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Contents

Introduction Technical Drawings 1 Construction Materials Concrete 9 Isolation 11 Formwork Protective Oil 11 Formwork Separator Oil 11 Crane 12 Lifting Equipments Assembly Device 13 Lifting Triangle 13 Tools and Consumables For Tunnel Formwork Crew 14 For Rebar Crew 15 For Concreting Crew 15 Before Arrival of MESA-Supervisor 16

Assembly Preperation for Assembly Assembly Area 17 Crew for Assembly 18 Assembly of Tunnel Formwork Set Connection of Deck Panels 19 Connection of Lifting Beam 20 Connection of Inside Panels 21 Connection of Inclined Props 22 Connection of Inside and Deck Panels 23 Connection of Wheeled Prop and Wheeled Prop Support 24 Connection of Back Panel 25 Upholding the Tunnel Formwork Set 26 Assembly of Stop-ends 27 Assembly of Boxouts 28 Assembly of Outside Wallform Set Connection of Working Platform and Guardrails 29 Connection of Panel Supports and Ladder 30 Connection of Outside Wallforms 31 Upholding the Outside Wallform Set 32

Operation Preperation for Operation Before Starting the Operation 33 Crew for Operation 33 Alignment of Tunnel Formworks 33 Preperation of Foundation 35 Cleaning and Oiling of Formworks 38 Marking the Boxouts and Stopends 38 Daily Cycle Time Schedule 39 Striking 41 Formwork Setting 52 Concreting 68 Non-Standard Applications 72

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TRTF-Classic Tunnel Form System �� www.mesaimalat.com.tr�

General Remarks Safety Remarks

• This “User Manual” contains information about MESA-Formwork & Scaffolding systems. It describes setting up, utilisation, correction, maintenance and loading data of these products and systems, by helping to the site as a ‘Method Statement’.

• MESA products could only be used according to the Instruction or User Manuals, any Technical Details given in Documents provided by MESA.

• Due to avoid unwanted results such as accidents and damage to health or material damages, Owners and Users of MESA products or Systems should comply the directions given by the documents and data explained above.

• In the cases which require different deviations from these manuals, Owner or User of MESA products or systems must check the evidence of the technical solutions or supplementary instruction methods and procure revised static or dynamic calculations to MESA.

• Although these User Manual have to be read before installation or any usage; in order to provide all requirements of safety on site, user should take necessary precautions according to the international safety regulations and local safety rules.

• Schematic illustrations on this manual give only basic rules to be applied during assembly, erection and dismantling, therefore it not complete from the safety point of view.

• User should inspect and check the products and systems before use. Materials not having suitable conditions such as damaging and weakening due to rust, corrosion or wear, should be removed and reported to MESA immediately.

• Since combination of any material and component originated from other manufacturers with MESA products may be dangerous for health and property, they must not be combined with MESA products. In such a case, customer should contact with MESA.

• Only the skilled persons educated according to official documents of MESA are authorised to assemble, erect and dismantle of MESA products and systems.

• Users working with MESA products and systems should read, understand and accept the information included in this manual. Otherwise, they should be trained by the customer according to MESA documentation.�

• During all set up procedure, loads must be safely transferred. • During all construction phases, all components and units must be safely stabilised. • According to the formwork system choosen, admissible fresh concrete pressure must not be exceeded. Such a case will cause to formwork overload and more deflection both on formwork and concrete, even breakage and overload on tie-rods. Maximum working load of tie-rods used must be checked. • Person who works on the system in all phases (i.e. setting up, erection, concreting, dismantling and disassembly etc.) should be assure to have enough and safe workplace. • The formwork removal must be done after the concrete has reached sufficient strength. • Formwork removal must be done by using lever arms or other tools provided together with the formwork system but not the crane or any other devices which will cause unwanted results. • In order to keep the scaffolding, platform, formwork or other parts stable and safe, user should check the conditions where the procedure occurs during the formwork removal procedure.

• Any small parts used in the system should be fixed in their place to avoid loosing or falling freely. • All connecting parts must be used properly to provide correct functioning of them. Selecting of wrong part could cause leakage of the relevant products under loading. • All connections must be checked periodically. Especially bolt and nut connections and pin connections should be controlled.

• Enough number of Fire Extinguishers and any other necessary items against danger of fire should be kept available where the formwork and scaffolding systems need.

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� Instruction or User Manuals must be used while Formwork assemblies, accessory attachements and concrete casting. � It is not allowed to use hummer, sledgehummer, cranka and vs that cause physical demage on Formworks, and also applications of extra welding, cutting and drilling without permission of authorities. � It is not allowed to exceed the Max Concrete Pressure described in Technical or User Manuals. � Formwork should be used between + 40 °C and – 30 °C. � Formworks should be cleaned after each application to remove the concrete residues and active faces should be lubricated with suitable concrete/metal seperation oil. � After 250 applications, maintenance should be done at site. � This maintenance covers the flatning of active surface, repainting, welding and rust control. � After 500 applications, maintenance should be done at work shop where the necessary equipments exist. � During the storage period, all active surfaces should be lubricated with suitable oil to prevent rusting. � Stock area should be closed area; if it is not possible, formworks and accessories should be stocked in open areas by covering them with water resistant materials. � Maitenance procedure should be repeated for each 250 usages after first 500 usages are exceeded. ��

� Electrical power supply and connections must be suitable as written in the ınstruction or User Manuals given by MESA.

Operational Conditions

Warranty Period�

� Limited Warranty for two (2) years is promissed by Mesa �malat San.ve Tic. A.�. for Steel Face Formworks and Slab Formworks unless the Operational Conditions described above are violated. � This warranty covers defects of steel material, welding and painting. � For Hydraulic Cylinders and Hydraulic Power Units, the limited warranty period is one (1) year.

Service Life

� Steel Face Formworks and Slab Formworks, produced by Mesa �MALAT San.ve Tic.A.�., is good for 500 concrete castings unless The Operational Conditions described below are violated.

• This Booklet is the complementary of “Technical Manual” prepared for MESA-TRTF Classic Tunnel Formwork System and all information written on these two booklets should be considered together. • Users who will work with MESA-TRTF Classic Tunnel Formwork System and all types of MESA Platform and Scaffolding Systems should be educated and informed by skilled MESA personel.

• MESA will issue a “OPERATION CERTIFICATE” to persons that have undergone required training.

• If a person who do not have this “OPERATION CERTIFICATE”, he/she could not use MESA-TRTF Classic Tunnel Formwork System and all types of MESA Platform and Scaffolding Systems.

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Information

Important Note

Sight-Check

Warning

Symbols Used�

� Mesa Imalat reserves the right to make technical changes in the interests of progress.

© Copyright by MESA Imalat San. ve Tic A.S.-Ankara-Turkey

�� Technical Drawings

TRTF – Classic Tunnel Form System 1

�� www.mesaimalat.com.tr�

Formwork Layouts

TECHNICAL DRAWINGS�

o Setting Plan of Tunnel Formworks

o Assembly Codes and Tie-Rod Positions

o Setting Plan of Kicker Forms

o Setting Plan of Slab and Wall Stopends

o Setting Plan of Lifting Beams

o Setting Plan of Slab Boxouts

o Setting Plan of Platforms

o Assembly Charts of Tunnel Formworks

Setting Plan of Tunnel Formworks

Formwork Layouts prepared by MESA includes the following information ;

B C D E F G H I J

2

3

4

56

7

2

3

4

56

7

B C D E F G H I J

KN1=11

50

KN1=1150

Tunnel Number

Stripping Direction

Formwork Dimensions

Slab Stopend

Wall Stopend

Back Panel

Outside Wallform




Assembly Codes and Tie-rod Positions�

Assembly Code of Deck Panel

Assembly Code of Back Panel

Assembly Code of Inside Panel

Position of Tie-Rod and Cone

Assembly Code of Outside Panel

Detail A

Detail A




Setting Plan of Kicker Forms�

AUAUAU AU

Assembly Code of Straight Kicker Form

Assembly Code of Inner Kicker Form�

Assembly Code of Corner Kicker Form�

Detail A

Detail A




Setting Plan of Slab and Wall Stopends�

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

PB

Assembly Code of Wall Stop-end

Assembly Code of Slab Stop-end

Detail A

Detail A




Setting Plan of Lifting Beams�

Assembly Code of Lifting Beam

Rough Position of Lifting Beam

Detail A

Detail A




Setting Plan of Slab Boxouts�

Wall Boxout

Position of Wall Boxout

Slab Boxout

Detail A

Detail A




S2 S2

1A1A

F2

1C1C

DT2L

DT

1

1B

F1

1B1B

1C

E

Z

FREL

2

3

4

56

7

B C D E F G H I J

+3.14 KOTU DÖ�EMES� +3.14 KOTU DÖ�EMES�

1

1 1

FL

F1

1B

1C

ER

1A 1A

F2

1

1

1

1

11

B C D E F G H I J

2

3

4

56

7

DT2R

DT

1

1

1

E

Z

1

S2

DT2L

1B

E

Z

1

1

1

Setting Plan of Platforms�

Assembly Code of Landing Platform

Assembly Code of Gable-end Frame

Assembly Code of Stripping Platform

Detail A

Detail A




28

19505093

444

28

R6

Y4

Y4

TB

TB

1950

2583

565 571 543 5502064 2107 2152 2192

1719 1745 1773 1799

TUNNEL

ASSEMBLY CODE of LIFTING BEAM

ASSEMBLY CODE of WHEELED PROP SUPPORT

ASSEMBLY CODE of INCLINED PROP

TUNNEL LENGHT (mm)TUNNEL WIDTH (mm)

