ERTF User Man - Eng

ϭϮͬϮϬϭϬ hƐĞƌDĂŶƵĂů
0(6$(577)
0RGXODU7XQQH
HO)RUPZRUN6\VWH
HP

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
Asymmetrical Lifting Triangle 14
Tools and Consumables

For Tunnel Formwork Crew 15
For Concreting Crew 16
For Rebar Crew 16
Miscellaneous Tools 16
Before Arrival of MESA-Supervisor 17
Assembly
Preperation for Assembly
Assembly Area 18
Crew for Assembly 19
General Conditions 19
Assembly of Tunnel Formwork

Connection of Vertical Panel and Vertical Panel Extension 20
Connection of Deck Panel and Deck Panel Extension 22
Installation of Foldable Prop to Vertical Panel 23
Installation of Wheel Connector 23
Connection of Deck Panel and Vertical Panel 23
Installation of Foldable Prop to Deck Panel 24
Installation of Wheel Support to Vertical Panel and Wheel Connector 25
Installation of Tunnel Driving Wheel to Wheel Connector 25
Installation of Roof Keys to Deck Panel Extension 25
Installation of Vertical Panel Jack 26
Dimension and Alignment Check 26
Installation of Back Panel to Half Tunnel Formwork 27
Assembly of a Tunnel Formwork Set

Permanent Connection of Two Half Tunnels 29
Drilling of Lifting Hole on Deck Panel 31
Installation of Lifting Beam 32
Upholding the Tunnel Formwork Set 33
Assembly of Stop-ends 34
Assembly of Boxouts 35
Assembly of Outside Wallform Set
Connection of Vertical Panel and Vertical Panel Extension 36
Installation of Working Platform 37
Installation of Guardrail Post 38
Installation of Panel Support and Vertical Panel Jack 38
Installation of Ladder Support and Ladder 39
Connection of Outside Wallforms 40
Installation of Guardrail Timbers 41
Upholding the Outside Wallform Set 42
Operation
Preperation for Operation
Before Starting the Operation 43
Crew for Operation 43
Alignment of Tunnel Formworks 43
Preperation of Foundation 45
Cleaning and Oiling of Formworks 48
Marking the Boxouts and Stop-ends 48
Lifting the Tunnel Formwork Set 49
Daily Cycle
Time Schedule 50
Striking 52
Formwork Setting 63
Concreting 79
Non-Standard Applications 83

General Remarks Safety Remarks

• This “User Manual” contains information • During all set up procedure, loads must be
about MESA-Formwork & Scaffolding systems. It safely transferred.
describes setting up, utilisation, correction,
maintenance and loading data of these products and • During all construction phases, all components
systems, by helping to the site as a ‘Method and units must be safely stabilised.
Statement’.
• According to the formwork system choosen,
• MESA products could only be used according
admissible fresh concrete pressure must not be
to the Instruction or User Manuals, any Technical Details
exceeded. Such a case will cause to formwork
given in Documents provided by MESA.
overload and more deflection both on formwork and
• Due to avoid unwanted results such as concrete, even breakage and overload on tie-rods.
accidents and damage to health or material Maximum working load of tie-rods used must be
damages, Owners and Users of MESA products or checked.
Systems should comply the directions given by the
documents and data explained above. • Person who works on the system in all phases
(i.e. setting up, erection, concreting, dismantling and
• In the cases which require different deviations disassembly etc.) should be assure to have enough and
from these manuals, Owner or User of MESA products safe workplace.
or systems must check the evidence of the technical
solutions or supplementary instruction methods and • The formwork removal must be done after
procure revised static or dynamic calculations to MESA. the concrete has reached sufficient strength.
• Although these User Manual have to be read
before installation or any usage; in order to provide • Formwork removal must be done by using lever
all requirements of safety on site, user should take arms or other tools provided together with the formwork
necessary precautions according to the system but not the crane or any other devices which will
international safety regulations and local safety cause unwanted results.
rules.
• In order to keep the scaffolding, platform,
• Schematic illustrations on this manual give only formwork or other parts stable and safe, user should
basic rules to be applied during assembly, erection and check the conditions where the procedure occurs
dismantling, therefore it not complete from the safety during the formwork removal procedure.
point of view.
• Any small parts used in the system should be
• User should inspect and check the products
fixed in their place to avoid loosing or falling freely.
and systems before use. Materials not having
suitable conditions such as damaging and
• All connecting parts must be used properly
weakening due to rust, corrosion or wear, should be
to provide correct functioning of them. Selecting of
removed and reported to MESA immediately.
wrong part could cause leakage of the relevant
• Since combination of any material and products under loading.
component originated from other manufacturers with
MESA products may be dangerous for health and • All connections must be checked periodically.
property, they must not be combined with MESA Especially bolt and nut connections and pin connections
products. In such a case, customer should contact with should be controlled.
MESA.
• Enough number of Fire Extinguishers and
• Only the skilled persons educated any other necessary items against danger of fire
according to official documents of MESA are should be kept available where the formwork and
authorised to assemble, erect and dismantle of scaffolding systems need.
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.
ERTF-Modular Tunnel Formwork System
86(50$18$/²www.mesaimalat.com.tr

Operational Conditions Warranty Period

Instruction or User Manuals must be used Limited Warranty for two (2) years is
while Formwork assemblies, accessory attachements promissed by Mesa ømalat San.ve Tic. A.ù. for Steel
and concrete casting. Face Formworks and Slab Formworks unless the
Operational Conditions described above are violated.
It is not allowed to use hummer, sledgehummer,
cranka and vs that cause physical demage on Formworks, This warranty covers defects of steel material,
and also applications of extra welding, cutting and drilling welding and painting.
without permission of authorities.
For Hydraulic Cylinders and Hydraulic Power
It is not allowed to exceed the Max Concrete Units, the limited warranty period is one (1) year.
Pressure described in Technical or User Manuals.
Formwork should be used between + 40 °C and

– 30 °C.
Formworks should be cleaned after each Service Life

application to remove the concrete residues and
active faces should be lubricated with suitable
concrete/metal seperation oil. Steel Face Formworks and Slab Formworks,
produced by Mesa øMALAT San.ve Tic.A.ù., is good
After 250 applications, maintenance should be for 500 concrete castings unless The Operational
done at site. Conditions described below are violated.
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
• This Booklet is the complementary of
open areas by covering them with water resistant
“Technical Manual” prepared for MESA-ERTF
materials.
Modular Tunnel Formwork System and all
information written on these two booklets should be
Maitenance procedure should be repeated for
considered together.
each 250 usages after first 500 usages are exceeded.

• Users who will work with MESA-ERTF
Electrical power supply and connections must be
Modular Tunnel Formwork System and all types of
suitable as written in the ınstruction or User Manuals
MESA Platform and Scaffolding Systems should be
given by MESA.
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-ERTF Modular Tunnel Formwork System and
all types of MESA Platform and Scaffolding
Systems.

