Ulma MK Structure User Manual

Construcción

User’s Guide

MK STRUCTURE

MK STRUCTUREMK STRUCTURE

MK STRUCTURE

E03FFN

Construcción

ConstrucciónConstrucción

Construcción

IMPORTANT

:

Any safety provisions as directed by the appropriate
governing agencies must be observed when using our
products.

The pictures in this document are snapshots of situations at
different stages of assembly, and therefore are not complete
images. For the purpose of safety, they should not be
deemed as definitive.

All of the indications regarding safety and operations
contained in this documents, and the data on stress and
loads should be respected. ULMA Construcción’s Technical
Department must be consulted anytime that field changes
alter our equipment installation drawings.

The loads featured in this document, related to the basic
elements of the product, are approximate.

Our equipment is designed to work with accessories and
items produced by our company only. Combining such
equipment with other brands is not only dangerous without
having made all corresponding verifications, it also voids any
or all our warranties.

The company reserves the right to introduce any
modifications deemed necessary for the technical

development of the

product.

““““

Original document”

Original document” Original document”

Original document”

produced and

produced andproduced and

produced and

approved by ULMA Construcción.

approved by ULMA Construcción.approved by ULMA Construcción.

approved by ULMA Construcción.

All rights reserved.

Neither all nor part of this document may be reproduced or transmitted in any way by any electronic or mechanical procedure,
including photocopy, magnetic recording or any other form of information storage or retrieval system without the permission of ULMA

ULMA ULMA

ULMA

Construcción.

Construcción.Construcción.

Construcción.

© Copyright by ULMA C y E, S. Coop

Information note

Information noteInformation note

Information note

Safety

Safety Safety

Safety

note

notenote

note

Warning note

Warning noteWarning note

Warning note

Control note

Control noteControl note

Control note

Construcción

ConstrucciónConstrucción

Construcción

3

INDEX

INDEXINDEX

INDEX

1. PRODUCT DESCRIPTI

1. PRODUCT DESCRIPTI1. PRODUCT DESCRIPTI

1. PRODUCT DESCRIPTION

ONON

ON ................................

................................................................

.....................................

..........

..... 4444

1.1. MK TRUSS ....................................................... 5

1.2. MK FORM CARRIERS ........................................ 7

2. SYSTEM COMPONENTS

2. SYSTEM COMPONENTS2. SYSTEM COMPONENTS

2. SYSTEM COMPONENTS AND ACCESSORIES

AND ACCESSORIESAND ACCESSORIES

AND ACCESSORIES ......

............

...... 13

1313

13

2.1. GRAPHIC DESCRIPTION ................................... 13

2.2. ITEMS DESCRIPTION ....................................... 17

3. ASSEMBLY, USE AND

3. ASSEMBLY, USE AND3. ASSEMBLY, USE AND

3. ASSEMBLY, USE AND DISMANTLING

DISMANTLINGDISMANTLING

DISMANTLING .................

..................................

................. 25

2525

25

3.1. TECHNICHAL ASSEMBLY INSTRUCTIONS.

GENERAL ASSEMBLY .............................................. 25

4. SOLUTIONS

4. SOLUTIONS4. SOLUTIONS

4. SOLUTIONS ................................

................................................................

......................................................

............................................

...................... 29

2929

29

4.1. STRUCTURE TYPES .......................................... 32

4.2. STRUCTURE LAYOUTS ..................................... 34

4.3. BRACING BETWEEN STRUCTURES .................... 38

4.4. STRUCTURE CONNECTION WITH SHORING

SYSTEM .................................................................. 39

4.5. STRUCTURE LEVELLING .................................... 40

4.6. FORWARD-MOVING OF STRUCTURES: ROLLING

SYSTEM .................................................................. 41

4.7. SAFETY AND ACCESS PLATFORMS ................... 42

5. SYSTEM PROPERTIES

5. SYSTEM PROPERTIES5. SYSTEM PROPERTIES

5. SYSTEM PROPERTIES ................................

................................................................

.......................................

..............

....... 43

4343

43

5.1. MAIN ITEM PROPERTIES ................................... 43

5.2. LIMITS FOR STANDARD STRUCTURES ................ 50

6. TERMS AND CONDITI

6. TERMS AND CONDITI6. TERMS AND CONDITI

6. TERMS AND CONDITIONS OF USE

ONS OF USEONS OF USE

ONS OF USE ....................

........................................

.................... 55

5555

55

6.1. SAFE OPERATING GUIDELINES .......................... 55

6.2. TRANSPORT, HANDLING AND STORAGE ........... 58

6.3. INSPECTION AND MAINTENANCE ..................... 59

7. LEGAL REFERENCES

7. LEGAL REFERENCES7. LEGAL REFERENCES

7. LEGAL REFERENCES ................................

................................................................

.........................................

..................

......... 61

6161

61

Construcción

ConstrucciónConstrucción

Construcción

4

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

1.

1.1.

1. PRODUCT DESCRIPTION

PRODUCT DESCRIPTIONPRODUCT DESCRIPTION

PRODUCT DESCRIPTION

The MK System is a product designed for heavy-duty structures of high load-bearing capacity mainly used in civil
engineering.

Its main feature is its versatility to configure all types of structures such as gantry structures, formwork carriers and
tunnel structures, shoring structures, horizontal and vertical formwork, other structures for formwork support,
climbing brackets, slab perimeter protection structures and other applications.

The core item for all these solutions is the Waler MK. Its elaborated design and the combination with various
accessories, both unique of the MK system as well as shared with other ULMA products, enable to adapt it to all
those above mentioned applications.

With the MK Structure system, two or more load-bearing structures are formed in one direction, the so-called main
axis. These structures are braced to each other giving the required stability to the whole as well as absorbing wind
loads acting on the structure in perpendicular direction to the main axis.

Depending on their field of application, mainly two structure types are distinguished:

− MK Truss Structure

MK Truss StructureMK Truss Structure

MK Truss Structure

− MK Form Carrier Structure

MK Form Carrier StructureMK Form Carrier Structure

MK Form Carrier Structure

In the following, the two structure types are described in detail.

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5

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

1.1. MK TRUSS

MK TRUSSMK TRUSS

MK TRUSS

A truss structure, bi- or multi-supported, supports the formwork and absorbs the loads acting on the formwork.
The formwork systems commonly used with the MK Truss Structure are Enkoform VMK or Enkoform H-120.

The typical truss form of the structure is achieved with equilateral triangles consisting of Walers MK and Nodes MK
assembled in the same plane. These structures are braced to each other with joints and tubes. Depending on the
required load-bearing capacity of the truss, the main axis can be reinforced with push-pull props and tubes.

The Waler MK range allows assembling trusses of different load-bearing capacities. The most optimum load­bearing capacity-weight ratio is the one given by a distance of 3 m between nodes axes and 2.6 m between waler
axes.

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6

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

If the span of the upper boom (or element that works at compression) is sought to be reduced or the bending
capacity to be increased, a vertical tube is used to make the structure bear higher loads.

The spans possible to cover with the MK Truss Structure change depending on the waler length used. Moreover,
the permissible working load changes depending on the layout of the truss structure.

The combination of the MK Truss Structure system with the MK Shoring system offers an even wider range of
solutions as shown in the following figures.

Solution combining the MK Truss Structure and MK Shoring system

Solution combining the MK Truss Structure and MK Shoring systemSolution combining the MK Truss Structure and MK Shoring system

Solution combining the MK Truss Structure and MK Shoring system

Solution combining the MK Truss and MK Form Carrier Structure

Solution combining the MK Truss and MK Form Carrier Structure Solution combining the MK Truss and MK Form Carrier Structure

Solution combining the MK Truss and MK Form Carrier Structure

MK - 2625 MK - 2625MK - 2625 MK - 2625

MK - 2625

M

K

­2

6
2
5

MK - 2625

M
K

­2
6
2

5

M
K

­2
6
2

5

M
K

­2
6
2

5

M

K

-

2

6

2

5

M

K

-

2

6

2

5

M

K

-

2

6

2

5

M

K

-

2

6

2

5

MK -4625

MK -4625

MK - 2625

MK - 2625

MK - 1125

MK - 1125

MK - 2625

MK - 1125

MK - 1125

MK - 2625

MK - 2625

M
K

­2
6
2

5

M

K

-

2

6

2

5

MK - 2625

MK - 2625

M
K

­2
6
2

5

M

K

-

2

6

2

5

MK - 2625

MK -4625

MK -4625

MK - 2625

MK - 2625

MK - 1125

MK - 1125

MK - 2625

MK - 1125

MK - 1125

MK - 1250

MK - 1250

MK - 1250

MK - 1250

MK - 1250

MK - 1250

MK - 1250

MK - 1250

MK - 1250

MK - 1250

MK - 1250

MK - 1250

MK - 2625

M
K

­2
6

2
5

M

K

-

2

6

2

5

MK - 2625

M
K

­2
6
2

5

M

K

-

2

6

2

5

MK - 2625

MK - 2625

M
K

­2
6
2

5

M

K

-

2

6

2

5

MK -4625

MK -4625

MK - 1125

MK - 1125

MK - 1125

MK - 1125

MK -5625

MK -5625

MK -5625

MK - 2625

Construcción

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7

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

1.2. MK FORM CARRIERS

MK FORM CARRIERSMK FORM CARRIERS

MK FORM CARRIERS

The following types of form carriers can be erected with the MK system:

− Deck flange form carrier

− Parapet form carrier

− Vertical formwork carrier

− Cut-and-cover tunnel form carrier

1.2.1. DECK FLANGE FORM CARRIER

DECK FLANGE FORM CARRIERDECK FLANGE FORM CARRIER

DECK FLANGE FORM CARRIER

In the case of metallic bridges which are made up of pre-cast components or of a pre-cast centre part, it is
common to build the wings in a subsequent stage. This can be done with deck flange form carriers. These are
heavy-duty form carriers as the jacks are able to withstand a maximum load of approximately 360 kN. Due to the
load borne by the structure, the forward-moving of the form carrier is achieved by means of pull or push auxiliary
devices.

A deck flange form carrier with these properties usually consists of the following parts:

o Main structure: structure bearing the concrete load.
o Forward-moving structure: secondary structure which effects the movement and bears the forces

during such.

o Bracing: components that withstand wind effects and transverse movements.
o Formwork: part in touch with the concrete shaping it, allowing its adjustment and opening if this is

required for the movement of the structure.

o Rolling and levelling system: components that enable the rolling of the truss and its levelling at a

specific place, as well as its stripping.

o Safety items and access: walkway platforms, handrails etc., depending on the requirements of each

project.

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8

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

There are two types of deck flange form carriers:

− Those where the rolling system is part of the form carrier (i.e. integrated in the secondary structure) or

− Those where the rolling system is not part of the form carrier.

A further distinction may be the requirement to cast both wings at the same time or one after the other.

In the first case, the rolling system rests on a guide rail to move the formwork to subsequent casting positions. It
can be applied in those cases where there is a solid base (pre-fabricated or pre-cast) to support the guide rail and
the levelling jacks on.

Deck flange form carrier for a bridge with a pre

Deck flange form carrier for a bridge with a preDeck flange form carrier for a bridge with a pre

Deck flange form carrier for a bridge with a pre----cast core

cast corecast core

cast core

In the second case, it is the other way around. The bogie forms part of the secondary structure and the rolling
system is fixed to the bridge. This is rather common where there is no pre-cast structure (e.g. metallic bridges).

Deck flange form carrier for a metallic bridge

Deck flange form carrier for a metallic bridgeDeck flange form carrier for a metallic bridge

Deck flange form carrier for a metallic bridge

TF - 0121

TF - 0121

TF - 0121

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9

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

1.2.2. PARAPET FORM CARRIER

PARAPET FORM CARRIERPARAPET FORM CARRIER

PARAPET FORM CARRIER

This form carrier is a lighter version of the previous one. It is used for applications with lower load-bearing and
forward-moving capacities. Unlike the one mentioned beforehand, the parapet form carrier can be moved manually
and requires a solid base where the guide rail rests on. The jacks of this form carrier type are able to withstand a
maximum load of approximately 150 kN.

The most common applications for parapet form carriers are the construction of protection parapets for bridges or
solutions that do not require high load-bearing capacity, mainly projects with formwork tables.

Form carrier for bridge parapets

Form carrier for bridge parapetsForm carrier for bridge parapets

Form carrier for bridge parapets

A parapet form carrier usually consists of the following parts:

o Main structure: structure bearing the concrete load.
o Bracing: components that withstand wind effects and transverse movements.
o Formwork: part in touch with the concrete shaping it, allowing its adjustment and opening if this is

required for the movement of the structure.

o Rolling and levelling system: components that enable the rolling of the truss and its levelling at a

specific place, as well as its stripping.

o Safety items and access: walkway platforms, handrails etc., depending on the requirements of each

project.

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10

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

1.2.3. VERTICAL FORMWORK CARRIER

VERTICAL FORMWORK CARRIERVERTICAL FORMWORK CARRIER

VERTICAL FORMWORK CARRIER

The main feature that distinguishes the vertical formwork carrier from others is that the vertical loads acting on the
structure are exclusively caused by the self-weight of the structure. Its load-bearing and forward-moving capacities
are still lower than the ones of the above mentioned form carriers. The jacks of this form carrier type are able to
withstand a maximum load of approximately 60 kN.

As the parapet form carrier, the vertical formwork carrier can be moved manually and requires a solid base where
the guide rail rests on. It is mainly used in the construction of single-sided or double-sided concrete walls. In the
case of single-sided walls, there are considerable horizontal loads which must be taken into account when using
the vertical formwork carrier.