MESA �MALAT SANAY�� VE T�CARET A�.Atatürk mah.Kayı cad.No:92/A,Yenikent 06378 ANKARA / TÜRK�YE

Tel : +90.312.277 33 00(pbx) - Fax : +90.312.277 37 00 (pbx)[email protected] www.mesaimalat.com-

SLAB AND WALL STOPEND

WITHWALL STOPEND

WITHSLAB STOPEND

WITHWALL STOPEND

WITHOUT

TUNNEL WEIGHT (kg)

TO VERTICAL PANEL (mm)

TO END OF TUNNEL (mm)

POSITION of LIFTING HOLECENTER OF GRAVITYTUNNEL NO :

Assembly Charts of Tunnel Formworks

Weight

Position of Lifting Hole

Tunnel Dimensions

Assembly Code of Main Connectors�

Tunnel Number

Assembly Code of Deck Panel

Assembly Code of Back Panel�

Assembly Code of Inside Panel�

�� Construction Materials



As described in the booklet “TRTF-

Technical Manual”, hydrostatic pressure of

concrete applied on Panels should not be

greater then 63 kN/m2.

Concrete�

CONSTRUCTION MATERIALS�

For earthquake zones, concrete and rebar

required for construction are as follows;

o Concrete : 0.34 – 0.45 m3/m2 in plan

o Rebar : 27 – 35 kg/m2 in plan

t� ; total time for end of setting of concrete

(= 5 h)

γγγγc ; density of fresh concrete (25 kN / m3)

σσσσhk,max ; max.pressure of fresh concrete (kN/m2)

v ; the rate of concrete placing (m/h)

hs ; the height of hydrostatic pressure (m)

K 1 ; consistency factor

The table shows the rate of

concrete placing for TRTF–

Classic Tunnel Formwork

System, according to the

maximum allowable

hydrostatic pressure (63

kN/m2) ;

Rate of Placing of Concrete

Concrete Consumption

Fresh Concrete Pressure for � hk,max = 63 kN/m2

� hk,max (kN/m2) v (m/h)

F1 Solid (5 � v + 21) � K 1 � 25 8.40

F2 Semi-solid (10 � v + 19) � K 1 � 25 4.40

F3 Rigid (14 � v + 18) � K 1 � 25 3.21

F4 Plastic (17 � v + 17) � K 1 � 25 2.71

F5 Soft (30 � v + 25) � K 1 � 30 1.27

F6 Fluid (38 � v + 25) � K 1 � 30 1.00

SVB Self-Compacting (33 � v + 25) � K 1 � 30 1.15

Class of Consistency




Heating capacitiesof LPG-Heater and Radiant Burner are 15,000

and 28,500 kcal/hour respectively. �

Take 1 set of LPG-Heater � 30 m3 and 1 set of Radiant Burner � 60 m3.

For heating a 100 m3 room; 100 / 30 = 3.3 � 4 LPG-Heaters or 100 / 60 = 1.7 � 2 Radiant-Burners are required.�

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Refer to technical features of other types of Heaters or Burners

given by their own Manufacturers.�

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Heating of the Concrete

As a rule;

The temperature should not be

greater than 80°C.

Economically, heating the full tunnel

space between 50°C and 70°C will be

sufficient.

The rate of increase in temperature

should not exceed 20 °C per hour. Otherwise,

rapid water-loss before the concrete setting

could be possible.

Water-loss reduces the concrete

strength (10% water loss cause 40% concrete

strength loss).

To avoid a rapid loss of water by

evaporation during the heating of the

concrete, the slab covered with an

appropriate insulation sheet.

As shown in the graph;

0% content of water refers to 100% of

strength of concrete that means of no loss on

the strength.

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By adding 20% crude oil to grease as a diluting agent, it

could be used as protective material for short period of

time under 3 months.

Protection period of the selected oil should be at least; 6-9 months (for outdoor) 12-18 months (for indoor)

Approximately 1 litre of separation oil could be used on

25-40 m2 of formwork area according to the oil type

choosen.

In considerably low temperatures, double layer sandwich type Tunnel Curtain should be used. In that case, the top of the slab is also need to be insulated with proper covering materials. �

Formwork Protective Oil

Formwork Separator Oil

Formwork protective oil should be rust

preventive and should possess good water

displacement property.

Product codes of oils frequently preferred

for protection of the concrete surfaces of panels

are as follows;

Castrol Rustilo DWX 32

Mobilarma 798

Table gives the optimum characteristics of a formwork

protective oil (example is extracted from Castrol Rustilo DWX 32).

Formwork separation oil should provide

easy release of the formwork from the concrete,

long formwork life, decreasing on air-bubbles on

the concrete surface. Concrete surface should be

clean and smooth.

Product codes of oils frequently preferred

for separation of the concrete surfaces from panels

are as follows;

YKS-Yapol

SIKA-Separol S3

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Table gives the optimum characteristics of a formwork

separation oil (example is extracted from YKS-Yapol).

Isolation

Insulating material (Tunnel Curtain) covering the open ends of

the tunnel formworks are made from plastic based material having a

grade of ll00 dny.




Generally, a Tower Crane whose loading capacity is about 2,000 kg. at 45-50 metres of jib-length would be sufficient.

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Location of the crane should allow to lifting and stripping operations of tunnel formworks and other equipments partaking on the construction area.

Max.Wind Speed for safe operating conditions should be taken as 40 km/h.

Refer to the operating conditions for cranes given by its manufacturer.

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Crane

Since TRTF-Classic Tunnel Formwork System is

crane dependent, determination of type and capacity of

the crane is very important.

During assembly and operation, tunnel

formworks, outside wallforms, stripping and landing

platforms, gable end frames, kicker forms, stopends and

boxouts are lifted and transferred by crane.

Crane Type

During the assembly, the crane

must be on service for 2-4 hours per day.

Daily time schedule of the crane should

be determined in order to plan and

organize the assembly precedure.

Crane could be mobile or telescopic type or a

tower crane. In order to determine the crane type, below

parameters are taken into consideration;

o Site plan

Positions of the buildings to be constructed by

tunnel formwork system will affect the type of the

crane.

o Site conditions

Geographic condition of the whole area is an

important factor directing the determination of

type of crane.

o Type of the buildings

Size and shape of the building in plan directly

determine the type and capacitiy of the crane as

well as the height or the number of levels.

o Climatic and meteorological conditions

Comperatively low or high temperature, wind,

rain and snow will affect the capacity and type of

the crane to be selected also.

Time Schedule

Crane Capacity

The heaviest of the load at the farthest location

will determine the required capacity.

In order to identify the critical load;

o Set the Position of the crane on tunnel formwork

layout

o Draw the range of the crane

o Evaluate the weight of tunnel formwork at the

farthest location

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�� Lifting Equipments



Assembly Device cannot be used for lifting and carrying the Tunnel Formwork.

Allowable working load to be applied on the Assembly Device is 1,000 kg.

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Max. Load = 1,000 kg.

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Max. Allowable Load = 4,000 kg. Before each lifting operation, ensure that the Wing Nut of the Lifting Triangle is fastened tightly. Ensure that the Tunnel Formworks are not pulled onto the Stripping Platform by using the Lifting Triangle. Avoid to apply only vertical forces to the Bearing Rod but not horizontal forces. Weekly check the Bearing Rod against any damage or fracture on the surface.�

LIFTING EQUIPMENTS�

Assembly Device

Lifting Triangle

This apparatus is supplied only to protect

the usage of Lifting Triangle out of purpose.

Such usage is generally realised during

the assembling of Tunnel Formworks.

�� Tunnel Formworks are set up onto their

positions by this apparatus so that it is installed at

the hook of the crane.