Symbols Used
Information
Important Note
Sight-Check
Warning
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
TECHNICAL DRAWINGS
Formwork Layouts
• Formwork Layouts prepared by MESA includes
the following information ;
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 and Wall Boxouts
o Setting Plan of Platforms
o Assembly Charts of Tunnel Formworks
Setting Plan of Tunnel Formworks
Formwork
Dimensions
Wall
Stopend
24 23
Slab 23 24
Stopend 27 28 31 32
22 21
21 22
Stripping
20 19
Direction
25 26 29 30 15 16
19 20
Back
Panel 18 9 10
17
7 8 13 14
17
18
Tunnel
1 2 3 4 3 4 1 2
Number
11 12
5 6
Outside
Wallform
ERTF – Modular Tunnel Formwork System

1
86(50$18$/² www.mesaimalat.com.tr
Technical Drawings
Assembly codes and Tie-rod Positions
S2+SA
U5
FL
V9L+VB
V9R+VA
V14R+VA
HBB
HB
H5
V14L+VA
HB
HB
H6 H4
S+SB
S+SA
U5
FR
V4+VB V4+VB
V13R+VA
V13L+VA
V+VA
V+VA
V+VB
S+SA S+SA V4+VA
HB
HB
HB
HB
H5 H5 H6 H4
U2 U2 H2 24 23
L5
HBB HB
HB HB
R5
H2 H2 23 24
HB
HB
HB
HB
H6 H4
V12R+VA
V12L+VA
V9R+VB
H5 H5
V+VA
V+VA
V+VA V4+VA
27 28 31 32
V+VA V+VA
H2 H2
22 21
L6
HB HB
HB HB
R6
21 22
V11R+VA
V11L+VA
H2 H2 V+VA
V+VA
V+VA
V+VA
HB
HB
HG
HG
H4 H2 H6 H4
HB
HB
V+VA V+VA H5 H5
V+VA V+VA
L8
H3 H3
20 19
HB HB
HB
HB
HB
HB
V10R+VA
V10L+VA
H5 H5 H6
HG
HG
H4 H2 H4
V+VA
V+VA
V+VA
HB HB
V+VA
25 26 29 30 15 16
19 20
R8
H3 H3
S+SB R15 L15 R12A ERA L13

V+VA V+VA
G
G11 G10
G
S+SA V2L+VA V1+VA L15 R15 L17 R13
U2 H2 H2
L6
18 9 10
V15L+VA
V15R+VA
V5R+VA
V5L+VA
V15R+VA
17
V15L+VA
UB HB HB 7 8 13 14
HG
HG
UB HB HB H4 H2
HB
HB
HB
HB
H5 H5 H6 H4
U3 H3 H3 17
R9
18
S+SA V2R+VA V3+VA
ER
V6R+VA
V6L+VA
EL
L10 R1
HB
HB
R3 L3 H5 H5
HG
HG
V+VA
V+VA
H4 H2
V+VA
V+VA
HB
HB
H6 H4
V4+VB
V4+VA
V4+VA
V4+VB
V+VA
V+VA
1 2 3 4 3 4 1 2
HB
HB
HF
HF
H1 H1 H3 H1
V7L+VA
V9R+VB
V7R+VA
11 12
S+SA
S+SA
V+VA
S+SB
S+SB
V+VA
UF
UF
U1 U1 5 6
HB
HB
H6 H4
HB
HB
H5 H5
V+VA
V+VA
HB
HB
H3 H1
S+SB
V8L+VA
V9L+VA
HB
HB
H6 H4
S1+SB
HB
HB
V9R+VA
V8R+VA
V9L+VB
H5 H5
Detail A
Detail A
Position of Tie-Rod and Cone

S+SA V2R+VA V
EL
Assembly Code of Back Panel R3 L3 L
Assembly Code of Inside Panel and Inside Panel Extension

V4+VB
V4+VA
V4+VA
V+VA
1 2
HF
HF
Assembly Code of Deck Panel H1 H1

S+SA
S+SA
S+SB
Assembly Code of Deck Panel Extension

UF
UF
U1 U1
V+VA
S+SB
Assembly Code of Outside Panel and Outside Panel Extension

2
Technical Drawings
Setting Plan of Kicker Forms
4A 4A
2A LA
24 23
CA
23 24
2A RA
27 28 31 32
2A LA
22 4A 4A
21
CA
21 22
2A RA
2A LA
4A 4A
20 19
EA
25 26 29 30 15 16
19 20
2A RA RA KA LA
8A 8A
3A LA LA KA RA
18 9 10
17
7 8 13 14
DA
17
18
3A RA 4A 4A
LA BA RA LA CA RA
2A 2A
1 2 3 4 3 4 1 2
11 12
5 6
1A 1A
2A 2A
4A 4A
Detail A
Detail A
3A
Assembly Code of Corner Kicker Form LA BA RA LA
Assembly Code of Inner Kicker Form

1 2
Assembly Code of Straight Kicker Form 1A 1A
2A

3
Technical Drawings
Setting Plan of Slab and Wall Stopends

P1 P1
P1
24 23
23 24
P1 27 28 31 32
22 21
21 22
P1
20 19
25 26 29 30 15 16
19 20
P1
18 9 10
17
7 8 13 14
17
18
1 2 3 4 3 4 1 2
11 12
5 6
P1
P1
Detail A Detail A
P1 P1
1 2
Assembly Code of Slab Stop-end
Assembly Code of Wall Stop-end P1
P1

4
Technical Drawings
Setting Plan of Lifting Beams
24 23
23 24
27 28 31 32
22 21
21 22
20 19
25 26 29 30 15 16
19 20
18 9 10
17
7 8 13 14
17
18
1 2 3 4 3 4 1 2
11 12
5 6
Detail A
Detail A
Rough Position of Lifting Beam
1 2
Assembly Code of Lifting Beam

5
Technical Drawings
Setting Plan of Slab and Wall Boxouts
24 23
23 24
235x90
235x90
27 28 31 32
22 21
21 22
235x90
235x90
20 19
245x116
245x116
25 26 29 30 15 16
19 20
235x90
235x90
235x110 235x110
235x100
235x100
18 9 10
17
7 8 13 14
235x90
235x90
17
18
235x180 235x180
Detail A
235x90
235x90
150x140
150x140
1 2 3 4 3 4 1 2
265x320
265x320
11 12
5 6
Detail A
Slab Boxout
245x116
25 26
235x100
Wall Boxout
7 8

6
Technical Drawings
Setting Plan of Platforms
GAL GAR
DT2 DT2
DT1
DT1
1
1A 1A S1 1A 1A
1
24 G1 23
A
A
23 24
1 1
27 28 31 32
1
S2 1
22 21
A
A
21 22
1 1
1 1
20 19
C
C
19
25
S3 26 29 30 15
S3 16 20
1 1
1 1
18 9 10
17
7 8 13 14
B
B
17
18
1 1
4 4 4 4
DT4
DT4
1 2 3 4 3 4 1 2
1 1 1 1
11 12
1 5 6 1 1 1
S1
G1
A4L A4R
A A
GR GL
Assembly Code of Assembly Code of Assembly Code of