Vertical formwork carrier for double

Vertical formwork carrier for doubleVertical formwork carrier for double

Vertical formwork carrier for double----sided walls

sided wallssided walls

sided walls

Vertical formwork carrier for single

Vertical formwork carrier for singleVertical formwork carrier for single

Vertical formwork carrier for single----sided walls

sided wallssided walls

sided walls

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11

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

1.2.4. CUT

CUTCUT

CUT----AND

ANDAND

AND----COVER TUNNEL FORM CARRIER

COVER TUNNEL FORM CARRIERCOVER TUNNEL FORM CARRIER

COVER TUNNEL FORM CARRIER

The solution with the MK system for cut-and-cover tunnels can be regarded another type of form carrier adapted to
the particular requirements of tunnel construction where the structure must adapt to the vault shape of the tunnel.
This form carrier type also applies to applications where walls and slabs are cast at once as it is the case of
rectangular section tunnels.

Vaulted tunnels are usually not cast at once but in stages: first the gables then the top part of the vault. Cut-and­cover tunnel form carriers are complemented with swivel parts to facilitate the stripping and forward-moving of the
structure.

An all-round solution for cut-and-cover tunnels combines the MK Structure system for the top part of the vault
with the MK Shoring system. A cut-and-cover tunnel form carrier usually consists of the following parts:

o Main structure: structure bearing the concrete load, both the vertical as well as the horizontal loads.
o Forward-moving structure: secondary structure which effects the movement and bears the forces

during such.

o Bracing: components that withstand wind effects and transverse movements.
o Formwork: part in touch with the concrete shaping it, allowing its adjustment and opening if this is

required for the movement of the structure.

o Rolling and levelling system: components that enable the rolling of the truss and its levelling at a

specific place, as well as its stripping.

o Safety items and access: walkway platforms, handrails etc., depending on the requirements of each

project.

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12

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

Cut-and-cover tunnel from carriers vary depending on aspects such as the load-bearing capacity and the area
where it is supported on and moved forward. Two types of cut-and-cover tunnel form carriers are distinguished
regarding a restricted or free support area. In all cases, the rolling system forms part of the form carrier, i.e. it is
integrated in the bogie.

Cut

CutCut

Cut----and

andand

and----cover tunnel form carrier with free support area

cover tunnel form carrier with free support areacover tunnel form carrier with free support area

cover tunnel form carrier with free support area

Cut

CutCut

Cut----and

andand

and----cover tunnel form carrier with restricted su

cover tunnel form carrier with restricted sucover tunnel form carrier with restricted su

cover tunnel form carrier with restricted support area

pport areapport area

pport area

Form carrier for slab and wall in rectangular section tunnel

Form carrier for slab and wall in rectangular section tunnelForm carrier for slab and wall in rectangular section tunnel

Form carrier for slab and wall in rectangular section tunnel

C
onstrucción

Constr

ucc

ión

C
onstru

cci

ón

Construcción

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13

MK

MK MK

MK STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

2.

2.2.

2. SYSTEM COMPONENTS AND ACCESSORIES

SYSTEM COMPONENTS AND ACCESSORIESSYSTEM COMPONENTS AND ACCESSORIES

SYSTEM COMPONENTS AND ACCESSORIES

2.1.

2.1.2.1.

2.1. GRAPHIC DESCRIPTION

GRAPHIC DESCRIPTIONGRAPHIC DESCRIPTION

GRAPHIC DESCRIPTION

Item no.

Item no.Item no.

Item no.

Weight

Weight Weight

Weight

(kg)

(kg)(kg)

(kg)

Item name

Item nameItem name

Item name

WALERS AND

WALERS AND WALERS AND

WALERS AND PROFILES MK

PROFILES MKPROFILES MK

PROFILES MK----120

120120

120

1990104

1990105
1990106
1990107
1990163

6

7.5

9.1

10.7

97.6

PROFILE MK

-

120 / 0.5

PROFILE MK-120 / 0.625
PROFILE MK-120 / 0.75
PROFILE MK-120 / 0.875
PROFILE MK-120 / 7.875

1990209

1990211
1990213
1990215
1990217
1990219
1990221
1990225
1990229
1990233
1990237
1990239
1990245

29.4

35.4

41.9

48.3

54.3

60.5

68.6

80.9

93.4

107.6

120.1

126.3

146.7

WALER MK

-

120 / 1.125

WALER MK-120 / 1.375
WALER MK-120 / 1.625
WALER MK-120 / 1.875
WALER MK-120 / 2.125
WALER MK-120 / 2.375
WALER MK-120 / 2.625
WALER MK-120 / 3.125
WALER MK-120 / 3.625
WALER MK-120 / 4.125
WALER MK-120 / 4.625
WALER MK-120 / 4.875
WALER MK-120 / 5.625

1990200

0.46

SPACER TUBE MK

-

120 / 52

0241690

0.17

BOLT M16x90 DIN

-

931-8.8

0241600

0.03

NUT M16 DIN

-

934-8

Item no.

Item no.Item no.

Item no.

Weight

Weight Weight

Weight

(kg)

(kg)(kg)

(kg)

Item name

Item nameItem name

Item name

NODES AND TRUSS ITEMS

NODES AND TRUSS ITEMS NODES AND TRUSS ITEMS

NODES AND TRUSS ITEMS

1990485

30.8 NODE 180 MK

1990480

31.8 NODE 180 D40 MK

1990420

24.0 NODE 120 MK

1990390

18.8 NODE 90 MK

1990360

16.0

NODE 60 F MK

Construcción

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14

MK

MK MK

MK

STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

Item no.

Item no.Item no.

Item no.

Weight

Weight Weight

Weight

(kg)

(kg)(kg)

(kg)

Item name

Item nameItem name

Item name

1990361

21.4 NODE 60 M MK

1990300

1990301

15.0

23.0

AXIAL NODE M D40

MK

AXIAL NODE 90º M D40 MK

1990665

50.5 NODE 360 MK

1990365

40.2 NODE 60 SUPPORT MK

1990395

1991200

6.5

9.1

ORTHOGONAL

JOINT MK

ORTHOGONAL JOINT MK-180

1990590

1991458

1.5

5.2

AXIAL NODE M D20 MK

AXIAL NODE M 2-D20 MK

Item no.

Item no.Item no.

Item no.

Weight

Weight Weight

Weight

(kg)

(kg)(kg)

(kg)

Item name

Item nameItem name

Item name

1990404

19.5 V BRACING TRUSS MK

1990403

1.3 JOINT PUSH

-

PULL PROP E

-

NODE MK

0242010

0242015

0.30

0.50

BOLT M20x100 DIN

-

931-8.8

BOLT M20x150 DIN-931-8.8

0242000

0.06 NUT M20 DIN

-

934-8

1980120

1.1 PIN D40x85

9023102

0.04

SAFETY

PIN D 7x50

PUSH

PUSHPUSH

PUSH----PULL PROPS E

PULL PROPS EPULL PROPS E

PULL PROPS E

1960210

1960100
1960110
1960115
1960130
1960125
1960410

10.6

14.1

18.8

24.1

33.4

38.1

45.0

PUSH-PULL PROP E 0.51

-

075

PUSH-PULL PROP E 0.75-1.05
PUSH-PULL PROP E 1-1.55
PUSH-PULL PROP E 1.51-2.2
PUSH-PULL PROP E 2.15-2.75
PUSH-PULL PROP E 2.7-3.3
PUSH-PULL PROP E 3.25-4

Construcción

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15

MK

MK MK

MK

STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

Item no.

Item no.Item no.

Item no.

Weight

Weight Weight

Weight

(kg)

(kg)(kg)

(kg)

Item name

Item nameItem name

Item name

0252070

0.28 PIN E20x70

0250000

0.03 COTTER PIN R/5

JOINTS AND BRACING ITEMS

JOINTS AND BRACING ITEMSJOINTS AND BRACING ITEMS

JOINTS AND BRACING ITEMS

1990521

3.8 U SECONDARY AXIS MK

1990421

2.7 U SECONDARY AXIS END MK

1990605

1990608
1990613
1990618
1990623

1.9

2.7

4.5

6.2

7.9

HORIZ. TUBE MK 0.75/ 550

HORIZ. TUBE MK 1/ 800
HORIZ. TUBE MK 1.5/ 1300
HORIZ. TUBE MK 2/ 1800
HORIZ. TUBE MK 2,5/ 2800

1990614

1990628

1990611
1990612
1990615
1990620

1990619
1990622
1990626
1990630

1990625
1990629
1990633

7.7

19.4

6.1

7.2

8.3

10.5

10.1

12.2

17.9

20.9

17.2

19.7

22.5

DIAGONAL MK 0.75x1.5 / 1396

DIAGONAL MK 0.75x3 / 2845

DIAGONAL MK 1x1 / 1110
DIAGONAL MK 1x1.25 / 1300
DIAGONAL MK 1x1.5 / 1508
DIAGONAL MK 1x2 / 1954

DIAGONAL MK 1.5x1.5 / 1818
DIAGONAL MK 1.5x2 / 2201
DIAGONAL MK 1.5x2.5 / 2624
DIAGONAL MK 1.5x3 / 3071

DIAGONAL MK 2x2 / 2524
DIAGONAL MK 2x2.5 / 1x3 / 2900
DIAGONAL MK 2x3 / 3310

Item no.

Item no.Item no.

Item no.

Weight

Weight Weight

Weight

(kg)

(kg)(kg)

(kg)

Item name

Item nameItem name

Item name

1990401

3.6 NODE-WALER 90º JOINT MK

1990402

3.7 WALER

-

WALER 90º JOINT MK

LEVELLING

LEVELLING LEVELLING

LEVELLING

AND FORWARD

AND FORWARDAND FORWARD

AND FORWARD

----

MOVING

MOVING MOVING

MOVING

ACCESORIES

ACCESORIESACCESORIES

ACCESORIES

1990550

40.2 JACK 360 MK

1990515

37.7 JACK 150 MK

1990506

7.4 JACK 60 MK

1990530

1990551
1990552
1990553

115.0

161.0

207.0

253.0

JACK WALER MK 0.5 / 1000

JACK WALER MK 1 / 1500
JACK WALER MK 1.5 / 2000
JACK WALER MK 2 / 2500

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16

MK

MK MK

MK

STRUCTURE

STRUCTURESTRUCTURE

STRUCTURE

Item no.

Item no.Item no.

Item no.

Weight

Weight Weight

Weight

(kg)

(kg)(kg)

(kg)

Item name

Item nameItem name

Item name

0242460

0.30 BOLT M24x60 DIN

-

931-8.8

0242400

0.11 NUT M24 DIN

-

934-8

1990655

89.0 WHEEL 100 MK

1990660

19.3 WHEEL 15 MK

1990645

93.0 TRIANGULAR BASE

CARRIER

1500 MK

1990504

25.9 HEAD JOINT MK

Item no.

Item no.Item no.

Item no.

Weight

Weight Weight

Weight

(kg)

(kg)(kg)

(kg)

Item name

Item nameItem name

Item name

1990374

25.5 HEAD JOINT 74 MK

1990400

17.0 PLATE NODE HEAD MK

1990405

15.7 HEAD JOINT MK

1990570

0.85 HANDRAIL HEAD MK

PROFILES MK

PROFILES MKPROFILES MK

PROFILES MK----180

180180

180

1990017

1990021
1990025
1990029
1990037
1990045
1990061
1990085

44,10

54,50
64,90
75,40

96,30
117,10
159,00
222,00

PROFILE MK

-

180/2,125

PROFILE MK-180/2,625
PROFILE MK-180/3,125
PROFILE MK-180/3,625
PROFILE MK-180/4,625
PROFILE MK-180/5,625
PROFILE MK-180/7,625
PROFILE MK-180/10,625

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2.2. ITEMS DESCRIPTION

ITEMS DESCRIPTIONITEMS DESCRIPTION

ITEMS DESCRIPTION

The following connections with bolt and nut will
be shortly describes as M16, M20 and M24 in this
document, meaning:

- M16: Bolt M16 DIN 931-8.8 + Nut M16
DIN 934-8

- M20: Bolt M20 DIN 931-8.8 + Nut M20
DIN 934-8

- M24. Bolt M24 DIN 931-8.8 + Nut M24 DIN
934-8 + 2 Washers 24 DIN125

2.2.1. WALERS MK-120

The Waler MK is the element all MK applications have
in common. Its main feature is the double row of
holes it provides for the connection of different parts.

The waler consists of two UPN-120 profiles joined
back face-to-face. There are three rows of holes. The

holes of the outer rows have a diameter of ∅17 mm

and the spacing between holes of the same row and
towards the other outer row is 62.5 mm.

In the centre row, holes and slots alternate, the holes
have a diameter of ∅20 mm, the slots have a length
of 45.5 mm. The spacing between the holes in the
centre row is 125 mm.

The centre rows always start and end with ∅20 mm
holes.

2.2.2. NODE 180 MK AND NODE 180 D40 MK

The Node 180 MK enables to connect up to 4 walers
placed at 60º. That is, two walers are connected
lengthwise with a remaining gap of 375 mm
between their respective ends, and the other two are
placed at 60º to the previous ones. The connections
are fastened with 6 bolts M16 inserted into the D17
holes.

The Node 180 D40 MK differs from the previous one
with respect to the connection of another (male)
item to the node centre in a hinged way pointing
downwards. The connection is fastened with pins
D40.

In both cases, the D20 holes are mainly used for the
connection of secondary components, i.e., bracing
items.

2 Tornillos M16

+

2 Tuercas

Autoblocantes

Agujero

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2.2.3. NODE 120 MK

This node enables to connect up to 3 walers at 60º.
The connections are fastened with 6 bolts M16
inserted into the D17 holes.

