HEAVY DUTY PANEL ASSEMBLY 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.

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PRODUCT FEATURES

VERTICAL PANELS
HEIGHT 1000 MM

VERTICAL PANELS
HEIGHT 3000 MM

A – panel B – distance C - nº of
width between reinforceme-
(mm) panels (mm) nts
300 0 0
350 0 0
400 0 0
450 0 0
500 0 0
550 0 0
600 210 1
900 243 2
1200 243 2

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 PRODUCT FEATURES

PANEL VERTICAL HEIGHT 3000 MM BY 2400 MM WIDE

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PRODUCT FEATURES

UNIVERSAL PANELS
HEIGHT 3000 MM

UNIVSERAL PANELS
HEIGHT 1000 MM

A (mm) B (mm) C N

550 0 0 8

750 285 1 12

950 243 2 16

1350 243 2 24

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 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 z e 3.0x0.55m

Weight (Kg) 83.8 Wei ght (Kg) 88.6 Wei ght (Kg) 93.4

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

Wei ght (Kg) 100.7 Weight (Kg) 132 W ei ght ( K g) 180

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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 (k g) 29.5

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

Weight (Kg) 31 .3 Wei ght (K g) 3 3 . 25 Weight (Kg) 35 .2

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 COMPONENTS

Size 1.0x0.60m Siz e 1.0x0.90m Si ze 1.0x1.20m

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

UNIVERSAL PANELS 3.0M - FD MAX®

Siz e 3.0x0.55m Si z e 3.0x0.75m Si ze 3.0x0.95m

Weight (Kg) 93.4 Weight (Kg) 122.8 Wei ght (Kg) 136.8

Size 3.0x1.35m

Weight (Kg) 176

7
COMPONENTS

UNIVERSAL PANELS 1.0M - FD MAX®

Measurement 1.0x0.55m Measurement 1.0x0.75m Measurement 1.0x0.95m

Weight (Kg) 35 . 2 Wei ght ( K g) 45.3 Wei ght (K g) 55.5

CORNER PANELS - FD MAX®

M e a s ure me nt 1.0x1.35m M easur ement 1.0x0.30x0.30m M e asur ement 3.0x0.30x0.30m

Wei ght (K g ) 70.9 Weight (Kg) 39 Weight (Kg) 108

ARTICULATED CORNER PANELS - FD MAX®

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

Weight (Kg) 41 Wei g ht (Kg) 113

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 COMPONENTS

CLAMPS - FD MAX®

Fixed Clamp C l o sin g w i th o u te r co r n er w all s Uni ve r s a l F i x i ng

Weight (Kg) 5.43 Weight (Kg) 2.21 Weight (Kg) 0.92

ACCESS BRACKET - ACCESSORIES - FD MAX®

FD MAX®

Plug Ø34x27,5mm
Lifting Hook (Brown)

Wei ght (K g ) 5.71 Weight (Kg) -

0.9 0 m Plug Ø 25x18mm (Yel l o w )

Weight (Kg) 14.5 Weight (Kg) -

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ELEMENTS OF CONNECTORS & ANCHORS

Steel Walers

close to corner
outer wall

Universal fixing
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
 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

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
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.

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 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.

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CORNER SOLUTIONS

Arrangement of panels for a Arrangement of panels for a Arrangement of panels for a

wall of 250 mm thickness. 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 Arrangement of panels for a

wall of 400 mm thickness wall of 450 mm thickness wall of 500 mm thickness
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.

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 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 150mm T Example for a 200mm T Example for a 250mm T

Junction wall using a Junction wall using a Junction wall using a 50mm
150mm timber make up. 100mm timber make up. timber make up.

Example for a 300mm T Example for a 350mm T Example for a 400mm T

Junction wall. Junction wall using a 50mm Junction wall using a
timber make up. 100mm timber make up.

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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.

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 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 ° maximum range: 109 °

between outer edges)

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ASSEMBLY INSTRUCTIONS

STEP 1 STEP 2

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

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 ASSEMBLY INSTRUCTIONS

STEP 4
The assembly of the panels is raised from the
ground and placed at the construction site of
the wall
STEP 5
Add the inner and outer corner panels to the
wall panels whilst fixing the nuts and bolts
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

Face exterior Face interior

Face exterior

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ASSEMBLY INSTRUCTIONS

Typical corner detail below.

Interior view. Exterior view.

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 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 é
supports to the panel. hole. panel.

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PLATFORM ASSEMBLY INSTRUCTIONS

STEP 7 STEP 8 STEP 9

Open the side railings Place below the Mount a second ladder
trapdoor. directly below the
trapdoor. Stabilize the
struts to the panel.

NOTE: If the product does not come with a concreting coupler panel, this should be mounted
according to the following figure.

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 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 Ma x® Lifting Hook

COUPLING SCHEME

1st Step 2nd Step 3rd Step

23
LIFTING HOOKS

The maximum weight supported by each lifting hook is 1.5 ton. Lifting chains must make a maximum angle
of 60 ° to each other.

máx. 60º

24
 FORMWORK COLUMNS

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

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

Formwork column 1 m

Formwork column 3 m

NOTE: the link between the

columns panels can be made with
the universal fixings and super plates.

You can also use the corner clamp for

various column sizes..

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

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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 Combination of universal Combination of 750mm

Universal panels for panels 750mm for columns of Universal panels for
columns of 400mm2 600 mm2 columns of 300mm2
(maximum possible).

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 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

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FORMWORK COLUMNS

ASSEMBLY INSTRUCTIONS FOR FORMWORK COLUMNS:

STEP 1 STEP 2 STEP 3

STEP 4 STEP 5 STEP 6

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 PERSONAL NOTES

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PERSONAL NOTES

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PANEL SYSTEMS
FALSEWORK
SCAFFOLDING
EDGE PROTECTION
FORMWORK ACCESSORIES
CONSTRUCTION CHEMICALS
SAFETY EQUIPMENT