Tunnel System DokaCC

999811302 - 04/2016
en-GB
The Formwork Experts.
Tunnel system DokaCC

Cut and cover
User Information
Instructions for assembly and use (Method statement)
© by Doka GmbH, A-3300 Amstetten
98113-202-07
© by Doka GmbH, A-3300 Amstetten
User Information Tunnel system DokaCC
2 999811302 - 04/2016
User Information Tunnel system DokaCC
Contents
4 Introduction 44 Assembly instructions
4 Elementary safety warnings 44 General instructions for site-erection
7 Eurocodes at Doka 46 List of tools needed for assembly
8 Doka services
48 Pre-assembly
10 System description 48 Girderframes
10 DokaCC - the economical tunnel formwork 52 Lifting mechanism
system for cut-and-cover 54 Top longitudinal beams
11 System overview 55 Formwork elements
12 Girderframe in detail
14 Height adjustment 56 Assembly
17 Adjusting girderframe spacing 56 Positioning rails and supports
20 Adjusting, aligning and lowering 57 Assembly of the supporting construction
22 Load transfer 68 Mounting the inside formwork
23 Tie rod system 75 Mounting the stop-end formwork
24 Traveller systems 76 Mounting the outside formwork
25 Stop-end formwork construction
26 Safety features 79 Dismantling
27 Regular sequence 80 Maintenance and troubleshooting

27 General instructions on typical use 80 Maintenance plan
28 Stripping out the formwork 84 Troubleshooting
33 Repositioning
34 Closing the formwork 86 General remarks
42 Pouring 86 Hydraulic system
89 Ladder system
92 Transporting, stacking and storing
96 Component overview
999811302 - 04/2016 3
Introduction User Information Tunnel system DokaCC
Introduction
Elementary safety warnings
User target groups Remarks on this booklet
▪ This booklet is aimed at all persons who will be work- ▪ This booklet can also be used as a generic method
ing with the Doka product or system that it describes. statement or incorporated with a site-specific
It contains information on the standard design for method statement.
setting up this system, and on correct, compliant uti- ▪ Many of the illustrations in this booklet show the
lisation of the system. situation during formwork assembly and are
▪ All persons working with the product described therefore not always complete from the safety
herein must be familiar with the contents of this point of view.
booklet and with all the safety instructions it contains. Any safety accessories not shown in these illustra-
▪ Persons who are incapable of reading and under- tions must still be used by the customer, in accord-
standing this booklet, or who can do so only with dif- ance with the applicable rules and regulations.
ficulty, must be instructed and trained by the cus- ▪ Further safety instructions, especially warnings,
tomer. will be found in the individual sections of this
▪ The customer is to ensure that the information mate- booklet!
rials provided by Doka (e.g. User Information book-
lets, Instructions for Assembly and Use, Operating
Instruction manuals, plans etc.) are up to date and Planning
available to all users, and that they have been made
aware of them and have easy access to them at the ▪ Provide safe workplaces for those using the form-
usage location. work (e.g. for when it is being erected/dismantled,
▪ In the relevant technical documentation and form- modified or repositioned etc). It must be possible to
work utilisation plans, Doka shows the workplace get to and from these workplaces via safe access
safety precautions that are necessary in order to use routes!
the Doka products safely in the usage situations ▪ If you are considering any deviation from the
shown. details and instructions given in this booklet, or
In all cases, users are obliged to ensure compliance any application which goes beyond those
with national laws, standards and regulations described in the booklet, then revised static cal-
throughout the entire project and to take appropriate culations must be produced for checking, as well
additional or alternative workplace safety precau- as supplementary assembly instructions.
tions where necessary.
Hazard assessment Regulations; industrial safety

▪ All laws, Standards, industrial safety regulations and
▪ The customer is responsible for drawing up, docu- other safety rules applying to the utilisation of our
menting, implementing and continually updating a products in the country and/or region in which you
hazard assessment at every job-site. are operating must be observed at all times.
This booklet serves as the basis for the site-specific
hazard assessment, and for the instructions given to ▪ If a person or object falls against, or into, the side-
users on how to prepare and utilise the system. It guard component and/or any of its accessories, the
does not substitute for these, however. component affected may only continue in use after it
has been inspected and passed by an expert.
4 999811302 - 04/2016
User Information Tunnel system DokaCC Introduction
Rules applying during all phases of Assembly

the assignment
▪ The equipment/system must be inspected by the
customer before use, to ensure that it is in suitable
▪ The customer must ensure that this product is condition. Steps must be taken to rule out the use of
erected and dismantled, reset and generally used for any components that are damaged, deformed, or
its intended purpose in accordance with the applica- weakened due to wear, corrosion or rot.
ble laws, standards and rules, under the direction
and supervision of suitably skilled persons.
▪ Combining our formwork systems with those of other
manufacturers could be dangerous, risking damage
These persons' mental and physical capacity must
to both health and property. If you intend to combine
not in any way be impaired by alcohol, medicines or
different systems, please contact Doka for advice
drugs.
first.
▪ Doka products are technical working appliances
which are intended for industrial / commercial use ▪ The equipment/system must be assembled and
only, always in accordance with the respective Doka erected in accordance with the applicable laws,
User Information booklets or other technical docu- Standards and rules by suitably skilled personnel of
mentation authored by Doka. the customer's, having regard to any and all required
safety inspections.
▪ The stability of all components and units must be
ensured during all phases of the construction work! ▪ It is not permitted to modify Doka products; any such
modifications constitute a safety risk.
▪ The functional / technical instructions, safety warn-
ings and loading data must all be strictly observed
and complied with. Failure to do so can cause acci- Closing the formwork
dents and severe (even life-threatening) damage to
health, as well as very great material damage.
▪ Fire-sources are not permitted anywhere near the ▪ Doka products and systems must be set up so that
formwork. Heating appliances are only allowed if all loads acting upon them are safely transferred!
properly and expertly used, and set up a safe dis-
tance away from the formwork.
Pouring
▪ The work must take account of the weather condi-
tions (e.g. risk of slippage). In extreme weather,
steps must be taken in good time to safeguard the ▪ Do not exceed the permitted fresh-concrete pres-
equipment, and the immediate vicinity of the equip- sures. Over-high pouring rates overload the form-
ment, and to protect employees. work, cause greater deflection and risk breakage.
▪ All connections must be checked at regular intervals
to ensure that they are secure and in full working
order.
Stripping out the formwork
In particular threaded connections and wedged con- ▪ Do not strip out the formwork until the concrete has
nections have to be checked and retightened as nec- reached sufficient strength and the person in charge
essary in accordance with activity on the jobsite and has given the order for the formwork to be stripped
especially after out-of-the-ordinary occurrences (e.g. out!
after a storm). ▪ When stripping out the formwork, never use the
▪ It is strictly forbidden to weld Doka products – in par- crane to break concrete cohesion. Use suitable tools
ticular anchoring/tying components, suspension such as timber wedges, special pry-bars or system
components, connector components and castings features such as Framax stripping corners.
etc. – or otherwise subject them to heating. ▪ When stripping out the formwork, do not endanger
Welding causes serious change in the microstruc- the stability of any part of the structure, or of any
ture of the materials from which these components scaffolding, platforms or formwork that is still in
are made. This leads to a dramatic drop in the failure place!
load, representing a very great risk to safety.
The only articles which are allowed to be welded are
those for which the Doka literature expressly points
out that welding is permitted.
999811302 - 04/2016 5
Transporting, stacking and storing Symbols used

▪ Observe all regulations applying to the handling of The following symbols are used in this booklet:
formwork and scaffolding. In addition, the Doka
▪
slinging means must be used - this is a mandatory
requirement.
Remove any loose parts or fix them in place so that
☞ Important note
Failure to observe this may lead to malfunc-
tion or damage.
they cannot be dislodged or fall free!
▪ All components must be stored safely, following all
the special Doka instructions given in the relevant CAUTION / WARNING / DANGER
sections of this booklet! Failure to observe this may lead to material
damage, and to injury to health which may
Maintenance range up to the severe or even life-threaten-
ing.
▪ Only original Doka components may be used as

spare parts. Repairs may only be carried out by the Instruction
manufacturer or authorised facilities.
This symbol indicates that actions need to be
taken by the user.
Miscellaneous
We reserve the right to make alterations in the interests Sight-check
of technical progress. Indicates that you need to do a sight-check
to make sure that necessary actions have
been carried out.
Tip
Points out useful practical tips.
Reference
Refers to other documents and materials.
6 999811302 - 04/2016
Eurocodes at Doka
In Europe, a uniform series of Standards known as The widely used "Permissible stress design" (compar-
Eurocodes (EC) was developed for the construction ing the actual stresses with the permissible stresses)
field by the end of 2007. These are intended to provide has been superseded by a new safety concept in the
a uniform basis, valid throughout Europe, for product EC.
specifications, tenders and mathematical verification. The EC contrast the actions (loads) with the resistance
The EC are the world's most highly developed Stand- (capacity). The previous safety factor in the permissible
ards in the construction field. stresses is now divided into several partial factors. The
In the Doka Group, the EC are to be used as standard safety level remains the same!
from the end of 2008. They will thus supersede the DIN
norms as the "Doka standard" for product design.
Ed Rd
Ed Design value of effect of actions Rd Design value of the resistance

(E ... effect; d ... design) (R ... resistance; d ... design)
Internal forces from action Fd Design capacity of cross-section
(VEd, NEd, MEd) (VRd, NRd, MRd)
Fd Design value of an action Rk Rk
Steel: Rd = Timber: Rd = kmod ·
Fd = F · Fk M M
(F ... force)
Fk Characteristic value of an action Rk Characteristic value of the resistance
"actual load", service load e.g. moment resistance to yield stress
(k ... characteristic)
e.g. dead weight, live load, concrete pressure,
wind
F Partial factor for actions M Partial factor for a material property
(in terms of load; F ... force) (in terms of material; M...material)
e.g. for dead weight, live load, concrete pres- e.g. for steel or timber
sure, wind Values from EN 12812
Values from EN 12812
kmod Modification factor (only for timber – to take
account of the moisture and the duration of load
action)
e.g. for Doka beam H20
Values as given in EN 1995-1-1 and EN 13377
Comparison of the safety concepts (example)

Permissible stress design EC/DIN concept The "permissible values" communicated in
Doka documents (e.g.: Qpermissible = 70 kN)
Fyield Rk
115.5 [kN] 115.5 [kN] do not correspond to the design values
Rd gM = 1.1 (e.g.: VRd = 105 kN)!
90<105 [kN]
n ~ 1.65 A
➤ Avoid any confusion between the two!
Ed
90 [kN] ➤ Our documents will continue to state the per-
missible values.
Fpermissible gF = 1.5 Allowance has been made for the following par-
60<70 [kN]
Factual A tial factors:
60 [kN] F = 1.5
M, timber = 1.3
M, steel = 1.1
kmod = 0.9
In this way, all the design values needed in an
EC design calculation can be ascertained from
98013-100
98013-102
the permissible values.
Factual Fpermissible Ed Rd

A Utilisation factor
999811302 - 04/2016 7
Doka services
Support in every stage of the project
Doka offers a broad spectrum of services, all with a sin-
gle aim: to help you succeed on the site.
Every project is unique. Nevertheless, there is one
thing that all construction projects have in common –
and that is a basic structure with five stages. We at
Doka know our clients' varying requirements. With our
consulting, planning and other services, we help you
achieve effective implementation of your formwork
assignment using our formwork products – in every one
of these stages.
1 2 3
Project Development Stage Bidding Stage Operations Scheduling Stage
Taking well-founded decisions Optimising the preliminary work Controlled, regular forming oper-
thanks to professional advice and with Doka as an experienced part- ations, for greater efficiency
consulting ner resulting from realistically calculated
formwork concepts
Find precisely the right formwork Draw up potentially winning bids, by Plan cost-effectively right from the
solutions, with the aid of ▪ basing them on realistically calcu- outset, thanks to
▪ help with the bid invitation lated guideline prices ▪ detailed offers
▪ in-depth analysis of the initial sit- ▪ making the right formwork ▪ determination of the commission-
uation choices ing quantities
▪ objective evaluation of the plan- ▪ having an optimum time-calcula- ▪ co-ordination of lead-times and
ning, execution, and time-risks tion basis handover deadlines
8 999811302 - 04/2016
The advantages for you

thanks to professional advice and
consulting
4 5 ▪ Cost savings and time gains
When we advise and support you
right from the word "go", we can
Concrete Construction Stage Project Close-out Stage make sure that the right formwork
systems are chosen and then
used as planned. This lets you
achieve optimum utilisation of the
formwork equipment, and effec-
tive forming operations because
your workflows will be correct.
▪ Maximised workplace safety

The advice and support we can
give you in how to use the equip-
ment correctly, and as planned,
leads to greater safety on the job.
▪ Transparency
Because our services and costs
Optimum resource utilisation Seeing things through to a posi- are completely transparent, there
with assistance from the Doka tive conclusion is no need for improvisation dur-
Formwork Experts with professional support ing the project – and no unpleas-
ant surprises at the end of it.
▪ Reduced close-out costs

Workflow optimisation, thanks to Doka Services are a byword for Our professional advice on the
▪ thorough utilisation planning transparency and efficiency here, selection, quality and correct use
▪ internationally experienced pro- offering of the equipment helps you avoid
ject technicians ▪ jointly handled return of rented damage, and minimise wear-and-
▪ appropriate transport logistics formwork tear.
▪ on-site support ▪ professional dismantling
▪ efficient cleaning and recondition-
ing using special equipment
999811302 - 04/2016 9
System description User Information Tunnel system DokaCC
System description
DokaCC - the economical tunnel formwork system for cut-and-cover
With the modular Tunnel system DokaCC, rectan- Rapid working
gular or circular cross-sections of cut-and-cover
tunnels can be formed swiftly and using less mate-
rial. The applicability on all common types of foun- assisted by its site-ready system details
dations provides additional benefit in terms of effi- ▪ Less assembly work needed on the site, as there are
ciency only a small number of shoring frames.
▪ Shorter assembly times, as the site is supplied with
pre-assembled units.
Highly cost-efficient ▪ Lifting, lowering and fine-adjusting the tunnel form-
work traveller is made easy by the hydraulic travel-
by optimised system concept ling and lifting appliances.
▪ Small number of shoring frames, made possible by ▪ Fast closing and opening of the formwork elements
statically optimised load-bearing system with either mechanical or all-hydraulic stripping solu-
▪ Less work needed for temporary foundations, as the tion.
system allows loads to be transferred into the wall ▪ A practical slide mechanism makes the stop-end
footings formwork easy to open and close.
▪ Needs less labour, as there are fewer points needing
to be operated.
Versatility
High safety Height-variable and width-variable
▪ Rectangular cross-sections from 4.5 to 8.0 m in
in all stages of the work height and 8.0 to 14.0 m in width.
▪ Detailed project-specific planning by Doka Engineer- Load-variable
ing. ▪ Roof-slab thicknesses for rectangular cross-sections
▪ The parallel girderframe units can be pre-assembled from 0.5 - 1.5 m.
flat on the ground and safely lifted into the vertical ▪ Roof-slab thicknesses for circular cross-sections
because of their bolted and solidly pinned joints. from 0.5 - 1.0 m.
▪ Safe up/down access via integrated caged ladder-
way. Note:
▪ stop-end formwork can be operated in safety from For tunnel projects involving larger sizes, consult your
the spacious working platforms. Doka technician!
▪ Longitudinal gradients of up to 8 % can be negoti-
ated safely (hydraulic drive) Use with different
types of foundation
▪ Wall footings along sides
▪ Full-width invert
98113-223-02 98113-221-03
10 999811302 - 04/2016
User Information Tunnel system DokaCC System description
System overview
Cross-section
P B O
E Q H A K
N
J
F
R
G
98113-202-03
Shown here without outside formwork
Longitudinal section
M
O
B
L
H
D
A
C B
F
G
98113-200-24
A Girderframe (see the section headed 'Girderframe in detail')

B Top100 tec walings WU14
C Diagonal strut DokaCC (extension of the lifting-mechanism unit)
D Lifting-mechanism unit
E Spindle strut
F Lowering wedge
G Rail distance piece S49 DokaCC
H Bracing
I Hydraulic platform
J Hydraulic unit SL-1 V180
K Working platform
L End-platform
M Stop-end formwork
N Inside formwork, wall
O Slab formwork
P Joint plate
Q Ladder system XS
R Squared-timber support
999811302 - 04/2016 11
Girderframe in detail
D System beam
G
N C Technical data:
A Section modulus: 1,678 cm3
B O
F Moment of inertia: 27,693 cm4
System beam DokaCC (A)

K
H Basic beam for length adaptation
E
5.00m 4.00m 3.00m 1.00m 0.50m 0.25m
Bolted together to form the roof-slab cross-beam.
K
Mounted parts
▪ Vertical strut connector DokaCC (B)

- Connects the Vertical strut DokaCC to the Sys-
tem beam DokaCC.
M
O
▪ Diagonal strut connector DokaCC (C)
- Connects the Diagonal strut DokaCC to the Sys-
L tem beam DokaCC.
98113-203-05
▪ Longitudinal beam connector WU14 DokaCC top
A System beam DokaCC (D)
B Vertical strut connector DokaCC - Connects Top100 tec walings (roof-slab longitu-
C Diagonal strut connector DokaCC dinal beam) to the System beam DokaCC.
D Longitudinal beam connector WU14 DokaCC top
E
F
Vertical strut DokaCC
Vertical strut endpiece DokaCC
Vertical strut
G Packing plate(s)
H Strut connection DokaCC
Technical data:
I Vertical strut DokaCC spindle connection
Perm. strut load: 300 kN
J Diagonal strut DokaCC
K Diagonal strut endpiece DokaCC Valid with max. 3 profile end-face joins, strut length* ≤
L Load distributor DokaCC
7.0 m
*) Distance between connecting pins at top and bottom edge of load distributor at
M Longitudinal beam connector WU14 DokaCC bottom
bottom
N Connecting pin DokaCC D60 140
☞
O Connecting pin DokaCC D60 235
Important note:
The vertical struts have to be held in the weak
profile direction at least every 3.0 m to prevent
buckling (see the section headed 'Spindle strut
bracing in longitudinal direction')!
12 999811302 - 04/2016
Vertical strut DokaCC (E) Diagonal strut DokaCC (J)