The D20 holes are mainly used for the connection of
secondary components, i.e., bracing items.

Moreover, another (male) item can be connected to
the node centre in a hinged way pointing
downwards. The connection is fastened with pins
D40.

2.2.4. NODE 60 F MK AND NODE 60 M MK

These nodes enable to connect up to 2 walers at 60º.
The connections are fastened with 6 bolts M16
inserted into the D17 holes.

The D20 holes are mainly used for the connection of
secondary components, i.e., bracing items.

There are two node types: a female (F) and a male
(M). Both enable to connect another item (male or
female) to the node centre in in a hinged way with
pins D40.

2.2.5. AXIAL NODE M D40 MK AND AXIAL NODE
90º M D40 MK

Both nodes enable to connect any waler to an
already assembled structure in a hinged way. The
connections are fastened with 6 bolts M16 inserted
into the D17 holes. These nodes provide high load­bearing capacity.

They are male nodes connected to a female node of
the structure with pins D40.

2.2.6. NODE 360 MK

This node enables to connect up to 6 walers. The
connections are fastened with 6 bolts M16 inserted
into the D17 holes. Two of the six walers are
connected lengthwise with a remaining gap of 375
mm between their respective ends.

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The D20 holes are mainly used for the connection of
secondary components, i.e., bracing items.

2.2.7. NODE 90 MK

These nodes enable to connect up to 2 walers at 90º.
The connections are fastened with 6 bolts M16
inserted into the D17 holes.

The D20 holes are mainly used for the connection of
secondary components, i.e., bracing items.

2.2.8. NODE 60 SUPPORT MK

The Node 60 Support MK is a kind of foot to support
the structure on something, mainly on profiles. It
works as support of a bi-supported truss.

It enables to connect up to 2 walers at 60º as the
Node 60 MK does. The connections are fastened with
6 bolts M16 inserted into the D17 holes.

The support plate provides D25 (25 mm diameter)
and D22 holes to connect other items and
accessories.

2.2.9. ORTHOGONAL JOINT MK

The Orthogonal Joint MK connects up to 3 walers
perpendicular to each other. The connection with the
waler is fastened with 4 bolts M16 inserted into the
D17 holes.

It can also connect 2 walers lengthwise. In this case,
each waler is fastened with 6 bolts M16 inserted into
the D17 holes .

This connector has medium load-bearing capacity
and is mainly used in light form carriers.

2.2.10. AXIAL NODE M D20 MK

This node enables to connect one waler to another in
a hinged way, always in the main plane. The waler
and the node are fastened with 2 bolts M16 inserted
into the D17 holes. Unlike the Axial Node M D40,
this one does not have high load-bearing capacity.

The hinged connection between the waler and the
node is fastened with pins E20x70.

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2.2.11. V BRACING TRUSS MK

This part serves to reinforce certain points of the
structure in its main plane where loads on the
structure require such a reinforcement of the waler.

It is connected to the structure with pins E20x70
inserted into the D20 holes, in front view. One side is
connected to a joint and the other to the waler.

There is only one type available to brace the
triangular structure of 3x3. Any other structure is
reinforced with push–pull props E.

The D20 holes enable to connect other walers to the
main structure, in cross section view.

2.2.12. PUSH-PULL PROP E

To reinforce a triangular structure other than 3x3,
push-pull props E are used. The props are fastened to
the structure with pins E20x70.

Push-pull props E are used to reinforce the structure
in its main plane against forces acting on it.

Lengths available are those shared with other systems
and their properties depend on the prop used in each
case.

Push

PushPush

Push----Pull Prop E range up to 2.2

Pull Prop E range up to 2.2Pull Prop E range up to 2.2

Pull Prop E range up to 2.2

Push

PushPush

Push----Pull Prop E range from 2.2

Pull Prop E range from 2.2Pull Prop E range from 2.2

Pull Prop E range from 2.2

2.2.13. PUSH-PULL PROP E - NODE MK JOINT

This item is used to connect the push-pull prop E to
any node. The connection to the node is fastened
with 2 pins E20x70, whereas the prop is fastened to
the joint with only 1 pin E20x70 allowing of a hinged
joint.

2.2.14. PIN D40x85

This is the item that fastens male to female node
joints. It offers high load-bearing capacity joints
which are used for applications where hinged joint
are required.

Each pin D40x85 is secured with a Cotter pin D6x42.

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2.2.15. HORIZONTAL BRACES MK AND
DIAGONALS MK

These items make the bracing of the structures.

In top view, the horizontal brace is the item placed
perpendicular to the main axis of the structure to
keep the distance between two adjoining structures.
In order to distinguish them from the diagonals, the
horizontal braces are D48 tubes.

L refers to the tube length. The number in the item
name refers to the distance in metres at which the
structures are kept.

The diagonals complement the bracing, providing the
required stiffness to the structure.

L refers to the tube length. The number in the item
name refers to the vertical and horizontal projections
AxB (in m) of the length of the diagonal.

2.2.16. U SECONDARY AXIS MK

This item connects horizontal braces and diagonals
to the structure. It can be placed either on walers or
on nodes.

It is fastened to the waler or node with bolts M20
and to the horizontal braces and diagonals with pins
E20x70.

An important feature of this joint type is that it
enables to connect the bracing back to the waler axis
thus obtaining high load-bearing capacity bracing.

2.2.17. U SECONDARY AXIS END MK

This item has the same function as the previous one
but is placed at the beginning and the end of the
bracing. That is why it can only be assembled on
nodes.

It is fastened to the node with bolts M20 and to the
horizontal braces and diagonals with pins E20x70.

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2.2.18. WALER - WALER 90º JOINT MK AND
NODE - WALER 90º JOINT MK

The Waler - Waler 90º Joint enables to connect 2
walers perpendicular to each other, in the secondary
axis.

The Node -Waler 90º Joint enables to connect a
waler perpendicular to a node, in the secondary axis.
It complements the previous one.

Both are mainly used for applications where a
structure is required to be connected perpendicularly
to an already existing structure. They do not work at
tension hence such loads must be avoided when
using these items.

2.2.19. PIN E20x70

This item is used to fasten all connections between
walers, nodes, joints, push-pull props E, horizontal
braces or diagonals, respectively, where these are
required to be hinged. Each pin E20x70 is secured
with a Cotter pin R/5.

2.2.20. JACK 360 MK

The jacks are the elements which allow of the vertical
adjustment, that is, the levelling of the form carrier.
They are placed at the base of the carrier bogies. The
Jack 360 MK is used to adjust heavy-duty form
carriers. It has an adjustment range of 220 mm and a
working load capacity up to 360 kN. It is fastened to
the jack waler with 4 bolts M24.

2.2.21. JACK 150 MK

The Jack 150 MK is used to level medium load­bearing capacity form carriers. It has an adjustment
range of 220 mm and a working load capacity up to
150 kN. It is fastened to any END PLATE of the MK
Shoring System with 4 bolts M24.

2.2.22. JACK 60 MK

The Jack 60 kN is used to level low load-bearing
capacity form carriers. It has an adjustment range of
220 mm and a working load capacity up to 60 kN. It
is fastened to the walers with 4 bolts M16.

All jacks must be lubricated before use.

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2.2.23. JACK WALER MK

The jack walers form the bogie of heavy-duty form
carriers. The bogie length can be adjusted at an
interval of every 0.5 m. The jack walers are fastened
together with 8 bolts M24 inserted into the D25
holes of their end-plate joints, thus creating a longer
jack waler profile.

The end-plate joints which determine the layout of
the form carrier structure at its base rest on the jack
walers. To the other side of the jack waler, the jacks
and the wheels to move the form carrier are
connected and fastened with 4 bolts M24.

2.2.24. WHEEL 100 MK

The Wheel 100 MK is used for the travel of heavy
form carriers. It is fastened to the jack waler that
forms the bogie with 4 bolts M24 at the indicated
positions.
The load-bearing capacity of the Wheel 100 MK lies
between 90-100 kN to move form carriers that bear
up to 360-400 kN (36-40 tons).

If the distance between wheel and bogie needs to be
increased, a spacer can be placed between them.

2.2.25. WHEEL 15 MK

The Wheel 15 MK is used for the travel of the
medium-weight form carriers. It is fastened directly
to the waler that forms the structure with 4 bolts
M16.

The load-bearing capacity per wheel is limited to 15
kN hence a 60 kN (6 tons) form carrier can move by 4
Wheels 15 MK.

2.2.26. TRIANGULAR BASE CARRIER 1500 MK

If there is not enough space for the support of the
form carrier at the base, it can be elevated with the
triangular base. It is mainly used for heavy-duty cut­and-cover tunnel form carriers.
The top is connected to the end-plate joints of the
structure and the bottom to the bogie. Both joints
are fastened with bolts M24.

It has protrusions at both ends to stabilise and plumb
the structure at erection.

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2.2.27. END JOINT 74 MK AND END JOINT MK

Both items are used to connect the structures to the
bogies.

The End Joint 74 MK is applied directly on the
structure when the structure itself is high enough to
match/obtain? the height of the form carrier?. One
end is connected to the walers with 6 bolts M16, the
other to the bogie with 4 bolts M24.

The End Joint MK is used to form vertical structures
or towers modules, that is, what the previous head
joint makes at 74º, the Head Joint MK makes at 90º.

2.2.28. NODE END-PLATE JOINT MK and WALER
END-PLATE JOINT MK

The Node End-Plate Joint MK enables an end joint of
structures whenever a hinged support on the same is
required. It is connected directly onto the MK Shoring
Towers or to the bogie.

Likewise, the Waler End-Plate Joint MK enables an
end joint of structures on the walers of the structure.
It is connected directly onto the MK Shoring Towers
or to the bogie.

One end is fastened to the structure with pin D40 in
the case of the node end-plate and with 6 bolts M16
in the case of the waler end-plate. The other end is
fastened to the shoring towers with 4 bolts M24 or
to the main beams with Clamps 16/70.

2.2.29. HANDRAIL HEAD MK

The handrail head serves to place tubes D48 to create
a handrail system at any height of the waler. It is
fastened with 2 bolts M16.

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3.

3.3.

3. AAAASSEMBLY, USE AND

SSEMBLY, USE AND SSEMBLY, USE AND

SSEMBLY, USE AND DISMANTLING

DISMANTLINGDISMANTLING

DISMANTLING

3.1.

3.1.3.1.

3.1. TECHNICHAL ASSEMBLY INSTRUCTIONS. GENERAL ASSEMBLY

TECHNICHAL ASSEMBLY INSTRUCTIONS. GENERAL ASSEMBLYTECHNICHAL ASSEMBLY INSTRUCTIONS. GENERAL ASSEMBLY

TECHNICHAL ASSEMBLY INSTRUCTIONS. GENERAL ASSEMBLY

For further information on this section, it is advisable to read and follow the respective technical assembly
instructions for the different products offered by the MK System with regard to their erection, dismantling and
handling.

ITM_MK01-01 “ERECTION OF THE MK TRUSS SYSTEM WITH AND WITHOUT BOTTOM PLATFORMS IN HORIZONTAL
POSITION”
ITM_MK02-01 “DISMANTLING OF THE MK TRUSS SYSTEM WITH AND WITHOUT BOTTOM PLATFORMS IN
HORIZONTAL POSITION”
ITM_MK03-01 “ERECTION OF THE MK TRUSS SYSTEM WITH AND WITHOUT BOTTOM PLATFORMS IN VERTICAL
POSITION”
ITM_MK04-01 “DISMANTLING OF THE MK TRUSS SYSTEM WITH AND WITHOUT BOTTOM PLATFORMS IN VERTICAL
POSITION”
ITM_MK05-01 “ERECTION OF THE MK FORM CARRIER SYSTEM WITH AND WITHOUT BOTTOM PLATFORMS IN
HORIZONTAL POSITION”
ITM_MK06-01 “DISMANTLING OF THE MK FORM CARRIER SYSTEM WITH AND WITHOUT BOTTOM PLATFORMS IN
HORIZONTAL POSITION”
ITM_MK07-01 “ERECTION OF THE MK FORM CARRIER SYSTEM WITH AND WITHOUT BOTTOM PLATFORMS IN
VERTICAL POSITION”
ITM_MK08-01 “DISMANTLING OF THE MK FORM CARRIER SYSTEM WITH AND WITHOUT BOTTOM PLATFORMS IN
VERTICAL POSITION”
ITM_MK09-01 “ERECTION OF THE MK CUT-AND-COVER FORM CARRIER WITH BOTTOM PLATFORMS IN VERTICAL
POSITION”
ITM_MK10-01 “DISMANTLING OF THE MK CUT-AND-COVER FORM CARRIER WITH BOTTOM PLATFORMS IN
VERTICAL POSITION”

3.1.1. Main structure erection. Node assembly

- Start with the assembly of the booms and
diagonals. Place the nodes on the waler according to
the indications in the assembly drawings.

All waler-node joints are fastened with bolts
M16x90. 6 bolts are required for a joint with high
load-bearing capacity at compression, 4 bolts for a
medium load-bearing capacity and 2 for a low load­bearing capacity. For capacity calculations, all waler­node joints are assumed to be hinged.

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- If indicated in the assembly drawings, the V Bracing
Truss MK is assembled next. Connect it to the node
using the bolt M20x90 and to the waler using 2 bolts
M16x90. Insert the V Bracing Truss MK into the gap
between the waler UPN profiles and connect it to the
node of the opposite boom.

3.1.2. Joints and braces assembly. Diagonals
and horizontal braces on main axis.

- Place the U secondary axis joints on nodes and

walers of the main axis in direction of the secondary
axis and fasten with bolts M20x90.