Maximum allowable load applied on the

Lifting Triangle is 4,000 kg. and maximum service

life of Lifting Triangle is 250 times.

Clean the Bearing Rod by using thinner or

diesel oil with a brush weekly.

It will be not allowed to crash or swing the

Tunnels during lifting operation.

All feedbacks about the Lifting Triangle

could be done by using the Serial Number written

on the product.

The Bearing rod must be removed and replaced with the new one

If;

� It is bended or wrapped. � It’s screws are corroded. � The service life of 250 times is

completed.

�� Tools and Consumables



For Tunnel Formwork Crew�

TOOLS and CONSUMABLES�

Wlding Electrode Rutile 3.25

Steel Wire Brush

Spiral Cutter Disk

Spiral Grinder Disk

Formwork Oil

Rubber Grease

Powder Coat

TOOLS given by MESA

Socket Wrench 13 (1/2)






Hexagon Key Wrench 14

Ratchet for Jack Ø38 (31K-20")

Ratchet 1/2" w/LOCK

Ratchet Arm 5" (1/2)

2-Ended Open Jaw Spanner 19-22



Punch Ø16

Punch Ø20

Punch Ø27

Punch Ø35

Hammer (1.5 kg)

Magnetic Plumb

Chalk Line

Steel Tape (5 metre)

Metal Marker

Deck Panel Wrench

Back Panel Wrench

Punch to Remove Cones

Punch to Remove Dilatation Cones

Spatula

Lever

TOOLS to be provided by SITE

Welding Machine 400 A

Grinding Machine

Hand Drill

Club Hammer 5 kg

Ladder 200 cm.

Adze

Screw Driver

Plier

Welding Equipments (Holder,Mask and Cable)

Oiling Swab

Main tools for assembly and operation already exist in the Tool-Box supplied by MESA. Content of this Tool-Box are

listed in the section of “Complementary Equipments” on the Buuklet of “Technical Manual” given by MESA.

Additionaly, table at right shows the extra tools to be needed. These tools will be supplied by Site.

Tools

Consumables

�� Tools and Consumables



For Concreting Crew�

For Rebar Crew�

Miscellaneous Tools

Converet w/2-output

Needle Vibrator

Needle Vibrator

Trowel

Wheelbarrow

Hoe

Protective Glove

Rubber Glove

Protective Boiler Suit

Boiler Suit

Safety Clothes (Raincoat, Helmet vs.)

Single-Sling with Hook 100 cm. 16 mm.

Quatro-Sling with Hook 400 cm. 14 mm.

Chain Sling 12 mm.

Eye Bolt for Chain Sling 12 mm.

Extension Cord 380 V.

Extension Cord 220 V.

Miscellaneous Wall Box

Roller type Extension Cord 380-220 V

Wood Power Saw

Oxygen Cutting (Set)

Rotary Hammer Drill

LPG

Tie Wire

Concrete Cover for wall 8-14/20

Concrete Cover for slab Round

Lateral Reinforcement Lever

Iron-bending Wrench 14 mm.



Iron Cutter 75 cm.

Cutting Pliers 280 mm.

Wire Mesh-bending Wrench 3 mt.

Tools

Consumables

Tools

Consumables

�� Before Arrival of MESA-Supervisor



Check all drawings, plans and details for formwork application and ensure that they were prepared and revised according to the valid statical construction drawings.�

Maximum weight of the packages is approximately 2,500 kg.

Pallets and packages supplied by MESA should not be opened until arrival of MESA-Supervisor.

It is requested to place the request for technical assistance at least two weeks before the desired date.

The surface of the panels and other surfaces which are facing concrete are coated with a thin film of protective oil. It will be removed by using a solvent before concreting.

BEFORE ARRIVAL of MESA-SUPERVISOR�

MESA will give all necessary drawings for both

assembly and operation purposes. These are listed in the

section of “Technical Drawings” of this booklet.

Make ready the drawings of sanitary installation

and electric conduits which will be necessary during

Tunnel Formwork application. Boxouts required for these

installation will be fixed on formworks.

Drawings, Layouts and Details

Materials and Equipments

Site Conditions

In order to get the maximum benefit from the period of assistance and instruction, one must avoid time losses caused by

late preparation of necessary arguments explained below.

Check all of the materials and quantities

comparing with the documents supplied by MESA.

Debar all materials from any exterior damages

caused by climatic conditions, steal or any other

influences.

Make ready the required tools and equipments

which are necessary for assembling precedure.

Prepare the assembly area as described in the

section of “Preperation for Assembly” of this booklet.

Make ready the crane to be needed for assembly.

Clarify and prepare the assembly crew.

�� Preperation for Assembly



If the foundation is ready, all of the equipments could be placed directly to their own locations where they will be used for the first time.

Assembly Area should not be out of range of the crane.

Ensure that all requirements explained in the Section of “Before Arrival of MESA-Supervisor” on this Booklet are provided.

Do not stack too many packages onto each other.

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If the material will remain in the stack area for a relatively long period of time, it is advised that to protect the formworks from bad weather conditions.

Assembly of Gable end-frames, Stripping and Landing Platforms given wtih the Set of TRTF-Tunnel Formwork System are described in relevant Booklets given by MESA.

PREPERATION for ASSEMBLY �

Assembly Area

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Size of the Assembly Area should be 300 m2 at

least, leaving 2/3 of this as empty for working and the rest

for stacking the material.

The stacks should be separated from each other,

each stack containing only one type of material like

panels, platforms, accessory boxes, timber for platforms,

etc.

The assembly area should be located close to

the foundation or slab where the forms will be used for the

first time.

The ground should be relatively smooth and be

on level.

Use timber blocks between the packages in

order to avoid dents and scratches.

Figure below shows the typical assembly area.

�� Preperation for Assembly



ASSEMBLY CREW

5-6 persons for assembling of - Tunnel Formworks, - Outside Wallforms - Stripping Platforms - Gable end Frames and - Landing Platforms

3-4 persons for assembling of - Timbers on Platforms - First Kicker Forms on their locations

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All of the persons in the Assembly Crew should have been educated on necessary safety regulations.

Crew for Assembly

It is recommended that the Crew who will work

on the operation of Tunnel Formwork should work on

assembling procedure also. This will increase the

motivation and efficiency of those while working on

Tunnel Formwork operations.

In the leadership of Mesa-Supervisor, a crew

consisted of 8-10 persons totally will be sufficient for all

assembling period.

�� Assembly of Tunnel Formwork Set



Assembly of Tunnel Formwork will be realised with the connection components described and listed on the Section of “Permanent Connections” on the Booklet “TRTF-Technical Manual” given by MESA.

Before starting the assembly procedure, ensure that all connectors and necessary equipments are provided.

Ensure that all safety precautions were taken properly on site.

Use Tunnel Assembly Charts given by MESA in order to check the Assembly codes of Panels and other components with the number of Tunnel which will be set off with these elements.

There must be one free hole between each U Alignment-45.

There should be M14x80 bolts&nuts at the holes on the foremost positions of both ends of the UPF profile as shown in details “a” and “b”.

Ensure that there is no any difference at junction points of two Panels.

Connections realised by using Bolt& Nut sets will require at least two washers having proper sizes.

ASSEMBLY of TUNNEL FORMWORK SET�

Locate Deck Panel on two timbers so that the

steel surface is below as shown in the figure.

Connect U Alignments-45 with M14x30 bolt&nut

to the edge from which the other Deck Panel will be

connected.

Connection of Deck Panels

Close the second Deck Panel to the first and

insert U Alignments-45 previously installed to the first

panel into the UPF profile of the second panel.

Match the holes on both panels and connect

them with M14x80 bolt&nuts through free holes on the first

panel.

Detail b Detail a

Drill the Lifting Hole of the Tunnel in accordance

with the dimensions given in the Tunnel Assembly Chart.

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Ensure that Lifting hole of the Tunnel (Ø35mm) was drilled on Deck Panel properly.

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Check the assembly code of the Lifting Beam by comparing it with the code written in Tunnel Assembly Chart.

Connection of Lifting Beam�

a

Locate the Lifting Beam on Deck Panel at the

same line of the lifting hole previously drilled.

By using M6x160 bolt&nut, install the Lifting

Beam to the Deck Panel through the Lifting Beam NPL

and Lifting Beam Socket.

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Detail a

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Connection of Inside Panels�

Locate Inside Panel on two timbers so that the

steel surface is below as shown in the figure.

Close the second Inside Panel to the first and

insert U Alignments-45 previously installed to the first

panel into the UPF profile of the second panel.



panel.


to the edge from which the other Inside Panel will be

connected.

