be at right-angles to the surface of the con-crete maximum angle of deviation: 2.

Do not exceed the tolerances for the loca-tions of the positioning point and suspension point.

Embed the Universal climbing cone so that it is flush with the concrete surface.

Protect the thread from soiling.

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Anchoring on the structure User information Protection screen Xclimb 60


Suspension point Screw a Cone screw B 7cm into the end face of the

Floor support.

a ... 35 mm Fix the Floor support Xclimb 60 in the Universal

climbing cone 15.0 with a second Cone screw B 7cm. A tightening torque of 100 Nm (20 kg assuming a ratchet-length of approx. 50 cm) is sufficient.

Forcibly tightening the Cone screw B 7cm any more than this may cause damage and even cause the form-tie to break!

The only tool allowed to be used for screwing in and fix-ing the Cone screw B 7cm in the Universal climbing cone is the Reversible ratchet 3/4".

Remove the safety pin. Push the "Guiding shoe" onto the cone screw on the

"Floor support". Tighten the cone screw. A tightening torque of

100 Nm (20 kg assuming a ratchet-length of approx. 50 cm) is sufficient.

Insert the safety pin into the "Guiding shoe" until it is fully engaged

Turn the safety pin downwards.

The "Guiding shoe" is now secured against acciden-tal lift-out.

Reversible ratchet 3/4"

Reversible ratchet 3/4" with extension Ratchet MF 3/4" SW 50

98009-249-02

a

98009-249-01

Tr687-200-01Tr687-200-01 Tr687-200-01

I Safety pin

C Cone screw B 7cmI Safety pin

The handle of the safety pin must be pointing downwards!

98009-283-01

I

98009-304-01

C

I

User information Protection screen Xclimb 60 Anchoring on the structure

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Retrofitting a safe suspension pointe.g. if the crew forgot to prepare a positioning-point. Drill a hole of diam. 25 mm. Drill a hole of diam. 55 mm and 130 mm depth. Screw the Cone screw B 7cm into the Universal

climbing cone. Screw the tie-rod into the Universal climbing cone

until it is fully engaged, and put the rod part-way into the hole.

Paste the ready-mix mortar (site-provided) into the drilled hole with a spatula.

a ... 25 mm b ... 130 mm c ... 55mm

Insert the unit so that the Universal climbing cone is flush with the concrete surface.Scrape away the excess ready-mix mortar with the spatula.

Screw the welded Super-plate onto the underside of the concrete floor-slab and secure it with a screw and dowel so that it cannot be accidentally unscrewed.

Mount the "Floor support" and "Guiding shoe" in the same way as for the standard suspension point.

Dimensioning the suspension pointA Universal climbing cone 15.0B Sealing sleeve K (expendable anchoring component)C Cone screw B 7cmD Tie-rod 15.0mmE Ready-mix mortar

98009-276-01

A

B

C

D

E

a

b

c

Important note: Weld a seam onto the Super-plate to join the nut and the plate. Do this BEFORE screwing the Super-plate onto the tie-rod.

E Super-plate 15.0F Dowel, 12G Hexagon timber screw 10x50H Weld-seam

The required cube compressive strength of the con-crete and ready-mix mortar at the time of loading must be specified separately for each project by the struc-tural designer. It will depend on the following factors: load actually occurring slab thickness reinforcement / extra reinforcement steel distance from edgeThe introduction of the forces, the transfer of these forces into the structure, and the stability of the overall construction, must all be verified by the structural designer.The required cube compressive strength fck,cube,current must be at least 10 N/mm2, however.

98009-277-01

I

F

G

H

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Assembly instructions User information Protection screen Xclimb 60


Assembly instructionsAssembly instructionsThe modular design of the Xclimb 60 system means that many different combinations are possible.Depending on the project, the actual design may thus differ very greatly from the basic type described here. In these cases, you should discuss the assembly

procedure with your Doka technician. Follow the shop drawing / assembly plan exactly.

Note:The plank and board thicknesses given here comply with the C24 category of EN 338 (S10 of DIN 4074).

In Germany, wooden deck-boards must bear the "-symbol" mark of conformity.

Overview of assembly steps

1. Lay down the Vertical profiles Xclimb 60.2. Mount the Connectors WS10 Xclimb 603. Mount the bracing tubes.4. Mount the Shackles Xclimb 60 6.5to.5. Mount squared timbers.6. Mount the sideguards.7. Mount the gap decking.8. Assemble the working platform.9. Mount the trapezoidal sheeting.10.Assemble the enclosure of the working platform.

Important note: A hard, flat, firm surface is needed! Prepare a sufficiently large assembly area. Tightening torque of the couplers for the

bracing tubes: 50 Nm

98009-210-011

3

5

6

7

8

9

10

24

User information Protection screen Xclimb 60 Assembly instructions

23999800902 - 10/2010


Laying down the Vertical profiles Xclimb 60 Prepare squared timbers to lay the vertical profiles

down upon (height: at least 0.2 m). Lay down the vertical profiles, spaced apart by the

exact centre-to-centre distance.The climbing cams must be facing down here.

Arrange the vertical profiles so that both diagonals are the same.

a ... centre-to-centre spacing (tolerance max. 5 mm)x = y ... diagonals (tolerance max. 10 mm)

Mounting the Connectors WS10 Xclimb Screw the Connectors WS10 to the planned posi-

tions on the vertical profile. Insert the screws as shown, from above.Width-across 24 mm

Included in scope of supply: 4 hexagonal bolts M16x50 4 hexagon nuts M16 4 washers 17 1 Connecting pin 10cm 1 Spring cotter 5mm

Fitting the bracing Brace the vertical profiles both horizontally and diag-

onally.Width-across 22 mm

Distance between swivel coupler and screw-on cou-pler: max. 160 mm.

Mounting the "Shackle Xclimb 60 6.5to" Bolt the shackle to the vertical profile with a threaded

bolt and hexagon nut.Width-across 36 mm

Secure the hexagon nut with a cotter pin.