- Connect the horizontal braces to the U secondary

axis joints with pins E20x70.

3.1.3. Bracing assembly. Diagonals and
horizontal braces assembly between
structures.

- Assemble another structure equal to the first by

following the steps described in 3.1.1.

- Lift the whole or part of the structure and place it

parallel to the first with the horizontal braces already
in place. Fasten the braces to the lifted structure with
pins E20x70.

- Assemble the diagonals to finish the bracing of the

module.

3.1.4. Bogie assembly

- By following the indications in the assembly

drawings, place the jack waler with jacks and wheels
fastened with bolts M24. Likewise, the jack walers
are connected to each other with bolts M24.

- Put the already assembled set on the wheels, and if

indicated in the assembly drawings, place more jack
walers perpendicular to the previous ones, and fasten
with bolts M24.

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- Likewise proceed if it is required to assemble the
Triangular Base MK.

- Adjust the entity in height and direction with the
jacks aided by topography techniques if necessary. If
working with triangular bases, use props to plumb
the structure at the base.

3.1.5. Platforms and handrail system assembly

If the assembly drawings indicate the installation of
working platforms and handrail system, those must
be installed before the lifting of the structure.

Platforms can be created in the following ways:

- With B

With BWith B

With BRIO platforms placed onto the horizontal

RIO platforms placed onto the horizontal RIO platforms placed onto the horizontal

RIO platforms placed onto the horizontal

braces:

braces:braces:

braces: no need of extra components.

- With BRIO platforms placed on tubes D48:

With BRIO platforms placed on tubes D48:With BRIO platforms placed on tubes D48:

With BRIO platforms placed on tubes D48: fix the
tube onto the Handrail Head MK and fasten with
couplers 48. Insert the head into the gap
between the waler UPN profiles at the height
indicated in the assembly drawings and fasten
with bolts M16.

- With Beams VM20 and board:

With Beams VM20 and board:With Beams VM20 and board:

With Beams VM20 and board: place another
waler with the Axial Node M D20 MK fastened
with bolt M16 additionally to the pin E20x70 at
the height indicated in the assembly drawings.

To form the handrail, use tubes D48 connected with
the Handrail Head MK and couplers 48. The head is
fastened to the waler with bolt M16.

An alternative is to use 2 Tie Rods 15 with Plate Nuts
15 at both sides, as also common for other solutions.

3.1.6. Lifting and positioning of standard
structures

- Attach auxiliary load lifting means to the modules

assembled in section 3.1.3 and position the module
vertically by means of a mechanical load lifting
device.

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- Move the lifted modules to support them on the
jack walers and fasten with bolts M24. Check the
levelling of the structure.

- Likewise proceed with as many structures as
indicated in the assembly drawings. Usually two
structures are lifted together. The bracing with
horizontal braces and diagonals between the
structures is made after having placed them in their
final position.

- In the case of combinations between MK Shoring
Towers and MK Structure (Cut-and-cover tunnel form
carrier), the lifting is carried out in several steps. To
place the structure on towers, use walkway
platforms.

- Lift the structure and connect it to the towers with
bolts M24. Use a pointed pin to help inserting the
bolts into the holes.

- Remove the statutory auxiliary lifting means, and

platforms and auxiliary ladders (if applies).

- Proceed with covering the parts of the structure

with plywood which are indicated in the assembly
drawings.

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4.

4.4.

4. Solutions

SolutionsSolutions

Solutions

High load-bearing capacity structures up to 360 kN
are obtained with triangular structures. These
structures are mainly used for solutions such as
gantry shoring systems, trusses, deck flange and cut­and-cover tunnel form carriers.

These structures are characterised by using walers for
all diagonal and horizontal connections in direction
of the main axis, and by using such nodes that allow
of connecting one, two, three or more walers at 60º.
Those can be alternated at determined points of the
structure with nodes allowing of waler connections
at 90º and 45º.

All high load-bearing capacity joints are fastened
with 6 bolts M16 quality 8.8 and their corresponding
nuts providing a maximum tensile or compression
load of 360 kN to the node.

The triangular structures are formed with the same
waler size, the load-bearing capacity increasing
proportionally to the waler length. However, there is
another limitation to the structure at buckling in the
direction of the weak or secondary axis.

The waler providing the best structure weight–
working load ratio is the Waler MK-120 / 2.625
enabling a distance between nodes of 3 m.
Usually the structure is assembled at once, although
it might be useful to divide the assembly in modules

in order to ease future operations such as the placing
of the structure into its final position.

Medium load-bearing capacity structures up to 150
kN are characterised by using more frequently
tubular elements for the diagonal and horizontal
connections, reserving the walers for the most
demanding parts of the structure. These structures
are mainly used for solutions such as vertical
formwork carriers or parapet form carriers.

Medium load-bearing capacity joints are fastened
with pins D20 providing a maximum tensile or
compression load of 75 kN to the diagonals and 360
kN to the walers. Moreover, there is the load
limitation of the tube used for the diagonals and
horizontal braces.

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4.1 STRUCTURE TYPES

4.1.1 Truss structure

4.1.2 Hanging structure

4.1.3 Structure of form carriers

4.1.4 Forward-moving structure

4.2 STRUCTURE LAYOUTS

4.2.1 High load-bearing capacity structure

4.2.2 Reinforced main axis structure

4.2.3 Medium load-bearing capacity

structure

4.2.4 Secondary axis structure

4.3 BRACING BETWEEN STRUCTURES

4.3.1 Bracing on waler axis

4.3.2 Bracing off waler axis

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4.4 STRUCTURE CONNECTION WITH SHORING
SYSTEM

4.4.1 Support on shoring towers or props

4.4.2 Support on bogie

4.5 STRUCTURE LEVELLING

4.5.1 High load-bearing structure

4.5.2 Medium load-bearing structure

4.6 FORWARD-MOVING OF STRUCTURES

4.6.1 High load-bearing structure

4.6.2 Medium load-bearing structure

4.7 SAFETY AND ACCESS PLATFORMS

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4.1.

4.1.4.1.

4.1. STRUCTURE TYPES

STRUCTURE TYPESSTRUCTURE TYPES

STRUCTURE TYPES

4.1.1. Bi- or multi-supported truss structure

This refers to truss structures resting on at least two
supports. These are mainly used for high load­bearing capacity structures up to 360 kN on
horizontal braces and diagonals.

The structures can be supported on the ends or on
the central part thus working as a beam at bending
with point load or distributed load.

Truss structures are adapted to the spans between
supports and to the load-bearing capacity required
for the structure.

Solutions with constant and metric distances
between nodes are preferred hence the most
commonly used waler lengths for this structure type
are:

Theoretical length

Theoretical lengthTheoretical length

Theoretical length Nodes distance

Nodes distanceNodes distance

Nodes distance

1.625 m 2 m

2.125 m 2.5 m

2.625 m 3 m

Truss structures are frequently combined with the MK
Shoring system. The levelling and adjustment
elements applied are usually of high load-bearing
capacity (360kN).

The forward-moving of those heavy structures is
carried out with the Wheel 100 MK.

4.1.2. Hanging structures

This refers to structures which are not directly
supported on the ground or floor but are hanging
from others which are supported though.

Hanging structures usually hold the formwork and
must only be able to bear loads in order to transmit
them to the structures being supported on the
ground.

MK - 2625 MK - 2625

MK - 2625MK - 2625 MK - 2625

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In general, they are tied directly to the main
structures with pins D40 allowing of a fast and safe
on-site assembly.

Hanging structure in a MK deck flange form carrier

Hanging structure in a MK deck flange form carrierHanging structure in a MK deck flange form carrier

Hanging structure in a MK deck flange form carrier

Hanging structure in a MK vertical formwork

Hanging structure in a MK vertical formworkHanging structure in a MK vertical formwork

Hanging structure in a MK vertical formwork carrier

carriercarrier

carrier

Hanging structure in a MK cut

Hanging structure in a MK cutHanging structure in a MK cut

Hanging structure in a MK cut----and

andand

and----cover tunnel form carrier

cover tunnel form carriercover tunnel form carrier

cover tunnel form carrier

4.1.3. Structure of form carriers

Such structures must only bear their self-weight plus
the formwork they hold. They are medium load­bearing capacity structures and light, in general.

MK

MKMK

MK parapet form carrier structure

parapet form carrier structureparapet form carrier structure

parapet form carrier structure

The horizontal braces and diagonals are tubes in all
directions, reserving the walers for the most
demanding areas of the structure, in this case, to
connect levelling and rolling elements.

The rolling and levelling parts have lower load­bearing capacity: 150 kN and 60 kN for the jacks and
25 kN for the wheels.

Occasionally, when these structures are submitted to
concrete loads caused by lateral forces or they
support single-sided wall formwork, walers are used
to reinforce the horizontal axis.

MK vertical formwork carrier structure

MK vertical formwork carrier structureMK vertical formwork carrier structure

MK vertical formwork carrier structure

TF - 0121

TF - 0121

TF - 0121

TF - 0121

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4.1.4. Forward-moving structures

For the forward-moving of heavy structures, an
auxiliary structure is required.

Such complementary or secondary structure (bogie) is
placed perpendicular to the main structure easing the
forward-moving of the overall structure consisting of
several main structures.

The bogie must bear the loads during the forward­moving of the overall structure but does not
necessarily have to bear the loads during concrete
placement or working stage.

It can be rather simple consisting of jack walers
joined together, and supporting the structure and
jacks on one side and the rolling elements on the
other.

The bogie can be reinforced with elements of the MK
system. This might apply when the jack walers alone
are not able to bear the weight of the overall
structure or to provide extra stability to it, as in the
case of very tall structures.

Forward

ForwardForward

Forward----moving structure in a MK deck flange form carrier

moving structure in a MK deck flange form carriermoving structure in a MK deck flange form carrier

moving structure in a MK deck flange form carrier

Forward

ForwardForward

Forward----moving structure in a

moving structure in a moving structure in a

moving structure in a MK cut

MK cutMK cut

MK cut----and

andand

and----cover tunnel form

cover tunnel form cover tunnel form

cover tunnel form

carrier

carriercarrier

carrier

4.2.

4.2.4.2.

4.2. STRUCTURE LAYOUTS

STRUCTURE LAYOUTS STRUCTURE LAYOUTS

STRUCTURE LAYOUTS

4.2.1. High load-bearing capacity structure

There are various structures of this kind in all sorts of
applications, and inside them, there are different
node connection types depending on the area
required to be solved.

 60º joint
Used at the ends which require a termination of the
structure at 60º. Moreover useful when a pre­assembled structure (or tower) shall be quickly joined
to an already existing one.

 120º joint
Used at the ends which require a termination of the
structure at 120º. Moreover useful when a pre­assembled structure (or tower) shall be quickly joined
to an already existing one.

MK - 3625 MK - 3625 MK - 3625

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 180º joint
Used for the intermediate nodes of the structure.

There are two options depending on the requirement
to quickly join a pre-assembled structure (or tower)
to the intermediate joints or not. In the latter case,
the waler could pass through the node and 4 bolts
on each side of the joint would be sufficient.

 60º joint with support
Used at the ends which require a termination of the
structure at 60º and at the same time a support
located on the top part of the truss.

 90º joint
Used at the ends which require a termination of the
structure at 90º. Moreover useful when a pre­assembled structure (or tower) shall be quickly joined
to an already existing one.

 74º joint
Used at the ends which require an end joint at 74º.
This joint provides a single support in direction of the
main axis, as it is the case on bogies.

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 Joint with pins
It is used to join two structures quickly and
effectively. These are usually end joints which require
a male end element on one structure and a female
on the other. There are several parts fulfilling this
function.

The joint is fastened with a conical tip pin D40.

4.2.2. Reinforced main axis structure

For the reinforcement of the waler centre or a
specific part of the structure of high load-bearing
capacity structures, the V Bracing Truss MK is used.

This part only serves to reinforce the most common
triangular structure layout of 3 m between nodes. If
the distance between nodes is bigger or smaller,
push-pull props E and heads are used.

The joints are fastened with pins E20x70.

4.2.3. Medium load-bearing capacity structure

As mentioned beforehand, there are various
structures of this kind in all sorts of applications, and
inside them, there are different node connection
types depending on the area required to be solved.

 Longitudinal joints between walers
There are two types of longitudinal joints for walers
offering different additional features:

- The first waler joint can be stiffened with diagonals

and braced in the secondary axis. It moreover allows
of a 375 mm gap between the walers.

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- The second waler joint is a joint only between
walers. The bracing of the secondary axis is made at
another point. It enables either a butt joint fastened
with 6 bolts each or a joint with a 125 mm gap
between walers fastened with 4 bolts. In the latter
case, walers can be crossed.

4.2.4. Secondary axis structure. Waler joints at
different level

This refers to joints between walers perpendicular
between the main axis and the secondary axis. There
are various possible solutions depending on the
specific application.

The walers can be independent (formwork) or part of
other structures to be installed in this direction.

These joints can only work at compression, never at
tension. Therefore the joints must be assembled to
support the secondary walers on the main ones and
never the other way around.

 Waler on waler joint
The Waler-Waler 90º Joint MK is used to join walers
of the secondary axis on top of the walers of the
main axis.

The joint can be fixed at any point of the waler,
aligned with a hole or slot every 62.5 mm, in both
directions.

 Waler on node joint
In accordance with the previous joint, the Node­Waler 90º Joint MK is used to join the secondary axis
waler on top of a node of the main axis. This joint
can only be connected to the centre of the node.

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 Waler on V Bracing Truss MK joint
There is still another way to join two walers. That is
with the V Bracing Truss MK and without any
additional part. The V bracing can only be fixed to
the centre of a main truss waler, and only if tubes are
used in the application.

