HEAVY DUTY PANEL ASSEMBLY MANUAL & USER GUIDE

HEAVY DUTY PANEL ASSEMBLEY MANUAL & USER GUIDE

This instruction manual provides the information necessary for the proper use of
FD Max formwork and important details on how to handle and properly use the product.
All the instructions that are described here must be followed correctly.
To ensure the safe use of our products, you should always respect the basic safety
standards and regulations of National Institutions Insurance Accidents and Public
Authorities.
The staff responsible for the assembly must be trained to assemble and meet all safety
standards.
As a fundamental principle, only original parts should be used and in excellent condition.
Damaged parts should be removed from circulation. In case of repair, only FDI original
parts in good condition should be used.
Before starting the assembly of the formwork system, it must be inspected by the team
leader erecting the material and defective equipment should never be used.
It should be subject to additional supervision if you want to combine the use of our
formwork system with other equipment from different vendors.
All illustrations in this catalogue are to be used as an example.
CONTENTS
1. Product Features
5. Components
10. Elements of connecting and anchors
11. Distribution of fasteners and anchors
12. Combinations of panels
13. Corner Solutions
15. T-Joints
17. Hinged Corners
18. Assembly Instructions
21. Platform Assembly Instructions
23. Lifting Hooks
25. Formwork Columns
Certification and certified products:
Formwork Direct International is in constant process of improvement and is a certified company since 2000 in accordance with
the norm NP EN ISO 9002: 1995 (APCER).
To insure the high standards of quality of our products in 2003 the company makes a transition to the UNE EN ISO 9001: 2000
and in 2004 the two scaffolding systems are certified according to the UNE 76502: 1990-HD 1000: 1998 CEN (AENOR).
At present, both scaffolding system have the new norm, EN12810 and EN12811 (this norm was adopted by UK in
01/2011 and is recognised since then as BS EN 12811-1)
All European Standards are at equal level as the British Standards
PRODUCT FEATURES
FD Max is a highly versatile heavy duty vertical shuttering system. It is a system suitable for all types of
works, such as walls, shutters, beams and columns. All panels can be combined vertically and horizontally,
without limitations
.
FD Max consists of a lightweight metal frame and a special steel structure reinforcement to
prevent deflection of the panels. The surface casing that fits into the frame is 18mm thick plywood with two faces
coated with a phenolic film 240g/m2 to ensure good quality concrete finishing and greater durability of the panels.
The FD clamp allows you to connect and secure the panels together. These can be aligned automatically,
or you can preassemble the panels with the help of a crane.
The permissible pressure for FD Max is 90kn/m2 for a single height of panels and
80kn/m2 when applied when overlapping as provided by the standard DIN 18202.
FD Max panels are available in heights of 1.0 m and 3.0 m and in 14 different widths from 0.30m to 2.40m
which makes different combinations possible as seen in this brochure.
The universal FD Max panel allows the shuttering of columns with sizes varying from 5x5cm to a maximum of
1.20 x 1.20m.
FD Max can also make use of normal vertical panels to form columns with the aid of the clamps and corner clamps
as seen in this brochure.
1
PRODUCT FEATURES
VERTICAL PANELS
HEIGHT 1000 MM
VERTICAL PANELS
HEIGHT 3000 MM
A panel
wi dt h
(mm)
300
350
400
450
50 0
550
600
900
1200
B di st ance C - n of
between rei nf or ceme-
panel s (mm) nts
0 0
0 0
0 0
0 0
0 0
0 0
210 1
243 2
243 2
2
PRODUCT FEATURES
PANEL VERTICAL HEIGHT 3000 MM BY 2400 MM WIDE
3
PRODUCT FEATURES
UNIVERSAL PANELS
HEIGHT 3000 MM
UNIVSERAL PANELS
HEIGHT 1000 MM
A (mm) B (mm) C N
550 0 0 8
750 285
950 243
1350 243
1 12
2 16
2 24
4
COMPONENTS
UNIVERSAL PANELS 3.0M - FD MAX
Siz e 3. 0x0. 30m Size 3.0x0. 35m Siz e 3.0x0. 40m
Weight (Kg) 69. 5 Weight (Kg) 74.3 Weight (Kg) 79
Siz e 3.0x0.45m Size 3.0x0. 50m Si ze 3.0x0. 55m
Weight (Kg) 83. 8 Wei ght (Kg) 88.6 Wei ght (Kg) 93. 4
Size 3. 0x0.60m Size 3. 0 x0. 90m Si ze 3. 0x1. 20m
Wei ght (Kg) 100.7 Weight (Kg) 132 Wei ght ( Kg) 180
5
COMPONENTS
Size 3.0x2. 40
Weight ( Kg) 329
UNIVERSAL PANELS 1.0M - FD MAX
Size 1.0x0. 30m Size 1.0x0. 35m Size 1.0x0.40m
Weight (kg) 25.6 Weight (kg) 27.5 Weight (kg) 29.5
Siz e 1 0x0 45 m Siz e 1 0x0 50m Siz e 1 0x0 55 m
Weight (Kg) 31 3 Wei ght (Kg) 33 25 Weight (Kg) 35 2
6
. . .