Included in scope of supply: 1 threaded bolt M24 1 hexagon nut M24 1 cotter pin

A Vertical profile Xclimb 60 10.75m

B Connector WS10 Xclimb 60

98009-211-01

xy

a

A

98009-213-01

B

C Screw-on coupler 48mm 50D Swivel coupler 48mmE Scaffold tube 48.3mm

F Shackle Xclimb 60 6.5to

Follow the directions in the "Shackle Xclimb 60 6.5to" Operating Instructions!

C

E

D

98009-212-01

98009-214-01

F

24 999800902 - 10/2010



Mounting the squared timbersThe cross-section and spacing of the squared timbers will depend on the project in question. Place the squared timbers onto the vertical profiles

and screw them on.Width-across 17 mm Bore diameter: 12 mm

Cross-section of squared timbers: min. 10 x10 cm Spacing between squared timbers: max. 110 cm

Connecting the squared timbers to the vertical pro-files

Nuts & bolts etc. required for each connection: 2 square bolts M10

(length will depend on the cross-section of the squared timbers)

2 washers V 11 DIN 440 (on timber side) 2 washers R 11 DIN 440 (on steel side) 2 hexagon nuts M 10

Note:See the section headed "Design variants" for informa-tion on how to use the Strengthening profile Xclimb 60 2.00m.

Mounting the sideguards Fix squared timbers to both end faces, using univer-

sal countersunk screws.

Attach the rubber sheet to the squared timber on one side of the the screen unit, with wooden battens and universal countersunk screws.

a ... 100 mm

G Squared timber

98009-217-01G

98009-229-01

G Squared timberH Wooden battenI Rubber sheet, 0.35x10.00mJ Universal countersunk screws

98009-218-01

G

G

98009-222-01

a

GG

I

H

J


25999800902 - 10/2010


Mounting the gap decking

Screw planking hinges to the gap decking and the squared timber.Width-across 17 mm Bore diameter: 12 mm

... swivelling range 180

Nuts & bolts etc. required for each hinge 4 square bolts M10


2 square bolts M10x50 6 washers A10.5 6 hexagon nuts M 10

Opening cut out of the gap decking

a ... 455 mm b ... 600 mm c ... 650 mm d ... 750 mm e ... 160 mm f ... 50 mm g ... 100 mmThese dimensions apply when the closed gap-decking unit is angled at between 0 and 25 to the concrete floor-slab. For steeper angles than this, wider gap decking units are required.

Note:A rubber sheet attached to the end faces of the gap decking prevents any small items falling off.

Screw a "Securing chain 18cm" onto the gap deck-ing.Width-across 17 mm

Raise the gap decking and hook the "Securing chain 18cm" into the appropriate hole in the vertical profile.

Nuts & bolts etc. required for each "Securing chain 18cm" 1 square bolt M10x50 1 washer A10.5 1 hexagon nut M10

Note:For information on preparing the gap decking for vary-ing storey heights, see the section headed "Design var-iants".

Where the storey heights remain constant, the gap decking can be mounted directly to the pro-tection screen.

A Planking hinge 39cmB Gap decking (e.g. web board 32mm)

A

98009-275-03

B

a

d

b

e

c

f g

98009-326-01

C Securing chain 18cm

C

C

98009-275-04

98009-275-01

26 999800902 - 10/2010



Assembling the working platform Mount Doka beams H20 to the multipurpose walings.

Width-across 13 mm Bore diameter: 10 mm

a ... centre-to-centre spacing (tolerance max. 5 mm)

Beam screws H8/70

Fasten deck-boards to the Doka beams with univer-sal countersunk screws 6x90.

Cut-out needed in platform decking

a ... 90 mm b ... 260 mm c ... 240 mm d ... 140 mm e ... 260 mm f ... 200 mm g ... 325 mm h ... 1050 mm Bolt Connecting pins 10cm to the Multipurpose wal-

ings and secure them with Spring cotters 5mm. Attach a lifting chain to the connecting pins. Fly the working platform to the protection screen.

... max. 30

K Multi-purpose waling WS10 Top50 0.50mL Doka beam H20

M Board 50x200 mm

Every deck-board must be fixed with 4 screws!Do a sight-check to make sure that the deck-boards have been fixed properly!

98009-215-02

a

L

K

9732

-240

-01

98009-215-01

98009-215-03

M

N Connecting pin 10cm + Spring cotter 5mm

98009-235-01

b

d

f

a

ce

g

h

N

N

98009-216-01


27999800902 - 10/2010


Bolt the working platform to the Connectors WS10 with Connecting pins 10cm, and secure these with Spring cotters 5mm.

Fix the working platform so that it cannot tip over, then detach it from the crane.

Mounting the trapezoidal sheeting Align the trapezoidal sheets on the protection

screen, and screw them down.

Mount further trapezoidal sheets with an overlap.

Make cut-outs in the trapezoidal sheeting around the connection points for the working platforms.

a ... 300 mm b ... 120 mm c ... 200 mm d ... 680 mm

B Connector WS10 Xclimb 60

The drilling screws must be screwed into the squared timbers under every corrugation trough

O Trapezoidal metal sheet 35x207mmP Drilling screw 6.3x50mm

98009-223-01

B

98009-219-01

98009-224-01

O P

WARNINGSharp edges Use personal protective equipment or fit

edge protectors around the cut-out edges of the trapezoidal sheeting.

When working on the trapezoidal sheeting, always stand or kneel on a formwork sheet, not on the metal sheeting. This spreads the load and prevents the trapezoidal sheeting getting dirty.

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a

b

a

cd

98009-220-01

28 999800902 - 10/2010



Assembling the enclosure of the working platform Lay a Multi-purpose waling WU12 across a pair of

trestles. Bolt a corner connecting plate and a pressure strut to

the Multi-purpose waling with Connecting pins 10cm, and secure these with Spring cotters 5mm.

Prepare the second Multi-purpose waling in the same way.

Place squared timbers onto the Multi-purpose wal-ing.

a ... centre-to-centre spacing (tolerance max. 5 mm)

Screw the squared timbers onto the Multipurpose walings.Width-across 17 mm Bore diameter: 12 mm

Nuts & bolts etc. required for each connection: 2 square bolts M10


2 washers V 11 DIN 440 (on timber side) 2 limpet washers 11 (on the steel side) 2 hexagon nuts M 10(not included with product)

Note:See the section headed "Design variants" for informa-tion on how to use the Strengthening profile Xclimb 60 2.00m.

