fd max user guide uk

HEAVY DUTY PANEL ASSEMBLY MANUAL & USER GUIDE

HEAVY DUTY PANEL ASSEMBLEY MANUAL & USER GUIDE

This instruction manual provides the information necessary for the proper use of FD Max ® formwork and important details on how to handle and properly use the product. All the instructions that are described here must be followed correctly.

To ensure the safe use of our products, you should always respect the basic safety standards and regulations of National Institutions Insurance Accidents and Public Authorities.

The staff responsible for the assembly must be trained to assemble and meet all safety standards.

As a fundamental principle, only original parts should be used and in excellent condition.

Damaged parts should be removed from circulation. In case of repair, only FDI original parts in good condition should be used.

Before starting the assembly of the formwork system, it must be inspected by the team leader erecting the material and defective equipment should never be used.

It should be subject to additional supervision if you want to combine the use of our formwork system with other equipment from different vendors.

All illustrations in this catalogue are to be used as an example.

CONTENTS

1. Product Features

5. Components

10. Elements of connecting and anchors

11. Distribution of fasteners and anchors

12. Combinations of panels

13. Corner Solutions

15. T-Joints

17. Hinged Corners

18. Assembly Instructions

21. Platform Assembly Instructions

23. Lifting Hooks

25. Formwork Columns

Certification and certified products:

Formwork Direct International is in constant process of improvement and is a certified company since 2000 in accordance with

the norm NP EN ISO 9002: 1995 (APCER).

To insure the high standards of quality of our products in 2003 the company makes a transition to the UNE EN ISO 9001: 2000

and in 2004 the two scaffolding systems are certified according to the UNE 76502: 1990-HD 1000: 1998 CEN (AENOR).

At present, both scaffolding system have the new norm, EN12810 and EN12811 (this norm was adopted by UK in

01/2011 and is recognised since then as BS EN 12811-1)

All European Standards are at equal level as the British Standards

PRODUCT FEATURES

FD Max ® is a highly versatile heavy duty vertical shuttering system. It is a system suitable for all types of

works, such as walls, shutters, beams and columns. All panels can be combined vertically and horizontally,

without limitations

.

FD Max ® consists of a lightweight metal frame and a special steel structure reinforcement to

prevent deflection of the panels. The surface casing that fits into the frame is 18mm thick plywood with two faces

coated with a phenolic film 240g/m2 to ensure good quality concrete finishing and greater durability of the panels.

The FD clamp allows you to connect and secure the panels together. These can be aligned automatically,

or you can preassemble the panels with the help of a crane.

The permissible pressure for FD Max is 90kn/m2 for a single height of panels and

80kn/m2 when applied when overlapping as provided by the standard DIN 18202.

FD Max ® panels are available in heights of 1.0 m and 3.0 m and in 14 different widths from 0.30m to 2.40m

which makes different combinations possible as seen in this brochure.

The universal FD Max panel allows the shuttering of columns with sizes varying from 5x5cm to a maximum of

1.20 x 1.20m.

FD Max® can also make use of normal vertical panels to form columns with the aid of the clamps and corner clamps

as seen in this brochure.

1

PRODUCT FEATURES

VERTICAL PANELS HEIGHT 1000 MM

VERTICAL PANELS

HEIGHT 3000 MM

A – pa nel

wi dt h

(mm)

30 0

350

400

450

50 0

550

60 0

90 0

1200

B – di st ance C - nº of

between reinf orceme-

panels (mm) nts

0 0

0 0

0 0

0 0

0 0

0 0

21 0 1

243 2

243 2

2

PRODUCT FEATURES

PANEL VERTICAL HEIGHT 3000 MM BY 2400 MM WIDE

3

PRODUCT FEATURES

UNIVERSAL PANELS

HEIGHT 3000 MM

UNIVSERAL PANELS

HEIGHT 1000 MM

A (mm) B (mm) C N

550 0 0 8

750 285

950 243

1350 243

1 12

2 16

2 24

4

COM PONENTS

UNIVERSAL PANELS 3.0M - FD MAX®

Siz e 3. 0x0.30 m Size 3.0x0.3 5m Siz e 3.0 x0. 40 m

Weight (Kg) 69.5 Weight (Kg) 74.3 Weight (Kg) 79

Siz e 3.0x0.45 m Size 3.0 x0.5 0m Si ze 3.0 x0.55 m

Weight (Kg) 83. 8 Weight (Kg) 88.6 Weight (Kg) 93.4

Size 3.0x0.60 m Size 3.0 x0.90m Si ze 3.0 x1. 20 m

Wei ght (Kg) 100.7 Weight (Kg) 132 Weight (Kg) 180

5

COM PONENTS

Size 3.0 x 2. 40

Weight (Kg) 329


Size 1.0x0.30m Size 1.0x0.35m Size 1.0x0.40m

Weight (kg) 25.6 Weight (kg) 27.5 Weight (k g) 29.5

Siz e 1 0x0 45 m Siz e 1 0x0 50m Siz e 1 0x0 55 m

Weight (Kg) 31 3 Weight (Kg) 33 25 Weight (Kg) 35 2

6

. . .