4.3.

4.3.4.3.

4.3. BRACING BETWEEN STRUCTURES

BRACING BETWEEN STRUCTURES BRACING BETWEEN STRUCTURES

BRACING BETWEEN STRUCTURES

Bracing between structures is understood as all tubes
and joints used to connect two or more equal
structures parallel to each other and thus also
reinforcing them in the secondary plane.

This tubes and joints framework structure must
mainly be able to absorb secondary actions such as
lateral wind, forces during the process of forward­moving of the structures and forces due to
inclinations or slopes of the application.

In some cases, these loads might happen to be
important, therefore the requirement to use bracing
which transmits the actions to the structure axis.

There is another possibility to externally brace the
structures. However, this bracing does not offer the
same qualities of the previous one and may only be

used when actions in the secondary plane are
certainly not important.

4.3.1. Bracing on waler axis

For this type of bracing, diagonals and horizontal
braces are used, joined to the walers with U
secondary axis joints fastened and with pins D20.
Hence these connections are all hinged which
requires them to be also braced diagonally at some
points to achieve an appropriate bracing for all the
structures.

The bracing system transmits the forces to the waler
axis, and the horizontal braces join and determine
the distance between two adjacent structures. More
structures can be braced parallel to the other, always
in the secondary plane.

4.3.2. Bracing off waler axis

Tubes and couplers are directly fixed to the Handrail
Head MK joined to the walers and fastened with 2
bolts M16.

This type of bracing does not offer the same qualities
of the previous one and is not advisable to be used
with high load-bearing capacity structures.

Its main advantage is its simplicity (few elements) and
ease of assembly hence it is very useful for the
bracing of light structures. It may also be used to join
two independent, that is, self-standing sets or form
carriers which are not supposed to be moved.

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4.4.

4.4.4.4.

4.4. STRUCTURE CONNECTION WITH

STRUCTURE CONNECTION WITH STRUCTURE CONNECTION WITH

STRUCTURE CONNECTION WITH

SHORING SYSTEM

SHORING SYSTEMSHORING SYSTEM

SHORING SYSTEM

There are two types of connections between
standard truss structures and support structures.

4.4.1. Support on shoring towers or props

The support of the structure on the shoring can as
well be secured in two different ways:

 Directly on the shoring: The structure rests

directly on top of one shoring leg.

The joint can be pinned or simply resting on the
shoring and being fastened subsequently with
bolts.

(1) The first case requires male-female joints as
the ones described before. Their implementation
is easier for structures of small height and or for
such being assembled on the ground.

This type is frequently used for connections with
the MK Prop system.

(2) For the second case, head joints are used as
end elements as well for the structure as for the
shoring or towers.

These joints allow of the pre-assembly of towers.
Only subsequently, the structure is supported on
and fastened to them.

This joint type suits best the requirements of
heavy and large structures.

MK truss structure supported on MK tower

MK truss structure supported on MK towerMK truss structure supported on MK tower

MK truss structure supported on MK tower

MK cut

MK cutMK cut

MK cut----and

andand

and----cover tunnel form carrier

cover tunnel form carriercover tunnel form carrier

cover tunnel form carrier

Both cases require high assembly accuracy as
well as the same number of structures and lines
of supports.

 With load distributing beam: This is the classical

support for gantry solutions. Its main advantage
lies in the better load and force distribution on
the supports.

This connection type does not require an equal
number of lines of supports and structures with
the correspondent savings which this supposes.

Con

strucció
n

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4.4.2. Support on bogie

This is the case of cut-and-cover tunnel and deck
flange form carriers where the main structure rests
on the jack walers (or a similar profile acting as
bogie) and where the end joints fixed to the jack
walers form the end of the structures, tied on the
fastening points of the profiles.

In case the structure does not have end joints, a joint
with similar features shall be found for the
connection.

4.5.

4.5.4.5.

4.5. STRUCTURE LEVELLING

STRUCTURE LEVELLINGSTRUCTURE LEVELLING

STRUCTURE LEVELLING

4.5.1. High load-bearing capacity structure

These structures commonly have a bogie. The
levelling of these structures is done with the Jacks MK
360 below the jack walers that form the bogie. If the
acting loads allow it, Jacks MK 150 might also be
used.

The number of jacks necessary to level the structure
depends on the application. As general rule, one
levelling line per each main structure support is
required to avoid loading the bogie when the
structure is not in the process of forward-moving.

For ordinary form carrier solutions such as cut-and­cover tunnel or deck flange and always if a stable
support area of sufficient size is available, two pairs
of jacks at both sides of the bogie are placed to free
the guide rail used for the forward-moving of the
form carrier.

If only a reduced support area for the form carrier is
available, the same is reduced to only one row of
supports. In such case, the jacks should rest directly
on the guide rail. The levelling of this type of
structures supposes rather complicated solutions.

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4.5.2. Medium load-bearing capacity structure

For lighter form carriers, the levelling is done using
the Jack MK 60. These solutions do not require a
secondary structure for the forward-moving, and are
usually made up of 2 or 3 main structures. Common
applications are vertical formwork carriers or such
applications where load requirements of the structure
are not significant.

4.6.

4.6.4.6.

4.6. FORWARD

FORWARDFORWARD

FORWARD----MOVING OF STRUCTURES:

MOVING OF STRUCTURES: MOVING OF STRUCTURES:

MOVING OF STRUCTURES:

ROLLING SYSTEM

ROLLING SYSTEMROLLING SYSTEM

ROLLING SYSTEM

4.6.1. High load-bearing capacity structure

The forward-moving of this type of structures is done
with Wheels MK 100 attached directly onto the jack
walers which form the bogie. During the process of
forward-moving, the wheels run on a guide rail. The
guide rail rests directly on the ground and is
anchored to it.

The guide rail is quite heavy (HEB-200 type) due to
the loads it must bear. The pulling of the structure to

the next pouring stage is done with the aid of load
arrester devices (e.g. Tractels).

Each form carrier or structure usually has 4 wheels
which allows of moving up to 40 tons. The wheels
are also the support points for the secondary
structure (bogie). In this case, the bogie bears the
total weight of the form carrier. Once the forward­moving has finished, the form carrier gets blocked by
means of the jacks and the bogie gets not loaded any
more.

4.6.2. Medium load-bearing capacity structure

Lighter form carriers are moved forward with the
Wheel MK 15 up to 60 kN. These are made up of
several main structures, and the wheels are attached
directly to the jack walers.

A lighter guide rail is used (UPN type) and the
forward-moving of the structure is done manually.

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4.7.

4.7.4.7.

4.7. SAFETY AND ACCESS PLATFORMS

SAFETY AND ACCESS PLATFORMSSAFETY AND ACCESS PLATFORMS

SAFETY AND ACCESS PLATFORMS

Safety platforms are assembled directly on the
structures. This can be done in two ways:



Directly on two adjoining structures with the
available walers. Secondary beams and board
rest on the walers. Depending on the beam used,
the corresponding fixing system is employed.



Directly on the bracing tubes between structures
with metal scaffolding platforms on round or
square tubes.

Platforms can be installed at any point of the
structure to provide working areas at different levels
and thus assisting the assembly. Moreover, access
platforms provide access to higher areas if required.

The first option allows of installing cantilever
platforms, that is, platforms outside the structure.

Both options similarly serve to assemble platforms
inside the structure.

The safety handrail system can also be assembled in
two different ways:

 With Handrail Heads MK on secondary

beamsusing the appropriate handrails for each
case as in any other system.

 With Handrail Heads MK on walersassembling

the handrail heads directly onto the walers of the
structure. Tubes and couplers get fastened to the
head. Typically used with metal (scaffolding)
platforms, this option suits well any kind of
platform.

5.

5.5.

5.

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52

120

SYSTEM PROPERTIES

SYSTEM PROPERTIESSYSTEM PROPERTIES

SYSTEM PROPERTIES

It is rather difficult to define limits for the manifold possible structure options which can be formed with the MK
system. As for their variety, each structure must be calculated on an individual basis. Nevertheless, this chapter
gives the necessary data to perform these calculations, and presents some limits for the most critical elements.

Some working load tables for particular applications are given below which may serve as orientation on the
obtainable load-bearing capacity of these structures.

5.1.

5.1.5.1.

5.1. MAIN ITEM PROPERTIES

MAIN ITEM PROPERTIESMAIN ITEM PROPERTIES

MAIN ITEM PROPERTIES

5.1.1. WALER MK-120

The technical material properties of the WALER MK-120 are:

m = 27.5 [kg/m] weight/m
A = 27.5 10-4 [m2] net section area (without holes)
fy = 275 [MPa] yield strength

Main axis (strong axis):

Avzz =12,32 10-4 [m2] shear area
Iyy = 680 10-8 [m4] moment of inertia
W

elyy

= 113 10-6 [m3] Young's modulus

Secondary axis (weak axis):

Avyy =17,2 10-4 [m2] shear area
Izz = 311 10-8 [m4] moment of inertia
W

elzz

= 38 10-6 [m3] Young's modulus

W

plyy

= 128 10-6 [m3] plastic section modulus?

The technical properties of the WALER MK-120 are (for SLS loads):
MMMM

Rdyy

RdyyRdyy

Rdyy

= 21.33

= 21.33= 21.33

= 21.33 (kN m)

(kN m)(kN m)

(kN m) Maximum permissible bending moment on axis y-y

VVVV

Rdzz

RdzzRdzz

Rdzz

= 118,2

= 118,2 = 118,2

= 118,2 (kN)

(kN)(kN)

(kN) Maximum permissible shear force on axis y-y?

MMMM

Rdzz

RdzzRdzz

Rdzz

= 6.3

= 6.3= 6.3

= 6.3 (kN m)

(kN m) (kN m)

(kN m) Maximum permissible bending moment on axis z-z

y y

z

z

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Compression load of WALER MK

Compression load of WALER MKCompression load of WALER MK

Compression load of WALER MK----120

120120

120

Free length

Free lengthFree length

Free length Compression load N

Compression load NCompression load N

Compression load N

crd

crd crd

crd

(SLS)

(SLS)(SLS)

(SLS)

1.5 m

1.5 m1.5 m

1.5 m 360 kN **

360 kN **360 kN **

360 kN **

2 m

2 m2 m

2 m 336 kN

336 kN 336 kN

336 kN

2.5 m

2.5 m2.5 m

2.5 m 287 kN

287 kN287 kN

287 kN

3 m

3 m3 m

3 m 240 kN

240 kN240 kN

240 kN

** Limited by the joint with 6 bolts

Values of pure buckling, not considering bending moment effects on any axis

5.1.2. PIN E20X70 AND PUSH-PULL PROP E JOINTS

The working load of the pin E20x70 in the WALER MK-120

5.1.3. PIN E20X70 AND TUBE 50X6 JOINT (V BRACING TRUSS MK TUBE)

The working load of the pin E20x70 in the WALER MK-120

Designation

DesignationDesignation

Designation Working load (SLS)

Working load (SLS)Working load (SLS)

Working load (SLS)

PIN E20x70

PIN E20x70PIN E20x70

PIN E20x70 77 kN

77 kN77 kN

77 kN

5.1.4. PIN E20X70 AND TUBE 50X4 JOINT

The working load of the pin E20x70 in the WALER MK-120

Designation

DesignationDesignation

Designation Working load (SLS)

Working load (SLS)Working load (SLS)

Working load (SLS)

PIN E20X70

PIN E20X70PIN E20X70

PIN E20X70 30 kN **

30 kN **30 kN **

30 kN **

** The strength limit of the diagonals is given by the tearing of the hole

Designation

DesignationDesignation

Designation Working load (SLS)

Working load (SLS)Working load (SLS)

Working load (SLS)

PIN E20x70

PIN E20x70PIN E20x70

PIN E20x70 77 kN

77 kN77 kN

77 kN

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5.1.5. PINNED JOINTS: PIN D40 AND MK CONNECTOR / NODES / JOINTS

The working load of the pin D40 used in a joint of the structure:

Designation

DesignationDesignation

Designation Working load (SLS)

Working load (SLS)Working load (SLS)

Working load (SLS)

PIN E40X70

PIN E40X70PIN E40X70

PIN E40X70 426 kN

426 kN426 kN

426 kN

5.1.6. BOLTED JOINTS: WALERS AND NODES

The working load of a joint fixed with 6 bolts between Walers MK-120 and different nodes is:

Designation

DesignationDesignation

Designation Axile

Axile Axile

Axile

Max

MaxMax

Max

(SLS)

(SLS)(SLS)

(SLS) M

M M

M

Max

MaxMax

Max

(SLS)

(SLS)(SLS)

(SLS)

6666----bolt joint at tension

bolt joint at tensionbolt joint at tension

bolt joint at tension 360 kN

360 kN360 kN

360 kN 0 kNm

0 kNm0 kNm

0 kNm

6666----bolt joint at bending

bolt joint at bending bolt joint at bending

bolt joint at bending moment

momentmoment

moment 0 kN

0 kN0 kN

0 kN 16.4 kNm

16.4 kNm16.4 kNm

16.4 kNm

The working load of a joint fixed with 4 bolts between Walers MK-120 and different nodes is:

Designation

DesignationDesignation

Designation Axile

Axile Axile

Axile

Max

MaxMax

Max

(SLS)

(SLS)(SLS)

(SLS) M

M M

M

Max

MaxMax

Max

(SLS)

(SLS)(SLS)

(SLS)

4444----bolt joint at tension

bolt joint at tensionbolt joint at tension

bolt joint at tension 240 kN

240 kN240 kN

240 kN 0 kNm

0 kNm0 kNm

0 kNm

4444----bolt joint at bending moment

bolt joint at bending momentbolt joint at bending moment

bolt joint at bending moment 0 kN

0 kN0 kN

0 kN 10.6 kNm

10.6 kNm10.6 kNm

10.6 kNm

The working load of a joint fixed with 2 bolts between Walers MK-120 and different nodes is:

Designation

DesignationDesignation

Designation Axile

Axile Axile

Axile

Max

MaxMax

Max

(SLS)

(SLS)(SLS)

(SLS) M

M M

M

Max

MaxMax

Max

(SLS)

(SLS)(SLS)

(SLS)

2222----bolt joint at tension

bolt joint at tensionbolt joint at tension

bolt joint at tension 120 kN

120 kN120 kN

120 kN 0 kNm

0 kNm0 kNm

0 kNm

2222----bolt joint at bending moment

bolt joint at bending momentbolt joint at bending moment

bolt joint at bending moment 0 kN

0 kN0 kN

0 kN 3.7 kNm

3.7 kNm3.7 kNm

3.7 kNm

These values refer to the maximum working load of the joint at pure tension and bending moment. They do

not refer to the load combination of both.