Mount the sideguards and trapezoidal sheeting in the same way as on the protection screen .

N Connecting pin 10cm + Spring cotter 5mmQ Multi-purpose waling WU12 Top50 3.00mR Corner connecting plate SKS Pressure strut Xclimb 60 0.67m

G Squared timber

98009-225-01

S

R

N

Q

98009-221-01

98009-226-01

aG

98009-229-02

98009-227-01


29999800902 - 10/2010


Bolt Connecting pins 10cm to the Multipurpose wal-ings and secure them with Spring cotters 5mm.

Attach a lifting chain to the connecting pins.

Fly the working-platform enclosure to the protection screen.

Bolt the working-platform enclosure onto the Multi-purpose walings and the Connectors WS10 with Connecting pins 10cm, and secure these with Spring cotters 5mm.

Sideguards on exposed platform-endsOn corner configurations, suitable side protection must be provided on the narrowsides of the working plat-forms.1) Screw the Handrail-post shoe SK (narrowside) onto

the Doka beam H20.

2) Bolt the Handrail post SK 2.00m onto the Handrail-post shoe SK.

3) Mount the enclosure to the Handrail post SK 2.00m.


B Connector WS10 Xclimb 60K Multi-purpose waling WS10 Top50 0.50mN Connecting pin 10cm + Spring cotter 5mm

98009-228-01

N

N

98009-252-01

98009-253-01

B

K

N

G Handrail-post shoe SK (narrowside)

F Handrail post SK 2.00m

G

98010-290-01

F

98010-289-01

98009-319-01

30 999800902 - 10/2010



Starting up

Mount guard rails around all exposed edges. Mount the "Floor supports" and "Guiding shoes" (see

the section headed "Anchoring on the structure").Preparing all the "Guiding shoes"1) Pull the safety clip out of the guide tube.2) Pivot the guide cheeks to the rear.3) Bolt the safety clip back into the guide tube.

4) Move the pressure bolts on the "Guiding shoes" into the appropriate position.

Attaching the crane

Place the lifting-beam onto squared timbers.

Set the slinging points on the Lifting beam 110 kN 6.00m to the required centre-to-centre distance.

Attach the chains to the lifting-beam and to the shackles of the vertical profiles.

The chains are looped around the connecting pins in the Multi-purpose walings WU12.

Fix the protection screen to the suspension points Lift the protection screen by crane and guide it

towards the suspension points with the aid of tag-lines.

Put on personal protective equipment before starting to mount the guard rails.

G Guide tubeH Safety clipI Guide cheek

J Pressure boltK Fall-arrest barrier

CAUTIONOblique pull causes deformation of the vertical profiles. Use a Lifting beam 110 kN 6.00m when

repositioning the Protection screen Xclimb 60.

98009-250-01 98009-251-01

I

2

1

3

G

H

98009-245-02

K

K

J

J

9801

0-25

8-01

9801

0-25

5-01

Follow the directions in the "Lifting beam 110kN 6.00m" Operating Instructions!

K Fall-arrest barrierL Tag-line

98009-244-02

K

K

L

9800

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5-01


31999800902 - 10/2010


Lower the protection screen onto the pressure bolts.

Closing the guide cheeks on all the "Guiding shoes"1) Pull the safety clip out of the guide tube.2) Pivot the guide cheeks to the front.3) Push the guide cheeks up against the vertical pro-

file.4) Bolt the safety clip back into the guide tube.

Close the gap decking.

Detach the lifting chain from the protection screen.

J Pressure bolts


The guide cheeks (I) of the Guiding shoes Xclimb 60 must reach over the flange of the profile.The safety clips (H) must be bolted next to the guide cheeks in the guide tube (G) .

J

98010-253-01

9800

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5-01

H

G

I

9800

9-28

4-01

2

1

3

4

H

G

I

98009-267-02

Important note: Provide safe access routes to the slinging points.

The Fix-De-Fix 3150kg remote uncoupling system makes it possible to detach slinging chains by remote-control from ground level. Follow the directions in the Operating Instruc-tions!

98009-230-01

9800

9-24

6-02

32 999800902 - 10/2010

Repositioning User information Protection screen Xclimb 60


RepositioningHydraulic systemThe protection screen is moved by means of a hydrau-lic branch-line system.One hydraulic unit is sufficient to power 4 Xclimb 60 hydraulic cylinders.

Hydraulic unit Xclimb 60 50/60HzIs supplied to the site ready for operation.

Drive mechanismThe hydraulic unit transforms electrical energy into hydraulic energy.The hydraulic system is equipped with all necessary electrical and hydraulic control and safety elements for ensuring lasting safe operation. Required supply voltage:

400V/50Hz or 480V/60Hz

Installing the hydraulic system for the first time Bolt the lifting mechanism to the hydraulic cylinder,

and secure the bolt with a linch-pin.

Arrange the hydraulic hoses from the hydraulic unit and connect them to the hydraulic cylinders.

92810-804

L Hydraulic cylinder Xclimb 60M Lifting mechanism Xclimb 60

A Hydraulic unit Xclimb 60 50/60HzB Hydraulic hose Xclimb 60C Hydraulic cylinder Xclimb 60D Lifting mechanism Xclimb 60

Follow the directions in the "Doka automatic climbing formwork Xclimb 60" Operating Instructions!

98009-271-01

L

M

BA

C

92810-210-01

D

User information Protection screen Xclimb 60 Repositioning

33999800902 - 10/2010


Hydraulic repositioning

Instructions for safe resetting of the entire unit

Repositioning operationPreparing the lifting operation Mount the "Floor supports" and "Guiding shoes" (see

the section headed "Anchoring on the structure").

Pull the vertical profile towards the building with a chain hoist.



Important note: Before lifting: Remove all loose items from

platforms. "Passenger transportation" is forbidden! During the lifting/repositioning cycle, no site

personnel are allowed to be on the units to be climbed, or on adjacent units for reposi-tioning.

When one climbing unit is lifted and reposi-tioned, this opens up exposed fall-hazard locations on the remaining units. These exposed locations must be made safe by putting up an access prohibition barrier.

Follow the directions in the "Doka automatic climbing formwork Xclimb 60" Operating Instructions!