COM PONENTS

Size 1.0x 0. 6 0m Size 1.0x0. 9 0m Size 1.0x1. 2 0 m

Weight (Kg) 39.6 Weight (Kg) 53.5 Weight (Kg) 65


Siz e 3.0 x0.5 5m Siz e 3. 0x0.75 m Si ze 3. 0 x0. 95 m

Weight (Kg) 93. 4 Weight (Kg) 122.8 Weight (Kg) 136.8

Size 3. 0 x1. 35 m

Weight (Kg) 176

7

ARTICULATED CORNER PANELS - FD MAX®

Size 1.0 x0. 3 0 x0.30 m Siz e 3.0 x0. 30x0.3 0m

Weight (Kg) 41 Weight (Kg) 113

8

1.0x1.35m

70.9

COM PONENT S


Measurement 1.0x0.55 m Measurement

Weight (Kg) 35 . 2 Weight (Kg)

Measurement

Weight (Kg)

1.0x0.75m

45.3

1.0x0.95m

55.5

CORNER PANELS - FD MAX®

Measurement 1.0x0. 30 x0. 30m M easur ement 3.0x0.3 0x0.30 m

Weight (Kg) 39 Weight (Kg) 108

M easuremen

Weight (Kg)

t

COM PONENTS

CLAMPS - FD MAX®

Fixed Clamp C losin g wi th ou te r corner w all s Univer sal Fixing

Weight (Kg) 5.4 3 Weight (Kg) 2.21 Weight (Kg) 0.92

ACCESS BRACKET -

FD MAX®

ACCESSORIES - FD MAX®

Plug Ø 3 4x27,5mm

Lifting Hook (Brown)

Weight (Kg) 5.71 Weight (Kg) -

0.9 0 m Plug Ø25x18mm (Yell o w)

Weight (Kg) 14. 5 Weight (Kg) -

9

ELEMENTS OF CONNECTORS & ANCHORS

Steel W alers

close to corner

outer wall

Universal fi xi ng

bolt

Fixed

clamp

There are different combinations that can be performed to obtain different heights of Formwork.

To accomplish these combinations it is necessary to use fixed clamps. This component serves to join two

panels with pressure whilst aligning two adjacent panels. They can also be used in different types

of connections: horizontal and vertical. When anchoring the panels this is made through the

existing hole in the steel panel frame. Before the insertion of the tie rods the plugs should be removed.

The holes that are not used must be closed with plugs.

10

10

a – Typical elevation of components for single layer panels using 3.0 x 1.2 panels

b – Typical elevation of components for more than 1 level of panels using 3.0 x 1.2 panels.

c – Typical elevation of components for 2 levels of panels using 3.0 x 1.2 panels.

11

DISTRIBUTION OF FASTENERS AND ANCHORS

The alignment and anchoring fasteners (nut and rod) must be distributed evenly within the structure of the panels.

We can visualize the distribution of various components in the 3 different examples below.

a b c

COMBINATION OF PANELS

FD Max ® is composed of panels with heights of 3m and 1m with widths from 0.3 m to 2.4 m

These dimensions can be combined to obtain the desired height of the wall or base.

Example of combination of panels in heights up to 6m. This combination is valid for both wall panels and columns.

12

CORNER SOLUTIONS

FD MAX corner panels form the interior angles of 90 degrees and come in sizes of

3 m & 1m and width equals 300mm x 300mm.

Example of application

of corner panels

EXAMPLES OF CORNER SOLUTIONS

Combinations of FD Max ®

panels for thicknesses

between 150 mm and 500 mm with

50 mm increments:

Arrangement of panels for Arrangement of panels for walls of 150 mm thickness. walls of 200 mm thickness

using a 50 mm timber make

up.

13

using a 50 mm timber make using a 50 mm timber make up. up.

For any other dimensions of the wall you should follow the same pattern within reason (please check with our engineers) The adjustable clamps are used to create make ups between panels.

These make ups are usually timber. We can provide steel alignment fixings to enable a more effective connection these can also be used for stop ends.

14

Arrangement of panels for a Arrangement of panels for a wall of 300 mm thickness wall of 350 mm thickness using a 50 mm timber make using a 50 mm timber make up. up.

Arrangement of panels for a Arrangement of panels for a wall of 450 mm thickness wall of 500 mm thickness

CORNER SOLUTIONS

Arrangement of panels for a wall of 250 mm thickness.

Arrangement of panels for a wall of 400 mm thickness

Example for a 150mm T Junction wall using a 150mm timber make up.

Example for a 300mm T

Junction wall.

15

T JOINTS

T shaped wall set up. The panel system can be used for thicknesses up to 600 mm.