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5.1.7. DIAGONAL TUBES MK (50x4)

For any length of diagonals

DIAGONAL LENGTH

DIAGONAL LENGTHDIAGONAL LENGTH

DIAGONAL LENGTH TENSION (SLS)

TENSION (SLS)TENSION (SLS)

TENSION (SLS) COMPRESSION (SLS)

COMPRESSION (SLS)COMPRESSION (SLS)

COMPRESSION (SLS)

Any

AnyAny

Any 30 kN

30 kN30 kN

30 kN 30 kN

30 kN30 kN

30 kN

It is NOT

NOTNOT

NOT enough to verify the diagonals at buckling because diagonals submitted only to tension must be

verified with respect to the working load value NEVER

NEVERNEVER

NEVER exceeding 30 kN due to the tear of the ∅20 hole of the

diagonal. The maximum working load of the diagonals is given by the tearing of the hole.

5.1.8. HORIZONTAL BRACES MK

Two limit values are given below for the horizontal braces. The first value does not consider any working platform
installed on the braces hence they are only submitted to compression loads. The second value considers apart from
compression, the generation of bending moments along the brace due to working platforms.

For the first case and for any length of horizontal braces:

BRACE LENGTH

BRACE LENGTHBRACE LENGTH

BRACE LENGTH TENSION (SLS)

TENSION (SLS)TENSION (SLS)

TENSION (SLS) COMPRESSION (SLS)

COMPRESSION (SLS)COMPRESSION (SLS)

COMPRESSION (SLS)

Any

AnyAny

Any 20 kN

20 kN20 kN

20 kN 20 kN

20 kN20 kN

20 kN

It is NOT

NOTNOT

NOT enough to verify the horizontal braces at buckling because braces submitted only to tension must be

verified with respect to the working load value NEVER

NEVERNEVER

NEVER exceeding 20kN due to the tear of the ∅20 hole of the

diagonal. The maximum working load of the braces is given by the tearing of the hole.

CC

CC

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For the second case:

BRACE LENGTH

BRACE LENGTHBRACE LENGTH

BRACE LENGTH DISTRIBUTED LOAD (SLS) R

DISTRIBUTED LOAD (SLS) RDISTRIBUTED LOAD (SLS) R

DISTRIBUTED LOAD (SLS) R COMPRESSION (SLS)

COMPRESSION (SLS)COMPRESSION (SLS)

COMPRESSION (SLS)

0.75 m

0.75 m0.75 m

0.75 m ---- kN/m

kN/mkN/m

kN/m 10 kN

10 kN10 kN

10 kN

1 m

1 m1 m

1 m 17 kN/m

17 kN/m17 kN/m

17 kN/m 10 kN

10 kN10 kN

10 kN

1.5 m

1.5 m1.5 m

1.5 m 5.8 kN/m

5.8 kN/m5.8 kN/m

5.8 kN/m 10 kN

10 kN10 kN

10 kN

2 m

2 m2 m

2 m 2.6 kN/m

2.6 kN/m2.6 kN/m

2.6 kN/m 10 kN

10 kN10 kN

10 kN

2.5 m **

2.5 m **2.5 m **

2.5 m ** 1.1 kN/m

1.1 kN/m1.1 kN/m

1.1 kN/m 10 kN

10 kN10 kN

10 kN

3 m **

3 m **3 m **

3 m ** 1.9 kN/m

1.9 kN/m1.9 kN/m

1.9 kN/m 10 kN

10 kN10 kN

10 kN

** Due to the permissible load distribution, it is advisable not to install platforms on the horizontal braces of

2.5 m and 3 m. In any case, these braces require a previous verification.

5.1.9. BEAM VM20

Technical properties of the Beam VM20:

MMMM

ad

adad

ad

= 5

= 5 = 5

= 5 (kNm)

(kNm)(kNm)

(kNm) Maximum permissible bending moment

QQQQ

ad

adad

ad

= 11

= 11 = 11

= 11 (kN)

(kN)(kN)

(kN) Maximum permissible shear force

EI = 450

EI = 450 EI = 450

EI = 450 (kN m

(kN m(kN m

(kN m

2222

) Stiffness (EI)

5.1.10. PLYWOOD BOARDS (SHUTTERING FACE)

Regarding the high variety of different board types on the market, a separate document collects all mechanical
properties of formwork boards. For more information, please refer to that document.

CCCC

CCCC

RRRR

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5.1.11. JACK WALER MK

The jack waler is studied for the stripping at a 250 mm distance from the supporting areas of the posts. These
areas have to be properly stiffened.

F = 360 kN (SLS)

F = 360 kN (SLS)F = 360 kN (SLS)

F = 360 kN (SLS)

Technical properties of the Jack Waler MK:

m = 72.4 (kg/m) weight/m
A = 92.24 10-4 (m2) net section area (without holes)
Avzz =42.16 10-4 (m2) shear area Avyy =62.90 10-4 (m2) shear area
Iyy = 8590 10-8 (m4) moment of inertia Izz = 5274 10-8 (m4) moment of inertia
W

elyy

= 687 10-6 (m3) Young's modulus W

elzz

= 376 10-6 (m3) Young's modulus

fy = 355 (MPa) yield strength

The maximum permissible bending moment and shear force of the connection is:

8 bolts M24x60 8.8

Mmax yy (SLS) = 75 kNm ∼ 45 % waler strength

Tmax yy (SLS) = 300 kN

8 bolts M24x60 10.9

Mmax yy (SLS) = 100 kNm ∼ 60 % waler strength

Tmax yy (SLS) = 375 kN

T

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5.1.12. JACK MK 360

The working loads of the Jack MK 360 are indicated in the table below. The table shows the possible combinations
of axial (V) and horizontal (H) forces for the different jack extensions. In the same figure, two straight lines delimit
the values for which there might be a sliding of the nut with respect to the fixed base depending on some
estimated friction coefficients for a nut lubricated or non-lubricated on its base.

5.1.13. JACK MK 150

The working loads for the JACK MK 150:

VVVV max (SLS)

max (SLS)max (SLS)

max (SLS) H max (SLS)

H max (SLS)H max (SLS)

H max (SLS)

150 kN

150 kN150 kN

150 kN 8 kN

8 kN8 kN

8 kN

Combinacion AXIL-H ADMISIBLE

PARA EVITAR (DESLIZAMIENTO TUERCA o ROTURA HUSILLO )

0,0

20,0

40,0

60,0

80,0

100,0

120,0

0 50 100 150 200 250 300 350 4 00

AXIL MAXIMO ADMISIBLE E.L.S.(k N)

H MAXIMO ADMISIBLE E.L.S. (kN)

Extension Husillo 50 Extension Husillo 1 00 Extension Husillo 200

BASE TUERCA LUBRIC ADA BASE TUERCA SIN LUBRIC AR

POSIBLE DESLIZAMIENTO TUERCA
RESPECTO AL PERFIL HUSILLO EN
FUNCION DEL COEFI CIENTE DE
ROZAMIENTO EXISTENTE

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5.2.

5.2.5.2.

5.2. LIMITS FOR STANDARD STRUCTURES

LIMITS FOR STANDARD STRUCTURESLIMITS FOR STANDARD STRUCTURES

LIMITS FOR STANDARD STRUCTURES

The following information and data may merely act as reference. Formulas included in different calculation
bases for truss beams are used. They are valid as a first approximation but it is advisable to always verify individually
any truss application.

There are no whatsoever limits for possible truss deformations included herein. Those must be verified with
the help of calculation software for structures.

5.2.1. Bi-supported truss structure

This refers to a truss with supports at both ends as shown in the following figure. The spans possible to achieve
with this truss vary depending on the applied modulation. Three load application cases are analysed subsequently:

• As distributed load along the truss

• As point load applied on the centre of the upper boom

• As point loads applied on all nodes of the upper boom

The tables show the maximum permissible load in SLS for each truss (qmax) (Pmax): maximum reaction on prop­boom joint?, maximum bending moment the truss is able to absorb (M truss max), maximum bending moment in
the waler, maximum axial force in the waler and reactions on the supports depending on the distance between
nodes of the truss.

7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5

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5.2.1.1. Node distance 3 m

L

Truss

3

m

h

Truss

2,60

m

Longitud Total

Truss (m)

qmax kN/m

(ELS)

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

12 31,93 59,86 Tubo 50x50x6 574,67 8,98 221,19 191,56

15

24,08 45,15 Tubo 50x50x6 677,32 6,77 260,70 180,62

18

18,52 34,73 Tubo 50x50x6 750,10 5,21 288,71 166,69

21

14,55 27,28 Tubo 50x50x6 802,06 4,09 308,71 152,77

24

11,66 21,87 Tubo 50x50x6 839,82 3,28 323,25 139,97

27

9,52 17,86 Tubo 50x50x6 867,84 2,68 334,03 128,57

30

7,90 14,82 Tubo 50x50x6 889,05 2,22 342,19 118,54

7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5

L

Truss

3

m

h

Truss

2,60

m

Longitud Total

Truss (m)

qmax * kN/m

(ELS)

Pmax kN

(ELS

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

12

26,34 39,51 49,38 Tubo 50x50x6 474,08 11,14 182,48 158,03

15 20,76 31,14 38,92 Tubo 50x50x6 583,87 8,78 224,73 155,70

18

16,49 24,74 30,92 Tubo 50x50x6 667,89 6,98 257,07 148,42

21 13,27 19,90 24,88 Tubo 50x50x6 731,35 5,61 281,50 139,30

24

10,83 16,24 20,30 Tubo 50x50x6 779,41 4,58 299,99 129,90

27 8,96 13,44 16,79 Tubo 50x50x6 816,18 3,79 314,15 120,92

30 7,51 11,26 14,08 Tubo 50x50x6 844,69 3,18 325,12 112,63

Longitud Total

Truss (m)

qmax * kN/m

(ELS)

Pmax kN

(ELS

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

12

44,54 66,81 59,38 Tubo 50x50x6 801,69 0,00 308,57 300,63

15 33,26 49,88 45,35 Tubo 50x50x6 935,31 0,00 360,00 274,36

18

23,09 34,64 31,98 Tubo 50x50x6 935,31 0,00 360,00 225,17

21 16,97 25,45 23,75 Tubo 50x50x6 935,31 0,00 360,00 190,88

24

12,99 19,49 18,34 Tubo 50x50x6 935,31 0,00 360,00 165,63

27

10,26 15,40 14,59 Tubo 50x50x6 935,31 0,00 360,00 146,26

30 8,31 12,47 11,88 Tubo 50x50x6 935,31 0,00 360,00 130,94

* Valores orientativos (referencia para comparar)

10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0

10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0

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5.2.1.2. Node distance 2.5 m

L

Truss

2,5

m

h

Truss

2,17

m

Longitud Total

Truss (m)

qmax kN/m

(ELS)

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

10

42,65 66,64 Tensor E 1,5-2,2 533,10 8,33 246,23 213,24

12,5

31,76 49,62 Tensor E 1,5-2,2 620,31 6,20 286,51 198,50

15

24,21 37,82 Tensor E 1,5-2,2 680,81 4,73 314,45 181,55

17,5

18,90 29,52 Tensor E 1,5-2,2 723,35 3,69 334,10 165,34

20 15,08 23,56 Tensor E 1,5-2,2 753,92 2,94 348,22 150,78

22,5 12,27 19,17 Tensor E 1,5-2,2 776,42 2,40 358,61 138,03

25 9,98 15,59 Tensor E 1,5-2,2 779,42 1,95 360,00 124,71

7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5

L

Truss

2,5

m

h

Truss

2,17

m

Longitud Total

Truss (m)

qmax * kN/m

(ELS)

Pmax kN

(ELS

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

10 35,63 44,54 55,68 Tensor E 1,5-2,2 445,43 10,47 205,74 178,17

12,5 27,70 34,62 43,28 Tensor E 1,5-2,2 541,01 8,14 249,88 173,12

15 21,77 27,22 34,02 Tensor E 1,5-2,2 612,40 6,40 282,85 163,31

17,5 17,38 21,72 27,16 Tensor E 1,5-2,2 665,33 5,11 307,30 152,07

20 14,10 17,62 22,03 Tensor E 1,5-2,2 704,87 4,14 325,57 140,97

22,5 11,61 14,51 18,14 Tensor E 1,5-2,2 734,81 3,41 339,39 130,63

25 9,70 12,13 15,16 Tensor E 1,5-2,2 757,84 2,85 350,03 121,25

Longitud Total

Truss (m)

qmax * kN/m

(ELS)