2.80m 2.20m 1.60m 1.00m 0.60m 2.80m 2.20m 1.60m 1.00m 0.60m
To transfer the vertical loads For transferring loads diagonally from the System beam DokaCC to
the Load distributor DokaCC, or for extending the lifting-mechanism
▪ Bolted to Vertical strut endpiece DokaCC and Load distributor unit.
DokaCC.
▪ Bolted to two Diagonal strut endpieces DokaCC or to Lifting
mechanism box DokaCC and Load distributor DokaCC.
Vertical strut endpiece DokaCC (F)
1.00m 0.80m 0.60m Diagonal strut endpiece DokaCC (K)
1.60m 1.40m
Endpiece of the Vertical strut DokaCC for connection to the System

beam DokaCC.
▪ Bolted to Vertical strut DokaCC.
▪ Pinned with Connecting pin DokaCC D60 140 into Vertical strut
connector DokaCC at the top.
Endpiece of the Diagonal strut DokaCC.
Packing plate (G)

▪ Bolted to Diagonal strut DokaCC.
Packing plate DokaCC Packing plate SL-1
▪ Pinned with Connecting pins DokaCC D60 235 into Diagonal
strut connector DokaCC at the top and to Load
20mm 15mm 10mm 4mm 3mm 2mm distributor DokaCC at the bottom.
For precision adjustment of the girderframe height.
▪ Bolted to System beam DokaCC with Vertical strut endpiece
DokaCC. Load distributor
Mounted parts
Load distributor DokaCC (L)
▪ Strut connection DokaCC (H)
- Connects spindle struts to the Vertical strut Dok-
aCC.
▪ Vertical strut DokaCC spindle connection (I)
- Connects spindle struts to the Vertical strut Dok-
aCC.
Diagonal strut To dissipate the loads from the vertical struts and the diagonal
struts.
▪ Sits against the lowering wedge and is tied back with the rail dis-
tance piece.
Technical data:
Perm. strut load: 480 kN Mounted parts
Valid with max. 3 profile end-face joins, strut length* ≤
7.0 m ▪ Longitudinal beam connector WU14 DokaCC
*) Distance between connecting pins at top and bottom bottom (M)
- Connects Top100tec walings to the Load distrib-
utor DokaCC.
999811302 - 04/2016 13
Height adjustment
The individual components combine flexibly, which
means that the overall height of the girderframes can
be adapted to site specifics.
Standard heights
b
α [°] v [m] s [m] b [m] f [mm] Item a [mm]
M 3.80 64.3 2.20 3.00 1.50 41 1 231
4.05 66.0 2.40 3.20 1.50 11 261
60.0 3.60 2.00 5 267
H 4.25 2.60
67.5 3.40 1.50 29 2 243
D 90°
A a 4.45
61.7
2.80
3.80 2.00 34 238
68.8 3.60 1.50 44 228
C
70.0 3.80 1.50 8 264
4.70 3.00
63.3 4.00 2.00 9 263
G 3
4.90 64.6 3.20 4.20 2.00 32 240
B 5.10 60.0 4.60 2.50 21 251
3.40
5.15 65.9 4.40 2.00 2 270
61.4 4.80 2.50 0 272
5.35 3.60
Height of girderframe h [m]
67.0 4.60 2.00 20 4 252
62.6 5.00 2.50 27 245
5.55 3.80
F 68.0 4.80 2.00 37 235
v
63.7 5.20 2.50 0 271

5.80 1
h
68.9 4.20 5.00 2.00 2 270

B
5.95 60.0 5.60 3.00 37 4 235
69.7 5.20 2.00 16 265
6.00 4.40
64.8 5.40 2.50 23 249
61.1 5.80 3.00 16 1 256
G 6.20 4.60
65.8 5.60 2.50 43 229
6.40 62.2 6.00 3.00 44 228
4.80
6.45 66.6 5.80 2.50 11 261
63.2 6.20 3.00 19 253
6.65 5.00
f
E 67.5 6.00 2.50 29 2 243

K 1 64.1 6.40 3.00 42 230
L 6.85 5.20
M 2 68.2 6.20 2.50 45 227
3 68.9 6.40 2.50 9 263
7.10 5.40
a
4 64.9 6.60 3.00 14 258

D 3
I J C 69.6 6.60 2.50 23 249
D 7.30 5.60
98113-208-10 65.7 6.80 3.00 34 238
7.55 66.4 5.80 7.00 3.00 3 4 269
h ... girderframe height
α ... v-strut angle
v ... vertical strut length (see table, 'Vertical strut length')
s ... diagonal strut length (see table, 'Diagonal strut length')
b ... strut distance
f ... packing plate thickness (see table, 'Selection of packing plates')
Pos. (1 - 4) ... Position of the Connecting pin DokaCC D60 140 (L) in the Vertical strut connector DokaCC (D) (see close-up 'D')
a ... height of the lowering wedge (see section headed 'Adjusting and lowering')
A System beam DokaCC
B Vertical strut DokaCC
C Vertical strut endpiece DokaCC
D Vertical strut connector DokaCC
E Packing plate(s)
F Diagonal strut DokaCC
G Diagonal strut endpiece DokaCC
H Diagonal strut connector DokaCC
I Lowering wedge
J Rail distance piece S49 DokaCC
K Load distributor DokaCC
L Connecting pin DokaCC D60 140
M Connecting pin DokaCC D60 235
14 999811302 - 04/2016
System parts needed Vertical strut (girderframe with lifting mechanism)

Vertical strut end-
piece DokaCC
0.60m
0.80m
1.00m
0.60m
1.00m
1.60m
2.20m
2.80m
Diagonal strut
Diagonal strut end-
Diagonal strut DokaCC
piece DokaCC 2.2 1 — — — — 1 — —
1.40m 2.4 — 1 — — — 1 — —
1.60m
0.60m
1.00m
1.60m
2.20m
2.80m
2.6 — — 1 — — 1 — —
2.80 2 — — — — — — 2.8 1 — — 1 — 1 — —
3.00 1 1 — — — — — 3.0 — 1 — 1 — 1 — —
3.20 — 2 — — — — — 3.2 1 — — — 1 1 — —
3.40 2 — 1 — — — — 3.4 — 1 — — 1 1 — —
3.60 1 1 1 — — — — 3.6 — — 1 — 1 1 — —
3.80 — 2 1 — — — — 3.8 1 — — — — 2 — —
v [m]
4.00 1 1 — 1 — — — 4.0 — 1 — — — 2 — —
4.20 — 2 — 1 — — — 4.2 — — 1 — — 2 — —
4.40 2 — — — 1 — — 4.4 1 — — — — 1 1 —
4.60 1 1 — — 1 — — 4.6 — 1 — — — 1 1 —
4.80 — 2 — — 1 — — 4.8 — — 1 — — 1 1 —
s [m]
5.00 2 — — — — 1 — 5.0 1 — — — — 1 — 1
5.20 1 1 — — — 1 — 5.2 — 1 — — — 1 — 1
5.40 — 2 — — — 1 — 5.4 — — 1 — — 1 — 1
5.60 2 — — — — — 1 5.6 1 — — 1 — 1 — 1
5.80 1 1 — — — — 1 5.8 — 1 — 1 — 1 — 1
6.00 — 2 — — — — 1 v ... vertical strut length (see table, 'Standard heights')
6.20 1 1 — 1 — 1 —
6.40 — 2 — — 2 — — Note:
6.60 — 2 1 — — — 1 Installation of the lifting mechanism unit is possible only
6.80 1 1 — 1 — — 1 when a Vertical strut DokaCC 1.60m is used as the
7.00 — 2 — 1 — — 1 bottommost part of the vertical strut (see section
s ... diagonal strut length (see table, 'Standard heights') headed 'Assembling girderframe with lifting mecha-
nism').
Vertical strut (girderframe without lifting mecha-
nism)
Vertical strut end-
piece DokaCC
0.60m
0.80m
1.00m
0.60m
1.00m
1.60m
2.20m
2.80m
2.2 1 — — — — 1 — —
2.4 — 1 — — — 1 — —
2.6 — — 1 — — 1 — —
2.8 1 — — — — — 1 —
3.0 — 1 — — — — 1 —
3.2 — — 1 — — — 1 —
3.4 1 — — — — — — 1
3.6 — 1 — — — — — 1
3.8 1 — — — 1 — 1 —
v [m]
4.0 1 — — 1 — — — 1
4.2 — 1 — 1 — — — 1
4.4 1 — — — 1 — — 1
4.6 — 1 — — 1 — — 1
4.8 — — 1 — 1 — — 1
5.0 1 — — — — 1 — 1
5.2 — 1 — — — 1 — 1
5.4 — — 1 — — 1 — 1
5.6 1 — — — — — 1 1
5.8 — 1 — — — — 1 1
v ... vertical strut length (see table, 'Standard heights')
999811302 - 04/2016 15
Precision adjustment Selection of packing plates [pcs.]

Packing plate DokaCC Packing plate SL-1
Washer *)
Precision height adjustment by means of:
20mm
15mm
10mm
Bolted
4mm
3mm
2mm
▪ Vertical strut connector DokaCC (50 mm incre-
join
ments)
2 — — — — — 1 2
▪ Packing plates (1 mm increments) 3 — — — — 1 —
▪ Lowering wedge (see section headed 'Adjusting and 4 — — — 1 — — 1
lowering') 5 — — — — 1 1
6 — — — — 2 —
(A)
7 — — — 1 1 —
8 — — — 2 — —
—
9 — — — — 3 —
10 — — 1 — — —
A F 11 — — — 2 1 —
12 — — 1 — — 1
13 — — 1 — 1 — (B) —
14 — — 1 1 — —
15 — 1 — — — —
f
B 16 — — 1 1 — 1 2
17 — 1 — — — 1
1 18 — 1 — — 1 —
D
2 19 — 1 — 1 — —
a a a
20 1 — — — — — 1
3
21 — 1 — — 2 — (C)
4 22 1 — — — — 1
23 1 — — — 1 —
E C 24 1 — — 1 — —
f [mm]
98113-209-09
25 — 1 1 — — — —
26 1 — — — 2 —
a ... 50 mm
27 — 1 1 — — 1
f ... packing plate thickness (0 - 49 mm)
(see table, 'Selection of packing plates') 28 1 — — 2 — —
29 1 — — — 3 —
30 — 2 — — — — 1
B Packing plate(s)
31 — 1 1 — 2 —
C Vertical strut connector DokaCC
32 — 2 — — — 1
D Connecting pin DokaCC D60 140 (D)
33 — 2 — — 1 —
E Vertical strut DokaCC 34 — 2 — 1 — —
F Bolted join 35 1 1 — — — — —
(see table, 'Selection of packing plates') 36 1 — 1 — 2 —
37 1 1 — — — 1
38 1 1 — — 1 —
WARNING
39 1 1 — 1 — —
Eccentric load application is prohibited! 40 2 — — — — — 1
➤ The axis of the vertical strut must always be 41 1 1 — — 2 —
in line with the axis of the bolted join. 42 2 — — — — 1
(E)
43 2 — — — 1 —
44 2 — — 1 — —
G H G 45 — 3 — — — — —
46 2 — — — 2 —
47 2 — — 1 1 —
48 2 — — 2 — —
(F) —
49 — 3 — 1 — —
*) Number of washers d=3 mm needed additionally
A Screw-set M20x65 8.8
B Screw set for System beam DokaCC 10.9
C Kneebrace screw-set SL-1
D Screw-set M20x90 8.8
E Screw-set M20x100 8.8
F 4 x hexagon screw M20x110 8.8
H 4 x hexagon nut M20 8
98113-209-08 98113-209-13
8 x washer 21 DIN EN 14399-6
G Axis of bolted join
H Axis of Vertical strut DokaCC
16 999811302 - 04/2016
Adjusting girderframe spacing

Top longitudinal beams
Top100 tec walings WU14 are used for the top longitu-
dinal beams. They can be pinned into the Longitudinal
beam connector WU14 DokaCC top in a
50 mm increments grid.
a
98113-209-23
a ... centre-to-centre spacing of connecting pins min. 20 cm

A Top100 tec walings WU14
C Longitudinal beam connector WU14 DokaCC top
D System beam DokaCC
E Connecting pin 10cm + Spring cotter 5mm
Max. spacing of longitudinal beams
☞▪ Important note:
Always plan one longitudinal beam above
each strut connection.
▪ The need for additional longitudinal beams
depends on the spacing between the diago-
nal strut connectors and the acting axial
force Nperm..
b b b b
A A A A A
F G D
98113-200-20
Nperm. [kN] b [m]

100 3.00 (3.12)
200 2.50 (2.84)
300 2.50 (2.60)
400 2.00 (2.40)
b ... max. centre-to-centre spacing between longitudinal beams
(connection to system beam)
Values in parentheses are maximum values

D System beam DokaCC
F Vertical strut connector DokaCC
G Diagonal strut connector DokaCC
999811302 - 04/2016 17
Bottom longitudinal beams Pin position

Pos. 1a Pos. 1b
Fields without lifting mechanism
Top100 tec walings WU14 are used for the bottom lon-
gitudinal beams. They are pinned on both sides into the
Longitudinal beam connectors WU14 DokaCC bot-
tom. The girderframe centre-to-centre spacing can dif-
fer, depending on pin position and waling length. 98113-209-02 98113-209-03
Pos. 2 Pos. 3
98113-209-04 98113-209-05
A
possible
girderframe spacing a [m]
Waling (A)
Pos. Pos.
Pos. 1a Pos. 1b
98113-208-12
2 3
1.05 1.15 1.10 1.20 Top100 tec waling WU14 0.75m
a 1.80 1.90 1.85 1.95 Top100 tec waling WU14 1.50m
a ... possible girderframe spacing
☞ Important note:
Collision between the waling and the bolted
join of the longitudinal beam connector!
Pinning in the position shown here is not possi-
ble!
98113-209-06
18 999811302 - 04/2016
Fields with lifting mechanism Spindle strut bracing in longitudinal

Diagonal struts DokaCC are used as the bottom longi- direction
tudinal beams to extend the Lifting-mechanism boxes
DokaCC. The centre-to-centre spacings are therefore
defined.
a
C C
a
C
98113-208-09
a
98113-200-24
a ... possible girderframe spacing
a ... ≤ 3.0 m
possible C Spindle strut T7
girderframe spacing a Diagonal strut (B)
☞▪
[m]
1.70 Diagonal strut DokaCC 0.60m Important note:
2.10 Diagonal strut DokaCC 1.00m The vertical struts have to be held in the
2.70 Diagonal strut DokaCC 1.60m weak profile direction at least every 3.0 m to
3.30 Diagonal strut DokaCC 2.20m prevent buckling!
3.90 Diagonal strut DokaCC 2.80m ▪ For detailed statics verification, consult the
Statics department responsible!
999811302 - 04/2016 19
Adjusting, aligning and lowering

Lowering wedge 1000kN
Make sure that rail distance piece and load
distributor are parallel (axis of the cross
beam).
▪ Lowering wedges must not be used as sup-
port points for components which are loaded
in such a way that they are liable to rotate by
>1° at the support point.
▪ Note the position of the lowering wedge (axis
Follow the directions in the "Titan Lowering of the lowering wedge offset 20 mm (a)
Wedge" Instructions for Assembly and Use! ± 5 mm toward the wall relative to the verti-
cal strut axis)!
For precision height adjustment and for taking load off

the supporting construction units.
98113-208-15
A Supporting construction
B Lowering wedge 1000kN 98113-210-02
☞
Close-up of lowering wedge
Important note:
Use lowering wedges in the horizontal position
only!
▪ If the invert forms a gradient, use flat iron
h
packers to bring the rail distance piece to the

horizontal!
98113-209-31
h ... from 19.2* cm to 27.2 cm

* Dimension when fully lowered – wedge cannot be lowered any fur-
ther than this! A
98113-210-04 98113-210-05
A Adjusting rail distance piece to allow for invert gradient (flat iron
packer)
20 999811302 - 04/2016
Lifting mechanism Transverse adjustment

Transverse adjustment is by means of a tilt mechanism
▪ For hydraulically lifting, lowering and adjusting the of the lifting ram (as per surveyor's data).
DokaCC formwork traveller. 2 people working in parallel are needed.
▪ For precision adjustment of the DokaCC formwork
traveller in the tunnel's transverse direction (trans- Max. transverse adjustment: ± 50 mm
verse adjustment).
➤ Use Ring spanner 46 to turn the adjusting screw on
Permitted lifting capacity: 220 kN at the following total the Lifting-mechanism box DokaCC in the appropri-
gradient of the lifting mechanism: ate direction.
▪ Permitted lateral gradient: 8%
▪ Permitted longitudinal gradient: 8%
(permitted lateral and longitudinal gradients can occur at the same time)
98113-211-03
C
G
Turning adjusting
Turning adjusting
screw counter-
screw clockwise
clockwise
D
F
H
E
a a
98113-208-14
C Flanged wheel SL-1 with or without hydraulic drive