Gable-end Frame Stripping Platform Landing Platform
GAL GAR
DT2
DT1
1
1A 1A S1 1A 1A
24 G1
A
23
1
27 28 31 32
1
S2
22
A
21
1

7
Technical Drawings
Assembly Charts of Tunnel Formworks
TUNNEL
Tunnel Number 3
1650
1450 200
Assembly Code of
Deck Panel
H3 HB
H3 HB
Assembly Code of
Deck Panel Extension L10
V+VA
Assembly Code of
2763
Back Panel
V+VA
Assembly Code of
Inside Panel
Assembly Code of
Inside Panel Extension
Tunnel Dimensions
TUNNEL WIDTH (mm) 1650
TUNNEL LENGHT (mm) 5093
ASSEMBLY CODE of FOLDABLE PROP TK
Assembly Code of ASSEMBLY CODE of WHEEL CONNECTOR YC2 MESAøMALAT
Main Connectors ASSEMBLY CODE of WHEEL SUPPORT DB2 SANAYøø VE
ASSEMBLY CODE of LIFTING BEAM A4 TøCARET A.ù.
TUNNEL NO : 3 WITHOUT WITH WITH WITH

CENTER OF GRAVITY WALL STOPEND SLAB STOPEND WALL STOPEND SLAB AND WALL STOPEND
POSITION of LIFTING HOLE

Position of Lifting Hole
TO END OF TUNNEL (mm) 2120 2149 2195 2222
TO VERTICAL PANEL (mm) 425 429 410 415
Weight TUNNEL WEIGHT (kg) 2114 2136 2172 2194

8
CONSTRUCTION MATERIALS
Concrete
Rate of Placing of Concrete
tİ ; total time for end of setting of concrete

(= 5 h)
γc ; density of fresh concrete (25 kN / m3)
σhk,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
As described in the booklet “ERTF-

Technical Manual”, hydrostatic pressure of
concrete applied on Panels should not be
greater then 63 kN/m2.
Fresh Concrete Pressure for ı hk,max = 63 kN/m2 • The table shows the rate of
Class of Consistency
ı hk,max (kN/m2) v (m/h) concrete placing for ERTF–
F1 Solid (5 Â v + 21) Â K 1 25 8.40 Modular Tunnel Formwork
System, according to the
F2 Semi-solid (10 Â v + 19) Â K 1 25 4.40
maximum allowable
F3 Rigid (14 Â v + 18) Â K 1 25 3.21 hydrostatic pressure (63
F4 Plastic (17 Â v + 17) Â K 1 25 2.71 kN/m2) ;
F5 Soft (30 Â v + 25) Â K 1 30 1.27
F6 Fluid (38 Â v + 25) Â K 1 30 1.00
SVB Self-Compacting (33 Â v + 25) Â K 1 30 1.15
Concrete Consumption
• 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

9
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.
Heating capacitiesof LPG-Heater and Radiant Burner are 15,000

and 28,500 kcal/hour respectively.
Take 1 set of LPG-Heater ļ

30 m3 and
>W'Ͳ,ĞĂƚĞƌ 1 set of Radiant Burner 60 m3. ļ
For heating a 100 m3 room;
100 / 30 = 3.3 ĺ
4 LPG-Heaters or
100 / 60 = 1.7 ĺ
2 Radiant-Burners are
required.
Refer to technical features of other types of Heaters or Burners

given by their own Manufacturers.
ZĂĚŝĂŶƚƵƌŶĞƌ ĨĨĞĐƚƐŽĨtĂƚĞƌŽŶƚĞŶƚŽŶƚŚĞ^ƚƌĞŶŐƚŚŽĨŽŶĐƌĞƚĞ
• Water-loss reduces the concrete

strength (10% water loss cause 40% concrete
ŽŶĐƌĞƚĞ^ƚƌĞŶŐƚŚй
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 ŚĂŶŐĞŽŶtĂƚĞƌŽŶƚĞŶƚй
the strength.

10
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.
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 sealing materials.
Formwork Protective Oil

ƉƉĞƌĞĂŶĐĞ ůŽƵĚǇ&ůƵŝĚ
• Formwork protective oil should be rust
ŽůŽƵƌ ƌŽǁŶ
preventive and should possess good water
displacement property. ĞŶƐŝƚǇ Ϭ͘ϴϯϱŬŐͬůŝƚƌĞ
&ůĂƐŚWŽŝŶƚ 40°ŵŝŶŝŵƵŵ
• Product codes of oils frequently preferred ŽǀĞƌĂŐĞ;ĂƉƉƌŽǆ͘Ϳ ϲϰ͘ϱŵϮͬůŝƚƌĞ
for protection of the concrete surfaces of panels &ŝůŵdŚŝĐŬŶĞƐƐ;ĂƉƉƌŽǆ͘Ϳ ϰ͘ϭŵŝĐƌŽŶƐ
are as follows;
&ŝůŵĞŶƐŝƚǇ;ĂƉƉƌŽǆ͘Ϳ ϯ͘ϴŐŵͬŵϮ
Castrol Rustilo DWX 32 ƌǇŝŶŐdŝŵĞĂƚϮϭΣ;ƚŽϵϱйƐŽůǀĞŶƚůŽƐƐͿ ϴϱŵŝŶ͘
Mobilarma 798 ^Ăůƚ^ƉƌĞǇdĞƐƚ;^dDďͲϭϭϳͿ ϱϳϲŚŽƵƌƐ;ĂƉƉƌŽǆ͘Ϳ
Protection period of the • Table gives the optimum characteristics of a formwork

protective oil (example is extracted from Castrol Rustilo DWX 32).
selected oil should be at
least;
6-9 months (for outdoor) By adding 20% crude oil to grease as a diluting agent, it
could be used as protective material for short period of
12-18 months (for indoor)
time under 3 months.
Formwork Separator Oil
• Formwork separation oil should provide ƉƉĞƌĞĂŶĐĞ DŝŶĞƌĂůĂƐĞĚ

easy release of the formwork from the concrete, ŽůŽƵƌ KŝůzĞůůŽǁ͕ĐůĞĂƌůŝƋƵŝĚ
long formwork life, decreasing on air-bubbles on
ĞŶƐŝƚǇ Ϭ͘ϴϱŬŐͬůŝƚƌĞ
the concrete surface. Concrete surface should be
W,ǀĂůƵĞ ϲͲϳ
clean and smooth.
&ůĂƐŚWŽŝŶƚ ŽǀĞƌϵϱ°
• Table gives the optimum characteristics of a formwork

• Product codes of oils frequently preferred
separation oil (example is extracted from YKS-Yapol).
for separation of the concrete surfaces from panels
are as follows;
Approximately 1 litre of separation oil could be used on
YKS-Yapol 25-40 m2 of formwork area according to the oil type
SIKA-Separol S3 choosen.