Detail a

Detail b

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Ensure that the connected side of the Inclined Props are the side which has a screw and bearing boss.�

The standard adjustment of the screw should be 67 mm for standard Deck Panels.�

c

d Detail c

Detail d

Two pieces of U Alignment-89 are fitted to inner

surfaces of Mid Stiffeners of Inside Panels with 4 sets of

M14x80 bolt&nut as shown in “Detail c”.

One piece of U Alignment-109 is fitted to inner

surface of Undermost Stiffeners of Inside Panels with 2

sets of M14x30 bolt&nut as shown in “Detail d”.

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Connection of Inclined Props�

Detail a

a

67mm

Connect sufficient quantity of Inclined Props to

Inside Panels with M14x80 bolt&nut through the bearing

boss as shown in “Detail a”.




Use Wheeled Prop Slots on the Deck Panels to lift them.�

Use wooden wedge while hammering the Deck Panel. Otherwise, steel sheet on concrete surface would be damaged.

Ensure that the alignment is satisfied in both direction. Check the screw holes on Inside Panels and U Alignments-75 on Deck Panels are also be aligned.�

M14x80 bot&nut in connection of Inclined Prop and Deck Panel should not be tightened.

Alignment error on all junction points of Panels should not be allowed.

Connection of Inside and Deck Panels�

a

b

Detail b

Detail a Lift previously assembled

Deck Panel Set and drawn it up the

Inside Panel Set

Connect the uppermost heads

of Inclined Props to slots on Deck

Panels with M14x80 bolts&nuts as

shown in “Detail a”.

Insert U Alignments-65 which is welded at the inner face of U-

turn of Deck Panels into uppermost UPF profile of Inside Panels.

For being in alignment, hammer Deck Panels properly as

show in “Detail b”.

$�"��%3'�

Fit the Inside Panels and Deck Panels through U-Alignments-

65 and tighten M14x50 bolts&nuts as shown in “Detail b”.




Ensure that; If the length of Tunnel is 2500, Wheeled Prop Support is connected to the relevant slot alone (Detail a). If the length of Tunnel is 1250, Wheeled Prop Support is connected to the relevant slot together with Inclined Prop also (Detail b).

Assembly codes and shapes of the Wheeled Prop Supports are different and they must not be confused with each other.

a

b

Detail a Detail b

L = 2500 mm

L = 1250 mm

e

Detail e

d

Detail d

Connection of Wheeled Prop and Wheeled Prop Support�

Connect Proper Wheeled Prop

Supports to the slots located on Inside

Panels with M14x80 bolt&nut as shown in

“Details a & b”.

c

Detail c

Loosely fit the Wheeled Prop to

the slots located on Deck Panels by using

M14x80 bolt&nut as shown in “Details c”.

Join the slots on Wheeled Prop

and Wheeled Prop Supports and loosely

fit the M18x150 bolt&nut as shown in

“Detail d”.

If this assembled Tunnel

Formwork Set will be located at the right

side according to the formwork layout ;

Insert Key Locks to the Key Lock Bolts

wlded on the edges of Deck Panels and

loosely fit them with M18 nuts & washers

as shown in “Detail e”.

For the Tunnel Formwork which

will be located at the left side on formwork

layout;

Insert only M18 nuts&washers to the Key

Lock Bolts welded on Deck Panels.




Provide the angle between Inside and Deck Panels as 90° before the installation of Back Panel.�


There should be M14x80 bolts&nuts at the holes on the foremost positions of both ends of the UPF profile at the corner as shown in “Corner Detail”.

Ensure that there is no any difference at junction points of three panels.

�

Installation of Back Panel Wheel to the Back Panel should be completed.

Use wooden wedge while hammering the Back Panel. Otherwise, steel sheet on concrete surface would be damaged.

Connection of Back Panel�

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to the edges of Deck and Inside Panels from which Back

Panel will be connected as shown in “Detail a & b”

respectively. ��$�"��%&'��

a

b

Detail a

Detail b

Close Back Panel to Tunnel Formwork Set and

insert U Alignments-45 previously installed to Inside and

Deck Panels into the UPF profile of U-turn on Back Panel.

For being in alignment, hammer Back Panel

properly.

Corner Detail

Match the holes on all three panels and connect

them with M14x80 bolt&nuts through free holes on Back

panel.

c If this assembled Tunnel Formwork Set will be

located at the right side as in the sample shown in the

figure ;

Insert Key Locks to the Key Lock Bolts wlded on the edges

of Back Panels and loosely fit them with M18 nuts &

washers as shown in “Detail c”.

For the Tunnel Formwork which will be located at

the left side on formwork layout;

Insert only M18 nuts&washers to the Key Lock Bolts

welded on Back Panels.

Detail c




Check if there is any crack or bend on the Lifting Rod of Assembly Device.

�

Cracked, damaged or bended Lifting Rod must not be used in anyway.

Ensure that all connections are fitted properly.

�

For safety and security, check the stability of Tunnel Formwork and take precautions especially in windy conditions.

Upholding the Tunnel Formwork Set�

a

Detail a

As shown in “Detail a”, pass the Lifting Rod of

Assembly Device through the Lifting Hole previously drilled

on Deck Panel in dimensions given in Assembly Chart of

the Tunnel Formwork.

Screw the Lifting Nut tightly .

Lift the Tunnel Formwork by turning it so that it

will be on the wheels and wheeled props.

��

��.��

Loosen the Lifting Nut and take away the

Assembly Device.




Marking could be done by using any of three pre-holes located on the Stop-end Slides.

�

Holes to be drilled could not overlap 50x60 tube sections on Panels.

Assembly of Stop-ends�

Detail b

Detail a

a

b

Mark the position of Wall stop-end in accordance

with the wall length in the construction drawing.

Drill Ø16mm holes at the same level of Stop-end

Slides so that the holes should be between two adjacent

50x60mm tube sections welded on the Inside Panel sheet.

Install Wall Stop-end by fitting M14x50 bolt&nut

through the hole on the Stop-end Slide and the hole on the

Inside Panel.

��%��

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��%��

Samely, mark the position of Slab stop-end in

accordance with the slab length in the construction

drawing.

Drill Ø16mm holes through any of the holes

located on the Wall Stop-end Slides so that the holes

should not overlap 50x60 mm tube sections welded on the

Deck Panel sheet.

Install Slab Stop-end by fitting M14x50 bolt&nut

through the hole on the Stop-end Slide and the hole on the

Deck Panel.




For the first case of Formwork Setting, Boxouts are transferred with Tunnel Formworks.

Ensure that the Boxouts are stocked horizontally.

Assembly of Boxouts�

Mark the position of Wall Boxouts in accordance

with the wall length in the construction drawing.

Drill Ø20mm holes on the Vertical Panel through

the holes on the slides of Boxout so that the holes should

be between two adjacent 50x60mm tube sections welded

on the Vertical Panel sheet.

Weld a Boxout Nut in the inner surface of UPF

slide on the Boxout.

Install Boxout to the Vertical Panel by using

Boxout Bolt through the Boxout Nut welded on the Boxout

Slide.

b

Detail a

a

Detail b

�� Assembly of Outside Wallform Set



ASSEMBLY of OUTSIDE WALLFORM SET�

Connection of Working Platform And Guardrails�

Make ready all necessary componets and

connectors for assembly.

Lay down the Outside Panel on two timbers so

that the steel surface is below as shown in the figure.

Connect each of Platform Support to the Panel

with one set of M14x80 bolt&nut (Detail a).

Connect each Platform Connector to the Panel

with two sets of M14x30 bolt&nut (Detail b).

Detail c

b

a

Detail a Detail b

Detail d

c

d

Install Working Platform and make connection

between it and each Platform Support with two sets of

M14x30 bolt&nut.

For Outside Panels whose length L is 2500 mm,

connect each of Platform Support to the Guardrail Post

with two sets of M14x80 bolt&nut (Detail c).

�

For Outside Panels whose length L is 1250 mm,

introduce Guardrail Connectors by connecting them to the

Working Platform with two sets of M14x30 bolt&nut. Then

connect each Guradrail Post to the Guardrail Connector

with two sets of M14x80 bolt&nut.

Make each connection between Platform

connectors and Working Platform with two sets of M14x30

bolt&nut (Detail d).




Connection of Panel Supports and Ladder�

Detail h Detail j

Detail e Detail f

e

f

h

j

Detail g

g

Install Panel Supports to the Panel and make

connection between each Support and the Panel with two

sets of M14x30 bolt&nut (Detail e) and one set of M14x80

bolt&nut (Detail f).

If the assembly contains a ladder set, then

connect the ladder to the Working Platform with two sets

of M14x30 bolt&nut (Detail g).