COMPONENTS
Size 1. 0x0. 60m Size 1.0x0. 90m Si ze 1. 0x1. 20 m
Weight (Kg) 39. 6 Weight (Kg) 53.5 Weight (Kg) 65
UNIVERSAL PANELS 3.0M - FD MAX
Siz e 3.0x0. 5 5m Siz e 3. 0x0.75 m Si ze 3. 0 x0. 95m
Weight (Kg) 93. 4 Weight (Kg) 122. 8 Wei ght (Kg) 136.8
Size 3. 0x1. 35m
Weight (Kg) 176
7
ARTICULATED CORNER PANELS - FD MAX
Size 1.0x0. 30x0. 30m Siz e 3.0x0. 30x0. 3 0m
Weight ( Kg) 41 Wei ght (Kg) 113
8
1.0x1. 35m
70.9
COMPONENTS
UNIVERSAL PANELS 1.0M - FD MAX
Measurement 1. 0x0. 55 m Measurement
Weight (Kg) 35 . 2 Wei ght ( Kg)
Measurement
Wei ght (Kg)
1.0x0. 75m
45.3
1.0x0.95m
55.5
CORNER PANELS - FD MAX
Measurement 1.0x0. 30x0. 30m M easur ement 3.0x0. 30x0.30m
Weight (Kg) 39 Weight (Kg) 108
M easuremen
Wei ght (Kg)
t
COMPONENTS
CLAMPS - FD MAX
Fixed Cl amp C losin g wi th ou te r corner w all s Univer sal Fi xi ng
Weight (Kg) 5.4 3 Weight (Kg) 2. 21 Weight (Kg) 0.92
ACCESS BRACKET -
FD MAX
ACCESSORIES - FD MAX
Plug 34x27,5mm
Lifting Hook (Brown)
Wei ght (Kg) 5.71 Weight (Kg) -
0.9 0 m Plug 25x18mm (Yel l o w)
Weight (Kg) 14. 5 Weight (Kg) -
9
ELEMENTS OF CONNECTORS & ANCHORS
Steel Waler s
close to corner
out er wall
Uni versal fi xi ng
bolt
Fixed
clamp
There are different combinations that can be performed to obtain different heights of Formwork.
To accomplish these combinations it is necessary to use fixed clamps. This component serves to join two
panels with pressure whilst aligning two adjacent panels. They can also be used in different types
of connections: horizontal and vertical. When anchoring the panels this is made through the
existing hole in the steel panel frame. Before the insertion of the tie rods the plugs should be removed.
The holes that are not used must be closed with plugs.
10
10
a Typical elevation of components for single layer panels using 3.0 x 1.2 panels
b Typical elevation of components for more than 1 level of panels using 3.0 x 1.2 panels.
c Typical elevation of components for 2 levels of panels using 3.0 x 1.2 panels.
11
DISTRIBUTION OF FASTENERS AND ANCHORS
The alignment and anchoring fasteners (nut and rod) must be distributed evenly within the structure of
the panels.
We can visualize the distribution of various components in the 3 different examples below.
a b c
COMBINATION OF PANELS
FD Max is composed of panels with heights of 3m and 1m with widths from 0.3 m to 2.4 m
These dimensions can be combined to obtain the desired height of the wall or base.
Example of combination of panels in heights up to 6m. This combination is valid
for both wall panels and columns.
12
CORNER SOLUTIONS
FD MAX corner panels form the interior angles of 90 degrees and come in sizes of
3 m & 1m and width equals 300mm x 300mm.
Example of application
of corner panels
EXAMPLES OF CORNER SOLUTIONS
Combinations of FD Max
panels for thicknesses
between 150 mm and 500 mm with
50 mm increments:
Arrangement of panels for Arrangement of panels for
walls of 150 mm thickness. walls of 200 mm thickness
using a 50 mm timber make
up.
13
using a 50 mm timber make using a 50 mm timber make
up. up.
For any other dimensions of the wall you should follow the same pattern within reason (please check
with our engineers) The adjustable clamps are used to create make ups between panels.
These make ups are usually timber. We can provide steel alignment fixings to enable a more
effective connection these can also be used for stop ends.
14
Arrangement of panels for a Arrangement of panels for a
wall of 300 mm thickness wall of 350 mm thickness
using a 50 mm timber make using a 50 mm timber make
up. up.
Arrangement of panels for a Arrangement of panels for a
wall of 450 mm thickness wall of 500 mm thickness
CORNER SOLUTIONS
Arrangement of panels for a
wall of 250 mm thickness.
Arrangement of panels for a
wall of 400 mm thickness
Example for a 150mm T
Junction wall using a
150mm timber make up.
Example for a 300mm T
Junction wall.
15
T JOINTS
T shaped wall set up. The panel system can be used for thicknesses up to 600 mm.
It is possible to adapt different widths using timber make ups and adjustable clamps as demonstrated
below.
Example for a 250mm T
Junction wall using a 50mm
timber make up.