11
Crane
Max.Wind Speed for safe operating

• Since ERTF-Modular Tunnel Formwork System is
conditions should be taken as 40 km/h.
crane dependent, determination of type and capacity of
the crane is very important.
• During assembly and operation, tunnel Refer to the operating conditions for cranes
formworks, outside wallforms, stripping and landing given by its manufacturer.
platforms, gable end frames, kicker forms, stopends and
boxouts are lifted and transferred by crane.
Crane Type Crane Capacity
• Crane could be mobile or telescopic type or a

• The heaviest of the load at the farthest location
tower crane. In order to determine the crane type, below
will determine the required capacity.
parameters are taken into consideration;
o Site plan
• In order to identify the critical load;
Positions of the buildings to be constructed by
tunnel formwork system will affect the type of the
o Set the Position of the crane on tunnel formwork
crane.
layout
o Site conditions
o Draw the range of the crane
Geographic condition of the whole area is an
o Evaluate the weight of tunnel formwork at the
important factor directing the determination of
farthest location
type of crane.
o Type of the buildings
Size and shape of the building in plan directly Generally, a Tower Crane whose loading
determine the type and capacitiy of the crane as capacity is about 2,000 kg. at 45-50 metres of
well as the height or the number of levels. jib-length would be sufficient.
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.
ƌŝƚŝĐĂůŝƐƚĂŶĐĞƐ
;&ĂƌƚŚĞƐƚͿ
Time Schedule
ƌŝƚŝĐĂůdƵŶŶĞůƐ
;&ĂƌƚŚĞƐƚĂŶĚ,ĞĂǀŝĞƐƚͿ
• 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.
EĞĂƌĞƐƚdƵŶŶĞů
Location of the crane should
allow to lifting and stripping
operations of tunnel formworks
and other equipments partaking
on the construction area. ZĂŶŐĞŽĨŽŽŵ dŽǁĞƌƌĂŶĞ ZĂŶŐĞŽĨŽŽŵ

12
Lifting Equipments
LIFTING EQUIPMENTS
Assembly Device
Max. Load = 1,000 kg.
• 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.
Allowable working load to be applied on the Assembly Device cannot be used

Assembly Device is 1,000 kg.
for lifting and carrying the Tunnel
Formwork.
Lifting Triangle
ĞĂƌŝŶŐZŽĚ >ŝĨƚŝŶŐdƌŝĂŶŐůĞ
• 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
Before each lifting operation, ensure that
the Wing Nut of the Lifting Triangle is Max. Allowable Load = 4,000 kg.
fastened tightly.
The Bearing rod must be removed and
Ensure that the Tunnel Formworks are
replaced with the new one
not pulled onto the Stripping Platform by
using the Lifting Triangle. If;
Avoid to apply only vertical forces to the ¾ It is bended or wrapped.

Bearing Rod but not horizontal forces.
¾ It’s screws are corroded.
Weekly check the Bearing Rod against
any damage or fracture on the surface. ¾ The service life of 250 times is
completed.

13
Introduction Lifting Equipments
Asymmetrical Lifting Triangle
x The Asymetrical Lifting Triangle is designed so

that it can be set in place with the centre of gravity “LG” of
the Half Tunnel still inside the building by the help of its
asymmetrical shape. In this way the load of tunnels which
are moved on the rollers will not be taken by the Stripping
Platforms.
LTOT = Total Length of Half Tunnel Unit

LG = Dimension from Tunnel end to Axis of
Center of Gravity (equal to dimension from
Tunnel end to Axis of Crane Rope)
LLT = Dimension from Tunnel end to Axis of
Asymetrical Lifting Triangle Connection
x It is easier to handle and transport the

Asymetrical Lifting Triangle than the Classic Lifting
Triangle.
x Asymetrical Lifting Triangle will give the best

benefits when the timbers on Stripping Platforms are
mounted under-slab. Such a solution enables to use the
same platform at several floors with different slab finish
lines. For slabs with poor concrete finishing, assembly of
platform requires less workmanship since the timber
surface is inserted under the slab.
Platform timber under slab Stripping Half Tunnel
x Load Test of Asymetrical

LTOT
Lifting Triangle;
LG
Nominal load: 4000 kg.s LG > LLT
Test load : 6750 kg.s LLT
No permanent deformation has been
observed under 6750 kg.s.
x Test during operation:
Satisfactory results have been

obtained from a number of
accelerated tests applied to the
Bearing Rod under mock site
conditions.
Maximum usage of
the Bearing Rod
could not be greater
than 300 times .

14
USER MANUAL – 12/2010 www.mesaimalat.com.tr
TOOLS and CONSUMABLES

For Tunnel Formwork Crew
Tools
• 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.
ERTF - TOOLS given by MESA

Socket Wrench 13 (1/2)
TOOLS to be provided by SITE
Welding Machine 400 A
Grinding Machine
Hand Drill
Socket Wrench 27 (1/2) Club Hammer 5 kg
Hexagon Key Wrench 14 Ladder 200 cm.

Ratchet for Jack Ø38 (31K-20") Adze
Ratchet 1/2" w/LOCK Screw Driver
Ratchet Arm 5" (1/2) Plier
2-Ended Open Jaw Spanner 19-22 Welding Equipments (Holder,Mask and Cable)
2-Ended Open Jaw Spanner 22-24
Oiling Swab
2-Ended Open Jaw Spanner 27-30
Open Ended Slogging Spanner Ø 36
Drift Punch A350-5
Punch Ø16
Punch Ø20
Punch Ø27
Punch Ø35
Hammer (1.5 kg)
Magnetic Plumb Consumables
Chalk Line
Steel Tape (5 metre) Welding Electrode Rutile 3.25
Metal Marker Steel Wire Brush
Deck Panel Wrench Spiral Cutter Disk
Back Panel Wrench Spiral Grinder Disk
Punch to Remove Cones Formwork Oil
Punch to Remove Dilatation Cones Rubber Grease
Spatula Powder Coat
Lever Grease

15
For Concreting Crew
Tools Consumables
Converter w/2-output LPG

Needle Vibrator
Trowel
Wheelbarrow
Hoe
For Rebar Crew
Tools Consumables
Lateral Reinforcement Lever Tie Wire

Iron-bending Wrench 14 mm. Concrete Cover for wall 8-14/20
Iron-bending Wrench 16 mm. Concrete Cover for slab Round
Iron-bending Wrench 18 mm.
Iron Cutter 75 cm.
Cutting Pliers 280 mm.
Wire Mesh-bending Wrench 3 mt.
Miscellaneous Tools
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

16
Before Arrival of MESA-Supervisor
BEFORE ARRIVAL of MESA-SUPERVISOR

• 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.
It is requested to place the request for

technical assistance at least two weeks
before the desired date.
Drawings, Layouts and Details
• MESA will give all necessary drawings for both Check all drawings, plans and details for
assembly and operation purposes. These are listed in the formwork application and ensure that
section of “Technical Drawings” of this booklet. they were prepared and revised
according to the valid statical
• Make ready the drawings of sanitary installation construction drawings.
and electric conduits which will be necessary during
Tunnel Formwork application. Boxouts required for these
installation will be fixed on formworks.
Materials and Equipments
• Check all of the materials and quantities Pallets and packages supplied by
comparing with the documents supplied by MESA.
MESA should not be opened until
arrival of MESA-Supervisor.
• Debar all materials from any exterior damages
caused by climatic conditions, steal or any other
influences.
Maximum weight of the packages is
approximately 2,500 kg.
• Make ready the required tools and equipments
which are necessary for assembling precedure.
Site Conditions
• Prepare the assembly area as described in the

section of “Preperation for Assembly” of this booklet.
The surface of the panels and other
surfaces which are facing concrete are
• Make ready the crane to be needed for assembly.
coated with a thin film of protective oil. It
will be removed by using a solvent
• Clarify and prepare the assembly crew.
before concreting.