Ladder is fixed to the Panel with a Ladder

Connector. Installation is done by using one set of

M14x100 bolt&nut (Detail h) and one set of M14x80

bolt&nut (Detail j).

�







Connection of Outside WallForms�

As shown in “Detail a - �”, connect U Alignments-

45 with M14x30 bolt&nut to the edge from which the other

Outside Panel will be connected.

As shown in “Detail a - ��”, close the second

Outside Panel to the first and insert U Alignments-45

previously mounted to the first panel into the UPF profile of

the second panel.



panel.

a

Detail a - � Detail a - ��

d

c b


surfaces of Uppermost Stiffeners of two Outside Panels

with 4 sets of M14x80 bolt&nut as shown in “Detail b”.

Two pieces of U Alignment-89 are fitted to inner

surfaces of Mid Stiffeners of two Outside Panels with 4

sets of M14x80 bolt&nut as shown in “Detail c”.


surface of Undermost Stiffeners of two Outside Panels

with 2 sets of M14x30 bolt&nut as shown in the “Detail d”.

$�"��%'1�

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Detail b

Detail c

Detail d




The angle “�” between two ropes should not be greater than 60°.

At winddy conditions ( wind speed is geater than 72 km/h), Outside Wallform Sets must be stacked in horizontal position.

Upholding the Outside WallForm Set�

Pass the Crane Ropes (or hooks) through the

Lifting Hooks welded on the Outside Panels properly. �

��(/�

Lift the Outside Wallform Set and locate it in

vertical position.

If the Outside Wallform Set will be stacked in

vertical position, then lower the jacks on the Panels

Supports so that the Set will be inclined.

�� Preperation for Operation



OPERATION CREW

Min.12 persons for - Removing - Cleaning - Oiling - Stripping - Setting and adjustment

of Formworks and Platforms.

Min.6 persons for - Rebar Working

Min.4 persons for - Plumbing - Installation of electrical conduits

Persons in the Operation Crew should have been educated on necessary safety regulations.

Valid structural construction drawings, boxout plans, detaied drawings of plumbing and electric conduits should be ready.

o Operation Crew should be ready.��

o Tunnel Formworks, Outside Wallforms, Platforms, Stopends, Kicker Forms and Platforms should be ready for operation.

�

o Tools and consumable materials should be ready.

�

o Crane should have been placed in right way. �

o Climatic conditions should allow to operation.

WD

Crew for Operation

PREPERATION for OPERATION�

Alignment of Tunnel Formworks

For a 200 m2 of construction area in plan (which

is approximately equivalent of 650 m2 total formwork

area), crew needed for proper operation is listed below;

Before Starting the Operation

As a summary, before starting the setting up the

Tunnel Formwork, rebar working, concreting, stripping

and erection operations, It is recommended to provide the

below necessities.

90°

HT

LP HP

WD: Deck Panel Width HT : Tunnel Height HP : Wheeled Prop Height LP : Prop Length

In order to adjust the alignment of a Tunnel

Formwork;

Firstly it is necessary to provide the

perpendicularity of Deck Panel and Inside Panel. This is

obtained by adjusting either the length of Inclined Prop or

the height of Wheeled Prop or both.

Secondly, it will be needed to adjust the reverse

deflection of Deck Panels, which is described below.




Alignment of a Half Tunnel

90° 90°

<90°

>90° <90°

After providing the right angle between Deck and

Inside Panels, increase or decrease the length of

Wheeled Prop to obtain the verticality of Inside Panel.

If Inside Panel is in vertical position then;

o If the angle between Deck and Inside Panel is

less than 90°, then increase both the length of Inclined

Prop and the height of Wheeled Prop properly.

o If the angle is greater than 90°, then decrease

both the length of Inclined Prop and the height of

Wheeled Prop properly.

If Deck Panel is in horizontal position then;

o If the angle between Deck and Inside Panel is

less than 90°, then increase the length of Inclined Prop

only.

o If the angle is greater than 90°, then decrease

the length of Inclined Prop only.

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Symbols Used




Reinforcement bars embedded on the slab must be in correct positions.

Ensure the surface of the foundation is smooth and clear.

�

Ensure the distance between Kicker Forms are correct.

Overlapping of Reinforcement Bars and the centerlines drawn could not be allowed.

It is recommenended that Preperation of Foundation should be realised in the daytime.

Maximum dimensional tolerance for kicker is ±3mm.

Preperation of Foundation

Before starting the casting of first kicer, provide

the flatness of the foundation.

Offset the main centerlines

and draw chalk line.

Oil the surfaces of Kicker

Forms with suitable Formwork

Separation Oil.

Connect straight kicker forms

by M14x50 bolt&nut.

Connect corner and �nner

kicker forms by Key Locks and M14

nuts.

Place and Install Kicker

Forms as given in the Kicker Plan.




On the corners; cones and clamps are located on all directions.

Ensure that, construction site is ready for concreting.

�

Concrete setting period changes with the weather conditions.

In order to prevent from

closing of Kicker forms to each other,

locate Tie-Rod Cones instead of

Kicker Spacers on each 1.25 metre

length.

Locate the Kicker Clamps

near to each Cones in order to prevent

from openings of Kicker forms to each

other

Realise the concreting

procedure properly.

Measure the starting and

ending points of wall boxouts and

locate concrete stoppers to each

ends.

Clean the construction site

form concrete particles and dust.

Wait for concrete setting

about 12 hours.

Firstly remove the clamps

and then concrete stopers from the

concrete by using lever.




<90° 90° 90° <90°

Check whether the kicker is cracked or damaged and the required kicker height is achieved.�

Uneven level on kicker is not allowed for next operations.

If kicker dimensions are out of tolerances, Tunnel Formworks will be located on inproper positions which will cause unwanted results on all of the levels to be constructed.

Secondly remove the straight

kicker forms and then inner and corner

kicker forms from the concrete by

using lever.

Realise the rebar working of

walls properly.

Lift and transfer the kicker

forms by uisng the holder on them.

Collect all other components

(i.e. clamps, stopers, bolts and nuts

etc.) on the boxes given by MESA.




Refer to Lifting Triangle operational conditions described in the Section “Lifting Equipments” of this Manual.�

Provide necessary tightness on the Lifting Beam Nut to avoid from unwanted bending of the Lifting Rod.�

Positions of Wall and Slab Stopends and Boxouts are defined on relevant drawings.�

Provide the vertical alignment of Wall Stopends.�

Cleannig and Oiling of Formworks

Marking the Boxouts and Stopends

Clean the surface of the Inside Panels from

“prefabricated Formwork Protective Oil” with suitable tools.

Oil the surfaces with the oil described in the

Section “Formwork Separator Oil” of this Manual.

Pass the Lifting Rod of the Lifting Triangle

through the Lifting Hole on the Deck Pannel.

Screw the Lifting Beam Nut from under the Lifting

Beam tightly.

Measure te distance from one end of the Tunnel

Formwork Set to the place where the Wall Stopend is

fixed.

Mark the vertical level for Stopend firstly.

Secondly, choose the most suitable hole located

on the slides of the Stopend where a Ø18mm hole will be

drilled on the Inside Panel.

�n a same manner, mark and drill te connection

holes for Slab Stopends and Wall Boxouts.

�� Daily Cycle



DAILY CYCLE�

Time Schedule

This time schedule is prepared for a Tunnel Formwork application which has a 450-500 m2 construction area for one

floor

o Concreting Phases for One Floor : 2

o Formwork area : 1/2 of a floor (650 m2 approx.)

o Platform area :1/1 of a floor (full set for one floor)

o Climatic Conditions :approx. 20 °C in day and approx., 5 °C at night

o Working Hours : from 06h to 18h

o Working Crew : 12 persons in theTunnel Crew

6 persons in the Rebar Crew

4 persons in the Plumbing Crew

5 persons in the Concrete Crew (might be from the Tunnel Crew)

Striking of Formwork

Removing the Curtains and the Heaters �

�(! �2! ��! �,! ��! ��! 9�#��!��(!��! ��! �)! ��! �(!

Removing the Kicker Forms �

�

�

Striking the Wall Boxouts �

No.s of Persons

)

�

�

�

�

�

�

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�

�

�

�

�

Back Propping

Lowering and Striking the Second Half Tunnel Sets

Cleaning and Oiling the Second Half Tunnel Sets

�2!

Wall Reinforcement of Next Phase

Installation of Plumbing/Electrical Conduits on Wall

Removing the Slab Boxouts

Lowering and Striking the First Half Tunnel Sets

Cleaning and Oiling the First Half Tunnel Sets

Removing the Slab Stopends

Uninstallation of the Wall Boxouts

Marking the Half Tunnel levels on Kicker

Striking the Outside Wallforms

Removing Tie-Rods

Loosening the Roof Keys

STRIKING

Removing the Cones

�� 4 �� 4 �� 4 �� 4 ��4�/

�� Daily Cycle



See details of each operations scheduled above on the following pages.