It is possible to adapt different widths using timber make ups and adjustable clamps as demonstrated below.



Example for a 350mm T Example for a 400mm T Junction wall using a 50mm Junction wall using a timber make up. 100mm timber make up.

T JOINTS

Example for a 100mm T Junction wall using a Example for a 500mm T Junction wall using 2x 50mm timber make up. 100mm timber make up.

16

HINGED CORNERS

The hinged corners can be used for both inside corners and outside corners depending on the angle of the walls

FD Max®.

To set up oblique corners, simply clamp the hinged

corners. Linking the two sides of the panel system then you can slightly reduce or increase the angle formed. Please see

below for typical examples.

POSSIBLE SOLUTIONS FOR HINGED CORNERS

minimum range: 70 ° (or an angle of 290 ° between outer edges)

17

maximum range: 109 °

Distribution of vertical panels flat on More panels are added, making the the ground: size desired / allowable load by the crane:

Outer faces Outer faces

STEP 3

Panels are applied:

- The fixed clamps that make the connection between adjacent panels;

- Access brackets that allow you a working platform to work off for safe future concrete pouring

- Lifting hooks that allow safe transport of fully assembled panels with the use of a crane

18

STEP 2

ASSEMBLY INSTRUCTIONS

STEP 1

The assembly of the panels is raised from the Add the inner and outer corner panels to the ground and placed at the construction site of wall panels whilst fixing the nuts and bolts the wall that make the connection between the

opposite walls of formwork

Face interior

Face interior

Face exterior

Face exterior

STEP 6 STEP 7

Add any remaining tying systems to the Insert the working platform onto the panels as

panels if necessary. demonstrated below.

Face interior

STEP 5


STEP 4

Face exterior

Face exterior

19

Face interior


Typical corner detail below.

Interior view. Exterior view.

20

PLATFORM ASSEMBLEY INSTRUCTIONS

STEP 1 STEP 2 STEP 3

Place the panel flat on the Open up the panel as Rotate the platform 90 floor. indicated. degrees and add the

FD Max panel.


Add the diagonal Insert the ladder into the Place the ladder over the supports to the panel. hole. panel.

21

é

NOTE: If the product does not come with a concreting coupler panel, this should be mounted

according to the following figure.

22

PLATFORM ASSEMBLY INSTRUCTIONS


Open the side railings Place below the trapdoor.

Mount a second ladder

directly below the trapdoor. Stabilize the struts to the panel.

LIFTING HOOKS

The FD Max ® lifting hook is manufactured with the CE marking according to directive No. 2006/42/CE and the corresponding Decree-Law No. 103/2008.

HANDLING THE CRANE

• The lifting hook should be inserted wherever the joint panel, as

shown below.

• Panels should be lifted symmetrically whilst keeping the same

weight on each axle suspension;

• The lifting hook is inserted after self-locking

FD Max® Lifting Hook

COUPLING SCHEM E

1st Step

23

2nd Step 3rd Step

LIFTING HOOKS

The maximum weight supported by each lifting hook is 1.5 ton. Lifting chains must make a maximum angle

of 60 ° to each other.

máx. 60º

24

FORMWORK COLUMNS

The universal panels have a continuous series of holes and are used especially for shuttering of columns.

Using four panels as in the following examples, square and rectangular columns can be formed from 5x5cm up to 80x80cm.

Formwork column 1 m

Formwork column 3 m

NOTE: the link between the columns panels can be made with the universal fixings and super plates.

You can also use the corner clamp for

various column sizes..

Formwork Column 4m (3m panel + 1m panel).

25

FORMWORK COLUMNS

Possible combinations for universal panels

Combination of 1.350 Combination of 1.35mm Combination of 915mm Universal panels for Universal panels for Universal panels for columns of 1200mm2 columns of 600mm2 columns of 800mm2

Combination of 915m Universal panels for columns of 400mm2

Combination of universal panels 750mm for columns of 600 mm2 (maximum possible).

Combination of 750mm Universal panels for columns of 300mm2

26

FORMWORK COLUMNS

Combination of 550mm Combination of universal Universal panels for panels 550mm for columns columns of 400mm2. of 200mm.

You can combine FD Max ® panels for the construction of rectangular columns:

Combination of 1.35m and 750mm Combination of 950mm x 950mm + Universal panels for columns of 1200mm 750mm Universal panels for columns of x 600 1550mm x 800

27

FORMWORK COLUMNS

ASSEMBLY INSTRUCTIONS FOR FORMWORK COLUMNS:



28

PERSONAL NOTES

29

PERSONAL NOTES

30

PANEL SYSTEMS

FALSEWORK

SCAFFOLDING

EDGE PROTECTION

FORMWORK ACCESSORIES

CONSTRUCTION CHEMICALS

SAFETY EQUIPMENT

fd max user guide uk

Documents