17
PREPERATION for ASSEMBLY
Assembly Area
Size of the Assembly Area should be 300 m2 at Ensure that all requirements explained in the
least, leaving 2/3 of this as empty for working and the rest Section of “Before Arrival of MESA-
for stacking the material. Supervisor” on this Booklet are provided.
The stacks should be separated from each other, Assembly Area should not be out of
each stack containing only one type of material like range of the crane.
panels, platforms, accessory boxes, timber for platforms,
etc.
Assembly period will be shorter if tower crane
The assembly area should be located close to is used instead of any type of mobile crane.
the foundation or slab where the forms will be used for the
first time.
Do not stack more than ten packages of
panels onto each other.
The ground should be relatively smooth and be
on level.

If the material will remain in the stack area for

Use timber blocks between the packages in
a relatively long period of time, it is advised
order to avoid dents and scratches.
that to protect the formworks from bad
weather conditions.
Figure below shows the typical assembly area.
Assembly of Gable end-frames, Stripping and

If the foundation is ready, all of the
Landing Platforms given wtih the Set of ERTF-
equipments could be placed directly to their
Tunnel Formwork System are described in
own locations where they will be used for the
relevant Booklets given by MESA.
first time.
WĂŶŶĞůƐ
KƚŚĞƌƋƵŝƉŵĞŶƚƐ
dŝŵďĞƌƐĂŶĚ
tŽŽĚĞŶDĂƚĞƌŝĂůƐ
ƐƐĞŵďůǇƌĞĂ
WƌŽƉƐĂŶĚ^ƵƉƉŽƌƚƐ

18
Crew for Assembly General Conditions
It is recommended that the Crew who will work Assembly of Tunnel Formwork will be realised
on the operation of Tunnel Formwork should work on with the connection components described
assembling procedure also. This will increase the and listed on the Section of “Permanent
motivation and efficiency of those while working on Connections” on the Booklet “ERTF-Technical
Tunnel Formwork operations. Manual” given by MESA.
In the leadership of Mesa-Supervisor, a crew

Before starting the assembly procedure,
consisted of 8-10 persons totally will be sufficient for all
ensure that all connectors and necessary
assembling period.
equipments are provided.
Use Tunnel Assembly Charts given by MESA

ASSEMBLY CREW in order to check the Assembly codes of
Panels and other components with the
number of Tunnel which will be set off with
5-6 persons for assembling of
these elements.
- Tunnel Formworks,
- Outside Wallforms
- Stripping Platforms
Ensure that all safety precautions were
- Gable end Frames and
taken properly on site.
- Landing Platforms
3-4 persons for assembling of

- Timbers on Platforms Connections realised by using Bolt& Nut sets
- First Kicker Forms on their locations will require at least two washers with proper
size.

All of the persons in the Assembly Crew

should have been educated on necessary
safety regulations.

19
Assembly of a Half Tunnel Formwork
ASSEMBLY of a HALF TUNNEL FORMWORK
Connection of Vertical Panel and

Vertical Panel Extension
Locate “Vertical Panel” on two

timbers so that the steel surface is below as
shown in the figure.
Draw up the “Vertical Panel

Extension” to the “Vertical Panel”.
By following the installation details as

shown in the next page, connect “U
Alignments-45” with “M14x50” to “Vertical
Panel edge” from which the “Vertical Panel
Extension” will be connected.
Since October 2010, U-

Alignments-45 are welded on the
Vertical Panels Extensions. hůŝŐŶŵĞŶƚͲϰϱ
Therefore M14x50 bolts&nuts are
no longer used.
Insert previously installed “U

Alignments-45” to “Vertical Panel” into the
UPF profile of “Vertical Panel Extension”.
Locate “U Alignments-45” properly by

using a hammer and wooden wedges.
Match the holes on both panels and

connect them with “M14x80 bolt&nuts”
through the holes on both ends by following
the installation details as shown in the next
page.
Since October 2010, M14x30 bolts

are used to connect Vertical Panel
and U-Alignment-45 welded on the
Vertical Panel Extension as shown
in the figure on the next page.
Check the alignment of steel

plates.

20
Connect the “Hinge Bolts” with

“M14x80 bolts&nuts” through the slots on
“Vertical Panel”.
Insert the “Nut for Hinge Bolt” to the

“Hinge Bolt”.
Turn and locate the “Hinge Bolt” to

the slot on the “Vertical Panel Extension”.
Complete the connection by following

the installation details as shown below.
Ensure that there is no any

difference at junction points of
two Panels.
Set the alignment of both Panels by

adjusting the “Nut for Hinge Bolt” with a gauge
rod.
Installation Details of Vertical Panel and Vertical Panel Extension
>сϭϮϱϬŵŵ
sĞƌƚŝĐĂůǆƚĞŶƐŝŽŶ
sĞƌƚŝĐĂůWĂŶĞů
DϭϰǆϯϬďŽůƚ DϭϰǆϴϬďŽůƚΘŶƵƚ hůŝŐŶŵĞŶƚʹϰϱ;ǁĞůĚĞĚŽŶsĞƌƚŝĐĂůǆƚĞŶƐŝŽŶͿ
sĞƌƚŝĐĂůǆƚĞŶƐŝŽŶ
sĞƌƚŝĐĂůWĂŶĞů
>сϮϱϬϬŵŵ

21
Connection of Deck Panel and

Deck Panel Extension
Locate “Deck Panel” on two timbers

so that the steel surface is below as shown in
the figure and draw up the “Deck Panel
Extension” to the “Deck Panel”.
Connect “U Alignments-45” with

“M14x50 bolts&nuts” to “Deck Panel edge”
from which the “Deck Panel Extension” will be
connected.
Insert “U Alignments-45” previously

installed to “Deck Panel” into the UPF profile
of “Vertical Panel Extension”.
Locate “U Alignments-45” properly by

using a hammer and wooden wedges.
Since October 2010, U-

Alignments-45 are welded on the
Deck Panels Extensions. M14x30
bolts are used to connect Vertical
Panel and U-Alignment-45 welded
on the Vertical Panel Extension as
shown in the figure below.
Connect the “Hinge Bolts” and insert

the “Nut for Hinge Bolt” to the “Hinge Bolt” as
described in the Section “Vertical Panel and
Vertical Extension”.
Set the alignment of both Panels by

adjusting the “Nut for Hinge Bolt” with a gauge
rod.
Installation Details of >сϭϮϱϬŵŵ