G Floor support Xclimb 60 rigidH Guiding shoe Xclimb 60 rigid

98009-304-01

G H

9800

9-30

1-01



To make it easy to see the final position for the repositioning operation, a mark can be made on the vertical profile.

98009-302-01 98009-303-01

H

GI

2

1

3

4

H

G

I

98009-267-02

34 999800902 - 10/2010



Mount guard rails around all exposed edges. Move the pressure bolts on the "Guiding shoes" into

the relevant position.

The pressure bolts in the "Guiding shoes" of the last floor-slab to be poured must be deactivated.

Mounting hydraulic cylinders to the vertical pro-files of the unit for repositioning1) Place the hydraulic cylinder onto the "Guiding

shoe".2) Pull the guidepieces on the lifting mechanism to

either side.

3) Place the lifting mechanism up against the vertical profile.

4) Close the guidepieces on the lifting mechanism.

J Pressure boltK Fall-arrest barrier

98010-254-01

98009-286-01

K

K

J

J

98009-206-01

The profile guide (N) must be closed.

1

2

98009-272-01

3

4

98009-273-01

98009-273-02

N


35999800902 - 10/2010


Tilt up the gap decking and fix it with the securing chain.

Lifting Raise the protection-screen, step-by-step, to the

next casting section. Close the gap decking. After the repositioning operation is complete, retract

the cylinders, dismount them and transport them to the next unit for repositioning.

Dismounting the Floor supports and Guiding shoes

Open the guide cheeks on the bottom "Guiding shoes".Where the casting-section heights are less than 3.50 m, the vertical profiles will still be guided in the bottom "Guiding shoes".

Unscrew the cone screw on the bottom "Floor sup-port".

Remove the Floor support + Guiding shoe unit from the edge of the slab.

J Pressure bolts

The hydraulic cylinders can be placed on the hydraulic unit ready for transport to the next location.

98009-230-01

J

98010-253-01

J

98010-317-01

9800

9-24

6-01

CAUTION Do NOT dismount the "Guiding shoes" on

whose pressure bolts the screen unit is rest-ing!

Important note:The load from the Guiding shoe acts beyond the edge of the slab. A second person must secure the Guiding

shoe with a cable while the Floor support + Guiding shoe unit is being dismounted.

The Floor supports plus Guiding shoes can be put into Doka multi-trip transport boxes to be moved to the next usage location.

98009-358-01 98009-355-01

36 999800902 - 10/2010



Resetting by crane

Instructions for safe resetting of the entire unit

Repositioning operationPreparing the lifting operation Mount the "Floor supports" and "Guiding shoes" (see

the section headed "Anchoring on the structure").

Pull the vertical profile towards the building with a chain hoist.



Important note: A balancing lifting beam must be used when

resetting the screen unit by crane. Before lifting: Remove all loose items from

platforms. "Passenger transportation" is forbidden! During the lifting/repositioning cycle, no site

personnel are allowed to be on the units to be climbed, or on adjacent units for reposi-tioning.

When one climbing unit is lifted and reposi-tioned, this opens up exposed fall-hazard locations on the remaining units. These exposed locations must be made safe by putting up an access prohibition barrier.

G Floor support Xclimb 60 rigidH Guiding shoe Xclimb 60 rigid

98009-304-01

G H

9800

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1-01



To make it easy to see the final position for the repositioning operation, a mark can be made on the vertical profile.

98009-302-01 98009-303-01

H

GI

2

1

3

4

H

G

I

98009-267-02


37999800902 - 10/2010


Mount guard rails around all exposed edges. Move the pressure bolts on the "Guiding shoes" into

the relevant position.

The pressure bolts in the "Guiding shoes" of the last floor-slab to be poured must be deactivated.

Tilt up the gap decking and fix it with the securing chain.

Lifting

Place the lifting-beam onto squared timbers. Set the slinging points on the Lifting beam 110 kN

6.00m to the required centre-to-centre distance.

Attach the chains to the lifting-beam and to the shackles of the vertical profiles.

Close-up of crane hoisting point

Lift the protection-screen unit to the next casting sec-tion.

Close the gap decking.J Pressure boltK Fall-arrest barrier

J

J

98009-286-01

98010-254-01

98009-203-01

K

K

98009-230-01

CAUTIONOblique pull causes deformation of the vertical profiles. Use a Lifting beam 110 kN 6.00m when

repositioning the Protection screen Xclimb 60.

Follow the directions in the "Lifting beam 110kN 6.00m" Operating Instructions!

A Shackle Xclimb 60 6.5to

9800

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9-01

A

92842-204-01

38 999800902 - 10/2010



Detach the lifting chain from the protection screen.

Dismounting the Floor supports and Guiding shoes

Open the guide cheeks on the bottom "Guiding shoes".Where the casting-section heights are less than 3.50 m, the vertical profiles will still be guided in the bottom "Guiding shoes".

Unscrew the cone screw on the bottom "Floor sup-port".

Remove the Floor support + Guiding shoe unit from the edge of the slab.

Important note: Provide safe access routes to the slinging points.

J Pressure bolts

The Fix-De-Fix 3150kg remote uncoupling system makes it possible to detach slinging chains by remote-control from ground level. Follow the directions in the Operating Instruc-tions!

J

98010-253-01

J

98010-317-01

9800

9-24

6-03

CAUTION Do NOT dismount the "Guiding shoes" on

whose pressure bolts the screen unit is rest-ing!

Important note:The load from the Guiding shoe acts beyond the edge of the slab. A second person must secure the Guiding

shoe with a cable while the Floor support + Guiding shoe unit is being dismounted.

The Floor supports plus Guiding shoes can be put into Doka multi-trip transport boxes to be moved to the next usage location.

98009-357-01 98009-356-01

User information Protection screen Xclimb 60 Dismantling

39999800902 - 10/2010


DismantlingDismantling

General remarks

Mount guard rails around all exposed edges.Attaching the crane Attach the chains to the lifting-beam and to the

shackles of the vertical profiles (see the section headed "Resetting by crane").

Tension the chains slightly with the crane.

Pivot the guide cheeks to the rear1) Pull the safety clip out of the guide tube.2) Pivot the guide cheeks to the rear.3) Bolt the safety clip back into the guide tube.