�

Time Schedules and capacity of crew explained above tables give only basic ideas to be applied during the operation, therefore it could not be used directly on site since there might be many of factors affecting the operation program.

Setting of Formwork�

Concreting Operation�

Curing

CONCRETING

Last Check before Concreting

Installation of Heaters

Closing the Tunnel Curtains

Concreting

No.s of Persons

(! 2! �! ,! ��! ��! ��! ��! �)! ��! �(! �2! 9�#��!��!

�

�

�

�

�� 4 �� 4 �� 4 �� 4 ��4�/

�� 4 �� 4 �� 4 �� 4 ��4�/

Slab Reinforcement (highest level)

Alignment of Half Tunnels

Moving the idle Gable Platforms

Moving the idle Landing Platforms

Installation of Kicker Spacers

Installation of Kicker Forms and Clamps

Tightening of Top Tie-Rods

Adjustment of Opposite Deflection

Moving the idle Stripping Platforms

Leveling the Second Half Tunnel Sets

Installation of Slab Boxouts

SETTING��! ��! �)!

�

�

)

�

(! 2! �! ,! ��!

�

�

�

Tightening of Bottom and Mid Tie-Rods

Cleaning and Oiling the Deck Panels

��!

Moving and Setting the Outside Wallforms

Slab Reinforcement (lowest level)

Installation of Plumbing/Electrical Conduits on Slab

Moving and Setting the First Half Tunnel Sets

Leveling the First Half Tunnel Sets

Installation of Tie-Rods and Cones

Carrying and Installation of Wall Boxouts

Moving and Setting the Second Half Tunnel Sets

Installation of Plumbing/Electrical Conduits on Wall

Tightening of Roof Keys

Installation of Slab Stopends

No.s of Persons

�

��! �(! �2! 9�#��!��!

�

�

�

)

�

�

�

�

�

�

�

�

�

�

�

�

�� Daily Cycle



Wire-mesh usage as the reinforcement bar is recommended.

Place the rebars on the slab whose span “g” is the smallest. �

Ensure that rebars are vertical and corners are properly installed.

Striking

Wall Reinforcement of Next Phase

Prepare the rebars on the area reserved for rebar-

workering.

Place the rebars properly.

Use tower crane to carry all the required rebars to

the slab where the tunnel formworks will be used to cast

the concrete on the next phase.

�(! �2! ��! �,! ��! ��! ��! ��!

�� Daily Cycle



Finish all lifting and carrying operations before striking the formworks since The Lifting Triangle will be installed to the Crane Hook.�

In order not to became dangerous during the carrying of Tunnel formworks, ensure that the Curtains are not swung.

LPG tubes must be securely closed and hoses must be separated form the Heaters.

Removing the Curtains and the Heaters�

Installation of Plumbing and Electrical Conduits on Walls �

Carry and distribute required materials and

equipments to the slab properly.

Open the Tunnel Curtains and fold them properly.

Remove LPG tubes (if exist) on the Stripping

Platforms.

Start the installation of plumbing and electrical

circuits on walls properly.

�(! �2! ��! �,! ��! ��! ��! ��!

�(! �2! ��! �,! ��! ��! ��! ��!

��

TRTF – Classic Tunnel Form System

��

Ensure that the Kickers arprovide necessary alignments.

Removing the Kicker Forms�

Remove Kicker Clamps

Remove Kicker Stopers

Loosen the nuts on the Roof

Keys which connect the Inner and

Corner Kicker Forms.

Remove the Kicker Forms

from the concrete by using lever.

Remove the Kicker Spacers

from the concrete by using lever.

Fill concrete to the clearance

Kicker Spacers.

Check the height of Kickers.

Collect all Spacers, Clamps and

Accessory Box.

43 ��www.mesaimalat.com.tr�

re smooth and .

es caused from

d Stopers on the

�(! �2! ��! �

Daily Cycle

,! ��! ��! ��! ��!

�� Daily Cycle



Keep the boxouts securely.

Removing the Slab Boxouts�

Removing the Slab Stopends�

If the boxout consist four parts, loosen the nuts

on the Roof Keys which connect these parts to eachother.

Remove each part from the concrete by using

lever respectively.

If the boxout consist only one

part, remove it from the concrete by

using lever.

Remove only Stopend Locks.

Collect all Locks for the next

concreting phase.

Connect the parts in order to

use the boxout in the next concreting

phase.

�(! �2! ��! �,! ��! ��! ��! ��!

�(! �2! ��! �,! ��! ��! ��! ��!

�� Daily Cycle



Separate the parts of Boxouts from each oher before carrying if lifting the whole set is not possible.

Do not remove the Roof Keys from Pannels. They should still be on the Pannels.

Removing the Wall Boxouts�

Loosening the Roof Keys�

Loosen and remove all Wall Boxout Bolts.

Collect all Bolts for the next concreting phase.

After stripping of Tunnel Formworks, Door

Boxouts will be drawn into the room by using lever and

they will be carry on the Stripping Platforms by manpower

in order to lift and trasfer them to the next concreting

phase.

On the Deck Pannels, by using Deck Pannel

Wrench, loosen all Roof Key Bolts located on the hook

side of them.

On the Back Pannels, by using Back Pannel

Wrench, loosen all Roof Key Bolts located on the hook

side of them.

Turn Roof Key Bolts so that two Pannels will

easily be separated from each other.

�(! �2! ��! �,! ��! ��! ��! ��!

�(! �2! ��! �,! ��! ��! ��! ��!

�� Daily Cycle



Refer to system section for application given by MESA to take the Jack Height “K”.

Ensure that Tie-Rods and Notched Nuts have been withdrawn towards the Half Tunnels on the connections of Wall Formwork and Half Tunnel Set.

Since 2010, Flange Nuts have been used instead of Notched Nuts.

Marking the Half Tunnel levels on Kicker�

Removing Tie-Rods�

Unscrew and remove the Wing Nuts.

From the other side, withdraw the Tie-rods and

Notched Nuts together.

Collect Tie-rod sets on the Vertical Panel

Stiffeners.

On the kickers where the Tunnel Formworks are

transferred for next concreting phase, mark the level which

is equal to the Jack Height “K” for bottom edge of Vertical

Panel.

�(! �2! ��! �,! ��! ��! ��! ��!

�(! �2! ��! �,! ��! ��! ��! ��!

�� Daily Cycle



Complete all lifting and carrying operations before striking the formworks since The Lifting Triangle will be installed to the Crane Hook.�

Ensure the stocking area is safe and smooth.

Angle between the Lifting Ropes “�” must not greater than 60°.�

If the Outside Wallform Set will be located vertically, it must be in inclined position as described in the Section “Assembly of Outside Wallform” in this Manual.�

Striking the Outside Wallforms�

Install the lifting rope to the Lifting Hooks welded

on the Outside Panels properly.

�

By unscrewing the bolts on the connections

between Outside Panels, separate the Outside Wallform

Sets from each other.

Ground the Outside Wallform Set properly.

Lay down the Outside Wallform Set properly.

�(! �2! ��! �,! ��! ��! ��! ��!

�� Daily Cycle



Refer to Lifting Triangle operational conditions described in the Section “Lifting Equipments” of this Manual.�

Ensure the surface of the Stripping Platform is so clean that it allows to drive the Half Tunnel easily.

Security Net of the Stripping Platform must be lowered.�

Since the Stripping and carrying operations of Half Tunnels are started and the Lifting Triangle is installed to the Crane Hook, ensure all other lifting operations which do not need the Crane should be completed.

Striking Operation should start with the Half Tunnel Set which was located on the place where concreting operation was started.�

Refer to the “User Manual” of Stripping Platform given by MESA.

Lowering and Striking the First Half Tunnel Sets�

Seperate Half Tunnel Sets

from each other by unscrewing the

bolts connected two Deck Panels and

two Inside Panels.

Lower the First Half Tunnel

Set located in a room by lowering the

Inside Panel Jacks until the Wheeled

Prop touches the slab.

Drive the First Half Tunnel

Set throughout the Stripping Platform

until the Lifting Hole appears.

Lifting Hole

Pass the Lifting Rod of the Lifting Triangle

through the Lifting Hole on the Deck Pannel.

Screw the Lifting Beam Nut from under the Lifting

Beam tightly.

�(! �2! ��! �,! ��! ��! ��! ��!