Deck Panel and ĞĐŬWĂŶĞů
Deck Panel Extension ǆƚĞŶƐŝŽŶ
ĞĐŬWĂŶĞů
DϭϰǆϯϬďŽůƚ hDϭϰǆϯϬďŽůƚΘŶƵƚ hůŝŐŶŵĞŶƚʹϰϱ

;ǁĞůĚĞĚͿ
ĞĐŬWĂŶĞů
ǆƚĞŶƐŝŽŶ
ĞĐŬWĂŶĞů
>сϮϱϬϬŵŵ

22
Installation of Foldable Prop to

Vertical Panel
Ensure that the side of the

“Foldable Prop” which is to be
connected is the side which has a
screw and bearing boss.
Connect sufficient quantity of

“Foldable Prop” to “Vertical Panel” by passing
M16x100 bolt&nut through the slot on the
Panel bearing boss of the Prop as shown in
the figure.
Installation of Wheel Connector
Assembly codes and shapes of

the “Wheel Connector”s are
different and they must not be
confused with each other.
Loosely fit the “Wheel Connector” to

the slots on “Vertical Panel” by using
M16x100 bolt&nut as shown in the figure.
Connection of Deck Panel and

Vertical Panel
By using a hammer and a wooden

wedge, insert “U Alignments-65” which is
welded at the inner face of U-turn of “Deck
Panels” into uppermost UPF profile of
“Vertical Panel Extension”.
Use wooden wedge while

hammering the “Deck Panel”.
Otherwise, steel sheet on
concrete surface would be
damaged.

23
Check the screw holes on

“Vertical Panels” and “U
Alignments-65” on “Deck Panels”
are also be aligned.
Fit “Vertical Panels” and “Deck

Panels” through “U-Alignments-65” and
tighten M14x50 bolts&nuts as shown in the
figure.
hůŝŐŶŵĞŶƚͲϲϱ
Ensure that the alignment is

satisfied in both direction.
Alignment error on all junction

points of Panels should not be
allowed.
Installation of Foldable Prop to

Deck Panel
Connect the uppermost heads of

“Foldable Props” to slots on “Deck Panels”
with M16x100 bolts&nuts as shown in the
figure.
M16x100 bolt&nut in the

connection of “Foldable Prop”
and “Deck Panel” should not
be tightened.
LJ
Adjust the inside tube length “LJ”

and fix it with Ø16x104 pin.
1 2 3
Adjust the Jack length “LK” (figure 1)
and fix this dimension with the “Lock Nut” on it
(figure 2 & 3).
LK
Refer to “Telescopic Foldable
Prop” in Section “Parts in Detail”
on “ERTF-Technical Manual” for
distances of “LK” and “LJ”.

24
Installation of Wheel Support to

Vertical Panel and Wheel Connector
Connect Proper “Wheel Support” to

the slots on “Vertical Panels” and “Wheel
Connector” with M16x100 bolt&nut as shown
in the figure.
Assembly codes and shapes of

the Wheel Supports are
different and they must not be
confused with each other.
Installation of Tunnel Driving Wheel

to Wheel Connector
Insert the “Tunnel Driving Wheel” to

the slot on the “Wheel Connector” and join it
to the “Wheel Connector” with 4 sets of
M16x30 bolt&nut as shown in figure.
Installation of Roof Keys

to Deck Panel Extension
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

welded on the edges of Deck Panel
Extension and loosely fit them with M18
nuts & washers as shown in figure.
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. hůŝŐŶŵĞŶƚͲϲϱ

25
Installation of Vertical Panel Jack
Insert the “Vertical Panel Jack” to the

“Vertical Panel” by matching the holes on
both.
Screw 2 sets of M14x30 bolt&nut as

sĞƌƚŝĐĂůWĂŶĞů:ĂĐŬ
Dimension and Alignment Check
Ensure that the alignment is

satisfied between “Deck Panel”
and “Deck Panel Extesion”.
Measure Tunnel Height “HT”.

t
Measure Tunnel Width “WD + WDE”.
t
Measure the diagonal distance and

adjust the Foldable Prop Length.
,d
Provide the angle between

“Vertical and Deck Panels” as 90°
before the installation of Back
Panel.
Next ; Connection of Back

Panel

26
Installation of Back Panel to

Half Tunnel Formwork
Insert “Back Panel Wheeled Jack” to

the “Back Panel” by matching the holes on
both. Screw 2 sets of M14x30 bolt&nut as
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
welded on the edges of Back Panels and
ĂĐŬWĂŶĞůtŚĞĞůĞĚ:ĂĐŬ ZŽŽĨ<ĞǇ
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.
Install U Alignments-45 to inside of

UPF profiles on the edge of “Vertical and
Deck Panels” where the “Back Panel” will be
connected.
Close Back Panel to Tunnel

Formwork Set and insert these U Alignments-
45 previously installed to “Vertical and Deck
Panels” into UPF profile of U-turn on “Back
Panel”.

three panels.
For being in alignment, hammer

Back Panel properly.
Use wooden wedge while

hammering the “Back Panel”.
Otherwise, steel sheet on
concrete surface would be
damaged.
Match the holes on all three panels
and connect them with M14x80 bolt&nuts
through free holes on “Back Panel”.
See the order of “Connectors” for

connections on the next page.


27
Installation Details of Back Panels and Deck Panels Installation Details of

Back Panels and Vertical Panels
Ă ď Đ
d
Ă
ϭ
Ϯ
ϯ
tнtсϭϬϰϵŵŵ
ď
,sсϮϱϬϬŵŵ
tнtсϭϯϰϵŵŵ
Đ
tнtсϭϲϰϵŵŵ
tнtсϭϵϰϵŵŵ
ϰ ϭ
Legend
tнtсϮϮϰϵŵŵ 1 – Back Panel

2 – Deck Panel Extension
3 – Deck Panel
4 – Vertical Panel
a – M14x80 bolt&nut
b – M14x50 bolt&nut
c – U Alignment-45
tнtсϮϱϰϵŵŵ
tнtсϮϴϰϵŵŵ

28
Assembly of Tunnel Formwork Set
ASSEMBLY of a TUNNEL FORMWORK SET

Permanent Connection of
Two Half Tunnels
Install U Alignments-45 to inside of

UPF profile on the edge of “Vertical and Deck
Panels” where the other “Half Tunnel” will be
connected.
Refer to “Installation Details of

Back Panels and Deck Panels” for
the connection of two “Deck
Panels”.
Refer to ““Installation Details of

Back Panels and Vertical Panels”
for the connection of two “Vertical ĞƚĂŝůĂ ĞƚĂŝůĂ
Panels”.
Close the other “Half Tunnel” to the

first “Half Tunnel” and insert these U
Alignments-45 previously installed to “Vertical
and Deck Panels” into UPF profile of that of
the other “Half Tunnel”.