Gently raise the protection screen with the crane, and move it away from the building.

Lower the screen unit into a recess in the ground in order to pivot it over its centre of gravity.

Set down the screen unit and dismantle it.

The chains are looped around the connecting pins in the Multi-purpose walings WU12.

Important note: A hard, flat, firm surface is needed! Prepare a sufficiently large assembly area.


98009-280-01

98009-250-01 98009-251-01

I

2

1

3

G

H

K Fall-arrest barrier

CAUTION No persons are allowed anywhere in the

slewing range of the crane.

K

K

9800

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K

98009-244-02

40 999800902 - 10/2010

Additional areas of use User information Protection screen Xclimb 60


Additional areas of useAdditional areas of useThe Protection screen Xclimb 60 can also be used on complex shapes of building.For special requirements such as these, two different types of "Floor support" are available: Floor support Xclimb 60 Floor support Xclimb 60 variable

Floor support Xclimb 60 rigid+ Guiding shoe Xclimb 60 rigid

+ Cone screw B 7cm

Floor support Xclimb 60

Floor support Xclimb 60 variable

Variable clearance between floor-slab and vertical profile X X

Imposed loads

V ... permitted vertical load [kN] 30 30 45 60 30 45 60

H ... permitted horizontal load [kN] 60 60 60

Inclined facades

Max. forward or rearward inclination of vertical profile 10 10

Max. sideward inclination of vertical profile 10 10

Hydraulic repositioning where inclination remains constant

X X

Varying inclinations

Hydraulic repositioning on varying inclinations (vertical profile can be adjusted under load)

X

Tr852-200-01

User information Protection screen Xclimb 60 Additional areas of use

41999800902 - 10/2010


Variable clearance between floor-slab and vertical profilePossible clearances with Floor support Xclimb 60: 85 mm 215 mm 345 mmPossible clearances with Floor support Xclimb 60 variable: continuously adjustable between 85 mm and

345 mm

b ... 580 mm

Set-back floor-slabs

c ... 260 mm

a1 ... 85 mm clearance a2 ... 345 mm clearance

Important note:If cones are placed in different positions from those shown above, revised structural analysis will be required!

9800

9-33

3-01

a1b

9800

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a2b

9800

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c

42 999800902 - 10/2010



Imposed loadsThe Floor supports Xclimb 60 can be set to any of 3 loading ranges 30, 45 and 60 kN to sustain different vertical loads.

Floor support Xclimb 60

b ... 580 mm

Floor support Xclimb 60 adjustable

b ... 580 mm

The loading ranges are identified by markings on the "Floor supports".

A MarkingB Connecting pin 25cm

C Bolt position for the 30 kN loading range

D Bolt position for the 45 kN loading range

E Bolt position for the 60 kN loading range

Loading rangeV ... perm. vertical load 30 kN 45 kN 60 kNH ... perm. horizontal load 60 kN 60 kN 60 kN

a ... clearance 345 mm 215 mm 85 mm

98009-336-01B

A

C

D

E

V

98009-332-01 b a

H

C

V

98009-331-01 b a

H

D

V

98009-330-01 b a

H

E

A MarkingB Hexagon bolt M12x130 (load limiter)

C Bolt position for the 30 kN loading range (stand-by position)

D Bolt position for the 45 kN loading range

E Bolt position for the 60 kN loading range


a ... clearance 85 - 345 mm85 -

255 mm85 -

165 mm

92841-253-01

B

A

D

C

E

VH

98009-341-01 b a

C

V

98009-340-01 b a

HD

V

98009-339-01 b a

HE


43999800902 - 10/2010


Lateral horizontal loads To transfer lateral horizontal loads, fix the "Floor sup-

ports Xclimb 60" and/or "Floor supports Xclimb 60 adjustable" with a Doka Express anchor.

Anchoring forces per suspension point

c ... 475 mm (Floor support Xclimb 60) c ... 450 mm (Floor support Xclimb 60 adjustable)

Max. anchoring forces:

Important note:While being lifted, only one vertical profile of the screen unit should be secured against lateral horizontal loads. This prevents any constraints occurring during lifting.

Follow the directions in the "Doka Express anchor 16x125mm" Installation Instructions!


H2 ... perm. lateral hori-zontal load 5.3 kN 5.9 kN 6.5 kN

98009-343-01

98009-343-02

H2

H2

Loading rangeV ... perm. ver-tical load 30 kN 45 kN 60 kN

H ... perm. hor-izontal load 60 kN 60 kN 60 kN

FX, k(Ed)

60 kN(90 kN)

60 kN(90 kN)

60 kN(90 kN)

FZ(1), k(Ed)

40 kN(60 kN)

40 kN(60 kN)

51 kN(76.5 kN)

FZ(2), k(Ed)

71 kN(106.5 kN)

86 kN(129 kN)

111 kN(166.5 kN)

98009-330-02

FZ(1)

FX

FZ(2)c

44 999800902 - 10/2010



Inclined facades

Forward and rearward inclinationForward or rearward inclination: max. 10

Sideward inclinationSideward inclination: max 10

To transfer lateral horizontal loads, fix the "Floor sup-ports Xclimb 60" and/or "Floor supports Xclimb 60 adjustable" with a Doka Express anchor.

Important note:The diagrams shown in the "Structural design" chapter are not valid for inclined forming assignments. In these cases, revised static ver-ification is required.

9800

9-34

5-01

9800

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5-01

9800

9-34

5-01

Important note:While being lifted, only one vertical profile of the screen unit should be secured against lateral horizontal loads. This prevents any constraints occurring during lifting.

9800

9-35

0-02

9800

9-35

0-01

98009-359-01


45999800902 - 10/2010


Combining a forward or rearward inclination with a sideward inclination

Repositioning

Note:Crane-lifting the protection screen on inclined facades entails hazards, and requires separate verification.

Follow the instructions given under the heading "Repo-sitioning" for safe resetting of the entire unit!Aligning the vertical profiles Pull the vertical profile towards the building with a

chain hoist, or if necessary push it away from the building.

Important note:Arrange the vertical profiles in such a way that the bottom climbing cams are at the same height (parallel to the floor-slab).