Pmax kN

(ELS

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

10 62,35 77,94 69,28 Tensor E 1,5-2,2 779,42 0,00 360,00 350,74

12,5 39,91 49,88 45,35 Tensor E 1,5-2,2 779,42 0,00 360,00 274,36

15 27,71 34,64 31,98 Tensor E 1,5-2,2 779,42 0,00 360,00 225,17

17,5 20,36 25,45 23,75 Tensor E 1,5-2,2 779,42 0,00 360,00 190,88

20 15,59 19,49 18,34 Tensor E 1,5-2,2 779,42 0,00 360,00 165,63

22,5 12,32 15,40 14,59 Tensor E 1,5-2,2 779,42 0,00 360,00 146,26

25 9,98 12,47 11,88 Tensor E 1,5-2,2 779,42 0,00 360,00 130,94

* Valores orientativos (referencia para comparar)

10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0

10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0

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5.2.1.3. Node distance 2m

L

Truss

2

m

h

Truss

1,73

m

Longitud Total

Truss (m)

qmax kN/m

(ELS)

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

8 59,78 74,72 Tensor E 1-1,5 478,24 7,47 276,11 239,12

10 43,78 54,73 Tensor E 1-1,5 547,26 5,47 315,96 218,90

12

32,99 41,24 Tensor E 1-1,5 593,81 4,12 342,84 197,94

14

25,45 31,81 Tensor E 1-1,5 623,54 3,18 360,00 178,15

16

19,49 24,36 Tensor E 1-1,5 623,54 2,44 360,00 155,88

18

15,40 19,25 Tensor E 1-1,5 623,54 1,92 360,00 138,56

20

12,47 15,59 Tensor E 1-1,5 623,54 1,56 360,00 124,71

7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5

L

Truss

2

m

h

Truss

1,73

m

Longitud Total

Truss (m)

qmax * kN/m

(ELS)

Pmax kN

(ELS

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

8

50,81 50,81 63,51 Tensor E 1-1,5 406,47 9,55 234,68 203,24

10 38,77 38,77 48,46 Tensor E 1-1,5 484,59 7,29 279,78 193,84

12 30,06 30,06 37,58 Tensor E 1-1,5 541,09 5,65 312,40 180,36

14

23,75 23,75 29,69 Tensor E 1-1,5 582,00 4,47 336,02 166,28

16 19,13 19,13 23,91 Tensor E 1-1,5 612,03 3,60 353,36 153,01

18

15,40 15,40 19,25 Tensor E 1-1,5 623,54 2,89 360,00 138,56

20 12,47 12,47 15,59 Tensor E 1-1,5 623,54 2,34 360,00 124,71

Longitud Total

Truss (m)

qmax * kN/m

(ELS)

Pmax kN

(ELS

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

8 77,94 77,94 69,28 Tensor E 1-1,5 623,54 0,00 360,00 350,74

10

49,88 49,88 45,35 Tensor E 1-1,5 623,54 0,00 360,00 274,36

12

34,64 34,64 31,98 Tensor E 1-1,5 623,54 0,00 360,00 225,17

14 25,45 25,45 23,75 Tensor E 1-1,5 623,54 0,00 360,00 190,88

16

19,49 19,49 18,34 Tensor E 1-1,5 623,54 0,00 360,00 165,63

18 15,40 15,40 14,59 Tensor E 1-1,5 623,54 0,00 360,00 146,26

20 12,47 12,47 11,88 Tensor E 1-1,5 623,54 0,00 360,00 130,94

* Valores orientativos (referencia para comparar)

10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0

10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0

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5.2.1.4. Node distance 1.5m

L

Truss

1,5

m

h

Truss

1,30

m

Longitud Total

Truss (m)

qmax kN/m

(ELS)

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

6

90,25 84,60 OTRA OPCION 406,10 6,35 312,62 270,74

7,5 64,68 60,64 Tensor E 1-1,05 454,81 4,55 350,11 242,57

9

46,19 43,30 Tensor E 1-1,05 467,65 3,25 360,00 207,85

10,5

33,93 31,81 Tensor E 1-1,05 467,65 2,39 360,00 178,15

12 25,98 24,36 Tensor E 1-1,05 467,65 1,83 360,00 155,88

13,5

20,53 19,25 Tensor E 1-1,05 467,65 1,44 360,00 138,56

15

16,63 15,59 Tensor E 1-1,05 467,65 1,17 360,00 124,71

7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5

L

Truss

1,5

m

h

Truss

1,30

m

Longitud Total

Truss (m)

qmax * kN/m

(ELS)

Pmax kN

(ELS

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

6 78,48 58,86 73,57 Tensor E 1-1,05 353,15 8,30 271,86 235,44

7,5 58,41 43,81 54,76 Tensor E 1-1,05 410,68 6,18 316,14 219,03

9

44,50 33,37 41,72 Tensor E 1-1,05 450,54 4,71 346,83 200,24

10,5

33,93 25,45 31,81 Tensor E 1-1,05 467,65 3,59 360,00 178,15

12 25,98 19,49 24,36 Tensor E 1-1,05 467,65 2,75 360,00 155,88

13,5 20,53 15,40 19,25 Tensor E 1-1,05 467,65 2,17 360,00 138,56

15

16,63 12,47 15,59 Tensor E 1-1,05 467,65 1,76 360,00 124,71

Longitud Total

Truss (m)

qmax * kN/m

(ELS)

Pmax kN

(ELS

NTensor max

kN (ELS)

Tensor a utilizar

MCercha max

kNm (ELS)

Mmax Riostra

kNm (ELS)

Axil Max kN

(ELS)

R Apoyos kN

(ELS)

6 103,92 77,94 69,28 Tensor E 1-1,05 467,65 0,00 360,00 350,74

7,5

66,51 49,88 45,35 Tensor E 1-1,05 467,65 0,00 360,00 274,36

9

46,19 34,64 31,98 Tensor E 1-1,05 467,65 0,00 360,00 225,17

10,5 33,93 25,45 23,75 Tensor E 1-1,05 467,65 0,00 360,00 190,88

12 25,98 19,49 18,34 Tensor E 1-1,05 467,65 0,00 360,00 165,63

13,5

20,53 15,40 14,59 Tensor E 1-1,05 467,65 0,00 360,00 146,26

15

16,63 12,47 11,88 Tensor E 1-1,05 467,65 0,00 360,00 130,94

* Valores orientativos (referencia para comparar)

10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0

10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0

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6.

6.6.

6. TERMS AND CONDITIONS OF USE

TERMS AND CONDITIONS OF USETERMS AND CONDITIONS OF USE

TERMS AND CONDITIONS OF USE

6.1.

6.1.6.1.

6.1. SAFE OPERATING GUIDELINES

SAFE OPERATING GUIDELINES SAFE OPERATING GUIDELINES

SAFE OPERATING GUIDELINES

6.1.1. General guidelines

General guidelinesGeneral guidelines

General guidelines

• It is recommended to strictly follow the

instructions of the project plan, the health and

safety plan, as well as any further technical

and/or safety rules which might apply to the

project.

• Works are carried out by qualified personnel

only, and under the supervision of a competent

person.

• Instructions of use for the employed equipment

must be followed. Consult operating manuals of

the manufacturer or distributor.

• Only statutory auxiliary means and the

corresponding protection equipment, preferably

collective protection equipment are employed.

• Personal protective equipment (PPE) should

comprise at least safety helmet, safety footwear,

protective gloves and tool holder belt. Whenever

necessary use further PPE, such as reflective

jackets, anti-fall harness with lifeline, goggles,

breathing masks, earmuffs, etc.

• Avoid heavy impacts on working platform or

plywood. It is strictly forbidden to jump on

platforms or plywood, to abruptly unload

material or letting it fall from height onto the

platforms.

• If the building site is located nearby high voltage

power lines, it is recommended to work without

power supply. If this is not possible, the

appropriate measures according to the respective

reference standard should be taken.

• Under adverse weather conditions, works on the

building site should stop.

• Under heavy wind conditions, remove materials

and other objects from the platforms, and check

the stability of all ties, meshes, platform

anchorages, etc. before and afterwards.

• Before starting the stripping/dismantling

procedure, check that all structural components

(e.g. ties) are in place. If not, revise the assembly

before proceeding with stripping/dismantling.

• Furthermore, check that no loose material

remains on the structure, e.g. on working

platforms, in danger of falling from it, and

striking persons below.

• The following measures must be taken to restrict

access to the structure during erection and

dismantling or whenever the structure is not in

correct working conditions (e.g. missing collective

protection): signposting, fencing, closing or

demarcation with straps, barriers or meshes of

the working area and third-party passageways.

• Employees and any third party accessing a

structure without collective protection yet in

place, must wear all indicated PPE to prevent falls

from height or to be protected from falling

objects.

• The purchaser or lessee of the structure shall

instruct its employees on all necessary guidelines

for the safe operating of the structure.

• Any alterations of the structure must be executed

under the supervision of a competent person and

must comply with instructions in the operating

manuals of the manufacturer or distributor.

• The purchaser or lessee shall conduct periodic

checks of the assembly to verify the correct

installation of critical structural elements and to

identify the potential withdrawal of parts or the

alteration of the structure as such by employees

or a third party.

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6.1.2. Guidelines for

Guidelines for Guidelines for

Guidelines for structures

structuresstructures

structures

6.1.2.1. Structure assembly

• Mark and bound an area for the assembly so that

anyone outside the assembly will enter the area.

• Ensure the correct fastening of bolts and nuts

between different elements, and the correct

positioning and tightening of push-pull props.

• Ensure the fastening of ties, nuts, plate nuts, and

lots anchors and in general the correct anchorage

of those additional items to be tied to the

ground.

• Ensure the correct anchorage of the previous set,

before placing the next.

• Do not leave any part half-assembled or half-

dismantled.

• Ensure ground resistance to withstand the loads,

in terms of use, to which it will be subject, and

weather conditions, taking the necessary

measures (surface cleaning, foundation, …).

• In the event that loads are important, make a

geotechnical report and dimension the necessary

foundation by the contractor.

• When special foundations are needed, make a

foundation project with drawings and

calculations.

• Ensure structure stability, making the remarked

anchors according to the project or/and standard

configurations.

• If any product is spilled on the platforms, it will

be cleaned immediately.

• Do not accumulate material on the platforms,

only have the necessary equipment at all times.

6.1.2.2. Dismantling of structures

• Inspect the condition of the structure before

dismantling, in order to check if any items or

anchor is missing.

• Ensure that there are no loose elements on top

of the structure if the dismantling is done by

means of crane.

• Ensure that there are no workers in the vertical of

the removed gang or nearby.

• Take special care to ensure structure stability

when dismantling process.

• Do not accumulate material on the platforms

while dismantling, it must be lowered while

dismantling process is making.

6.1.3. Guidelines for

Guidelines for Guidelines for

Guidelines for structures

structuresstructures

structures

6.1.3.1. Formwork

• Place some sort of support to store or move the

formwork panels which prevent their damage

and ease the building site order, the panel

cleaning and the transport to their area of

operation.

• Ensure the fastening of plate nuts, and the

correct positioning and anchorage of push-pull

props to the ground.

• Ensure the correct anchorage of the previous

formwork set, before placing the next.

• Do not leave any part half-assembled or half-

dismantled.

• It is forbidden to climb on formwork except in

extraordinary cases duly studied and with

appropriate protection systems in place.

• Before concrete pouring, make sure the

formwork surfaces are clean.

• Clean panels after each use. Wire brushes are not

suitable for cleaning as they are damaging the

phenolic film of the plywood.

• It is important to state that the phenolic coating

rarely suffers from the chemical and abrasive

action of the concrete. But where it is already

damaged, e.g. at holes and deteriorated areas, it

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must be thoroughly sealed to prevent any further

damage to the plywood.

• Any cut edge of the plywood should be sealed as

soon as possible, because cut edges soak up

water from the concrete and swell, thus

increasing in thickness.

• In general, it is not recommended to use nails or

screws on the plywood.

• For storage, the panels should be stacked one on

top of the other, placing wood runners between

them. Use some sort of support to separate them

from the ground, and provide shelter. Prolonged

sun and rain exposure damages the panels.

6.1.3.2. Release agent

• Release agent helps separating the formwork

from the concrete, and thus increases the

number of uses and the life span of the panel in

general.

• It plays an important role for the quality of the

concrete finishing because it prevents holes from

air bubbles on the concrete surface and provides

a uniform colour.

• Apply the release agent uniformly and in thin

layers onto the panel, bearing in mind at all times

the instructions for correct use.

• Thoroughly clean the panel surface before

applying the release agent on it.

• Clean the metal frame and the panel off the

release agent after every 4 to 5 uses.

6.1.3.3. Concrete placement and compaction

• Comply with the maximum pressures according

to the instructions of the respective formwork

system.

• Continuously check the state of the formwork

during concrete casting. Stop further casting in

case of any incident.

• Place the concrete in uniform layers of 30 to 45

cm.

• For vertical concrete placement, cast the concrete

from the least height above the formwork

possible. Do never exceed 2 m height unless a

pipe or tube or any similar accessory is used to

channel the concrete. Deposit the concrete as

near as possible to the formwork base, centring

on one point without casting directly against the

formwork.

• When casting with bucket, take special care of

not hitting the formwork, and of complying with

the maximum load-bearing capacity of the crane.

• Avoid concrete splashes on the plywood as these

will reflect on the finished surface.

• Use the appropriate method for concrete

consolidation and compaction depending on the

concrete consistency and its workability.

• The preferred consolidation and compaction

method for wet cast-in-place concrete are poker

vibrators. Use external vibrators only when the

concrete cannot be accessed with poker vibrators

and for parts moulded already in the workshop.