D Lifting ram DokaCC 220kN C
E Lifting-mechanism box DokaCC
98113-211-01
98113-211-01
98113-211-01
F Lifting-mechanism frame DokaCC
G Hydraulic cylinder SL-1
H Diagonal strut DokaCC
B A A B A B
Max. stroke of the lifting mechanism
Close-up of position indicator:
98113-211-04 98113-211-04 98113-211-04

b
a ... max. 50 mm
A Rail axis
B Lifting mechanism axis
C Adjusting screw
D Position indicator
98113-211-05 The lifting mechanism axis moves up to 50 mm rela-

tive to the rail axis.
b ... max. 140 mm The position indicator shows the lateral setting.
999811302 - 04/2016 21
Load transfer
The loads from the roof slab transmitted into
Squared-timber support
the system beams are transferred by the ver- The squared timber is sized on the basis of squared
tical and diagonal struts to the load distribu- timber length a and load Nperm. acting on the support.
tors.
▪ The loads from the load distributor are trans-
98113-210-03
ferred by the anchor to the rail distance piece
and by a squared timber support provided by
site to the side wall kicker.
▪ The structural designer needs advance infor-
mation about the loads to be transmitted into
the wall kicker, in order to prevent overload
damage to the wall kicker and foundation!
▪ Releasing the lowering wedge (stripping the a
roof slab) permits, in combination with the
load-transferring construction (tie rods /
squared-timber supports), simultaneous
Example: Squared timber C24 (by site)
diminution of the horizontal and vertical
loads. 350
A
300
250 B
200
Nperm. [kN]
150
D
100 E
50
0
0.5 1 1.5 2 2.5 3 3.5 4
a
Squared timber length a [m]
C
A Squared timber 18x18 cm
E
G F B Squared timber 16x16 cm
C Squared timber 14x14 cm
F D Squared timber 12x12 cm
G
E Squared timber 10x10 cm
B
A
D Alternative to using squared timber supports:
98113-210-01
▪ Shear bolt
α ... 60 - 70° ▪ Tie together the two opposite load distributors or rail
A Squared timber support (by site) distance pieces.
B Wall kicker
C Load distributor DokaCC Note:
D Rail distance piece DokaCC For using a solution that is an alternative to squared
E Tie rod 20.0mm timber support, consult your Doka technician!
F Bracing bolt DokaCC
G Hexagon nut 20.0
22 999811302 - 04/2016
Tie rod system

Tie rod system 15.0 Tie rod system 20.0
D E
D E
B
B
A C A
C 9732-249-01
9729-246-01
A Top 50 element
A Top 50 element B Tie-rod 20.0
B Tie-rod 15.0 C Super plate 20.0 B
C Super plate 15.0 D Plastic tube 26mm
D Plastic tube 22mm E Universal cone 26mm
E Universal cone 22mm
Tie rod 20.0mm:
Tie rod 15.0mm: Permitted capacity, allowing a 1.6 : 1 factor of safety
Permitted capacity, allowing a 1.6 : 1 factor of safety against failure: 220 kN
against failure: 120 kN Permitted capacity to DIN 18216: 150 kN
Permitted capacity to DIN 18216: 90 kN
999811302 - 04/2016 23
Traveller systems
Repositioning with the Flanged wheel
SL-1
For rail-guided repositioning of heavy-duty supporting
units.
▪ Can be either self-powered or travelled with suitable
towing machines.
▪ There must be a firm (e.g. concrete) base that is
capable of supporting the load.
System dimensions:
98113-208-13
a ... 470 mm
b ... 400 mm
Design/construction of rail
A B
a
98113-200-25
a ... max. 155 mm

A Vignol S49 rail
B Rail distance piece S49 DokaCC
24 999811302 - 04/2016
Stop-end formwork construction

with Positioning unit DokaCC with Adjusting plate T
e.g. for parallel stripping out of end joints with joint-seal- e.g. with rebars extending through joints
ing tape on the inside.
F
C
C D
D
F H
E
A
I D G
98113-208-03 98113-217-02
A Positioning unit DokaCC C Stop-end panel

B Spindle strut T7 75/110cm D Connecting pin 10cm + Spring cotter 5mm
C Stop-end element with joint-sealing tape F Scaffold-tube bracing
D Connecting pin 10cm + Spring cotter 5mm G Adjusting plate T
E Connecting pin 25cm + Spring cotter 5mm H Spindle strut T7 100/150cm
F Scaffold-tube bracing I Top100 tec walings WU14
999811302 - 04/2016 25
Safety features
Platforms Connection of platforms to the Vertical strut
DokaCC (transverse platform)
Connection of platforms to the Vertical strut e.g. with Longitudinal beam connector WU14 DokaCC
DokaCC (longitudinal platform) bottom.
e.g. with Vertical strut DokaCC spindle connector and

Corner connecting plate 90/50.
Permitted moment of the corner connecting plate

6 kNm
H D E
98113-208-16
B G
A Vertical strut DokaCC
D Longitudinal beam connector WU14 DokaCC bottom
H F E Multi-purpose waling WS10
F Connecting pin 10cm with Spring cotter 5mm
E
C H Screw-set M20x160 8.8
98113-208-02
A Vertical strut DokaCC Note:

B Vertical strut DokaCC spindle connection Note the installation direction of bolt (H) .
C Corner connecting plate 90/50 The bolt must be installed with the head toward the con-
E Multi-purpose waling WS10 nection.
F Connecting pin 10cm with Spring cotter 5mm
G Connecting pin 25cm with Spring cotter 5mm
H Connecting pin 25cm with Spring cotter 5mm or
Screw-set M20x160 8.8
26 999811302 - 04/2016
User Information Tunnel system DokaCC Regular sequence
Regular sequence
General instructions on typical use
▪ The depictions and the description of the procedure
set out below are based on use for rectangular tun-
nel cross-sections, but they also apply by analogy to
use for circular tunnel cross-sections.
▪ Sections that apply only to circular tunnel cross-sec-
tions are marked appropriately.
▪ Depending on the project, the actual construction
and the procedure might not be as set out in the
description in this document.
▪ Always proceed in accordance with the execution
drawing or assembly drawing, or consult your Doka
technician.
WARNING
Danger of crushing!
➤ Before all formwork closing/opening
motions, and before the tunnel formwork
traveller is repositioned, a check must be
performed by at least 2 people to ensure that
there are no persons or potential collision
points within the range of motion.
➤ The operators must maintain sight or radio
contact to the trained watchmen at all times.
➤ 'Passenger transportation' is forbidden! (with
the exception of the operator during hydrau-
lic repositioning).
The first time of putting into service of the
hydraulic system must be supervised by a
Doka supervisor or other authorised techni-
cian.
▪ During closing, stripping and repositioning of
the formwork, the only persons allowed in
the vicinity of the traveller are the trained per-
sonnel tasked with carrying out the reposi-
tioning operation.
As regards fixing form ties and connecting form-

work panels and for information on cleaning and
the use of release agents, depending on which
formwork system is in use follow the directions
set out in the 'Large-area formwork Top 50' or
'Large-area formwork Top 100 tec' User Infor-
mation booklets!
999811302 - 04/2016 27
Regular sequence User Information Tunnel system DokaCC
Stripping out the formwork

Removing the back-anchoring of the Back-anchoring with climbing cone
tunnel formwork traveller ➤ Unscrew and remove the tie rod.
➤ Unscrew the Cone screw B7.
➤ Remove the Fixing bracket SL-1.
➤ Unscrew the Universal climbing cone 15.0.
98113-202-13
C
A
G F E D
A Formwork element
B Tie rod 15.0mm
C Super plate 15.0
D Hexagon nut 15.0
E Fixing bracket SL-1
F Cone screw B 7cm
G Universal climbing cone 15.0
98113-202-08
Removing uplift protection (optional
for circular cross-section)
Back-anchoring through form-tie hole
➤ Remove the Super plate and unscrew the tie rod
➤ Unscrew and remove the tie rod.
from the Anchoring cone 20.0.
➤ Remove threaded rod (or Tie-rod 20.0mm) and Fix-
ing brackets SL-1.
98113-202-09
C
A
F E D
A
B
A Formwork element
B Tie rod 15.0mm C
C Super plate 15.0

D Hexagon nut 15.0
F Threaded rod 20.0mm or Tie-rod 20.0mm
98113-224-01
A Tie rod 20.0mm

B Super plate 20.0 B
C Anchoring cone 20.0
28 999811302 - 04/2016
Stripping the stop-end formwork at with Adjusting plate T

the roof slab ➤ Work the Spindle strut T7 to release the stop-end
panel from the concrete and back it off.
with Positioning unit DokaCC
C
➤ Remove the Super plates 15.0 from the diagonal and
vertical Eye-lug anchors 15.0.
➤ Remove the vertical Eye-lug anchor 15.0.
A
A A
C
B
98113-208-03
A Super plate 15.0

98113-217-03
C Eye-lug anchor 15.0 without tie rod + tie rod 15.0 (vertical)
A Spindle strut T7 100/150cm
B Adjusting plate T
➤ Pin the Stripping lever DokaCC to the Positioning C Stop-end panel
unit DokaCC and secure it with the spring cotter.
➤ Work the stripping lever to release the positioning
unit and stop-end panel from the concrete and ease
back for enough to expose the joint-sealing tape.
1 2
A
C
98113-208-05 98113-208-06
98113-208-17
A Stripping lever DokaCC

B Positioning unit DokaCC
C Eye-lug anchor 15.0 without tie rod + tie rod 15.0
D Connecting pin 10cm + Spring cotter 5mm
E Stop-end panel + Spindle strut T7 75/110cm
999811302 - 04/2016 29
Stripping the stop-end formwork at Removing form ties

the wall
WARNING
Risk of outside formwork toppling!
Note:
The procedure set out below also applies by analogy to Absence of secure connection to the inside
the opposing stop-end formwork (roof slab and wall) in formwork.
the 1st casting section. ➤ Before removing the tie rods, set up panel
struts to secure the outside formwork to the
➤ Attach the stop-end panel to the crane. ground!
➤ Remove the Super plates 15.0 from the anchorage in ➤ Remove the wall anchors.
the wall formwork (e.g. Eye-lug anchor 15.0) and
remove the multi-purpose walings of the stop-end.
➤ Lift off the stop-end panel by crane.
A
98113-202-10
B
A Super plate
B Tie rod
Variant with Quick-release nut 20.0
98113-210-12
Follow the directions in the 'Quick-release nut

20.0' Fitting Instructions.
Stripping the wall-to-roof-slab

connection
➤ Detach the joint plates in the haunched area.
98113-201-14
30 999811302 - 04/2016
Stripping the inside formwork Hydraulic:

➤ Unscrew the spindle struts and tilt inward.
➤ Start up the hydraulic unit (as described in the Oper-
Stripping out the wall ating Instructions booklet entitled 'Hydraulic unit for
forming-operations').
WARNING ➤ As applicable, open the appropriate ball cocks at the
hydraulic distributors.
➤ No third persons are allowed anywhere near
➤ Use the hydraulic cylinders to detach the wall ele-
the formwork elements while these are being
ments from the concrete and tilt them inward.
tilted outward. The operators must always
stay in sight or radio contact.
Mechanical:
➤ Use the spindle struts or winches to detach the wall
elements from the concrete and tilt them inward.
98113-218-01
98113-210-11
98113-218-02
98113-210-10
999811302 - 04/2016 31
Striping the formwork from the roof-slab ➤ Remove the lowering wedges and the rail distance
(lowering) pieces.
Lashing straps (e.g. Lashing strap 3.7m Art.
☞ Caution on gradients:
Secure the carriage with a counteracting force!
No. 502783090) can be used to secure the rail
distance pieces to the formwork traveller during
the repositioning operation.
Permissible overall gradient of the lifting mechanism:

ating Instructions booklet entitled 'Hydraulic unit for
➤ As applicable, open the appropriate ball cocks at the
➤ Extend the Lifting ram DokaCC 220kN until the
Flanged wheel SL-1 is seated on the rail.
98113-210-13
Under these circumstances the anchorage

between rail distance piece and load distributor
can remain in place.
➤ Adjust the formwork traveller laterally as necessary

(see the section headed 'Adjusting and lowering').
➤ Work the lifting mechanisms to lower the entire form-
work traveller until it is possible to move it to the next
section.
98113-202-11
➤ Release the lowering wedges with a suitable slug-

ging spanner and lower.
98113-202-12
98113-208-19
➤ Remove the anchorage between the rail distance

piece and the load distributor.
32 999811302 - 04/2016
Repositioning
Repositioning the inside formwork
98113-202-04
Positioning the rails Repositioning with the Flanged wheel SL-1

and repositioning equipment supplied by site
☞ Important note:
There must be a flat, firm (e.g. concrete) base
that is capable of supporting the load. A suitable roll-stop (counteracting force)
➤ Dismount the rails in the previous pouring section. must be in place for upslopes or downslopes.
➤ Move the rails to the next casting section (transport ▪ Max. travel speed 2m/min.
by site). ➤ Connect the formwork traveller to the site-supplied
➤ As per the utilisation plan, position the rails in the repositioning equipment (winch, digger, etc.) at the
next pouring section, align them correctly and secure points provided for the purpose as per the utilisation
them to the slab in accordance with the load specifi- plan.
cations. ➤ Advance the tunnel formwork traveller to the next
pouring section.
Repositioning with the Flanged wheel SL-1 ➤ Secure the traveller in its final position so that it can-
and Hydraulic drive SL-1 not roll out of position.
➤ Disengage the connection to the repositioning equip-
➤ Start up the hydraulic unit (as described in the Oper- ment.
➤ Use the Hydraulic drive SL-1 to travel the tunnel Repositioning the outside formwork
formwork traveller to its new service position.
Note:
For repositioning the outside formwork see the section
headed 'Stripping, repositioning and closing the outside
formwork'!
999811302 - 04/2016 33
Closing the formwork

Install the positioning and fixing point Closing the inside formwork
(for back-anchoring and to prevent
uplift) Closing the roof-slab formwork (raising the
formwork traveller)
Note:
Depending on what type of back-anchoring or uplift pro-
tection is planned, the relevant Doka User Information
There must be a flat, firm (e.g. concrete)
base that is capable of supporting the load.
booklets or Fitting Instructions must be observed. ▪ Caution on gradients:
Secure the carriage with a counteracting
force!
Permissible overall gradient of the lifting mechanism:


➤ As applicable, open the appropriate ball cocks at the
➤ Raise the whole tunnel formwork traveller into its
final position with the aid of the lifting cylinders.
98113-202-12
➤ Adjust the formwork traveller laterally as necessary

(see the section headed 'Adjusting and lowering').
34 999811302 - 04/2016
☞
➤ Install the bracing bolts in the load distributor and in
Important note: the rail distance piece.
➤ It is absolutely essential to proceed in the ➤ Work the Tie rods 20.0 into the bracing bolts and
correct sequence for positioning! secure with Hexagon nuts 20.0 (omit this step if the
➤ Position squared timber support, rail distance piece rail distance piece was secured with a lashing strap
and lowering wedge in the sequence shown (1-3) for repositioning).
(see the section headed 'Load transfer'). ➤ Tighten the tie rods.
3
C
B
1 2
A
98113-210-09
98113-208-18
A Squared-timber support
B Rail distance piece DokaCC ➤ Retract the lifting rams of the hydraulic lifting mech-
C Lowering wedge 1000kN anisms. The tunnel formwork traveller should now be
standing on the lowering wedges.
Check that the entire tunnel formwork traveller
is correctly aligned!
➤ Continue tightening the lowering wedge to produce a

friction-locked connection between rail distance
piece, lowering wedge and load distributor.
98113-208-18
98113-202-11
999811302 - 04/2016 35
Closing the wall formwork Hydraulic:
CAUTION
WARNING
➤ Do not use the hydraulic cylinders to press
➤ No third persons are allowed anywhere near the formwork against the previously cast
the formwork elements while these are being concrete (wall kicker). (This might push the
tilted outward. The operators must always tunnel formwork traveller sideways).
stay in sight or radio contact.
Mechanical: ating Instructions booklet entitled 'Hydraulic unit for
➤ Use the spindle struts or winches to tilt the wall ele- forming-operations').
ments up to, and press them against, the wall kicker. ➤ As applicable, open the appropriate ball cocks at the
➤ Use the hydraulic cylinders to tilt the wall panels up
against the wall kicker.
98113-210-10
98113-218-02
98113-210-11
98113-218-01
➤ Use the spindle struts to press the wall panels

against the wall kicker.
36 999811302 - 04/2016
Forming the wall-to-roof-slab Lifting by crane

connection Depending on which formwork system is being
used, follow the directions in either the 'Large-
➤ Tighten the joint plate with the Super plate and area formwork Top50' or the 'Large-area form-
squared timber. work Top 100 tec' User Information booklet.
98113-201-14
Close-up of crane hoisting point
98113-216-02
A
Reinforcement A Lifting chain

B Connecting pin 10cm + Spring cotter 5mm
➤ Install the wall and roof-slab reinforcement. C Multi-purpose waling SL-1 WU16
The roof-slab reinforcement can also be
installed after the outside formwork has been
set up! Permitted load per Connecting pin 10cm in the waling-
gap: 10 kN
When a Sleeve Xclimb 60 D35 is used over the con-
Stripping, repositioning and closing necting pin: 30kN
the outside formwork Perform a statical check on the connection between
the multi-purpose waling (profiled timber former) and
the Doka beams!
☞▪
Note:
Important note:
The outside formwork is (usually) not repositioned until
after the inside formwork has been set up and the wall Do not exceed the max. element weight.
reinforcement is fully installed! ▪ If necessary, divide formwork panels as per
the utilisation plan.
▪ It is absolutely essential to use a load bal-
ancer when lifting a large gang-form with the
crane – check the maximum lifting capacity
of crane and all repositioning equipment.
▪ Do not detach the elements from the crane
until the two bottom rows of formwork ties
have been installed.
➤ Attach the gang-form to the crane by means of the
hoisting points as per the drawing.
➤ Move the gang-form to the next casting section.
➤ Working at ground level, install the two bottom rows
of formwork ties or securely position the gang-form
on the base slab with panel struts.
Before disconnecting from the crane:

➤ If there are no panel struts on the opposing
formwork, do not disconnect the panel from
the crane until a large enough number of
form ties have been installed to keep it safely
in the upright.
999811302 - 04/2016 37
Repositioning on travelling gear units (project- Advancing the outside formwork

specific)
WARNING
Exposed fall-hazard locations!
Note: Danger to life from fatal falls!
For information about repositioning on travelling gear ➤ Use personal protective equipment to pro-
units contact your Doka technician! tect against falls (e.g. Doka personal fall-
arrest set).
Repositioning with travelling structure (for ➤ Install plank lengthways on the reinforcement of the
circular cross-section tunnel) next casting section.
➤ As per the utilisation plan, position U-sections on the
outside foundation, align them correctly and secure
Note: them in accordance with the load specifications.
For mounting the travelling structure, see the section
headed 'Installing the outside formwork'.
Releasing the outside formwork from the concrete

C
➤ On the travelling structure, operate the winch to
press the solid tire wheel against the concrete. a
98113-224-07
C
B
98113-224-05
98113-221-02
D
98113-221-09
a ... plank thickness = from reinforcement to top edge of concrete