three panels.
Match the holes on both panels and

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

29
Fit two pieces of U Alignment-89 to L – Lowermost Stiffener

inner surfaces of Mid Stiffeners of “Vertical M – Mid Stiffener
U – Uppermost Stiffener
Panels” with 2 sets of M14x80 bolt&nut.
Fit one piece of U Alignment-89 to

inner surfaces of Undermost Stiffeners of sŝĞǁ
“Vertical Panels” with 2 sets of M14x80
bolt&nut.
Fit one piece of U Alignment-89 to

inner surfaces of Lowermost Stiffeners of
h
bolt&nut. D
sŝĞǁ >
sŝĞǁ sŝĞǁ
>
h
D D
h
>
Next ; Drilling of Lifting Hole


30
Drilling of Lifting Hole on Deck Panel
Read the coordinates of Lifting

Hole from the Assembly Chart of
that Tunnel given by MESA.
Measure X-coordinate from the

surface of “Vertical Panel “.
Mark it on the surface of “Deck

Panel”.
Measure Y-coordinate from the

surface of “Vertical Panel” or the end of “Deck
Panel”.
Mark it on the surface of “Deck

Panel”.
Make clear the position of the Lifting 1 2 3

Hole (Figure 1).
Drill a hole with a diameter of 35mm

properly (Figure 2).
Use Ø35mm Punch supplied with

ERTF-Tool box.

Next ; Connection of Lifting

Beam

31
Installation of Lifting Beam
Ensure that Lifting hole of the

Tunnel (Ø35mm) was drilled on
Deck Panel properly.
By using M6x160 bolt&nut, install two

of “Lifting Beam NPL”s to the “Deck Panel”
>ŝĨƚŝŶŐĞĂŵEW>Ϯ
through only one Socket welded on “Deck
Panel”.
>ŝĨƚŝŶŐĞĂŵEW>ϭ
Locate the Lifting Beam on Deck

Panel at the same line of the lifting hole
previously drilled.
Screw other M6x160 bolt&nut sets to

fix “Lifting Beam NPL”s so that it will carry the
“Lifting Beam”.
Check the assembly code of the

Lifting Beam by comparing it with
the code written in Tunnel
Assembly Chart.
Next ; Upholding the Tunnel

Formwork Set

32
Upholding the Tunnel Formwork Set
Pass the “Lifting Rod” of “Assembly >ŝĨƚŝŶŐEƵƚ

Device” through the “Lifting Hole” previously
drilled on Deck Panel.
Screw the “Lifting Nut” tightly.
Cracked, damaged or bended

Lifting Rod must not be used in
anyway.
>ŝĨƚŝŶŐZŽĚ
Lift the Tunnel Formwork by turning it 1 2

so that it will be on “Tunnel Driving Device”
and “Vertical Panel Jacks”.
Loosen the “Lifting Nut” and take

away the “Assembly Device”.
Check the “Tunnel Number” by dƵŶŶĞůEƵŵďĞƌ

comparing it with the code written
in Tunnel Assembly Chart.
Put the “Label Plate” which describes

the “Tunnel Number” for setting operation.
Stock “Half Tunnel Sets” on the

Stocking area properly.
For safety and security, check the

stability of Tunnel Formwork and
take necessary precautions.

33
Assembly of Stop-ends
Mark the position of “Wall Stop-end” Detail a

in accordance with the wall length as in the
construction drawing.
Detail a
Drill Ø16mm holes at the same level
of Stop-end Slides so that the holes should be
Stop-end Slides
between two adjacent 50x60mm tube 1
sections welded on the Inside Panel sheet. 2
3
Install Wall Stop-end by fitting M14x50 bolt&nut

through the holes “1-2-3” on the Stop-end Slide and the
hole on the Vertical Panel.
Check the hole on the Vertical Panel is

between two 50x60 tube sections on it.
Samely, mark the position of “Slab Stop-end Slides

Stop-end” in accordance with the slab length
as in the construction drawing.
Drill Ø16mm holes so that it will

coincide with the holes “1-2-3” located on the
“Stop-end Slides” so that the holes should not
overlap 50x60 mm tube sections welded on Detail b
the Deck Panel sheet.
Install “Slab Stop-end” by fitting

M14x50 bolt&nut through the holes “1-2-3” on
the Stop-end Slide and the hole on the Deck
Panel.
Detail b
3
2
Marking could be done by using any of three 1
pre-holes “1-2-3” located on the Stop-end
Slides.
Holes to be drilled could not overlap

50x60 tube sections on Panels.

34
Assembly of Boxouts
a
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
Detail a
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”.
Detail b b
Install “Boxout to the “Vertical Panel”
by using “Boxout Bolt” through the “Boxout
Nut” welded on the Boxout Slide.
For the first case of Formwork

Setting, Boxouts are transferred
with Tunnel Formworks.

35
ASSEMBLY of OUTSIDE WALLFORM SET
Connection of Vertical Panel and

Vertical Panel Extension
Make ready all necessary componets L – Lowermost Stiffener

and connectors for assembly. M – Mid Stiffener h
U – Uppermost Stiffener
Lay down the “Vertical Panel” and

D
“Vertical Panel Extension” close to each other
on two timbers so that the steel surface is
below (figure 1). >
Insert “U-Alignments-45” into the

UPF profile of the “Vertical Panel” and make
connection of two panels with “M14x30 bolts”
through these points (figure 2).
According to the installation details 1

below, complete the connection with “M14x80
hůŝŐŶŵĞŶƚͲϰϱ
bolts&nuts” through the free holes left
(figure 3).
Insert “Hinge Bolts (120)” to the slots

on the “Vertical Panel Extensions” and screw
them with “M14x80 bolts &nuts” (figure 4).
2 3
Slide the sharp edge of “Upper Panel
Supports” into the mid of “Nut for Hinge Bolts” hƉƉĞƌWĂŶĞů^ƵƉƉŽƌƚ
and locate the other edge to the slot on the
“Vertical Panel Support”. Screw with “M14x80
bolts &nuts” (figure 5). EƵƚĨŽƌ,ŝŶŐĞŽůƚ
,ŝŶŐĞŽůƚ;ϭϮϬͿ
Check the alignment of steel
plates and end points.
4 5
Installation Details of Vertical Panel and Vertical Panel Extensionon Outside Wallforms
>сϮϱϬϬŵŵ >сϭϮϱϬŵŵ
sĞƌƚŝĐĂůǆƚĞŶƐŝŽŶ sĞƌƚŝĐĂůǆƚĞŶƐŝŽŶ
sĞƌƚŝĐĂůWĂŶĞů sĞƌƚŝĐĂůWĂŶĞů
DϭϰǆϯϬďŽůƚ DϭϰǆϴϬďŽůƚΘŶƵƚ hůŝŐŶŵĞŶƚͲϰϱ DϭϰǆϴϬďŽůƚΘŶƵƚ DϭϰǆϯϬďŽůƚ