�� Daily Cycle



Longitudinal distance “L” between two adjacent props could not be greater than 1500 mm�

Make double Prop row, if the span “g” is greater than 4500mm.�

Cleaning and Oiling the First Half Tunnels�

Back Propping�

Clean the surface of the Inside Pannels from any

rust and concrete particles with spatula or suitable tools.



Since Propping will start just after the Stripping of

the Fist Half Tunnel Formwork Set, bring necessary

quantity of Adjustable Props inside the room

Install Adjustable Props properly.

Insert wooden wedges between the Prop and the

slab both on top and at the bottom.

L

g < 4500 mm g > 4500 mm

�(! �2! ��! �,! ��! ��! ��! ��!

�(! �2! ��! �,! ��! ��! ��! ��!

�� Daily Cycle



Comply with the descriptions and restrictions written in the Section “Lowering and Striking the First Half Tunnel Sets” of this Manual.

If lifting the whole set of boxout is not possible then separate the parts of Boxout from each oher before carrying.

Lowering and Striking the Second Half Tunnel Sets�

Cleaning and Oiling the Second Half Tunnels�

Striking the Wall Boxouts�

As in the Section “Lowering and Striking the First

Half Tunnel Sets”, seperate Half Tunnel Sets from each

other and lower the First Half Tunnel Set by lowering the

Inside Panel Jacks until the Wheeled Prop touches the

slab.

Drive the First Half Tunnel Set throughout the

Stripping Platform until the Lifting Hole appears.

Clean the surface of the Inside Pannels from any

rust and concrete particles with spatula or suitable tools.



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Lower the jacks under the boxouts.

Draw the boxout into the room by

using lever and carry on the Stripping

Platforms by manpower in order to lift and

trasfer them to the next concreting phase.

�� Daily Cycle



The side of the Cone which has small diameter must be on the Wall Fromwork side.�

Hammer the Cones by means of the “Punch to

Remove Cone” from the side where the diameter of the

cone is small.

Withdraw the cone from the othe side of the wall.

Collect and oil the cones.

Removing the Cones��(! �2! ��! �,! ��! ��! ��! ��!

��


��

The Half Tunnel Set is rcompletely and carry to the phase.

Ensure that there is enough spTunnel Set which has a Back Set will be located behind twhich has already set.

Comply with the operation rwind limits given by the CraManufacturer.�

Check the Tunnel Number isthat of the Half Tunnel SeFormwork Layout provided by

Before starting to carry the transferring of Gable End FStripping and Landing Paltfbe completed. Refer to “User Manual”s of platforms provided by MESA

Formwork Setting

Moving and Setting the First Ha

Carry the Half Tunnel Set and

place where it will be located on the

phase.

Unscrew the Lifting Nut and re

Triangle from the Half Tunnel.

Draw up the Half tunnel Set

touches the kicker.


ready to strip next concreting

pace for the Half k Panel if such a the Half Tunnel

rules, load and ane

s the same with et given in the y MESA.

Formworks, Frames and forms have to

those A.

alf Tunnel Sets

d leave it on the

next concreting

emove the Lifting

by lever until it

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Daily Cycle

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�� Daily Cycle



Check the Level by Levelling instrument.

�

At the rebar side, if Tie-Rod collides with rebar, cut that part of rebar properly.

Ensure that Tie-Rods did not go out of the Cones.

�

The side of the Cone which has small diameter must be on the Wall Formwork side.�

Make ready all components and spare parts for connections described in “TRTF-Technical Manual”.

Leveling the First Half Tunnel Sets�

Installation of Tie-Rods and Cones�

Adjust the bottom level of the Inside Panel with

Panel Jack so that the line marked on the Kicker will be

conisided with the bottom edgee of the Panel.

If there are two or more Half Tunnel sets to be

located longitudionally, connect them with proper bolts

explained in “TRTF-Technical Manual” provided by MESA.

Pass the Tie-Rod and Wing

Nut set through the tie-rod holes on

the Inside Panels.

Install Cones through the Tie-

Rods.

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�� Daily Cycle



Before carrying the First Half Tunnel Set of the adjoining room, ensure all necessary workings on this First Half Tunnel Set are completed properly.

Check if the dimensions of Boxouts is true.

�

Installation of Wall Boxouts�

Installation of Plumbing and Electrical Conduits on Wall�

Complete the plumbing connections and

installation of conduits box on the wall.

Carry the Wall Boxout as an assembly and

close to the place where it will be installed.

Draw up the Boxout by lever until it touches

the kicker.

Adjust the bottom level of the Boxout with

the Jack located at the bottom so that the connection

hole on it will coinside with the hole on the Inside

Panel.

From inside of the Half Tunnel, screw the

Boxout Bolt to connect it to the Inside Panel.

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�� Daily Cycle



Ensure that there is enough space for the Half Tunnel Set which has a Back Panel if such a Set will be located behind the Half Tunnel which has already set.

Check the Tunnel Number is the same with that of the Half Tunnel Set given in the Formwork Layout provided by MESA.

Check the Level by Levelling instrument.

�


Moving and Setting the Second Half Tunnel Sets�

Leveling the Second Half Tunnel Sets�

As in the Section “Moving and Setting the First

Half Tunnel Sets”, carry the Second Half Tunnel Set and

leave it on the place where it will be located on the next

concreting phase.

Pass the Tie-Rod and Wing Nut set through the

tie-rod holes on the Inside Panels.

Install Cones through the Tie-Rods.

As described in the “Leveling the First Half

Tunnel Sets”, adjust the bottom level of the Inside Panel

with Panel Jack so that the line marked on the Kicker will

be conisided with the bottom edgee of the Panel.

If there are two or more Half Tunnel sets to be

located longitudionally, connect them with proper bolts


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�� Daily Cycle



Ensure that all accessories, spare parts and components are already collected on accessory boxes and they are ready to transfer.

Check the space between two Stopends. This will also provide the checking the space between two Deck Panels.

Completing the Half Tunnel Setting (Total)�

Installation of Slab Stopends�

Carry the Half Tunnel Sets starting from the first

one to the second one for each room.

Repeat precedures explained on above pages.

After finishing the lifting and carrying operations

of Half Tunnel Sets, remove the Lifting Triangle from the

hook of crane.

Install Slab Stopend Lock between two adjacent

Stopends.

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�� Daily Cycle



Check the alignment of Deck Panels.

�

In some applications, Inside Panels could also be connected with each other by Roof Keys.

�

Equalize the level of Deck Panels so that the roof

Keys sould easily connect them.

Turn the Roof Key so that the sloteon it will locate

on the Key Bolt properly.

Tighten the nuts on the Key Bolts

Repeat the same procedure for Back Panels and

Outside Panels if exist.

Tightening the Roof Keys��! ��! ��! �)!�! ,! ��! ��!

��


��

The notch should be placedbetween two parts of th estiOtherwise after tightinf the will squeeze the stiffener.�

Do not use any tie-rods or ndamaged or rusty.�

Tightening of Bottom and Mid T

Cleaning and Oiling the Deck Pa

Pass the Tie-rod through the tie-

and Vertical Panels located at the other si

Screw the Notched Nut loos

touches to the stiffener.

Starting with Back Panels, screw

on the Tie-rod at the bottom tightly.

Screw the Wing Nut on the Tie-r

loosely.

Clean the surface of Deck Pann

and concrete particles with spatula or suit

Oil the surfaces with the oil

Section “Formwork Separator Oil” of this M


d in the space iffener. Wing Nut it

nuts which are

Tie-Rods�

anels�

rod Hole on Back

ide.

sely until it just

w the Wing Nuts

rod at the middle

nels from any rust

table tools.

described in the

Manual.

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Daily Cycle

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��

Slab Reinforcement (lowest leve

Installation of Plumbing anConduits on Slab�

Clean the surface of Deck

Pannels from any rust and concrete

particles with spatula or suitable tools.

Carry slab rebars and place

them onto the Deck Panels where the

spans “g” are smaller.

Oil the surfaces with the oil

described in the Section “Formwork

Separator Oil” of this Manual.

Place the concrete covers on

Deck Panels.

Proceed the slab rebar

working for the lowest level properly.

Carry all neceesary materials

onto the Deck Panels where the spans “g

Install the electrical condui

plumbings on the slab.


el)�

nd Electrical

and place them

” are smaller.

its and pipes,

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Daily Cycle

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Slab is now ready for installation of boxouts and kicker forms.

�

Comply with the operation rules, load and wind limits given by the Crane Manufacturer.�


Slab Reinforcement (highest level)�

Moving and Setting the Outside Wallforms�

Proceed the slab rebar working for the highest

level properly.

Carry the Outside Wallform Set and leave it on

the place where it will be located on the next concreting

phase.