C Plank (by site)
D U-profile (by site)
98113-224-04
A Solid tire wheel

B Winch
The outside formwork detaches from the concrete.
38 999811302 - 04/2016
➤ Advance the outside formwork to the next casting Fitting the anchors
section.
➤ Install the wall anchors.
98113-202-10
B
A Super plate
B Tie rod
Variant with Quick-release nut 20.0
98113-221-06
Follow the directions in the 'Quick-release nut
Closing the outside formwork 20.0' Fitting Instructions.
➤ Operate the winch to tilt the formwork toward the
reinforcement (spacers).
➤ Fully retract the solid tire wheel and remove the
plank from the reinforcement.
98113-224-03
999811302 - 04/2016 39
Closing the stop-end formwork at the with Adjusting plate T

roof slab ➤ Use the Adjusting plate T to align the stop-end panel
in the horizontal direction.
with Positioning unit DokaCC ➤ Use the Spindle strut T7 to bring the panel to its final
position.
➤ Pin the Stripping lever DokaCC to the Positioning
unit DokaCC and secure it with the spring cotter.
➤ Use the stripping lever to pull the positioning unit and C
the stop-end panel into the working position.
➤ Pin the vertical Eye-lug anchor 15.0 into position and
secure it with a spring cotter.
➤ Secure the diagonal and vertical Eye-lug anchors A
15.0 with Super plates 15.0.
3
1 2
B
A
98113-208-08 98113-208-07
98113-217-02
A Spindle strut T7 100/150cm

B Adjusting plate T
C Stop-end panel
Closing the stop-end formwork at the

wall
F
F
B
Note:
C
The procedure set out below also applies by analogy to
the opposing stop-end formwork (roof slab and wall) in
the 1st casting section.
98113-208-03
➤ Lift the stop-end panel into place with the crane.
➤ Push the multi-purpose waling of the stop-end form-
A Stripping lever DokaCC work on the anchor to the wall formwork (e.g. Eye-
B Positioning unit DokaCC lug anchor 15.0) and secure with Super plates 15.0.
C Tie rod 15.0mm
E Stop-end panel + Spindle strut T7 75/110cm
F Super plate 15.0
98113-210-12
40 999811302 - 04/2016
Mounting the back-anchoring of the Back-anchoring with climbing cone

tunnel formwork traveller ➤ Screw a Universal climbing cone 15.0 into the pre-
pared anchoring point.
▪ The back-anchor must be installed on the outside ➤ Fasten the Fixing bracket SL-1 with a Cone screw
and inside formwork! B7.
▪ Agree the necessary number of back-anchors with ➤ Install and tighten the tie rod.
the statics department responsible!
98113-202-13
C
A
G F E D
A Formwork element
B Tie rod 15.0mm
C Super plate 15.0
D Hexagon nut 15.0
F Cone screw B 7cm
G Universal climbing cone 15.0
Installing uplift protection (optional

for circular tunnel cross-section)
98113-202-08
➤ Screw an Anchoring cone 20.0 into the prepared
anchoring point.
Back-anchoring through form-tie hole ➤ Install the tie rod and secure it with a Super plate.
➤ Introduce the threaded rod (or Tie rod 20.0mm) into

the anchor hole of the previous casting section.
➤ Secure the Fixing brackets SL-1 on both sides to the
threaded rod (or Tie rod 20.0mm).
➤ Install and tighten the tie rod.
98113-202-09
C
A
A
F E D
B
B
C
A Formwork element
B Tie rod 15.0mm
98113-224-01
C Super plate 15.0
D Hexagon nut 15.0 A Tie rod 20.0mm
E Fixing bracket SL-1 B Super plate 20.0 B
F Threaded rod 20.0mm or Tie-rod 20.0mm C Anchoring cone 20.0
Threaded-fastener material required

▪ 2 Hexagon nuts M20 (DIN 934)
▪ 2 washers 20 (ISO 7089)
▪ Threaded rod 20.0mm 8.8 (length as per assembly
drawing)
999811302 - 04/2016 41
Pouring
Before pouring
Check the installed parts:
▪ Are all the spindle struts free of play?
▪ Are all the lowering wedges correctly positioned
(± 5 mm) and free of play?
▪ Squared timber supports between rail distance
pieces and wall kicker installed and free of play?
Check the anchoring components:
▪ Are all wall anchors installed/tightened?
▪ Are the ties for back-anchoring installed/tightened?
▪ Are the ties for uplift protection installed/tightened?
(circular tunnel cross-section)
▪ Is the Positioning unit DokaCC secured with eye-lug
anchors and Super plates?
▪ Is the anchorage between the rail distance piece and
the load distributor installed/tightened?
☞ Important note:
The stipulated concrete pressures, as stated in
the utilisation plan, must be complied with in
every case!
98113-202-07
42 999811302 - 04/2016
999811302 - 04/2016 43
Assembly instructions User Information Tunnel system DokaCC
Assembly instructions
General instructions for site-erection
Scope of this document Tools
▪ The depictions and the description of the procedure See the section headed 'List of tools needed for assem-
set out below are based on use for rectangular tun- bly' for a detailed list of necessary tools.
nel cross-sections, but they also apply by analogy to Have one torque wrench with a range of adjustment
use for circular tunnel cross-sections. from 75 - 400 Nm and one torque wrench with a range
▪ Sections that apply only to circular tunnel cross-sec- of adjustment up to 800 Nm ready to hand.
tions are marked appropriately.
▪ Depending on the project, the actual construction
and the procedure might not be as set out in the Setting up the assembly area
description in this document.
▪ Always proceed in accordance with the execution ➤ Arrange for the assembly area to be measured up by
drawing or assembly drawing, or consult your Doka the surveyor. The basis for this is given by the
technician. approved assembly plan.
➤ The loads to be expected at the support points can
be taken from the Doka drawings (e.g. for lowering-
Unloading / intermediate storage area wedges, lifting mechanisms, formwork bracing etc.).
➤ Check the clear width between the rails.
▪ The size of the unloading and intermediate storage ➤ Temporary foundations must be checked and
area must be specified in advance (length x width). approved by the site.
This prevents the assembly work being delayed by
long transport distances or by lack of storage space!
▪ Find out whether base slabs are suitable as interme- Bolted joints
diate storage areas and can be used for this pur-
pose.
All standardised joins are statically dimensioned as
shear / bolt-bearing joins.
Crane capacity and position
▪ When stationary cranes (e.g tower cranes) are used, WARNING
the site must ensure that the storage locations Risk of fracture if unsuitable bolts are used.
(unloading and intermediate storage area) and ➤ Use only the specified 'Screw-sets', without
assembly zones (formwork, assembly bench) lie exception.
within the cranes' range of action. ➤ Use NEW 'Screw-sets' every time the equip-
▪ It must still be possible to lift the loads even when ment is re-assembled.
longer crane outreach is required! ➤ The bolted joints must comply with
▪ The lifting accessories may be used only by experi- EN 1090-2.
enced, trained persons ('crane slingers'). ➤ In the case of 'Screw-sets' with 2 washers
▪ The weights of the components to be lifted are given per bolt:
in the 'Component overview' section of this User Fit one washer next to the nut, and the other
Information booklet. In cases where custom compo- washer next to the bolt-head.
☞
nents have been planned, the weights are stated on
the assembly plan. Important note:
Any attempt to lubricate the screws, e.g. with
Depending on which formwork system is being WD40 spray or the like, is not permitted!
used, follow the directions in either the 'Large-
area formwork Top50' or the 'Large-area form- The Offset pin SL-1 makes it easier to align the
work Top 100 tec' User Information booklet. drilled holes during assembly.
Assembly bench
Fall-protection measures
▪ Pre-assemble the formwork elements on an assem-
bly bench. Its size and load-bearing capacity will
The site must provide the following equipment for car-
depend on the project in question.
rying out the assembly and dismantling work:
▪ a suitable mobile scaffold tower
▪ use personal protective equipment to protect against
falls
44 999811302 - 04/2016
User Information Tunnel system DokaCC Assembly instructions
The sections headed 'Pre-assembly' and 'Assembly' A distinction is made between 2 types of pre-loaded
contain instructions on which activities these items of joints:
safety equipment are compulsory for. ▪ joints with reduced pre-loading force Fp,C*
☞ The basic rule is that whenever there is any
temporary falling-hazard in the course of
assembly operations, a personal fall-arrest sys-
▪ joints with full pre-loading force Fp,C
tem (PFAS) must be used.

Joints with reduced pre-loading force Fp,C*
Attach PFAS only to suitable components that These bolted joints must be made with the modified
have sufficient load-bearing capacity, e.g. to torque control method in accordance with DIN EN
stable DokaCC components with a bore diame- 1993-1-8/NA.
ter of min. 17 mm, e.g. System beams Dok-
aCC, Vertical strut DokaCC, and components Reduced Required tightening
that are specifically stated in this document or Bolt
pre-loading force Fp,C* torque MA*
in the assembly plan. M20 160 kN 450 Nm
Make sure that the attachment points have the M24 220 kN 800 Nm
required minimum height! M30 350 kN 1650 Nm
M36 510 kN 2800 Nm
Joints with full pre-loading force Fp,C

These bolted joints must be made with the combined
pre-loading method in accordance with EN 1090-2.
WARNING 1st tightening step
Danger from falling objects! ➤ Tighten the bolted joint to the specified pre-tighten-
➤ During all operations, ensure that no other ing torque.
persons are allowed anywhere near the area
where assembly is being carried out! Screw
Full Pre-tightening torque
pre-loading force Fp,C MA,MKV
➤ Mark or cordon off the area concerned!
M20 172 kN 335 Nm
M24 247 kN 578 Nm
M30 393 kN 1150 Nm
M36 572 kN 2008 Nm
2nd tightening step
➤ Turn the nut by the required angle of additional rota-
tion.
General instructions on high-strength t ... clamping length (including

Angle of additional
all shim plates and washers)
rotation to be turned
joints of strength grade 10.9 d = screw diameter
t < 2d 60 °
2d  t < 6d 90 °
▪ Tighten compliantly pre-loaded bolted joints as spec- 6d  t < 10d 120°
ified in EN 1090-2.
▪ For pre-loaded joints with high-strength bolts, use
only hot-dip galvanised bolt sets of strength grade
10.9 that meet the following standards:
- hexagon bolts and hexagon nuts acc. EN 14399-
4
- flat washers acc. EN 14399-6
▪ Pre-loading of the high-strength bolts must be veri-
fied and documented by Site Management.
▪ If an assembly which is pre-loaded to the specified
pre-loading force is later unscrewed, it must be
removed and replaced by a new one.
▪ The pre-loaded bolt sets must be identified by a col-
our marking (on both bolt and nut). This means that
if a set has been highlighted, it must generally not be
re-used after being unscrewed, and must be dis-
carded.
▪ The lubrication status of the bolts must not be
changed.
999811302 - 04/2016 45
Assembly instructions User Information Tunnel system DokaCC
List of tools needed for assembly
Element/type of bolt to be Tool box

Component; bolted to: Tool Loose
operated SL-1
Combination wrench 36 X
Box nut 36 3/4" X
System beam DokaCC to Sys- Screw set for System beam
Ratchet ring wrench 30/32 X
tem beam DokaCC DokaCC 10.9
Box nut 30 3/4" L X
Torque wrench 3/4" 75-400 Nm X
Torque wrench 3/4" up to 800 Nm X
Diagonal strut DokaCC to Combination wrench 30 X
Diagonal strut (end piece) Dok- Ratchet ring wrench 30/32 X
aCC Screw set for diagonal strut
DokaCC 10.9 Box nut 30 3/4" L X
Load distributor DokaCC to
Torque wrench 3/4" 75-400 Nm X
Diagonal strut DokaCC
Vertical strut DokaCC to Verti-
cal strut (end piece) DokaCC Screw set for vertical strut
Vertical strut DokaCC to Load DokaCC 10.9
distributor DokaCC
Lifting-mechanism box Dok-
aCC to Diagonal strut DokaCC Screw set for lifting-mecha-
Lifting-mechanism box Dok- nism box DokaCC 10.9
aCC to Load distributor DokaCC
System beam DokaCC to Diag-
onal strut connector DokaCC
System beam DokaCC to Lon-
gitudinal beam connector WU14
DokaCC top
Load distributor DokaCC to Screw-set M20x65
Longitudinal beam connector
WU14 DokaCC top
Lifting-mechanism box Dok-
aCC to Lifting-mechanism frame
DokaCC
Railing adapter XP DokaCC to
0.5 x Screw-set M20x65
Beam support WS10 - WU16
Vertical strut DokaCC to Strut
Screw-set M20x160
connection DokaCC
Split nut SL-1 to tie rod Split nut SL-1 Combination wrench 30 X
Tie-rod wrench 15.0/20.0 X
Lifting ram DokaCC 220kN to Screw set for lifting ram Dok- Combination wrench 36 X
Flanged wheel SL-1 aCC 8.8 Box nut 36 3/4" X
Hydraulic system to hydraulic
Set-screw M24x180
hoses
Bracing tubes:
Screw-on coupler 48mm 50 Combination wrench 22 X
Scaffold tube to screw-on cou-
Swivel coupler 48mm Box nut 22 3/4" L X
pler or swivel coupler
Positioning point to formwork Universal cone spanner 15.0/20.0 X
Back-anchoring: Fixing
bracket SL-1 to Cone screw B7 Cone screw B7
in the previously finished casting Box nut 50 3/4" X
section
46 999811302 - 04/2016
User Information Tunnel system DokaCC Assembly instructions
Element/type of bolt to be Tool box

Component; bolted to: Tool Loose
operated SL-1
Lifting-mechanism box Dok- Ring spanner 46 X
aCC for operation of transverse Drive screw D56/191.2
adjusters Slugging ring spanner 46 by site
Ring spanner 46 X
Lowering the formwork travel- Lowering wedge SL-1 420kN
Fork wrench 46 X
ler with lowering wedges Lowering wedge 1000kN
Ring spanner 80 X
Hydraulic drive to Flanged M10x90 DIN 912 8.8 Set of ball-head Allen keys X
wheel SL-1 220kN Hexagon nut M36 Slugging ring spanner 55 X
Flange clamp G, Doka beam
Flange clamp G, Doka beam Combination wrench 19 X
H20, Flange claw to multi-pur-
H20, Flange claw, M12 Box nut 19 1/2" L X
pose waling
Combination wrench 19
X
Box nut 19 1/2" L
Winch connector to winch M12, M16 X
Combination wrench 24
X
Box nut 24 3/4" L
Wood planking of platform to Set of Torx bits
Spax screws by site
planks Set of PZ ('Pozidriv') bits
999811302 - 04/2016 47
Pre-assembly User Information Tunnel system DokaCC
Pre-assembly
Girderframes
System beam Required tightening torque:
M20: 450 Nm (45 kgm)
☞
M24: 800 Nm (80 kgm)
Important note:
Follow the 'General instructions on high-strength
➤ Make sure that the trestles are steady and
joints of strength grade 10.9' in the section headed
strong enough to take the load!
'Assembly instructions'.
The weights of the components are given in the
'Component overview' section of this User ➤ Bolt the mounted parts to the system beam.
Information booklet. In cases where custom
components have been planned, the weights Vertical strut connector Diagonal strut connector
are stated on the assembly plan.
➤ Prepare the trestles to carry the system beams.
In this way the system beams and the mounted parts
E
can be bolted on all sides without having to be turned F G
over. D A A
☞ Important note:
➤ Make sure that the system beams are bolted H
together such that groove (C) in the end
plates of all system beams is always on the 98113-203-10 98113-203-11
same side (beam underside).
Longitudinal beam connector top Special support plate*)
➤ Lay the System beams DokaCC on the trestles and
bolt the beams together.
K
I J
A
H
A
98113-203-09
98113-203-08
*) As connection between the wall formwork and the supporting con-

struction. In view of the many different solutions that are possible,
these support plates are manufactured on a project-specific basis.
D Vertical strut connector DokaCC
98113-203-01
E Packing plate
F Bolted joint, see the section headed 'Height adaptation'
G Diagonal strut connector DokaCC
H Screw-set M20x65 8.8
B I Longitudinal beam connector WU14 DokaCC top
J Special support plate (project-specific)
K Kneebrace screw-set SL-1
A
C
Required tightening torque:
A
B 300 Nm (30 kgm)
Note:
98113-203-07
For selection of the packing plate and the necessary
A System beams DokaCC (see the assembly drawings for the threaded fasteners, see the section headed 'Height
lengths) adaptation'!
B Screw set for System beam DokaCC 10.9
48 999811302 - 04/2016
User Information Tunnel system DokaCC Pre-assembly
Vertical strut Join with full preloading force Fp,C

☞ Important note:
For each girderframe with lifting mechanism,
335 Nm (33.5 kgm)
Angle of additional rotation: 90°
note the following: Follow the 'General instructions on high-strength
▪ The bottommost part of the vertical strut joints of strength grade 10.9' in the section headed
must be a Vertical strut DokaCC 1.60m. 'Assembly instructions'.
▪ The holes in the Vertical strut DokaCC
1.60m are needed for installation of the lift- ➤ Bolt the mounted parts to the vertical strut.
ing-mechanism unit.
- Until the lifting-mechanism unit is Vertical strut DokaCC spindle
Strut connection DokaCC
connection
installed, install the strut connector for
the top spindle strut in the holes in the E H
next vertical strut up.
See the section headed 'Assembling girder- H
frame with lifting mechanism'. A A
F
➤ Prepare squared timbers to lay the vertical struts 98113-209-34 98113-209-20
(height: 200 mm) and the load distributor on (height:
Longitudinal beam connector bottom
135 mm).
➤ Lay the Vertical struts DokaCC on the squared tim-
ber supports and bolt the struts together. G
D
➤ Lay the Load distributor DokaCC on the squared tim-
ber supports and bolt it to the vertical struts. I
98113-209-33
A Vertical strut DokaCC

D Load distributor DokaCC
E Strut connection DokaCC
98113-203-02
F Vertical strut DokaCC spindle connector
G Longitudinal beam connector WU14 DokaCC bottom
C H Screw-set M20x160 8.8
A I Screw-set M20x65 8.8