External vibration requires a specific analysis.

• Completely immerse the poker 10 to 15 cm into

the concrete, and put it into each area of

concrete, only once. When concrete is poured in

layers, place the vibrator into the previous layer

to meld the two layers together.

• Never allow the vibrator to touch the formwork

to prevent exceeding the considered loads.

• Immerse vertically or slightly inclined and quickly,

but withdraw slowly.

6.1.3.4. Concrete curing and formwork stripping

• Check that curing is sufficiently advanced for

stripping without causing spalling at the concrete

surface which destroys the finishing and can

affect the strength and durability of the concrete.

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• Increase the curing time of the concrete when

facing fast drying and shrinkage due to

evaporation from wind or low temperatures.

• The time span between casting and stripping

shall be the same for all parts of the concrete

structure. This is justified when a high finishing

quality is aimed for because the tone of the

concrete surface depends on how long the

concrete surface is isolated from the outside.

• Ensure the absence of unauthorised people in the

vicinity where stripping takes place.

• Once stripping is finished, place the formwork on

a sort of support and proceed with its cleaning

and dismantling, if it is not going to be used for

further casts.

6.2.

6.2.6.2.

6.2. TRANSPORT, HANDLING AND

TRANSPORT, HANDLING AND TRANSPORT, HANDLING AND

TRANSPORT, HANDLING AND

STORAGE

STORAGESTORAGE

STORAGE

6.2.1. General guidelines

General guidelinesGeneral guidelines

General guidelines

• Get informed about hazards on the building site

and preventive measures to avoid those.

• Obey the instructions of the person-in-charge at

the workplace.

• Ensure adequate communication between the

employees working together.

• Use work equipment only when authorised,

trained and provided with all required

information to conduct it.

• Maintain minimum distances to mobile work

equipment (forklifts, lorries, cranes, other

construction machinery) and to areas with the

risk of falling objects.

• Do not stand, walk, or work under suspended

loads, nor under the trajectory or in the vicinity of

these loads.

• Avoid the parts suffering blows and crushing

during transport, handling and storage.

• The material is packed for transport in

appropriate containers such as wood or steel

pallets, boxes, or strapped in bundles with stable

base.

• Strap the bundles sufficiently stable to prevent

them from moving and getting damaged. If

necessary, protect the items with some sort of

buffer.

• Cut the metal strap, standing on the side, using

gloves and goggles to prevent getting cut by the

bouncing strap or caught in the strap.

6.2.2. Transport

TransportTransport

Transport

• Ensure the stable loading of the material,

complying with the instructions of the driver

(equilibrated distribution on the lorry bed,

fastening of auxiliary items, etc.).

• Keep your distance when opening the containers

after transport to prevent injuries from falling

objects.

6.2.3. Handling

HandlingHandling

Handling

6.2.3.1. Manual handling of loads

Some ergonomic principles to be followed are listed

below:

• Do not make any sudden jerky movements.

• Before lifting the load, examine it to detect any

sharp corners, dirt, etc. and decide according to

its shape, weight and volume for the best way to

get a secure grip of the load.

• Lift, separating the feet at shoulder distance,

duck, bending the knees, never the back.

• Do not attempt to lift alone, any load that is too

heavy, too large, or awkward. Use a mechanical

lifting device or get a helping hand from co-

workers.

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6.2.3.2. Mechanical handling of loads

• Only statutory mechanical lifting devices,

appropriate for the operation are allowed for

use.

• Check the condition of the lifting gear such as

slings or cables before each use and report any

defects.

• Place lifting accessories and step back to a secure

distance from the load and other materials which

could get affected.

• Comply with all instructions given by the team

chef who is specifically trained for this.

• Cause no sudden acceleration or deceleration of

the moving load.

• When conducting difficult or dangerous lifting

operations, or in the case that the crane operator

has no obstruction free visual control of the

entire trajectory of the load, the crane operations

are directed by a banksman who is in constant

communication with the crane operator by

means of a previously agreed sign code.

• If necessary, use tag lines to control the load

from distance. Keep hands clear of suspended

load if hands could get caught between the load

and another object. Swinging and/or unforeseen

movements with the load can cause serious

accidents.

6.2.4. Storage

StorageStorage

Storage

• Proper storage of the parts is fundamental to

keep them in good working condition.

• Wherever possible, store the material in a place

protected from atmospheric impact to avoid

wear.

• It is recommended to place parts of the same

type and dimensions in its respective container

(boxes, steel pallets, etc.).

• Ensure the stability of any piles, bearing in mind

the following aspects:

- Load-bearing capacity of the ground

- Varying ground levels

- Levelling of the packages

- Package or container support

- Package stability

- State of the strap

- State and capacity of the containers used

- Do not stack full containers on top of empty

or half-empty containers

- External conditions (wind, risk of another

object hitting the pile, etc.)

6.3.

6.3.6.3.

6.3. INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCEINSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE

6.3.1. General guidelines

General guidelinesGeneral guidelines

General guidelines

• ULMA is responsible for the delivery of the

products, for sale or rent, in good working

condition.

• From the moment of delivery, the responsibility

for correct use, inspection and product

maintenance passes on to the purchaser or

lessee. All damaged and broken parts, parts with

missing components, i.e. all parts in no proper

working condition must be removed from

service.

• For use, inspection and maintenance of the

product, special attention should be paid to the

following points:

- Items aimed to ensure people´s safety

- Items made of aluminium, as they are more

vulnerable to damages of the welded joints

and deformation

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6.3.2. Inspection instructions of

Inspection instructions of Inspection instructions of

Inspection instructions of elements

elementselements

elements appliances

appliances appliances

appliances

with CE marking of ULMA Construcción

with CE marking of ULMA Construcciónwith CE marking of ULMA Construcción

with CE marking of ULMA Construcción

Before each use, the condition of element appliances

with CE marking must be checked. In case that it

does not fulfil all defined requirements, it must be

removed from service.

For more information, consult ULMA Construcción.

6.3.3. Inspection instructions with CE marking of

Inspection instructions with CE marking of Inspection instructions with CE marking of

Inspection instructions with CE marking of

equipment marketed by ULMA Construcción

equipment marketed by ULMA Construcciónequipment marketed by ULMA Construcción

equipment marketed by ULMA Construcción

Equipment with CE marking marketed by ULMA

Constucción is checked following the instructions

stipulated in the User´s Guide of the respective
product.

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7.

7.7.

7. LLLLEGAL REFERENCES

EGAL REFERENCESEGAL REFERENCES

EGAL REFERENCES

• Council Directive 89/391/EEC

Council Directive 89/391/EECCouncil Directive 89/391/EEC

Council Directive 89/391/EEC of 12 June 1989 on the introduction of measures to encourage improvements in

the safety and health of workers at work.

• Council Directive

Council Directive Council Directive

Council Directive 89/654/EEC

89/654/EEC89/654/EEC

89/654/EEC of 30 November 1989 concerning the minimum safety and health requirements

for the workplace.

• Council Directive 89/656/EEC

Council Directive 89/656/EECCouncil Directive 89/656/EEC

Council Directive 89/656/EEC of 30 November 1989 on the minimum health and safety requirements for the

use by workers of personal protective equipment at the workplace.

• Council Directive 90/269/EEC

Council Directive 90/269/EECCouncil Directive 90/269/EEC

Council Directive 90/269/EEC of 29 May 1990 on the minimum health and safety requirements for the manual

handling of loads where there is a risk particularly of back injury to workers.

• Council Directive 92/57/EEC

Council Directive 92/57/EECCouncil Directive 92/57/EEC

Council Directive 92/57/EEC of 24 June 1992 on the implementation of minimum safety and health

requirements at temporary or mobile construction sites.

• Council Directive 92/58/EEC

Council Directive 92/58/EECCouncil Directive 92/58/EEC

Council Directive 92/58/EEC of 24 June 1992 on the minimum requirements for the provision of safety and/or

health signs at work.

• Council Directive 89/655/EEC

Council Directive 89/655/EEC Council Directive 89/655/EEC

Council Directive 89/655/EEC ---- Council Directive 95/63/EEC

Council Directive 95/63/EEC Council Directive 95/63/EEC

Council Directive 95/63/EEC ---- Directive 2001/45/EC

Directive 2001/45/ECDirective 2001/45/EC

Directive 2001/45/EC of the European Parliament

and of the Council of 27 June 2001 amending Council Directive 89/655/EEC concerning the minimum safety

and health requirements for the use of work equipment by workers at work.

• Directive 2002/44/EC

Directive 2002/44/ECDirective 2002/44/EC

Directive 2002/44/EC of the European Parliament and of the Council of 25 June 2002 on the minimum health

and safety requirements regarding the exposure of workers to the risks arising from physical agents (vibration).

• Directive 2003/10/EC

Directive 2003/10/ECDirective 2003/10/EC

Directive 2003/10/EC of the European Parliament and of the Council of 6 February 2003 on the minimum

health and safety requirements regarding the exposure of workers to the risks arising from physical agents

(noise).

• Directive 2006/42/EC

Directive 2006/42/ECDirective 2006/42/EC

Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and

amending Directive 95/16/EC (recast).

Standards:

• EN 12812:2008 Falsework. Performance requirements and general design

• EN 12811-1 Temporary works equipment. Part 1: Scaffolds. Performance requirements and general design

• EN 12811-2 Temporary works equipment. Part 2: Information on materials

• EN 12811-3 Temporary works equipment. Part 3: Load testing

• EN 13374 Temporary edge protection systems. Product specifications, test methods

• EN 74-1 Couplers, spigot pins and baseplates for use in falsework and scaffolds. Part 1: Couplers for tubes.

Requirements and test procedures

• EN 74-2_Couplers, spigot pins and baseplates for use in falsework and scaffolds. Part 2: Special couplers.
Requirements and test procedures

• EN 74-3_Couplers, spigot pins and baseplates for use in falsework and scaffolds. Part 3: Plain base plates and
spigot pins. Requirements and test procedures.

PRODUCTION PLANT
AND HEADQUARTERS

ULMA C y E, S. Coop.
Ps. Otadui, 3 - P.O. Box 13

20560 OÑATI (Guipúzcoa)
SPAIN
Phone: + 34 943 034900
Fax: + 34 943 034920

ULMA Construcción around the world

www.ulma-c.com

Construcción

EUROPE

 Germany

ULMA Betonschalungen
und Gerüste GmbH

RÖDERMARK
www.ulma-c.de

Nordwest Branch

NEUSS

Südwest Branch

GÖPPINGEN

 France

ULMA, S.A.R.L.

BONDOUFLE
www.ulma-c.fr

IDF Branch

BONDOUFLE

Eguilles Branch

EGUILLES

Nantes Branch

SAINT HERBLAIN

Lille Branch

LA CHAPELLE D’ARMENTIÈRES

Lescar Branch

LESCAR

Evénements Branch

LONS

Tarnos Branch

TARNOS

 Italy

ALPI, S.P.A.

MONGUELFO (BZ)
www.alpionline.net

 Kazakhstan

ULMA Kazakhstan

ASTANA
www.ulma-c.kz

 Poland

ULMA Construccion Polska S.A.

WARSAW
www.ulma-c.pl

WSCHÓD REGION
WARSZAWA Branch

WARSZAWA Office
OLSZTYN Office

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LUBLIN Office
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ZACHÓD REGION
POZNAŃ Branch

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POŁUDNIE REGION
JAWORZNO Branch

JAWORZNO Office
ŁÓDŹ Office

 Portugal

ULMA Portugal Lda.

São João da Talha - LISBON
www.ulma-c.pt

Porto Branch

Vila Nova de Gaia - PORTO

 Czech Republic

ULMA Construcción CZ, s.r.o.

BENÁTKY NAD JIZEROU
www.ulma-c.cz

 Slovac Republic

ULMA Construccion SK, s.r.o.

BRATISLAVA
www.ulma-c.sk

 Romania

ULMA Cofraje s.r.l.

BUCHAREST
www.ulma-c.ro

 Ukraine

ULMA Formwork Ukraine Ltd.

KIEV
www.ulma-c.com

Construcción

ASIA-AFRICA

 P.R. China

ULMA Formworks China R.O.

SHANGHAI
www.ulma-c.cn



UAE

ULMA Formworks UAE L.L.C.

DUBAI
www.ulma-c.ae

 India

ULMA FORMWORK SYSTEMS
INDIA PVT. LTD.

GURGAON - Haryana
www.ulma-c.in

 Singapore

ULMA Formwork Singapore PTE. LTD.

SINGAPUR
www.ulma-c.sg

 Spain

ULMA C y E, S. Coop.

www.ulma-c.es

ANDALUCÍA Branch

ALCALÁ DE GUADAIRA (Sevilla)
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CANARIAS Branch

INGENIO (Las Palmas)
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CENTRO Branch

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GALICIA Branch

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LEVANTE Branch

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 USA

ULMA Form Works, Inc.

Hawthorne - NEW JERSEY
www.ulma-c.us

West Branch (Phoenix)

Gilbert - ARIZONA

Mid-Atlantic Branch
(Baltimore)

Jessup - MARYLAND

 Mexico

ULMA Cimbras y Andamios de
México S.A. de C.V.

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(Mexico State)
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ULMA Encofrados Perú, S.A.

LIMA
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AMERICA

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ULMA Andamios y Encofrados
Argentina, S.A.

CAPITAL FEDERAL
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ULMA Brasil - Fôrmas e
Escoramentos Ltda.

Itapevi - SP
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ULMA Construction Systems Canada Inc.

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ULMA Chile - Andamios y Moldajes, S.A.

SANTIAGO
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CONCEPCIÓN