Draw up the Outside Wallform Set by lever until it

touches the kicker.

Adjust the bottom level of the Outside Panel with

Panel Jack so that the line marked on the Kicker will

coniside with the bottom edgee of the Panel.

If there are two or more Outside Wallform Sets to

be located longitudionally, connect them with proper bolts


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�� Daily Cycle




Installation of Slab Boxouts�

Cut the rebars where the Boxouts will be placed.

Carry and install the Boxouts properly.

In order to fix the boxouts, pass the pins through

the hole on the Deck Panels.

Detail a

Detail a

Pass the Tie-rod already installed on Vertical

Panel located at the other side through the tie-rod Hole on

the Outside Panel.

Screw the Notched Nut loosely until it just

touches to the stiffener.

Screw the Wing Nut on the Tie-rod at the bottom

tightly and screw the Wing Nut on the Tie-rod at the middle

loosely.

��! ��! ��! �)!�! ,! ��! ��!

�� Daily Cycle



Before installation, Kicker Forms should be oiled properly.

�

Distance between the Klicker Spacers should not greater than 1250 mm.�

Observe that there are still some gaps between two adjacent Half Tunnels, because the top Tie-Rods are not tightened.�



Installation of Kicker Spacers�

Installation of Kicker Forms and Clamps�

Put Kicker Spacers (two sided) between two

adjacent Deck Panels so that the lugs at the bottom on

them should touch Deck and Inside Panels.

Between Outside Panels and Half Tunnels, use

Single Sided-Kicker Spacers.

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��


��

Kicker Forms now supporSpacers and Slab Stopends.

�

Check the Kicker Spacers are wheeled props do not touch to

Tightening of Top Tie-Rods�

Pass the top Tie-rod through th

the Vertical Panel located at the other side

Screw the Notched Nut loos

touches to the stiffener.Screw the Wing N

rod loosely.

Tighten the Wing Nuts on the m

Tighten the Wing Nuts on the top Tie-rod

Transfer all Kicker Forms and Kic

to the working area.

Put Corner Kicker Forms firstly.

Connect them with the Inner K

Roof Keys.

Join the Straight Kicker Forms

Corner Kicker forms by bolts described

“Assembly of Kicker Forms” of “TRTF-T

provided by MESA.


rted by Kicker

wll installed and o the slab.

e tie-rod Hole on

e.

sely until it just

Nut on the top Tie-

mid Tie-rod firstly.

secondly.

cker Clamps near

Kicker Forms with

s to the end of

d in the Section

Technical Manual”

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Daily Cycle

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�� Daily Cycle



x

y

z

z y

x

z y

x

1 2

3

1

4 3 2

6 5

1

3 2

1 3

4 5 6

2

<90°

>90°

90°

If desired alignment is not provided or failed

somehow after assembling of Half Tunnel Set, it will be

needed to adjust the alignment similarly.

If Deck Panel is in horizontal position, then;

o Start to adjust the length of Inclined Prop from

one end of Half Tunnel Set (from no.1 to no.6 as shown in

the figure).

If Inside Panel is in vertical position, then;

o Start to adjust the length of Inclined Prop and

the height of Wheeled Prop from one end of Half Tunnel

Set (from no.1 to no.6 as shown in the figure).

If the perpendicularity of Deck and Inside Panel

is already provided, then;

o Start to adjust the height of Wheeled Prop from

one end of Half Tunnel Set (from no.1 to no.6 as shown in

the figure).

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&��

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Alignment of Half Tunnels��! ��! ��! �)!�! ,! ��! ��!

�� Daily Cycle



<90° <90° >90° >90°

<90° >90° 90° 90°

90° <90° <90° 90°

90° 90° <90° >90°

d

g�

Experienced results are listed above. The measure of Opposite Deflection “d” differ by the slab thickness, site conditions and experience of the Operation Crew itself.

Check the kicker level of Inside Panel Jack is in proper position.

Provide required dimension of the Inside Panel height which touches the kicker.

Ensure Inside Panels are in vertical positions and the alignment of Deck Panel give required opposite deflections.

Site is now ready to concreting procedure with well aligned Formworks and well prepared working area.

Adjustment of Opposite Deflection�

Before concreting, it is necessary to change the

setting of perpendicular angle between Deck and Inside

Panels, so that the horizonrtal alignment of slab will be

obtained without being affected by dead load of concrete

itself.

Below formulae give satisfactory opposite

deflections “d” changing with the range of span “g”.

2100mm � g � 3900 mm � d = 2 mm 3900mm < g � 5700 mm � d = 4 mm 5700mm < g � d = 8-20 mm

Before starting the concreting, be sure that the

Wheeled Prop does not touch the slab.

Adjust the length of Inclined Prop and the height

of Wheeled Prop properly in such a way that the vertical

alignment of Inside Panels are satisfied.

Figures show different cases which requires

necessary adjustments.

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�� Daily Cycle



Refer to the “User Manual” of the Stripping Platform provided by MESA.

Refer to the “User Manual” of the Gable End Frame provided by MESA.

Moving the Idle Stripping Platforms�

Moving Idle Gable Platforms�

Transfer the Stripping platforms which are in idle

position to the places for next concreting phase.

Transfer the Gable End Frames which are in idle

position to the places for next concreting phase.

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�� Daily Cycle



Refer to the “User Manual” of the Landing Platform provided by MESA.

Moving the Idle Landing Platforms�

Transfer the Landing Platforms which are in idle

position to the upper level for next concreting phase.

Figure shows the Landing Platform which has

already reaised one level.

��! ��! �)! ��! �(! �2! 9�#��!��!

�� Daily Cycle



Comply with all safety regulations and conditions.�

Concreting

Last Check before Concreting�

Before starting the concreting procedure,

from Safety point of view;

o Check all Safety Nets of Stripping Platforms are

in vertical position.

o Check all access points between Stripping

Platforms and Gable-end Frames are securily

provided.

o Check Working Platforms on Outside Wall

Formworks provides necessary access and

safety.

o Check all timber products are in good condition.

from Technical point of view;

o Remove all unnecessary materials away from the

concreting area.

o Check all Wing Nuts are screwed tightly.

o Check all kicker form components are well

installed.

o Check all Slab and Wall stopends are fixed.

o Check the positions of boxouts are correct and

they are properly installed.

o Check the position of Concrete Distribution

Boom.

o Check the position of Concrete Pump.

��! ��! �)! ��! �(! �2! 9�#��!��!

�� Daily Cycle



Ensure that all safety requirements are provided.

Technical documents should be reviewed in the Section “Construction Materials” of this Manual.

Ensure that air leakage at the bottom is prevented.

Closing the Tunnel Curtains�

Installation of Heaters�

Carry the heaters and required componenets

near to the Tunnel Formworks.

Place them inside Tunnel Formworks and make

necessary installations.

Operate the Heaters properly.

Close all Tunnel Curtains and tie two parts.

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��


��

Comply with rules and condrate of placing of concrete ethe Section “Construction Mthis Manual.�

At junction points on slabs where the concrete will be completed on the next phase; pour concrete having a width of 1/5 of the span “g”.

�

Concreting�

Starting point for pouring the

concrete will be clarified according to

the below parameters;

o Concreting should start from

the inside walls (or core

walls) to the outside walls.

o The walls which have the

largest boxout areas have the

first priority.

Continue to place the concrete w

Trowel by means of Kicker Form

and Slab Boxouts.

o Concreting should start from

Tunnel Formwork will be transfe

next concreting phase.


ditions for the explained in Material” of

with slab.

ms, Slab Stopends

the area whose

erred firstly for the

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Daily Cycle

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�� Daily Cycle



Ensure that the hourly increase in temperature inside the room should not be greater than 20 °C.

Maximum inside temperature should be 70 °C.�

�

Take required precautions for different climatic conditions.�

�

Periodic checking of the Heaters during night against any unwanted situation and fire is strongly recommended.

Curing�

Curing could be continued all night long.

Check the fuel quantity periodically.

Provide required wetness of concrete.

��! ��! �)! ��! �(! �2! 9�#��!��!

�� Non-standard Applications



In some buildings, the floor height of a basement,

ground level or any storey could be greater than the typical

floor. Then it could be necessary to pour the walls in two

phase.

Then install the Special Tunnel Raising Units to

the Half Tunnle Sets and follow the instructions provided

by MESA.

In some buildings, some of the spans colud be so

great that it could be necessary to introduce Table Forms

between two adjacent Tunnel Formwork Sets.

Then install the Special Table forms supplied by

MESA and follow the instructions.

NON-STANDARD APPLICATIONS�

Storeys with higher floor height

Rooms with greater spans than Standards

� ��



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