98009-354-01

98009-354-02

98009-359-01

Hydraulic lifting provides greater safety on assignments involving inclined facades.

Aligning made easy, with the "Floor support Xclimb 60 adjustable" Align the vertical profiles by turning the

screwjack mechanism on the "Floor sup-ports".

9800

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92841-259-01

46 999800902 - 10/2010



Varying inclinations

Note:Only "Floor supports Xclimb 60 adjustable" can be adjusted under load.The "Floor support Xclimb 60" is not suitable for use on facades with varying inclinations.

Kinks in the facade

Facades with radiiBy adjusting the "Floor supports" under load, the protection screen can be used on facades with varying inclinations (e.g. kinks, radii).

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Floor support Xclimb 60 / Floor support Xclimb 60 adjustable

Assembly instructions

Positioning point Prepare the positioning point (see "Anchoring on the

structure".

b ... 580 mm ( 10 mm)

Suspension point

Mount guard rails around all exposed edges.Preparing the "Floor supports Xclimb 60"

Fix the bolts in the the "Floor supports" to set them for the specified loading range.

Preparing the "Floor supports Xclimb 60 variable" Turn the screwjack mechanism to move the "Floor

support" in the guide block into the specified loading range.

Tools needed: Reversible ratchet 1/2" Box nut 24 1/2"

Use a self-locking nut to fix the hexagon bolt in the relevant position.

Important note:If cones are placed in different positions from those shown above, revised structural analysis will be required!

Important note: Use personal fall arrest systems (PFAS) to protect against fall hazards when working on unsecured slab-edges.

CAUTIONRisk of toppling! Do not attempt to set the loading ranges on

the Floor support Xclimb 60 at the edge of the floor-slab.

A Connecting pin 25cm


92841-222-01

b

98009-336-01A


CAUTIONWrong loading rangeIncorrect screwjack travel means that the "Floor support" will be overloaded! Use the hexagon bolt to limit the screwjack

travel to the loading range specified in the assembly and shop drawing.

A Hexagon bolt M12x130

92841-223-01

92841-253-01

A


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Fixing the "Floor support" to the floor-slab

Fix the "Floor support" in the Universal climbing cone 15.0 with a Cone screw B 7cm. A tightening torque of 100 Nm (20 kg assuming a ratchet-length of approx. 50 cm) is sufficient.

Forcibly tightening the Cone screw B 7cm any more than this may cause damage and even cause the form-tie to break!

The only tool allowed to be used for screwing in and fix-ing the Cone screw B 7cm in the Universal climbing cone is the Reversible ratchet 3/4".

Mounting the hydraulic cylindersMounting hydraulic cylinders to the vertical pro-files of the unit for repositioning1) Place the hydraulic cylinder onto the "Floor sup-

port".

2) Pull the guidepieces on the lifting mechanism to either side.

3) Place the lifting mechanism up against the vertical profile.

4) Close the guidepieces on the lifting mechanism.

CAUTIONRisk of toppling! Do not push the front support beyond the

edge of the floor-slab.

B Front support

Reversible ratchet 3/4"

Reversible ratchet 3/4" with extension Ratchet MF 3/4" SW 50

92841-251-01

B

Tr687-200-01Tr687-200-01 Tr687-200-01

Check that the hydraulic cylinder fits firmly onto the "Floor support".

The profile guide (N) must be closed.

1

2

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3

4

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Operating the systemActivating / deactivating the pressure boltsAs a basic rule, the pressure bolts in the "Floor sup-ports" must be activated on the same floor-slabs as when "Floor supports Xclimb 60 rigid" are used. Tilt up the dirt cover.

Use the pull-back handle to pull the pressure bolt in the "Floor support" inwards and latch it into place.

Lift the pull-back handle to activate the pressure bolt.

Fixing the vertical profile in the "Floor support" Pull the safety pin on the "Floor support" backwards

and slide the guide cheeks outwards.

Lift the protection screen by crane and guide it towards the suspension points with the aid of tag-lines.

Lower the protection screen onto the pressure bolts. Close the guide cheeks on all the "Floor supports".

B Pull-back handle with pressure bolt

The pressure bolt and pull-back handle must automatically snap foward.

98009-346-01

98009-338-01

B

1

2

A Safety pinB Guide cheek

The guide cheeks of the "Floor supports Xclimb 60" must reach over the flange of the profile.The safety pins must be bolted in the guide tube.

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1

2

2

A

B

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Transporting, stacking and storing

Doka stacking pallet 1.55x0.85mIdeal for "Floor supports Xclimb 60" and "Floor supports Xclimb 60 adjustable".Doka stacking pallets are transport and storage units that are only suitable for Doka components, provided that these are centrally loaded and fixed so that they cannot slide or tip out. Only one Doka stacking pallet may be lifted at a time. Use a suitable lifting chain. (Do not exceed the per-

mitted load capacity). E.g: Doka 4-part chain 3.20m Art.n 588620000.

Spread-angle max. 30! Load the items centrically. Secure any loose parts to the stacking pallet in such

a way that the parts cannot slide or tip. Durable Stackable Safe to lift by crane

Bolt-on castor set BThe Bolt-on caster set B turns the stacking pallet into a fast and manoeuvrable transport trolley.Suitable for drive-through access openings > 90 cm.

The Bolt-on caster set B can be mounted to the follow-ing multi-trip packaging items: Doka stacking pallets Doka accessory box

Max. load: 1100 kg

Follow the directions in the Operating Instruc-tions!

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Loading platform User information Protection screen Xclimb 60


Loading platformProtection screen Xclimb 60 with integral loading platformWorking platform integrated in the protection screen, for moving materials and equipment in and out.

a ... 3000 mm b ... 6000 mm c ... 4550 mm


Preparing the protection screen For detailed information on this, see the section

headed "Mounting instructions" for the Protection screen Xclimb 60.

Follow the directions in the section headed "Struc-tural design" to determine the influence width.

1) Screw extra Connectors WS10 to the planned posi-tions on the vertical profile.

2) Do not cover the opening needed for the loading platform with trapezoidal sheeting.

3) Mount end-to-end squared timbers beneath the Connectors WS10 Xclimb 60.