Example for a 200mm T
Junction wall using a
100mm timber make up.
Example for a 350mm T Example for a 400mm T
Junction wall using a 50mm Junction wall using a
timber make up. 100mm timber make up.
T JOINTS
Example for a 100mm T Junction wall using a Example for a 500mm T Junction wall using 2x
50mm timber make up. 100mm timber make up.
16
HINGED CORNERS
The hinged corners can be used for both inside corners and outside corners depending on the angle of the walls
FD Max.
To set up oblique corners,
simply clamp the hinged
corners.
Linking the two sides of the
panel system then you can
slightly reduce or increase the
angle formed. Please see
below for typical examples.
POSSIBLE SOLUTIONS FOR HINGED CORNERS
minimum range: 70 (or an angle of 290
between outer edges)
17
maximum range: 109
Distribution of vertical panels flat on More panels are added, making the
the ground: size desired / allowable load by the crane:
Outer faces Outer faces
STEP 3
Panels are applied:
- The fixed clamps that make the connection between adjacent panels;
- Access brackets that allow you a working platform to work off for safe future concrete pouring
- Lifting hooks that allow safe transport of fully assembled panels with the use of a crane
18
STEP 2
ASSEMBLY INSTRUCTIONS
STEP 1
The assembly of the panels is raised from the Add the inner and outer corner panels to the
ground and placed at the construction site of wall panels whilst fixing the nuts and bolts
the wall that make the connection between the
opposite walls of formwork
Face interior
Face interior
Face exterior
Face exterior
STEP 6 STEP 7
Add any remaining tying systems to the Insert the working platform onto the panels as
panels if necessary. demonstrated below.
Face interior
STEP 5
ASSEMBLY INSTRUCTIONS
STEP 4
Face exterior
Face exterior
19
Face interior
ASSEMBLY INSTRUCTIONS
Typical corner detail below.
Interior view. Exterior view.
20
PLATFORM ASSEMBLEY INSTRUCTIONS
STEP 1 STEP 2 STEP 3
Place the panel flat on the Open up the panel as Rotate the platform 90
floor. indicated. degrees and add the
FD Max panel.
STEP 4 STEP 5 STEP 6
Add the diagonal Insert the ladder into the Place the ladder over the
supports to the panel. hole. panel.
21

NOTE: If the product does not come with a concreting coupler panel, this should be mounted
according to the following figure.
22
PLATFORM ASSEMBLY INSTRUCTIONS
STEP 7 STEP 8 STEP 9
Open the side railings Place below the
trapdoor.
Mount a second ladder
directly below the
trapdoor. Stabilize the
struts to the panel.
LIFTING HOOKS
The FD Max lifting hook is manufactured with the CE marking according to directive No. 2006/42/CE and
the corresponding Decree-Law No. 103/2008.
HANDLING THE CRANE
The lifting hook should be inserted wherever the joint panel, as
shown below.
Panels should be lifted symmetrically whilst keeping the same
weight on each axle suspension;
The lifting hook is inserted after self-locking
FD Max Lifting Hook
COUPLING SCHEME
1st Step
23
2nd Step 3rd Step
LIFTING HOOKS
The maximum weight supported by each lifting hook is 1.5 ton. Lifting chains must make a maximum angle
of 60 to each other.
mx. 60
24
FORMWORK COLUMNS
The universal panels have a continuous series of holes and are used especially for shuttering of
columns.
Using four panels as in the following examples, square and rectangular columns can be formed
from 5x5cm up to 80x80cm.
Formwork column 1 m
Formwork column 3 m
NOTE: the link between the
columns panels can be made with
the universal fixings and super plates.
You can also use the corner clamp for
various column sizes..
Formwork Column 4m
(3m panel + 1m panel).
25
FORMWORK COLUMNS
Possible combinations for universal panels
Combination of 1.350 Combination of 1.35mm Combination of 915mm
Universal panels for Universal panels for Universal panels for
columns of 1200mm2 columns of 600mm2 columns of 800mm2
Combination of 915m
Universal panels for
columns of 400mm2
Combination of universal
panels 750mm for columns of
600 mm2
(maximum possible).
Combination of 750mm
Universal panels for
columns of 300mm2
26
FORMWORK COLUMNS
Combination of 550mm Combination of universal
Universal panels for panels 550mm for columns
columns of 400mm2. of 200mm.
You can combine FD Max panels for the construction of rectangular columns:
Combination of 1.35m and 750mm Combination of 950mm x 950mm +
Universal panels for columns of 1200mm 750mm Universal panels for columns of
x 600 1550mm x 800
27
FORMWORK COLUMNS
ASSEMBLY INSTRUCTIONS FOR FORMWORK COLUMNS:
STEP 1 STEP 2 STEP 3
STEP 4 STEP 5 STEP 6
28
PERSONAL NOTES
29
PERSONAL NOTES
30
PANEL SYSTEMS
FALSEWORK
SCAFFOLDING
EDGE PROTECTION
FORMWORK ACCESSORIES
CONSTRUCTION CHEMICALS
SAFETY EQUIPMENT