B 300 Nm (30 kgm)
98113-209-15
98113-209-16
A Vertical strut DokaCC (see the assembly drawings for the

lengths)
B Vertical strut DokaCC or Vertical strut endpiece DokaCC
C Screw set for vertical strut DokaCC 10.9
999811302 - 04/2016 49
Diagonal strut
➤ Prepare squared timbers to lay the diagonal struts
(height: 140 mm) and the diagonal strut endpieces
on (height: 170 mm).
➤ Lay the diagonal struts and the diagonal strut end-
pieces on the squared timber supports and bolt them
together.
98113-215-01
C
B
98113-209-17
A Diagonal strut DokaCC (see the assembly drawings for the

lengths)
B Diagonal strut endpiece DokaCC
C Diagonal strut screw-set DokaCC 10.9
Join with full preloading force Fp,C

335 Nm (33.5 kgm)
Angle of additional rotation: 90°
50 999811302 - 04/2016
Joining beams and struts Note:

For the position of the Connecting pin DokaCC D60
140 see the section headed 'Height adjustment'!
➤ Prepare squared timbers to lay the pre-assembled
system beams (height: 100 mm), vertical struts and
diagonal struts on (for heights see the section ➤ Pin the diagonal strut to the diagonal strut connector
headed 'Vertical struts' or 'Diagonal struts', as appli- with the Connecting pin DokaCC D60 235 and
cable). secure by inserting cotter pins at both ends.
➤ Lay the pre-assembled system beams, vertical struts
and diagonal struts on the squared timber supports. 98113-209-26
➤ Pin the vertical strut to the vertical strut connector

with the Connecting pin DokaCC D60 140 and A
secure by inserting cotter pins at both ends. I
98113-209-07 H
A I F
D
E
C
B
98113-209-14
D F
I A
C
E
B G
I
H 98113-203-06

B Vertical strut DokaCC
C Vertical strut connector DokaCC
D Connecting pin DokaCC D60 140
E Diagonal strut endpiece DokaCC
F Diagonal strut connector DokaCC
G Diagonal strut DokaCC
H Load distributor DokaCC
I Connecting pin DokaCC D60 235
999811302 - 04/2016 51
Lifting mechanism
➤ Prepare squared timbers as supports (height: min.
100 mm). WARNING
➤ Lay the Lifting ram DokaCC and the flanged wheel Risk of lifting ram falling out!
on the squared timber supports and bolt them ➤ For transport of the lifting-mechanism unit,
together. always secure the lifting ram to the lifting-
mechanism frame with a lashing strap (by
B A site)!
➤ Work the lifting ram complete with the flanged wheel
C into the lifting-ram guide of the lifting-mechanism box
and secure it with a lashing strap.
98113-219-02
A Flanged wheel SL-1 220kN

B Lifting ram DokaCC 220kN
C Lifting ram screw-set DokaCC 8.8
➤ Prepare squared timbers to lay the lifting-mecha-

nism frame on (height: 145 mm).
➤ Lay the lifting-mechanism frame on the squared tim- E
B
ber supports and bolt it to the lifting-mechanism box. 98113-219-05
D
E
H
B
D
F
98113-219-03
98113-219-01
D Lifting-mechanism frame DokaCC

D Lifting-mechanism frame DokaCC
F Screw-set M20x65 8.8
H Lashing strap 3.7m
➤ Prepare squared timbers to lay the hydraulic cylinder
on (height: 150 mm).
➤ Work the hydraulic cylinder into the frame, pin it into
position and secure the pin with a linch pin.
98113-219-04
G Hydraulic cylinder for lifting mechanism SL-1
52 999811302 - 04/2016
Mounting the Hydraulic drive SL-1

(if required)
Smooth long-term operation can be ensured only if the
hydraulic drive has been correctly installed on the trav-
eller system.
➤ Bolt the Hydraulic drive SL-1 to the gear-unit hous-
ing.
The necessary pins, hexagon nuts and gear-unit
receptacle are all included in the 'Connection set for
Flanged wheel SL-1'.
➤ To attach the hydraulic drive, use only the enclosed
16 hexagon socket cheese-head screws, M10x90
8.8 DIN 912. All the connection holes on the gear-
unit flanges must be used.
Tightening torque: 15-20 Nm
➤ Mount the BG3 hydraulic adapter plug to the Hydrau-

lic drive (for setting the direction of rotation).
98065-214-04 A
➤ Lubricate the multi-spline shaft of the hydraulic drive

with Never-Seeze, and insert it into the flanged
wheel.
➤ Place a lifting sling around the Hydraulic drive SL-1
and crane-lift it onto the upward-projecting multi-
spline shaft. If necessary, turn the wheel slightly until
the involute gearing clicks into place.
➤ Push the bolts through the holes in the gear-unit
housing.
➤ Attach the gear-unit receptacle to the flanged wheel
by means of hexagon nuts M36 (spanner size: 55
mm).
98113-219-06
A Hydraulic drive SL-1

B Gear-unit receptacle
C Pin
D Involute gearing
999811302 - 04/2016 53
Top longitudinal beams

➤ Prepare squared timber supports to lay the WU14 Depending on version and state of assembly, it
walings on (height: min. 100 mm). might be necessary to wait until the positioning
➤ Lay the WU14 walings on the squared timber sup- unit has been installed before installing the
ports and connect them with Top100 tec formwork Railing adapters XP and the Handrail posts XP.
element connectors.
➤ Pin the Beam supports WS10-WU16 into position
A and secure them with spring cotters.
➤ Bolt the Railing adapters XP DokaCC to the outside
B
Beam support WS10-WU16.
A ➤ Push the Handrail post XP into the post-holding fix-
ture on the Railing adapter XP Doka CC until the
locking mechanism engages.
98113-207-01
The locking mechanism must engage.
B
A with Positioning unit DokaCC
A
➤ Push the Positioning unit DokaCC on to the WU14
waling and secure it with 2 Eye-lug anchors 15.0 and
Super plates.
➤ Pin the connecting pins for striking and setting up
E and secure with spring cotters.
98113-207-02
J H J A
B Top100 tec formwork element connector
b
a I
98113-204-03
Longitudinal beam at the end- D D K
platform
a ... 650 mm
b ... 300 mm
G H Positioning unit DokaCC
A I Tie rod 15.0mm
J Super plate 15.0
K Eye-lug anchor 15.0 without tie rod
with Adjusting plate T

D
➤ Pin the Adjusting plate T to the WU14 waling and
secure with spring cotter.
D
E C A L
F C
98113-204-02
D
98113-217-01
C Beam support WS10-WU16
D Connecting pin 10cm + Spring cotter 5mm A Top100 tec walings WU14
E 0.5 x Screw-set M20x65 8.8 D Connecting pin 10cm + Spring cotter 5mm
F Railing adapter XP DokaCC L Adjusting plate T
G Handrail post XP
54 999811302 - 04/2016
Formwork elements
For the specifics of the procedure for installing Initially, install only 2-3 element connectors.
wall and slab formwork elements, follow the This makes the elements easier to fit together.
directions in the assembly drawings and in the Do not mount the remaining connectors until
'Large-area formwork Top 50' or 'Large-area the elements have been finally assembled.
formwork Top 100 tec' User Information book-
let, as applicable to the formwork system used!
Note:
The work steps described below are based on the pre-
assembly of wall elements.
For installation of attachments such as platforms, see
the assembly drawings and/or the appropriate section
detailing the assembly procedure!
➤ Set the formwork element down on a flat surface,

with the form-ply facing downwards.
98113-216-03
➤ Work the tie rod into position over the length of the
element.
➤ At each side of the element, secure the side multi-
purpose walings (for installation of the stop-end
formwork) with Super plates.
C A
98113-216-04
A Multi-purpose waling WS10 Top50

B Tie rod 15.0mm
C Super plate 15.0
➤ Pin the element connectors (e.g. Waling connectors

SL-1 WU16 0.75m) into position and secure with
spring cotters.
98113-216-05
D Element connector (e.g. Waling connector SL-1 WU16 0.75m)

E Steel waling (e.g. Multi-purpose waling SL-1 WU16)
999811302 - 04/2016 55
Assembly User Information Tunnel system DokaCC
Assembly
Positioning rails and supports
98113-200-02
➤ Position the rails, rail distance pieces and lowering

wedges.
Close-up
98113-200-21
A Rail
C Lowering wedge 1000kN (420kN)
56 999811302 - 04/2016
User Information Tunnel system DokaCC Assembly
Assembly of the supporting construction

Mounting the first girderframe ➤ Pin the spindle struts installed beforehand (top over-
turning protection) to the strut connection on the
ground and secure with cotter pins.
➤ Secure the strut connection and Rail distance piece
S49 DokaCC to the ground with Express anchors.
B
D
C C
98113-200-22 98113-200-21
E
A Strut connection DokaCC or SL-1
C Express anchor
➤ With the girderframe lying flat, pin the spindle struts 98113-200-03
(top overturning protection) to the strut connection
D Spindle strut (top overturning protection)
on the vertical strut and secure with cotter pins.
E Spindle strut (bottom overturning protection)
➤ Attach tag-lines to the girderframes. This makes
them easier to position at a later stage.
☞ Important note:
➤ Take suitable precautions to fix the lifting ☞ Important note:
➤ The lifting slings are disengaged by a crew
slings so that they cannot slip. member working from the mobile scaffold
➤ Place lifting slings around the girderframe and lift it tower.
into the upright. ➤ Disengage the lifting slings.
WARNING
There is a risk of the mobile scaffold tower
being knocked over when the crane lifts the gir-
derframe into place!
➤ Do not step onto the mobile scaffold tower
until the girderframe unit has been fixed to
the ground with the spindle struts to prevent
overturning.
➤ No third persons are allowed anywhere near
the supporting construction while it is being
crane-handled.
➤ Crane-lift the girderframe to the erection location.
Position it with tag-lines.
➤ Position the girderframe on the lowering wedges.
➤ Pin the spindle struts (bottom overturning protection)
to the load distributor and to the strut connection on
the ground and secure with cotter pins.
999811302 - 04/2016 57
Mounting further girderframes ➤ Adjust the spindle struts for the second girderframe
to the correct length as per the assembly drawing.
The field between the first and second girder-

frames to be erected should be without lifting
mechanism.
☞ Important note:
➤ The spindle struts are installed by crew
members working from the mobile scaffold
(Exception: configuration with 3 girderframes) tower.
➤ Position the second girderframe on the lowering
➤ Lift the WU14 waling into position, pin to the load dis-
wedge, pin it to the WU14 walings and spindle struts
tributor of the first girderframe and support on a tres-
and secure the components in position.
tle (height: approx. 800 mm).
98113-200-04 98113-200-05
Load distributor / WU14 waling Spindle struts / load distributor / vertical strut
F
A
F E
B
D
98113-209-28
98113-209-32
C
C C
98113-209-01

C Connecting pin 10cm + Spring cotter 5mm
B Longitudinal beam connector WU14 DokaCC bottom
E Strut connection DokaCC
F Spindle strut T7
Note:
For the position of the Connecting pin 10cm, see the Once at least two girderframes are in place and
section headed 'Length adaptation'! secured, the overturning protection (spindle struts
holding the first girderframe upright) can be
removed.
58 999811302 - 04/2016
➤ Proceed in accordance with the directions set out

above to install all the remaining girderframes in suc-
cession. Exception: Girderframe with lifting mecha-
nism (see the section headed 'Erecting girderframe
with lifting mechanism').
98113-200-06
999811302 - 04/2016 59
Erecting girderframe with lifting G E

mechanism 4
☞ Important note:
Follow these directions for pre-assembly of the
girderframe:
1
▪ The bottommost part of the vertical strut A
F 3
must be a Vertical strut DokaCC 1.60m.
▪ The holes in the Vertical strut DokaCC D
1.60m are needed for installation of the lift-
ing-mechanism unit.
- Until the lifting-mechanism unit is C
installed, install the strut connector for B 2
the top spindle strut in the holes in the
next vertical strut up.
Lifting pre-assembled lifting-mechanism unit

into position
98113-200-28
WARNING
Risk of lifting ram falling out!
➤ For transport of the lifting-mechanism unit,
always secure the lifting ram to the lifting-
mechanism frame with a lashing strap (by
site)!
D
➤ Lift the pre-assembled lifting-mechanism unit into
position with the crane. A
➤ Bolt the lifting-mechanism frame to the Vertical strut
DokaCC 1.60m together with the strut connection
I
(part of the lifting-mechanism frame) (1).
➤ Bolt the lifting-mechanism box to the load distributor
(2).
➤ Pin the bottom spindle strut to the bottom strut con- H
nection and secure the connection with the cotter pin
(3). J
➤ Swing the top spindle strut toward the bottom strut
connection, pin the two together and secure the con-
nection with the cotter pin (4).
98113-200-08
A Lifting-mechanism frame DokaCC

C Lashing strap 3.7m
D Vertical strut DokaCC 1.60m
E Top spindle strut
F Bottom spindle strut
G Strut connection DokaCC
H Load distributor DokaCC
I Lifting-mechanism box screw-set DokaCC 10.9
J Lifting-mechanism box DokaCC

450 Nm (45 kgm)
60 999811302 - 04/2016
Installing extension of the lifting-mechanism ➤ Adjust the spindle struts for the next girderframe to
unit the correct length as per the assembly drawing.
➤ Position the next girderframe on the lowering wedge.
➤ Bolt the diagonal strut DokaCC to the lifting-mecha- ➤ Bolt the girderframe to the Diagonal strut DokaCC,
nism box as an extension and support it on a trestle pin it to the spindle struts and secure the assembly
(height: approx. 740 mm). in position.
98113-200-27
Load distributor / diagonal strut / spindle strut

98113-200-07
Diagonal strut / lifting-mechanism box E

G
H
A
98113-209-21
A Diagonal strut DokaCC

B E Spindle strut T7
G Connecting pin 10cm + Spring cotter 5mm
C
H Diagonal strut screw-set DokaCC 10.9
A

450 Nm (45 kgm)
98113-209-27
A Diagonal strut DokaCC joints of strength grade 10.9' in the section headed
B Lifting-mechanism box DokaCC 'Assembly instructions'.
C Lifting-mechanism box screw-set DokaCC 10.9

450 Nm (45 kgm)
999811302 - 04/2016 61
Spindle struts / lifting-mechanism frame
98113-209-29
E Spindle strut T7
F Lifting-mechanism frame DokaCC
G Connecting pin 10cm + Spring cotter 5mm
98113-200-09
62 999811302 - 04/2016
Installing the top longitudinal beams
To simplify positioning and avoid using the

wrong pinning positions, mark the correct pin-
ning positions on the WU14 waling as per the
assembly drawing.
☞ Important note:
➤ The longitudinal beams are installed by crew
tower.
➤ Transport the pre-assembled longitudinal beams to
the erection location and position them with the
crane.
Check the spacing between the girderframes!
➤ Pin the beams to the girderframes.
B
98113-200-10
98113-209-23

B Longitudinal beam connector WU14 DokaCC top
➤ To pin the longitudinal beam, if necessary precision

adjust with the spindle struts.
999811302 - 04/2016 63
➤ Pin the topmost spindle struts to the girderframes

and to the top longitudinal beam.
98113-209-30 A
98113-200-11

D Spindle strut T7
Installing end-platform Mounting the ladder system
☞ Important note:
➤ The H20 beams and the deck-boards are
Note:
For directions on installing the ladder system see the
section headed 'Ladder system'
installed by crew members working from the
mobile scaffold tower.
WARNING
Danger to life from fatal falls!
➤ Use personal protective equipment to pro-
tect against falls (e.g. Doka personal fall-
arrest set).
➤ Secure Doka beams H20 in beam supports as
shown in the plan.
➤ Mount deck-boards on the Doka beams H20.
➤ Install guard-rail boards or scaffold tubes, as applica-
ble.
98113-200-14
64 999811302 - 04/2016
Mounting the tie-rod braces
Permitted tensile force: 56 kN
Example of horizontal tie-rod bracing (seen from

below)
A
98113-200-19
98113-213-01
Close-up A:
☞ Important note:
➤ Before and after fitting the tie-rod bracing, I
check the entire supporting construction for

correct alignment (control-dimensions as per
assembly plan).
➤ The tie-rod bracing is installed by crew mem-
bers working from the mobile scaffold tower.
➤ Install Fixing brackets SL-1 on the System beam G F H C B
DokaCC.
➤ Manoeuvre the tie rod into position for the diagonal 98113-213-02
bracing.
B Tie rod 15.0mm
➤ Secure the tie rod to a fixing bracket with two Hexa-
C Hexagon nut 15.0
gon nuts 15.0.
F Fixing bracket SL-1
➤ At the second fixing bracket secure with a Hexagon
G Split nut SL-1 15.0 or Hexagon nut 15.0
nut 15.0 on the inside and a Split nut SL1 15.0 on the
H Fixing bracket SL-1 screw-set
outside and tighten until free of slippage.
I System beam DokaCC
999811302 - 04/2016 65
Example of how to mount a hydraulic- ➤ Mount the bracing tubes.
unit platform
Note:
Platform specifics can vary on a project-specific basis,
depending on requirements. E
☞ Important note:
➤ The strut connections + eye-lug anchors are
installed by crew members working from the
mobile scaffold tower.
➤ Secure the strut connection to the underside of the H
system beam.
➤ Pin the eye-lug anchor to the strut connection. G G
D F 98113-200-15
A
D Eye-lug anchor 15.0 without tie rod
E Tie rod 15.0mm
C F Connecting pin 10cm + Spring cotter 5mm
G Multi-purpose waling WS10 Top50
B F H Scaffold tube + screw-on coupler
D
E ➤ Mount Doka beams H20.
➤ Attach the deck-boards.
➤ Install a diagonal plank underneath the decking for
98113-200-26 strength!
B Strut connection DokaCC
C Screw-set M20x160 8.8
D Eye-lug anchor 15.0 without tie rod
E Tie rod 15.0mm
F Connecting pin 10cm + Spring cotter 5mm