98009-240-01

98009-258-04

b

a c

Locally permitted service load: 3.0 kN/m2 (300 kg/m2)

Do not exceed the permitted vertical load of the suspension point!- 2 x 30 kN = 60 kN (with 2 vertical profiles)


Permitted point load (e.g. wheel load): 7.0 kN (700 kg) with 5x25 deck-boardsPermitted point load (e.g. wheel load): 5.0 kN (500 kg) with 5x20 deck-boards

Important note:A statical check must be performed on any divergent, project-specific adaptations. The permitted service load must also be revised if necessary.

98009-257-01

H1

2

3

User information Protection screen Xclimb 60 Loading platform

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Mounting the Multi-purpose walings Prepare squared timbers to place the Multi-purpose

walings onto. Lay down Multi-purpose walings (A) and (B) ,

spaced apart by the exact centre-to-centre distance and with identical diagonals.

Lay down Multi-purpose waling (C) .Joining the Multi-purpose walings together Push clamping plates onto the threaded rod and fix

them with 2 hexagon nuts on each side. Tighten the hexagon nuts firmly against one another,

i.e. "counter" them so that they cannot work loose.

a ... 3000 mm (tolerance max. 5 mm)b ... 300 mm c ... 1400 mm d ... 1600 mmx = y ... diagonals (tolerance max. 10 mm)

Attaching the platform decking Bolt the Bracing device Xclimb 60 15.0 to the

planned positions on the Multi-purpose waling WS 10 using Connecting pins 10cm, and secure these with spring cotters.

Mount Doka beams H20 to the multipurpose walings.Width-across 13 mm Bore diameter: 10 mm

Beam screws H8/70


c ... 4550 mm d ... 2600 mm e ... Beam centres max. 500 mm

One deck-board must be left out to enable the load-ing platform to be fixed to the protection screen.

A Multi-purpose waling WS10 Top50 5.00mB Multi-purpose waling WS10 Top50 2.25mC Multi-purpose waling WS10 Top50 4.00mD Threaded rod M16 270mmE Clamping plate for U-headF Hexagon nut M16G Squared timber

For adaptation to the storey height, fit a squared timber between the Multipurpose wal-ings WS10.

x

y

b cc d

B

A

A

C C CC

a

a/2

a/2

98009-254-01

98009-254-02

F

D

E

F

GD

E

98009-292-01

H Doka beam H20 5.90m I Deck-boardJ Bracing device Xclimb 60 15.0K Lifting rod 15.0

Do a sight-check to make sure that the deck-boards have been fixed properly!

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JJ

d

KK

c

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98009-255-01

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Crane slinging points Mount a Lifting rod 15.0 and Retaining plate 15.0 in

the planned positions.

Assembling the enclosure of the loading plat-formThe working-platform enclosure is set up using Univer-sal railings SK 2.00m.

Mounting the handrail posts and squared timbers Bolt the handrail posts onto the Multipurpose walings

with Connecting pins 10cm and secure these with Spring cotters 5mm.

Screw squared timbers onto the handrail posts.Width-across 17 mm Bore diameter: 12 mm

Nuts & bolts etc. required for each connection: 1 square bolt M10


1 limpet washer 11 1 hexagon nut M10(not included with product)Mounting the trapezoidal sheeting Align the trapezoidal sheets on the protection



Preparing the tension-rod bracing1) Screw the tie-rod into the bracing device.2) Push an anti-twist guard over the flat (unthreaded)

sides of the tie-rod.3) Fix the anti-twist guard with a hexagon bolt and

hexagon nut.

4) Screw the prepared tie-rod into the spindle compo-nent on the loading platform.

Tie-rods required for each loading platform: 2 tie-rods 15.0mm 3.35m 2 tie-rods 15.0mm 5.40m

K Lifting rod 15.0L Retaining plate 15.0

Follow the directions in the "Lifting rod 15.0" Operating Instructions!

Universal railing SK 2.00mOn either side At rear

M Universal railing SK 2.00mN Connecting pin 10cm + Spring cotter 5mmO Squared timber

K

L

98009-255-02

M

N

O

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M

N

O


Bracing device Xclimb 60 15.0:Permitted tensile force: 60.0 kN

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Mounting the loading platform to the protec-tion screen Attach the 2-part chain of the balancing lifting beam

to the Lifting rods 15.0.

... max. 30 Lift the loading platform by crane and guide it

towards the protection screen with the aid of tag-lines.

Bolt the loading platform to the Connectors WS10 with Connecting pins 10cm, and secure these with Spring cotters 5mm.

Bolt the bracing device to the Connectors WS10 with Connecting pins 10cm, and secure these with Spring cotters 5mm.

Detach the loading platform from the crane. Fit the missing deck-board.

f ... 2032 mm g ... 1965 mm h ... 3150 mm i ... 1050 mm

How to liftThe loading platform is repositioned in the same way as the protection screen (see the section headed "Reposi-tioning").

DismantlingTo dismantle, perform the above steps in reverse order.

Use personal protective equipment when attaching the loading platform to the protec-tion screen.

N Connecting pin 10cm + Spring cotter 5mmP Connector WS10 Xclimb 60Q Loading platform Xclimb 60R Bracing device Xclimb 60 15.0

98009-256-01

98009-258-03

Q

P

N

98009-258-02

P

R

N

J Pressure bolts

Important note:No payload (service load) is allowed on the loading platform while it is being repositioned.

f g

hi

98009-258-01

J

98010-253-01

J

98010-317-01

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Loading platform Xclimb 60 for constant storey heightsAn easy-to-reposition loading platform, for moving materials and equipment in and out.

a ... 3000 mm b ... 5000 mm c ... 4550 mm


Pre-assembling the Vertical profiles Xclimb 60For detailed information on this, see the section headed "Mounting instructions" for the Protection screen Xclimb 60.1) Lay down the vertical profiles, spaced apart by the

exact centre-to-centre distance.2) Bolt "Connectors WS10 Xclimb 60" onto the vertical

profile.3) Bolt spindle-strut connectors onto the vertical pro-

file.4) Brace the vertical profiles both horizontally and

diagonally.5) Mount the Shackles Xclimb 60 6.5to.

a ... 3000 mm f ... 595 mm g ... 2700 mm

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b

ac

Locally permitted service load: 3.0 kN/m2 (300 kg/m2)

Do not exceed the permitted vertical load of the suspension point!- 2 x 30 kN = 60 kN (with 2 vertical profiles)


Permitted point load (e.g. wheel load): 7.0 kN (700 kg) with 5x25 deck-boardsPermitted point load (e.g. wheel load): 5.0 kN (500 kg) with 5x20 deck-boards

Important note:A statical check must be performed on any divergent, project-specific adaptations. The permitted service load must also be revised if necessary.