300 Nm (30 kgm)
➤ Position the multi-purpose waling and pin with the tie J

rod to the bottom eye-lug anchor.
➤ Lay two multi-purpose walings across at right angles
and connect them to the bottom longitudinal beam I
and the suspended multi-purpose waling (e.g. with
eye-lug anchors and Super plates).
98113-200-16
I Doka beam H20

J Deck-boards
66 999811302 - 04/2016
➤ Position the hydraulic unit on the platform. ➤ Mount the handrail-post uprights and guard-rail
boards.
L
K
98113-200-17
98113-200-18
K Hydraulic unit SL-1 V180
L Guard-rail board
M Handrail clamp S
98113-201-01
999811302 - 04/2016 67
Mounting the inside formwork

General instructions on slinging and Permitted load per Connecting pin 10cm in the waling-
crane-handling the elements gap: 10 kN
When a Sleeve Xclimb 60 D35 is used over the con-
necting pin: 30kN
Wall elements Perform a statical check on the connection between
the multi-purpose waling (profiled timber former) and
the Doka beams!
D
Roof-slab elements
Version 1: with Dokamatic lifting strap
A B
98113-216-01
D Bracing (squared timber)
Position the crane slings at points approxi-
mately one-fifth of the overall length from
each end of the formwork element
▪ Brace the hoisting points of the formwork
element against one another (e.g. with 98113-201-10
squared timbers, secured so that they can-

not fall out). Max. load:
▪ Use tag ropes for safe guidance throughout 2000 kg per Dokamatic lifting strap 13.00m
the entire repositioning operation.
▪ Do not exceed the max. element weight. Version 2: with Lifting rod 15.0
▪ If necessary, divide formwork panels as per
the utilisation plan. A C
Close-up of crane hoisting point

98113-216-02
A
98113-201-09
A Roof-slab formwork element

B B Dokamatic lifting strap 13.00m
C Lifting rod 15.0
C
Max. load:
see the 'Lifting rod 15.0' Operating Instructions
A Lifting chain Follow the directions in the 'Dokamatic lifting

B Connecting pin 10cm + Spring cotter 5mm strap 13.00m' or 'Lifting rod 15.0' Operating
C Multi-purpose waling SL-1 WU16 Instructions, as applicable!
68 999811302 - 04/2016
Installing first wall element

➤ Pre-install the spindle struts for installation of the wall
elements on the supporting construction.
➤ Use a two-part lifting chain to attach the formwork
element to the crane along the waling line.
➤ Transport the formwork element to the installation
location and position it as per the assembly drawing.
➤ Secure the element in position by pinning it with two
sets of 2 spindle struts top and bottom.
➤ Detach the element from the crane.
A D
C
98113-201-11
A Formwork element
B Spindle strut 40/80cm
C Vertical strut DokaCC spindle connector
D Girderframes
98113-201-02
999811302 - 04/2016 69
Installing additional wall elements Assembling the working platform
➤ Lift the next formwork element into position with the

Note:
crane and connect it to the element below it with the
element connectors. Because there are so many different solutions and sets
of project requirements, the time when the working plat-
➤ Secure the element in position by pinning it with two
form is installed can vary, as can the way in which it is
sets of 2 spindle struts to the girderframe.
installed. Follow the directions in the assembly draw-
➤ Detach the element from the crane. ing!
Follow the same procedure to install all the remaining
wall elements. Example: Installation with the element on the flat
98113-205-09
98113-201-05
The missing element connectors and/or spindle struts

are installed at the end of the procedure.
70 999811302 - 04/2016
Installing roof-slab elements Version 1: Version 2:

With steel or plastic strapping Bolted
WARNING
Danger to life from fatal falls!
➤ Use personal protective equipment to pro- E A A
arrest set).
Rectangular tunnel cross-section D D
☞ Important note:
➤ The load suspension device is detached
98113-201-13
A Roof-slab formwork element

98113-201-12
from the roof-slab formwork element and the

element is fixed to the system beam by crew D System beam DokaCC
members working on the mobile scaffold E Steel or plastic strapping (by site)
tower.
➤ Attach the roof-slab formwork element to the crane, Threaded-fastener materials needed for version 2
transport it to the installation location and position it ▪ 1 hexagon bolt M20x100
as per the assembly drawing. ▪ 1 washer, ISO 7094
➤ Secure the element to the System beam DokaCC ▪ 1 washer, ISO 7089
(2x per element). ▪ 1 hexagon nut M20
(not included in scope of supply)
98113-201-06
999811302 - 04/2016 71
Circular tunnel cross-section

➤ Pin the spindle struts to the girderframe.
➤ Position the formwork element by crane and pin it to
the connecting plates.
➤ Now tilt the element up again by crane and pin it to 2
of the previously prepared spindle struts.
WARNING
Danger from suspended load!
➤ Stand off to one side, on the main platform,
when lifting-in the element. Beside the ele-
ment – not beneath the suspended load.
➤ Detach the formwork element from the crane, and
detach the tag-lines.
98113-220-03
➤ Fit the missing connecting plates.

➤ Mount the bracing of the spindle struts (in cases
where this is required for constructional/statical rea-
sons).
➤ Follow the same procedure to install all the remain-
ing roof-slab elements.
98113-220-05
72 999811302 - 04/2016
➤ Mount the opposite side of the formwork in the same

way.
98113-220-02
999811302 - 04/2016 73
Installing infills and joint plates Example: rectangular tunnel cross-section
☞ Important note:
➤ The infills for the wall are installed by crew
tower or the telescopic working platform!
➤ All persons working on installation of the
infills for the roof-slab formwork must use the
appropriate personal protective equipment!
➤ If necessary, do not install the topmost strips
of formwork sheeting (at the middle of the
formwork traveller) until after the outside
formwork has been positioned (fall protec-
tion).
➤ Install the strips of formwork sheeting between the
wall elements.
➤ Install the strips of formwork sheeting between the
roof-slab elements.
➤ At the wall-to-roof-slab transition, install joint plates
as per the drawing and clamp against squared tim- 98113-201-07
ber with Super plates.
98113-201-14
Example: circular tunnel cross-section
A Joint plate (project-specific)

B Tie rod 15.0mm
C Super plate 15.0
D Squared timber (by site)
98113-220-01
74 999811302 - 04/2016
Mounting the stop-end formwork

Mounting the roof-slab stop-end with Adjusting plate T
formwork
F
C
I D G
98113-217-02
C Stop-end panel
F Scaffold-tube bracing
98113-201-08 G Adjusting plate T
H Spindle strut T7 100/150cm
I Top100 tec walings WU14
with Positioning unit DokaCC
➤ Set the Spindle strut T7 as per the assembly drawing
and pin it to the WU-14 longitudinal section.
➤ Lift the stop-end formwork element and transport it to
the installation location.
C ➤ Pin the stop-end formwork element to the Adjusting
D plate T and support it with the Spindle strut T7
installed beforehand.
B
➤ Install the scaffold-tube bracing.
F
E
A Mounting the wall stop-end formwork
Note:
For directions on installing the stop-end formwork see
the section headed 'Closing the formwork".
98113-208-03
A Positioning unit DokaCC

B Spindle strut T7 75/110cm
C Stop-end element with joint-sealing tape
F Scaffold-tube bracing
➤ Install the bottom horizontal scaffold tube in the cou-

pler at the positioning unit.
➤ Set the Spindle strut T7 as per the assembly drawing
and pin it to the Positioning unit DokaCC.
➤ Lift the stop-end formwork element and transport it to
the installation location.
➤ Pin the stop-end formwork element to the positioning
unit and support it with the Spindle strut T7.
➤ Install the remaining scaffold-tube bracing
999811302 - 04/2016 75
Mounting the outside formwork

Note:
The outside formwork is (usually) not repositioned until Assembling the working platform
after the inside formwork has been set up and the wall
reinforcement is fully installed!
Note:
Depending on which formwork system is being Because there are so many different solutions and sets
used, follow the directions in either the 'Large- of project requirements, the time when the working plat-
area formwork Top50' or the 'Large-area form- form is installed can vary, as can the way in which it is
work Top 100 tec' User Information booklet. installed. Follow the directions in the assembly draw-
ing!
Note:
Example: Installation with the element on the flat
See also the sections headed 'Mounting the inside
formwork' and 'Repositioning the outside formwork'
Do not exceed the max. element weight.
▪ If necessary, divide formwork elements as
per the utilisation plan.
▪ Do not detach the elements from the crane
until the two bottom rows of formwork ties 98113-205-09
have been installed.
➤ Attach the gang-form to the crane by means of the
hoisting points as per the drawing and transport it to
the place of use.
➤ Working at ground level, install the two bottom rows
of formwork ties or securely position the gang-form
on the bottom slab with panel struts.
Before disconnecting from the crane:

➤ If there are no panel struts on the opposing
formwork, do not disconnect the panel from
the crane until a large enough number of
form ties have been installed to keep it safely
in the upright.
76 999811302 - 04/2016
Rectangular tunnel cross-section
98113-223-01
Circular tunnel cross-section
98113-221-07
Illustration without stop-end formwork
999811302 - 04/2016 77
Installing the travelling structure
Installation on the top formwork element

(laid flat on the ground)
➤ Pin the multi-purpose waling WS10 to the steel wal-
ing of the formwork element with an element connec-
tor and secure with spring cotter.
➤ Swing the Multi-purpose waling WS10 up and con-
nect it to the steel waling with the spindle strut.
➤ Pin the special support plate to the Multi-purpose
waling WS10 and secure it with a spring cotter.
➤ Brace the units with scaffold tubes.
C D
98113-225-05
➤ Install the winches + solid tire wheel on the special

support plate.
H
98113-225-04
A Multi-purpose waling WS10

B Formwork element connector FF20/50 Z
C Spindle strut T7
D Special support plate (project-specific)
E Scaffold-tube bracing
F Connecting pin 10cm + Spring cotter 5mm
G Winch
H Solid tire wheel
78 999811302 - 04/2016
User Information Tunnel system DokaCC Dismantling
Dismantling
The tunnel formwork traveller is dismantled in the oppo-
site order from that in which it was assembled.
The stability of the individual components must be
ensured during every phase of the dismantling opera-
tions.
999811302 - 04/2016 79
Maintenance and troubleshooting User Information Tunnel system DokaCC
Maintenance and troubleshooting

Maintenance plan
Hydraulic components
Maintenance interval Component Activity Comments

Before every time of using Flanged wheel SL-1 220kN Visual inspection of flanged This is to check whether the flanged wheel
wheel shows any signs of cracking or chipping as
a result of not being set down on the rail
properly. If there is any damage, change the
wheel immediately.
Hydraulic drive SL-1 Check the gear-oil level in the If necessary, top up the gear oil as shown in
sightglass the 'Hydraulic drive SL-1' Operating Instruc-
tions.
If the oil level is too low, contact the respon-
sible Doka branch.
1x per month Lifting-mechanism box DokaCC Relubricate the transverse- It is not permissible to have the form-
or if smooth running is (transverse adjustment) adjustment mechanism between work traveller standing on the travelling
impeded box and guide unit as shown on gear while this operation is in progress!
the info sticker (with Anti-Seez Dealing with coarse soiling (sand, dirt):
Doka ID n° 047110) ▪ Loosen the guide screws and completely
unscrew the guide unit.
▪ Clean the surfaces with a scraper, and
re-grease them.
1x per month Lifting ram DokaCC 220kN Relubricate the lifting-rams as Where coarse soiling (sand, dirt) has
or if squeaky noises occur shown on the info sticker (with occurred, clean the lifting-rams with a
during lifting Anti-Seez Doka ID n° 047110) scraper and re-grease them.
After 100 operating hours Hydraulic drive SL-1 Change the gear oil Follow the maintenance instructions given
(distance travelled 6 km) in the 'Hydraulic drive SL-1' Operating
or Instructions.
1x per year If the oil level is too low, contact the respon-
sible Doka branch.
1x per year Lowering cylinder SL-1 250kN Change the oil as shown in the 'Lowering cylinder SL-1
250kN' Operating Instructions
Carry out annual inspection in consultation with the responsible Doka
Branch
80 999811302 - 04/2016
User Information Tunnel system DokaCC Maintenance and troubleshooting

1x per year Hydraulic unit SL-1 V180 Change the hydraulic oil Change the oil as shown in the Operating
or if the oil is badly contam- Instructions for the hydraulic unit being
inated (can be seen on the used – in consultation with the responsible
sightglass of the hydraulic Doka branch.
unit)
Oscillating volume:
Make sure that all the hydraulic cylinders
are retracted, so as to allow for the fluctua-
tions in the oil level as the cylinders are
retracted and extended. If this is not possi-
ble, the oscillating volume must be calcu-
lated in order to determine the quantity of oil
need – only top up after calculating this
quantity.
General instructions:
Only use oil of the correct quality and misci-
bility. Only pump oil into the reservoir
through a filter (not directly from the drum).
Order replacement filters in good time
(return-flow and aeration filters). Order the
seals needed for the oil-change in good
time.
When changing the oil or Change the return-flow filter By making the oil very viscous, very low out-
if the 'Filter clogged' indica- side temperatures may cause the soiling
tor lights up gauge to light up in error. For this reason,
bring the oil up to operating temperature. If
the indicator stays lit up, change the filter
(before the next lifting operation – in consul-
tation with the responsible Doka branch).
When changing the oil. Change the aeration filter
If the oil level falls below the Top up with hydraulic oil See the note on 'Oscillating volume' in the
minimum. Hydraulic unit point headed 'Change the hydraulic oil'.
cuts out automatically. If the oil level is too low, contact the respon-
Control lamp 'Oil level < sible Doka branch.
min.' lights up.
☞ Important note:
If there are clear signs of damage to compo-
nents, the responsible Doka branch must be
notified immediately.
999811302 - 04/2016 81
Motion spindles, rollers, winches,

wedges

Immediately, whenever the Tie rod Replace the tie rod with a new If there is any permanent deformation (i.e.
need arises one rod is bent), replace it immediately.
Before every time of using Winch Do a sight-check Look out for any signs of damage and visi-
ble deformation. Damaged or deformed
winches and mounted parts that do not
meet the following criteria must be with-
drawn from use immediately:
▪ Crack-free and notch-free welds
▪ No deformation
▪ Rating plate in place and clearly legible
▪ Safety catch must function when tested
in unloaded state
Every week Lowering wedge SL-1 420kN or Do a sight-check Lowering-shoes and lowering-wedges do
1000kN not need any particular maintenance. How-
ever, if they suffer any permanent deforma-
tion, they must be exchanged or repaired.
Keep the lowering-wedges grease-free, and
always degrease them immediately if any
grease gets onto them.
If the cheek plates are greased, there is a
risk of the tie rod breaking!
After 5 casting sections Super plate 15.0 Check for increased play in the Change the Super plate if it is difficult to
or thread turn, or if there is increased axial or radial
1x per month play in the thread.
1x per month Winch Grease the pinion-rack The pinion-rack must be extended when it is
greased.
Spindle strut T6 / T7 Relubricate the thread (only if it is Where coarse soiling (sand, dust) has
difficult to turn) occurred, clean the thread and grease it
with Anti-Seez (Doka ID n° 047110).
98113-222-01
82 999811302 - 04/2016

1x per year Winch Grease the gear reduction unit Refill the gear reduction unit with new
grease.
With the safety crank-handle, make sure
that no grease gets onto the brake-pads!
Steel structure shoring tower

After first-time assembly: Tie-rod braces Check of the diagonal bracings of ▪ Have the tie rods been tensioned?
▪ once a week in the first the supporting construction at the ▪ Have the check-nuts been tightened?
System beams DokaCC.
month ▪ Has the 'Fixing bracket screw-set SL-1'
▪ then every 6 months been tightened?
98113-213-02
Scaffold-tube braces Inspect the scaffold-tube braces Have the couplers been tightened?
on the spindle struts, and (where ▪ Clamping connections (swivel couplers,
applicable) also on heavy-duty screw-on couplers)
props etc.
▪ Bolted joints of screw-on couplers
Joints between load-bearing compo- Inspect the bolted joints of the Check the bolted joints on load-bearing
nents supporting construction. components (these joints are pre-loaded to
300 Nm on assembly, and then marked with
blue coloured spray). Using a ratchet and
box nut, check whether the joints can easily
be loosened (but do not undo them)!
98113-203-12
Permanent deformations caused by Check for permanent deforma- Inspect the supporting construction for
e.g. exceeding the permitted form- tion in the supporting construc- increased play and/or permanent deforma-
work load. tion or on the formwork. tion:
▪ Increased play in the connecting plates?
(Causes the joints between the form-
work sheets to widen).
▪ Bent load-bearing components (walings,
spindles, etc.)
If any of these parts are deformed, report
this immediately to the responsible Doka
branch.
999811302 - 04/2016 83
Troubleshooting
Malfunction Possible cause Counter-measure