1

32

4

5

f ga

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Mounting the Multi-purpose walings Prepare squared timbers to place the Multi-purpose

walings onto. Lay down Multi-purpose walings (A) and (B) ,

spaced apart by the exact centre-to-centre distance and with identical diagonals.

Lay down Multi-purpose waling (C) .Joining the Multi-purpose walings together Push clamping plates onto the threaded rod and fix

them with 2 hexagon nuts on each side. Tighten the hexagon nuts firmly against one another,

i.e. "counter" them so that they cannot work loose.

a ... 3000 mm (tolerance max. 5 mm)b ... 200 mm c ... 1150 mm d ... 1180 mm e ... 1110 mmx = y ... diagonals (tolerance max. 10 mm)

Attaching the platform decking Mount Doka beams H20 to the multipurpose walings.

Width-across 13 mm Bore diameter: 10 mm

Beam screws H8/70


c ... 4550 mm d ... 2600 mm e ... Beam centres max. 500 mmf ... 390 mm g ... 160 mm h ... 460 mm i ... 140 mm

A Multi-purpose waling WS10 Top50 4.00mB Multi-purpose waling WS10 Top50 2.25mC Multi-purpose waling WS10 Top50 4.00mD Threaded rod M16 270mmE Clamping plate for U-headF Hexagon nut M16G Squared timber

For adaptation to the storey height, fit a squared timber between the Multipurpose wal-ings WS10.

b c d e

B

A

A

C CC

xy

a

a/2

98009-260-01

a/2

98009-254-02

F

D

E

F

GD

E

98009-292-01 H Doka beam H20 5.90m I Deck-boardK Lifting rod 15.0

Do a sight-check to make sure that the deck-boards have been fixed properly!

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98009-261-01

c

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df g e

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Crane slinging points Mount a Lifting rod 15.0 and Retaining plate 15.0 in

the planned positions.

Assembling the enclosure of the loading plat-formThe enclosure on both sides of the loading platform is set up using the Universal railing SK 2.00m.At the rear of the loading platform, the enclosure is set up using Multipurpose walings WS10.

Mounting the handrail posts and squared timbers Bolt the handrail posts onto the Multipurpose walings

with Connecting pins 10cm and secure these with Spring cotters 5mm.

Screw squared timbers onto the handrail posts.Width-across 17 mm Bore diameter: 12 mm

Nuts & bolts etc. required for each connection: 1 square bolt M10


1 limpet washer 11 1 hexagon nut M10(not included with product)Mounting the trapezoidal sheeting Align the trapezoidal sheets on the protection



Mounting the loading platform onto the Verti-cal profiles Xclimb 60 Bolt Connecting pins 10cm to the Multipurpose wal-

ings and secure them with Spring cotters 5mm. Attach the 2-part chain of the balancing lifting beam

to the connecting pins. Fly the loading platform to the vertical profiles.

K Lifting rod 15.0L Retaining plate 15.0

Follow the directions in the "Lifting rod 15.0" Operating Instructions!

Universal railing SK 2.00m Multi-purpose waling WS10 +Corner connecting plate SK

M Universal railing SK 2.00mN Connecting pin 10cm + Spring cotter 5mmO Squared timberP Corner connecting plate SKQ Multi-purpose waling WS10 Top50 2.50m

K

L

98009-261-02

M

N

O

9800

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NP

Q

O

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98009-264-01

NN


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Bolt the loading platform to the Connectors WS10 with Connecting pins 10cm, and secure these with Spring cotters 5mm.

Bolt the spindle strut onto the Multi-purpose waling WS10 and onto the Connector WS10 Xclimb 60 with Connecting pins 10cm, and secure these with Spring cotters 5mm.

Detach the loading platform from the crane.

Fixing the loading platform to the building

Note:Follow the directions in the section headed "Starting up"!

Attach the 2-part chain of the balancing lifting beam to the shackles of the vertical profiles and at the rear to the Lifting rods 15.0.

Lift the loading platform by crane and fix it to the building.

... max. 30h ... 2353 mm

How to liftThe loading platform is repositioned in the same way as the protection screen (see the section headed "Reposi-tioning").

DismantlingTo dismantle, perform the above steps in reverse order.

N Connecting pin 10cm + Spring cotter 5mmR Connector WS10 Xclimb 60

N Connecting pin 10cm + Spring cotter 5mmS Spindle strut T10 350/400cmT Connector for Spindle strut Xclimb 60

9800

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RN

9800

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9800

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4-04

S

T

S

N

N

CAUTIONThere is a risk of tipping if the centre-of-gravity position is altered. Persons must stay well outside the opera-

tional range of the crane!

J Pressure bolts

Important note:No payload (service load) is allowed on the loading platform while it is being repositioned.

98009-286-01

J

J

98010-317-01

J

98010-253-01

h

98009-265-01

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Loading platform Xclimb 60 for non-constant storey heightsAn easy-to-reposition loading platform, for moving materials and equipment in and out.

a ... 3000 mm b ... 5000 mm c ... 4550 mm


Pre-assembling the Vertical profiles Xclimb 60For detailed information on this, see the section headed "Mounting instructions" for the Protection screen Xclimb 60.1) Bolt the vertical profiles together with a D25/135

bolt, and secure this with a 6x42 linch pin.

2) Lay down the vertical profiles, spaced apart by the exact centre-to-centre distance.

3) Bolt "Connectors WS10 Xclimb 60" onto the vertical profile.

4) Bolt spindle-strut connectors onto the vertical pro-file.

5) Brace the vertical profiles both horizontally and diagonally.

a ... 3000 mm d ... 595 mm e ... 2700 mm

Locally permitted

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