When the distribution valves are actuated, the Fault in the supply cable. A phase or PEN con- An electrician must check the supply cable.
motor protection switch on the hydraulic unit is ductor is missing.
tripped. The star-delta start-up phase of the motor has After switching on the motor, wait for approx.
not finished. 15 sec. until the system can be put into service
again.
Hydraulic cylinders and/or hydraulic drives can- Threaded couplings have not been properly Switch off the hydraulic unit and depressurise
not be moved after first-time assembly. screwed together. the hydraulic hoses by actuating the distribution
valves. Tighten the threaded couplings.
Hydraulic unit makes 'rattling' noises after being Low outside temperatures. Oil is too cold and Switch off the hydraulic unit and enclose it from
switched on. too viscous. Pump cavitates in the suction the weather. Heat this enclosed space.
stage. If appropriate, refill with thinner oil => you
MUST consult Doka before doing this!
The hat-shaped cap of the aeration filter has not Switch off the hydraulic unit immediately and
been unscrewed – the pump is cavitating as no remove the cap.
oil is being drawn in. (Negative pressure in the
reservoir)
'Lowering cylinders 250kN' cannot be Cylinder was stored on its side – hydraulic oil Top up with hydraulic oil as shown in the 'Low-
extended. has run out. ering cylinder 250kN' Operating Instructions.
Increased deformation is occurring on the wall The permitted concrete pressure has been Consult with the concrete technologist. Ask
formwork, and/or the form-ties are difficult to exceeded. him/her for the time until the end of setting, and
undo. for the reference temperature. Adjust the pour-
ing rate and/or the mix formulation.
84 999811302 - 04/2016
999811302 - 04/2016 85
General remarks User Information Tunnel system DokaCC
General remarks
Hydraulic system
Hydraulic unit SL-1 V180 Hydraulic forming-operations
Is supplied to the site ready for operation. The Hydraulic unit SL-1 V180 is also used for raising,
lowering and stripping out Doka formwork systems with
the aid of hydraulic cylinders.
Note:
If the unit needs to be lifted, it should only be slung Note:
from, and lifted by, the crane hoisting lugs provided.
The European Directive for Machines (2006/42/EC)
stipulates that all formwork systems that are moved
either electrically or hydraulically are subject to manda-
tory CE labelling requirements. For this reason, a risk
assessment and an Operating Instructions manual
must be drawn up for the entire system, in every case.
The formwork is moved by means of a hydraulic

branch-line system.
▪ The hydraulic unit has 6 hydraulic outlets.
These assure the same constant delivery rates,
regardless of the load pressure.
▪ In practice, 6 cylinders are often not sufficient.
It is possible to increase the number of cylinders by
using the Hydraulic distributor, Art.n° 580808000.
This divides up the 6 hydraulic circuits A-F into 3
groups of 6 hydraulic circuits (makes it possible to
connect up to 18 cylinders).
92840-808
B
Follow the directions in the Operating Instruc-
tions!
9266-123
Repositioning heavy-duty supporting units B Hydraulic distributor
Up to 2 Hydraulic drives SL-1 can be connected to the Due to the many different strokes and load ratings for
Hydraulic unit SL-1 V180. hydraulic cylinders used in the formwork technology
field, it is difficult or impossible to standardise cylinders.
Note: This is why custom cylinders are often used.
Hydraulic tubes are not included in the scope of supply.
2 pairs of hydraulic tubes are needed for each hydraulic Planning note
drive.
Suitable pairs of hydraulic tubes: Important where the cylinder is subjected to

Name Art.n°
Pair of hydraulic tubes 5.00m 580873000
push/pull loads:
☞
Pair of hydraulic tubes 7.50m 580874000
Pair of hydraulic tubes 10.00m 580875000 When the distribution valves are being switched
over, the switch passes through an intermedi-
ate position which may cause unintentional low-
ering of the load.
Remedy: Fit lowering brake-valves to the load-
side of the hydraulic cylinders.
86 999811302 - 04/2016
User Information Tunnel system DokaCC General remarks
Hydraulic branch-line system Cylinder connection directly on the hydraulic

unit
Cylinder connection via hydraulic distributors
C
A
C
A
9759-293-01
A Hydraulic cylinder
C Lowering brake-valve
9759-292-01
A Hydraulic cylinder
B Hydraulic distributor
C Lowering brake-valve
999811302 - 04/2016 87
Mounting the hydraulic system
Hydraulic unit
The position of the hydraulic unit will mainly
depend on the available space, and should
thus be planned as needed for each individ-
ual project.
▪ Position the hydraulic unit so that the opera-
tor is always looking in the direction of travel
and has a clear view of all moving parts! If
this is not possible, a 2nd person is needed,
who must stay in radio contact with the oper-
ator.
Hydraulic cylinder
☞ Important note:
The size and position of the hydraulic cylinders
must be such that no collisions can occur when
slewing motions are carried out.
Hydraulic hoses
☞ Important note:
➤ Do not kink the hoses.
➤ Arrange the hoses so that nothing rubs
against them during the motion sequences.
(Risk of hoses bursting because of mechan-
ical damage).
➤ In the area near the hydraulic cylinders,
arrange the hoses so that there is sufficient
length of hose available even when the cylin-
der is fully extended (make loops).
➤ Arrange the hydraulic hoses on the tunnel formwork
traveller and fasten them with hose clamps and/or
cable ties.
Hydraulic drive SL-1
Note:
See the section headed 'Lifting mechanism' in the
instructions for pre-assembly
88 999811302 - 04/2016
Ladder system
For safe up-and-down access to the platforms. Pre-assembly
☞▪
Note:
The Ladder system XS must be implemented in such a Important note:
way that all national regulations are complied with. Only pre-assemble max. 2 ladder segments
at a time. (Total length max. 6.7 m).
➤ Pre-assemble each ladder unit on the ground
CAUTION
(placed on two timber supports or on Doka beams).
➤ The Ladders XS may only be used as part of
the XS system, and must NOT be used sep- D
arately (as "lean-to" ladders).
F
98065-225-01
A System ladder XS 4.40m

B Ladder extension XS 2.30m
D Ladder cage exit XS
F Ladder cage XS 1.00m
Telescoping ladder extension (for adjusting to

ground level)
➤ To telescope the ladders past one another, lift the
safety latch on the ladder and fix the Ladder exten-
sion XS 2.30m onto the desired rung of the other lad-
der.
C
A
Tr625-201-04
Close-up
C
B
Tr625-201-03
98113-210-14 A System ladder XS 4.40m

B Ladder extension XS 2.30m
C Safety latch
A telescoping join between two Ladder extensions

XS 2.30m can be made in the same way.
999811302 - 04/2016 89
Permanently fixed ladder extension ➤ Fix the Ladder cage XS 1.00m (F) onto the next
➤ Insert the Ladder extension XS 2.30m into the available rung. The safety latches (J) prevent the
uprights of the System ladder XS 4.40m, with its cage being accidentally lifted out. Add further Ladder
hooking brackets facing downwards, and fasten it. cages XS 1.00m, in each case fixing them onto the
Tighten the screws only very slightly! next available rung.
A
C
F
Tr625-202-01
Screws (C) are included in the scope of supply of the System ladder
XS 4.40m and the Ladder extension XS 2.30m.
J
A System ladder XS 4.40m
B Ladder extension XS 2.30m Tr625-201-02
C Screws, width-across 17 mm
Two Ladder extensions XS 2.30m can be fixed

together in the same way. Assembly
Ladder cage
Depending on the project, the actual construction and
☞ Important note:
➤ Always observe all relevant safety regula-
the procedure might not be as set out in the description
in this document.
▪ Always proceed in accordance with the final drawing
tions applying to the use of the Ladder cage
XS in the country in which you are operating or assembly drawing, or consult your Doka techni-
(e.g. in Germany: BGV D 36). cian.
➤ Attach the Ladder cage exit XS (the bottom of the
cage must always be at the same height as the plat- WARNING
form). The safety latches prevent the cage from Exposed fall-hazard locations!
being accidentally lifted out. Danger to life from fatal falls!
➤ Use personal protective equipment to pro-
arrest set).
D
Installing the connectors on the supporting
construction
➤ With the multi-purpose waling laid flat on the ground,
pin the Connector XS DM/SL-1 into the waling.
D
J B
A
98065-225-02
C
D Ladder cage exit XS
J Safety latch (lift-out guard)
98065-214-05
A Connector XS DM/SL-1
B Multi-purpose waling WS10 Top50
C Connecting pin 10cm
D Spring cotter 5mm
90 999811302 - 04/2016
➤ Attach the multi-purpose waling with the pre-assem- Fixing the ladder
bled ladder connector to the crane, transport the
assembly to the supporting construction and install it. ➤ Lift in the Ladder system XS and fasten it to the bot-
tom Connector XS DM/SL-1. (See 'Top connector'
Top connector secured to the multi-purpose waling for step-by-step instructions).
of the working platform, for example with tie rod
➤ Pull out the push-in bolt at the top connector, and
and Super plate:
pivot the two safety hooks out of the way.
➤ Close the safety hooks.
A
➤ Insert the push-in bolt into whichever rung of the lad-
B der is suitable for the height of the platform, and
secure it with a linch pin.
C 98065-205-07
Bottom connector pinned to Longitudinal beam C

connector WU14 DokaCC, for example:
a
98065-226-02
- in the front position (a)

A Push-in bolt
B Safety hook
C System ladder XS 4.40m
98113-210-15 D Mobile scaffold tower
999811302 - 04/2016 91
Transporting, stacking and storing

The following instructions must be complied with when To make the "Doka skeleton transport box" easier to
storing and transporting separate parts or assemblies. load and unload, one of its sidewalls can be opened.
This ensures careful, safe treatment of the equipment:
▪ The parts must be onloaded and off-loaded, trans- Max. load: 700 kg
ported and stacked in such a way that it is not possi- Permitted imposed load: 3150 kg
ble for them to fall off, tip over or slide apart.
▪ Only set down the parts or assembly units on flat,
firm, clean surfaces.
▪ Spread-angle of slinging chains: max. 30°.
☞▪ Multi-trip packaging items that each contain
very different loads must be stacked with the
heaviest ones at the bottom and the lightest
▪ Do not detach parts from the lifting straps until they ones at the top!
have been safely set down. ▪ Rating plate must be in place and clearly leg-
▪ When transporting the equipment by truck, bundle ible
the components or otherwise secure them against
slippage, or else transport them in suitable contain- Using Doka skeleton transport boxes
ers.
1.70x0.80m as storage units
▪ Protect all components against soiling, as this pro-
longs their service life.
▪ Clearly arranged, logical storage arrangements Max. n° of boxes on top of one another
reduce the time needed for assembly. Outdoors (on the site) Indoors
▪ Using intermediate packing timbers during storage Floor gradient up to 3% Floor gradient up to 1%
and transport lessens the risk of damage. 2 5
Please co-ordinate arrangements for return delivery of It is not allowed to stack empty
pallets on top of one another!
the equipment with the Doka branch responsible.
Utilise the benefits of Doka multi-trip packaging Using Doka skeleton transport boxes
on your site. 1.70x0.80m as transport devices
Multi-trip packaging such as containers, stacking pal-
lets and skeleton transport boxes keep everything in Lifting by crane
place on the site, minimise time wasted searching for
parts, and streamline the storage and transport of sys-
tem components, small items and accessories. ➤ Only lift the boxes when their sidewalls are
closed!
Doka skeleton transport box

1.70x0.80m ☞ ▪▪ Multi-trip packaging items may only be lifted
one at a time.
Use a suitable lifting chain
(e.g. Doka 4-part chain 3.20m).
Do not exceed the permitted load-bearing
capacity.
▪ Spread-angle  max. 30°!
9234-203-01
Repositioning by forklift truck or pallet stacking

truck
Storage and transport devices for small items:
▪ durable The forks can be inserted under either the broadside or
the narrowside of the containers.
▪ stackable
Suitable transport appliances:
▪ crane
▪ pallet stacking truck
▪ forklift truck
92 999811302 - 04/2016
Doka multi-trip transport box Possible ways of dividing the box

Multi-trip transport
1.20x0.80m galv. box partition
Lengthways Crossways
1.20m max. 3 partitions -
0.80m - max. 3 partitions
Tr755-200-04 Tr755-200-05
Using Doka multi-trip transport boxes as

storage units
Max. n° of boxes on top of one another

Outdoors (on the site) Indoors
Floor gradient up to 3% Floor gradient up to 1%
Storage and transport devices for small items:
3 6
▪ durable It is not allowed to stack empty
▪ stackable pallets on top of one another!
▪ crane
▪ pallet stacking truck Using Doka multi-trip transport boxes as
▪ forklift truck transport devices
Max. load: 1500 kg Lifting by crane

Permitted imposed load: 7900 kg

☞ ▪▪ Multi-trip packaging items may only be lifted
one at a time.
heaviest ones at the bottom and the lightest (e.g. Doka 4-part chain 3.20m).
ones at the top! Do not exceed the permitted load-bearing
▪ Rating plate must be in place and clearly leg- capacity.
ible ▪ Spread-angle  max. 30°!
Multi-trip transport box partition

Different items in the Multi-trip transport box can be
kept separate with the Multi-trip transport box partitions
1.20m or 0.80m.
A
Tr755-200-02
9206-202-01

truck
A Slide-bolt for fixing the partition
The forks can be inserted under either the broadside or
999811302 - 04/2016 93
Doka stacking pallet 1.55x0.85m and Using Doka stacking pallets as transport
1.20x0.80m devices
Lifting by crane
Storage and transport devices for long items:
☞ ▪▪
▪ durable Multi-trip packaging items may only be lifted
▪ stackable one at a time.
Suitable transport appliances: Use a suitable lifting chain
▪ crane (e.g. Doka 4-part chain 3.20m).
▪ pallet stacking truck Do not exceed the permitted load-bearing
capacity.
▪ forklift truck
▪ Load the items centrically.
The Bolt-on caster set B turns the stacking pallet into a ▪ Fasten the load to the stacking pallet so that
fast and manoeuvrable transport trolley. it cannot slide or tip out.
Follow the directions in the "Bolt-on castor set ▪ When lifting stacking pallets to which Bolt-on
B" Operating Instructions! castor sets B have been attached, you must
also follow the directions in these Operating
Instructions!
= =
a
92815-224-01
Max. load: 1100 kg
Permitted imposed load: 5900 kg a
Doka stacking pallet 1.55x0.85m max. 4.0 m

Doka stacking pallet 1.20x0.80m max. 3.0 m

ones at the top! truck
▪ Rating plate must be in place and clearly leg-
ible
☞ ▪▪ Load the items centrically.
Fasten the load to the stacking pallet so that
it cannot slide or tip out.
Using Doka stacking pallets as storage units
Max. n° of units on top of one another

Outdoors (on the site) Indoors
Floor gradient up to 3% Floor gradient up to 1%
2 6
It is not allowed to stack empty
pallets on top of one another!
☞▪ How to use with bolt-on castor set:

Always apply the fixing brake when the con-
tainer is "parked".
When Doka stacking pallets are stacked, the
bottom pallet must NOT be one with a bolt-on
caster set mounted to it.
94 999811302 - 04/2016
Doka accessory box Doka accessory box as transport devices
Storage and transport devices for small items: Lifting by crane

▪ durable
▪ stackable
☞ ▪▪ Multi-trip packaging items may only be lifted
one at a time.
▪ crane (e.g. Doka 4-part chain 3.20m).
▪ pallet stacking truck Do not exceed the permitted load-bearing
▪ forklift truck capacity.
The Doka accessory box is the tidy, easy-to-find way of
▪ When lifting stacking pallets to which Bolt-on
castor sets B have been attached, you must
storing and stacking all interconnection and form-tie
also follow the directions in these Operating
components.
Instructions!
The Bolt-on caster set B turns the stacking pallet into a
fast and manoeuvrable transport trolley.
Follow the directions in the "Bolt-on castor set

B" Operating Instructions!
92816-206-01

truck
The forks can be inserted under either the broadside or

Max. load: 1000 kg Bolt-on castor set B

Permitted imposed load: 5530 kg
The Bolt-on caster set B turns the stacking pallet into a
☞ ▪ Multi-trip packaging items that each contain

fast and manoeuvrable transport trolley.
Suitable for drive-through access openings > 90 cm.
ones at the top!

▪ Rating plate must be in place and clearly leg-
ible
Doka accessory boxes as storage units
Max. n° of boxes on top of one another The Bolt-on caster set B can be mounted to the follow-
Outdoors (on the site) Indoors ing multi-trip packaging items:
Floor gradient up to 3% Floor gradient up to 1% ▪ Doka accessory box
3 6 ▪ Doka stacking pallets
It is not allowed to stack empty
pallets on top of one another! Follow the directions in the Operating Instruc-
☞ ▪ How to use with bolt-on castor set:

Always apply the fixing brake when the con-
tainer is "parked".
tions!
When Doka accessory boxes are stacked,

the bottom box must NOT be one with a bolt-
on castor set mounted to it.
999811302 - 04/2016 95
Component overview User Information Tunnel system DokaCC
[kg] Article n° [kg] Article n°

Component
Article
[kg] n° overview
System beam DokaCC 5.00m 640.8 583306000 Packing plate SL-1 2mm 0.69 582864000
System beam DokaCC 1.00m 167.9 583303000 Futterplatte SL-1
System beam DokaCC 0.50m 99.4 583302000 Galvanised
System beam DokaCC 0.25m 73.5 583301000 Length: 22 cm
Systemträger DokaCC
Width: 22 cm
Painted blue
Diagonal strut DokaCC 2.80m 163.1 583330000

System beam screw-set DokaCC 10.9 8.9 583346000 Schrägstütze DokaCC
Schraubensatz Systemträger DokaCC 10.9 Painted blue
Galvanised
Diagonal strut endpiece DokaCC 1.40m 87.1 583335000

Diagonal strut endpiece DokaCC 1.60m 95.5 583336000
Schrägstützenendstück DokaCC
Vertical strut DokaCC 2.80m 93.5 583320000
Vertical strut DokaCC 2.20m 73.5 583321000 Painted blue
Vertikalstütze DokaCC
Painted blue
Diagonal strut connector DokaCC 24.5 583338000

Schrägstützenanschluss DokaCC
Galvanised
Vertical strut endpiece DokaCC 1.00m 38.2 583329000

Vertikalstützenendstück DokaCC
Painted blue Diagonal strut screw-set DokaCC 10.9 3.1 583347000
Schraubensatz Schrägstütze DokaCC 10.9
Galvanised
Vertical strut connector DokaCC 29.5 583326000

Vertikalstützenanschluss DokaCC
Galvanised
Connecting pin DokaCC D60 140 4.5 583325000

Verbindungsbolzen DokaCC D60 140
Galvanised
Vertical strut screw-set DokaCC 10.9 2.3 583348000

Schraubensatz Vertikalstütze DokaCC 10.9
Galvanised
Connecting pin DokaCC D60 235 6.7 583337000

Verbindungsbolzen DokaCC D60 235
Galvanised
Packing plate DokaCC 10mm 3.7 583317000

Futterplatte DokaCC
Galvanised
96 999811302 - 04/2016
User Information Tunnel system DokaCC Component overview
Load distributor DokaCC 168.0 583310000 Strut connection DokaCC 8.1 583316000
Lastverteiler DokaCC Strebenanschluss DokaCC
Galvanised Galvanised
Strut connection SL-1 8.2 582806000

Strebenanschluss SL-1
Galvanised
Length: 30 cm
Screw-set M20x65 8.8 1.2 582851000 Width: 20 cm
Schraubensatz M20x65 8.8 Height: 10 cm
Galvanised
Width-across: 30 mm
Screw-set M20x160 8.8 2.3 583349000

Schraubensatz M20x160 8.8
Galvanised
Top100 tec waling WU14 0.50m 15.2 586901000

Top100 tec waling WU14 2.75m 79.0 586910000 Spindle strut T7 75/110cm 13.2 584308000
Spindelstrebe T7
Top100 tec waling WU14 6.00m 182.2 586917000 Galvanised
Top100 tec-Riegel WU14
Painted blue
Top100 tec formwork element connector 11.6 586923000

Top100 tec-Elementverbinder
Painted blue
Length: 76 cm
Connecting pin 10cm 0.34 580201000

Verbindungsbolzen 10cm
Galvanised
Longitudinal beam connector WU14 DokaCC top 10.0 583314000 Length: 14 cm
Längsträgeranschluss WU14 DokaCC oben
Painted blue
Connecting pin 25cm 0.58 580202000

Verbindungsbolzen 25cm
Galvanised
Length: 25 cm
Longit. beam connector WU14 DokaCC bottom 6.0 583313000
Längsträgeranschluss WU14 DokaCC unten
Galvanised
Spring cotter 5mm 0.05 580204000

Federvorstecker 5mm
Vertical strut DokaCC spindle connector 7.8 583315000 Galvanised
Spindelanschluss Vertikalstütze DokaCC Length: 13 cm
Galvanised
999811302 - 04/2016 97
Lifting-mechanism frame DokaCC 111.5 583340000 Flanged wheel SL-1 220kN 139.3 582890000
Hubwerkrahmen DokaCC Spurkranzrad SL-1 220kN
Painted blue Length: 47 cm
Width: 22 cm
Height: 40 cm
Connection set for flanged wheel SL-1 52.0 582891000

Anschlussset Spurkranzrad SL-1
Lifting-mechanism box DokaCC 191.0 583341000

Hubwerkkasten DokaCC
Painted blue
Hydraulic drive SL-1 87.0 582828000

Hydraulikantrieb SL-1
Painted blue
Lifting-mechanism box screw-set DokaCC 10.9 7.3 583351000 Length: 44 cm
Schraubensatz Hubwerkkasten DokaCC 10.9 Follow the directions in the "Opera-
Galvanised ting Instructions"!
Hydraulic unit SL-1 V180 756.0 582893000

Hydraulikaggregat SL-1 V180
Painted blue
Length: 112 cm
Width: 80 cm
Height: 183 cm
Follow the directions in the "Opera-
ting Instructions"!
Lifting ram DokaCC 220kN 59.1 583342000
Hubstempel DokaCC 220kN
Galvanised
Lowering cylinder SL-1 250kN 27.2 582870000

Absenkzylinder SL-1 250kN
Painted blue
Lifting ram screw-set DokaCC 8.8 1.6 583350000 Height: 28-56 cm
Schraubensatz Hubstempel DokaCC 8.8 Follow the directions in the "Opera-
Galvanised ting Instructions"!
Rail distance piece S49 DokaCC 56.8 583311000

Schienendistanz S49 DokaCC
Hydraulic cylinder for lifting mechanism SL-1 87.5 582899000 Galvanised
Hydraulikzylinder Hubwerk SL-1
Galvanised
Length: 65 cm
Lowering wedge 1000kN 53.5 582905000

Absenkkeil 1000kN
Painted blue
Height: 19.2 - 27.2 cm
98 999811302 - 04/2016
Lowering wedge SL-1 420kN 30.0 582821000 Tie rod 15.0mm galvanised 0.50m 0.72 581821000
Absenkkeil SL-1 420kN Tie rod 15.0mm galvanised 0.75m 1.1 581822000
Painted blue Tie rod 15.0mm galvanised 1.00m 1.4 581823000
Height: 16.8 - 26.8 cm Tie rod 15.0mm galvanised 1.25m 1.8 581826000
Tie rod 15.0mm galvanised 1.50m 2.2 581827000
Tie rod 15.0mm galvanised .....m 1.4 581824000
Tie rod 15.0mm non-treated 0.50m 0.73 581870000
Bracing bolt DokaCC 15.4 583312000 Tie rod 15.0mm non-treated 1.50m 2.1 581876000
Abspannbolzen DokaCC
Galvanised Tie rod 15.0mm non-treated 2.00m 2.9 581875000
Fixing bracket SL-1 7.5 582849000 Tie rod 15.0mm non-treated 7.50m 10.7 581882000
Spannkonsole SL-1 Tie rod 15.0mm non-treated .....m 1.4 581873000
Galvanised Ankerstab 15,0mm
Length: 22 cm
Width: 13 cm
Height: 12 cm

Tie rod 20.0mm galvanised 1.25m 3.2 581418000 Super plate 15.0 1.1 581966000
Tie rod 20.0mm galvanised 1.50m 3.8 581413000 Superplatte 15,0
Tie rod 20.0mm galvanised 2.00m 5.0 581414000 Galvanised
Tie rod 20.0mm galvanised 2.50m 6.3 581430000 Height: 6 cm
Tie rod 20.0mm galvanised .....m 2.5 581410000 Diameter: 12 cm
Tie rod 20.0mm non-treated 0.50m 1.3 581405000 Width-across: 27 mm
Tie rod 20.0mm non-treated 1.50m 3.8 581407000 Hexagon nut 15.0 0.23 581964000
Tie rod 20.0mm non-treated 2.00m 5.0 581408000 Sechskantmutter 15,0
Tie rod 20.0mm non-treated .....m 2.5 581403000 Galvanised
Ankerstab 20,0mm Length: 5 cm
Width-across: 30 mm
Split nut SL-1 15.0 0.70 582835000

Spannmutter SL-1 15,0
Galvanised
Length: 9-11 cm
Width-across: 30/41 mm
Super plate 20.0 B 2.0 581424000

Superplatte 20,0 B
Galvanised Positioning unit DokaCC 24.5 583343000
Verfahreinheit DokaCC
Height: 7 cm
Galvanised
Diameter: 14 cm
Width-across: 34 mm
Hexagon nut 20.0 0.60 581420000

Sechskantmutter 20,0
Galvanised
Length: 7 cm
Width-across: 41 mm
Stripping lever DokaCC 5.6 583344000
Ausschalhebel DokaCC
Quick-release nut 20.0 5.9 581428000
Lösemutter 20,0 Galvanised
Galvanised
Length: 22 cm
Follow fitting instructions!
Threaded rod 20.0mm .....m 2.5 581477000 Beam support WS10-WU16 5.4 581582000
Gewindestab 20,0mm .....m Trägerauflage WS10-WU16
Galvanised Galvanised
999811302 - 04/2016 99
Railing adapter XP DokaCC 4.5 583345000 Scaffold tube 48.3mm 0.50m 1.7 682026000
Geländeradapter XP DokaCC Scaffold tube 48.3mm 1.00m 3.6 682014000
Galvanised Scaffold tube 48.3mm 1.50m 5.4 682015000
Scaffold tube 48.3mm 2.00m 7.2 682016000
Handrail post XP 1.20m 4.1 586460000 Scaffold tube 48.3mm 6.00m 21.6 682025000
Geländersteher XP 1,20m Scaffold tube 48.3mm .....m 3.6 682001000
Gerüstrohr 48,3mm
Galvanised
Galvanised
Height: 118 cm
Multi-purpose waling WS10 Top50 0.50m 10.2 580001000

Handrail clamp S 11.5 580470000 Multi-purpose waling WS10 Top50 2.75m 54.2 580010000
Schutzgeländerzwinge S Multi-purpose waling WS10 Top50 3.00m 58.9 580011000
Galvanised Multi-purpose waling WS10 Top50 3.50m 68.4 580012000
Height: 123 - 171 cm Multi-purpose waling WS10 Top50 4.00m 79.4 580013000
Mehrzweckriegel WS10 Top50
Painted blue
Adjusting plate T 6.5 584393000 Formwork element connector FF20/50 Z 6.0 587533000
Justierlasche T Elementverbinder FF20/50 Z
Painted blue Painted blue
Length: 23.5 cm Length: 55 cm
Eye-lug anchor 15.0 without tie rod 1.2 580649000

Ösenanker 15,0 ohne Ankerstab
Galvanised Multi-purpose waling SL-1 WU16 0.625m 24.0 582875000
Length: 11 cm Multi-purpose waling SL-1 WU16 0.75m 26.5 582876000
Multi-purpose waling SL-1 WU16 1.00m 35.0 582877000
Swivel coupler 48mm 1.5 582560000 Multi-purpose waling SL-1 WU16 2.00m 72.1 582881000
Drehkupplung 48mm Multi-purpose waling SL-1 WU16 2.25m 86.0 582882000
Galvanised Multi-purpose waling SL-1 WU16 2.50m 89.9 582883000
Width-across: 22 mm Multi-purpose waling SL-1 WU16 3.00m 107.0 582888000
Mehrzweckriegel SL-1
Painted blue
Screw-on coupler 48mm 50 0.84 682002000

Anschraubkupplung 48mm 50
Galvanised
Width-across: 22 mm
Waling connector SL-1 WU16 0.75m 31.0 582886000
Riegelverbinder SL-1 WU16 0,75m
Galvanised
Length: 75 cm
100 999811302 - 04/2016

Stacking plate H20 8.3 580310000 Dokamatic lifting strap 13.00m 10.5 586231000
Aufstocklasche H20 Dokamatic-Umsetzgurt 13,00m
Galvanised Green
Length: 68.8 cm Follow the directions in the "Opera-
ting Instructions"!
Spindle strut 40/80cm 9.4 583247000 Lifting rod 15.0 1.9 586074000
Spindelstrebe 40/80cm Umsetzstab 15,0
Galvanised Painted blue
Height: 57 cm
ting Instructions"!
Height adjuster WS10-WU16 10.1 580206500

Höhenjustierung WS10-WU16
Galvanised Doka express anchor 16x125mm 0.31 588631000
Doka-Expressanker 16x125mm
Height: 45 cm
Galvanised
Length: 18 cm
Corner connecting plate 90/50 13.8 580603000

Winkellasche 90/50 Doka coil 16mm 0.009 588633000
Doka-Coil 16mm
Painted blue
Galvanised
Length: 51 cm
Diameter: 1.6 cm
Width: 40 cm
Doka personal fall-arrest set 3.6 583022000

Doka-Auffanggurt
ting Instructions"!
Winch 70 31.0 582779000
Zahnstangenwinde 70
Painted blue
Height: 126 cm
ting Instructions"!
Winch 125 63.8 582780000

Zahnstangenwinde 125
Painted blue
Height: 189 cm
ting Instructions"!
Solid tire wheel 34.5 582573000

Vollelastikrad
Painted blue
Height: 45 cm
999811302 - 04/2016 101

Tools Set of ball-head hexagon-socket screw keys 0.60 586346000

Inbus-Kugelkopfschlüsselsatz
Tool box SL-1 19.9 582836000
Werkzeugbox SL-1
included in scope of supply:
(A) Combination wrench 19 0.14 582837000
(B) Combination wrench 22 0.20 582838000
(C) Combination wrench 24 0.25 582839000
(D) Combination wrench 30 0.43 582840000
(E) Combination wrench 32 0.75 582859000
(F) Combination wrench 34 1.1 582936000
(G) Combination wrench 36 0.75 582860000 Slugging ring spanner 55 1.8 582919000
Schlag-Ringschlüssel 55
(H) Combination wrench 41 1.5 582841000
Length: 27.5 cm
(I) Ratcher-ring wrench 30/32 1.3 582843000
(J) Box nut 19 1/2" L 0.16 580598000
(K) Box nut 22 3/4" L 0.22 582844000
(L) Box nut 24 3/4" L 0.25 582845000
(M) Box nut 30 3/4" L 0.52 582846000
(N) Extension 20cm 3/4" 0.68 580683000
(O) Reversible ratchet 3/4" 1.5 580894000 Ladder system XS
Galvanised
Length: 50 cm
(P) Tie-rod wrench 15.0/20.0 1.9 580594000 Connector XS DM/SL-1 11.7 588672000
Anschluss XS DM/SL-1
Galvanised
Galvanised
Length: 37 cm
Diameter: 8 cm Length: 100 cm
(Q) Transition piece A 1/2"x3/4" 0.18 580684000
(R) Angular arbor SL-1 1.4 582867000
(S) Fork wrench 46 0.87 582869000
(T) Ring spanner 46 0.96 582868000
System ladder XS 4.40m 33.2 588640000
A B C D E F G
System-Leiter XS 4,40m
Galvanised
I
H
S
R
O
N
Q M
L
K P
Torque wrench 3/4" 75-400Nm 2.3 586374000

Drehmomentschlüssel 3/4" 75-400Nm
Galvanised
Length: 69 cm
Ladder extension XS 2.30m 19.1 588641000

Leiternverlängerung XS 2,30m
Box nut 36 3/4" L 0.67 580895000 Galvanised
Stecknuss 36 3/4" L
Box nut 50 3/4" 0.81 581449000

Stecknuss 50 3/4"
Universal cone spanner 15.0/20.0 0.90 581448000

Universal-Konusschlüssel 15,0/20,0 Securing barrier XS 4.9 588669000
Sicherungsschranke XS
Galvanised
Galvanised
Length: 9 cm
Length: 80 cm
Width-across: 50 mm
Ring spanner 80 3.8 582906000

Ringschlüssel 80
Galvanised
Length: 62.4 cm
102 999811302 - 04/2016

Ladder cage XS 1.00m 16.5 588643000 Doka stacking pallet 1.55x0.85m 41.0 586151000
Ladder cage XS 0.25m 10.5 588670000 Doka-Stapelpalette 1,55x0,85m
Rückenschutz XS Galvanised
Galvanised Height: 77 cm
Ladder cage exit XS 17.0 588666000

Rückenschutz-Ausstieg XS
Galvanised Doka stacking pallet 1.20x0.80m 38.0 583016000
Doka-Stapelpalette 1,20x0,80m
Height: 132 cm
Galvanised
Height: 77 cm
Doka accessory box 106.4 583010000

Multi-trip packaging Doka-Kleinteilebox
Timber parts varnished yellow
Steel parts galvanised
Doka skeleton transport box 1.70x0.80m 87.0 583012000
Doka-Gitterbox 1,70x0,80m Length: 154 cm
Galvanised Width: 83 cm
Height: 113 cm Height: 77 cm
Bolt-on castor set B 33.6 586168000

Anklemm-Radsatz B
Painted blue
Doka multi-trip transport box 1.20x0.80m 70.0 583011000

Doka-Mehrwegcontainer 1,20x0,80m
Galvanised
Height: 78 cm
Multi-trip transport box partition 0.80m 3.7 583018000

Multi-trip transport box partition 1.20m 5.5 583017000
Mehrwegcontainer Unterteilung
Timber parts varnished yellow
Steel parts galvanised
999811302 - 04/2016 103

Near to you, worldwide
Doka is one of the world leaders in developing, manu- technical support are provided swiftly and profession-
facturing and distributing formwork technology for use in ally.
all fields of the construction sector. An enterprise forming part of the Umdasch Group, the
With more than 160 sales and logistics facilities in over Doka Group employs a worldwide workforce of more
70 countries, the Doka Group has a highly efficient dis- than 6000.
tribution network which ensures that equipment and
Doka GmbH | Josef Umdasch Platz 1 | 3300 Amstetten | Austria | T +43 7472 605-0 | F +43 7472 66430 | info@doka.com | www.doka.com 999811302 - 04/2016

Tunnel System DokaCC

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Tunnel System DokaCC

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999811302 - 04/2016

The Formwork Experts.

Tunnel system DokaCC

27 Regular sequence 80 Maintenance and troubleshooting

Hazard assessment Regulations; industrial safety

Rules applying during all phases of Assembly

Transporting, stacking and storing Symbols used

▪ Only original Doka components may be used as

Ed Design value of effect of actions Rd Design value of the resistance

Comparison of the safety concepts (example)

the permissible values.

Factual Fpermissible Ed Rd

The advantages for you

▪ Maximised workplace safety

▪ Reduced close-out costs

A Girderframe (see the section headed 'Girderframe in detail')

System beam DokaCC (A)

Bolted together to form the roof-slab cross-beam.

▪ Vertical strut connector DokaCC (B)

Vertical strut DokaCC (E) Diagonal strut DokaCC (J)

Endpiece of the Vertical strut DokaCC for connection to the System

Packing plate (G)

63.7 5.20 2.50 0 271

68.9 4.20 5.00 2.00 2 270

E 67.5 6.00 2.50 29 2 243

4 64.9 6.60 3.00 14 258

System parts needed Vertical strut (girderframe with lifting mechanism)

Precision adjustment Selection of packing plates [pcs.]

Adjusting girderframe spacing

a ... centre-to-centre spacing of connecting pins min. 20 cm

Max. spacing of longitudinal beams

Nperm. [kN] b [m]

Values in parentheses are maximum values

Bottom longitudinal beams Pin position

Fields with lifting mechanism Spindle strut bracing in longitudinal

Adjusting, aligning and lowering

For precision height adjustment and for taking load off

packers to bring the rail distance piece to the

h ... from 19.2* cm to 27.2 cm

Lifting mechanism Transverse adjustment

C Flanged wheel SL-1 with or without hydraulic drive

98113-211-04 98113-211-04 98113-211-04

98113-211-05 The lifting mechanism axis moves up to 50 mm rela-

Tie rod system

a ... max. 155 mm

Stop-end formwork construction

A Positioning unit DokaCC C Stop-end panel

e.g. with Vertical strut DokaCC spindle connector and

Permitted moment of the corner connecting plate

A Vertical strut DokaCC Note:

As regards fixing form ties and connecting form-

Stripping out the formwork

C Super plate 15.0

A Tie rod 20.0mm

Stripping the stop-end formwork at with Adjusting plate T

A Super plate 15.0

A Stripping lever DokaCC

Stripping the stop-end formwork at Removing form ties

Variant with Quick-release nut 20.0

Follow the directions in the 'Quick-release nut

Stripping the wall-to-roof-slab

Stripping the inside formwork Hydraulic:

➤ Start up the hydraulic unit (as described in the Oper-

Under these circumstances the anchorage