36
Installation of Working Platform
Insert “Platform Supports” into the

Mid Stiffeners on the “Vertical Panel” and
connect them with only one set of “M14x80
bolt&nut” (view A).
If Length “L” of the “Vertical B

Panel” is less than or equal to
1250mm, use only one “Platform
Support”.
A
Connect two pieces of “Platform
Connector”s to the slots on Uppermost
Stiffeners of the Vertical Panel with “M14x80
bolt&nut” (detail B).
View A Detail B
anyone of
WůĂƚĨŽƌŵŽŶŶĞĐƚŽƌ
these bolts
Connect “Working Platform” and

“Platform Connector” with two sets of
“M14x30 bolt&nut” (detail A).
Locate “Working Platform” on the

angle profile of the “Platform Support” and B
make connection with only one set of
“M14x80 bolt&nut” superposing the holes on
both (view B).
A
anyone of
these bolts
Detail A View B

37
Installation of Guardrail Post
If the Length “L” of Vertical Panel is L = 2500mm L = 1250mm

2500mm then ;
o Locate “Guardrail Post” on the angle
profile of the “Platform Support”
(view A-1). A B

o Make connection with two sets of
“M14x80 bolt&nut” superposing the
holes on both (view A-2).
If the Length “L” of Vertical Panel is

1250mm or less then ;
o Insert “Guardrail Connector” to the
“Working Platform” and connect
them with two sets of “M14x80
bolt&nut” (view B-1). View A -1 View B -1 'ƵĂƌĚƌĂŝůŽŶŶĞĐƚŽƌ
o Locate “Guardrail Post” on the angle
profile of the “Platform Support” and
make connection with two sets of
“M14x80 bolt&nut” superposing the
holes on both (view B-2).

View A -2 View B -2
Installation of Panel Support

and Vertical Panel Jack
Slide two heads of “Panel Supports” L = 2500mm L = 1250mm

inside through the Lower and Mid Stiffeners of
“Vertical Panel” and connect them with two
sets of “M14x80 bolt&nut” (detail A).
A
Locate the upper heads of two
“Vertical Panel Jacks” inside the Undermost
B
Stiffener of the “Vertical Panel” and connect
them with two sets of “M14x30 bolt&nut”
(detail B).
detail A detail B
If Length “L” of the “Vertical

Panel” is less than or equal to
1250mm, use only one “Panel
Support”.

38
Installation of Ladder Support and

Ladder
If the assembly contains a ladder set,

install “Ladder Connector” to the Mid Stiffener
of “Vertical Panel” and fasten it “M14x80
bolt&nut” (detail A).
Make connection between “Ladder”

and “Working Platform” with two sets of
“M14x30 bolt&nut” (detail B). A
Fix “Ladder” to “Ladder Connector”

with one set of M14x100 bolt&nut (detail A).
B
Check the Ladder and the Access

Trap Door are in alignment.
detail A detail B

39
Connection of Outside Wallforms
Refer to ““Installation Details of

Outside Wallforms” for the
connection of two “Vertical
Panels”.
Install “U Alignments-45” with

“M14x30 Bolt&Nut” to the “Outside Wallform”
edge from which the second “Outside
Wallform” will be connected (detail A).
A
U Alignments-45 should be detail A

connected to the Panel whose
length “L” is larger.
Close the second Outside Panel to

the first one and insert U Alignments-45
previously mounted to the first panel into the
UPF profile of the second panel. B
Match the holes on both panels and detail B

connect them with “M14x80 Bolt&Nuts
through free holes (detail B). Installation Details of Outside Wallforms
sĞƌƚŝĐĂůWĂŶĞů,ĞŝŐŚƚ,YсϮϱϬϬŵŵ &ŽƌŝĨĨĞƌĞŶƚ,ĞŝŐŚƚƐŽĨ
sĞƌƚŝĐĂůWĂŶĞůǆƚĞŶƐŝŽŶ,ĞŝŐŚƚ,Yсϯϯϯŵŵ sĞƌƚŝĐĂůWĂŶĞůǆƚĞŶƐŝŽŶƐ
difference at junction points of two
Panels. Vertical Panel
333
383
Extensions
533
Vertical Panels
2500
583
DϭϰǆϴϬďŽůƚΘŶƵƚ
hůŝŐŶŵĞŶƚͲϰϱ
DϭϰǆϱϬďŽůƚ

40
Fit two pieces of “U Alignment-89” to

inner surfaces of Mid Stiffeners of “Vertical
Panels” with 2 sets of “M14x80 bolt&nut”.
A
Fit one piece of “U Alignment-89” to
inner surfaces of Undermost Stiffeners of
bolt&nut. B
Fit one piece of “U Alignment-89” to

inner surfaces of Lowermost Stiffeners of
“Vertical Panels” with 2 sets of M14x80 hůŝŐŶŵĞŶƚͲϴϵ hůŝŐŶŵĞŶƚͲϱϭ
bolt&nut.
Hammer one piece of “U Alignment-

51” to inner surfaces of U Profile on the edges
of two “Vertical Panel Extensions”.
detail A detail B
Installation of Guardrail Timbers
Prepare three timbers for each

“Working Platform”. Timber Slot
O
Slide one piece of timber through
“adjustable plinth brackets” of two adjacent
“Guardrail”. Adjust the positions of “adjustable
plinth brackets” and tighten the screws on
them.
View A
Insert two pieces of timbers inside A
“Timber Slots” on Guardrails and fix them by
Log Screws. Adjustable B
Plinth Bracket
K
W PP
Do not use damaged and
W K PP
knotty woods.
View B O ZRUNLQJSODWIRUPOHQJWK

41
Upholding the Outside WallForm Set
Pass the Crane Ropes (or hooks)

through the Lifting Hooks welded on “Vertical
Panels” properly (detail A).
Į
The angle “Į” between two

ropes should not be greater
than 60°.
>ŝĨƚŝŶŐ,ŽŽŬ
detail A
Lift “Outside Wallform Set” and

locate it in vertical position.
If “Outside Wallform Set” will be

stacked in vertical position, then lower the
jacks on the “Panels Supports” so that the Set
will be inclined.
At windy conditions ( wind

speed is geater than 72 km/h),
“Outside Wallform Sets” must
be stacked in horizontal
position.

42
PREPERATION for OPERATION
Before Starting the Operation Crew for Operation
As a summary, before starting the setting up the For a 250 m2 of concreting area in plan (which is
Tunnel Formwork, rebar working, concreting, stripping approximately equivalent of 800 m2 total formwork area),
and erection operations, It is recommended to provide the crew needed for proper operation is listed below;
below necessities.
Valid structural construction drawings,

boxout plans, detaied drawings of plumbing OPERATION CREW
and electric conduits should be ready.
o Operation Crew should be ready.

Min.12 persons for
- Removing
o Tunnel Formworks, Outside Wallforms, - Cleaning
Platforms, Stopends, Kicker Forms and Platforms - Oiling
should be ready for operation.
- Stripping

o Tools and consumable materials should be - Setting and adjustment
ready. of Formworks and Platforms.

o Crane should have been placed in right way.
Min.6 persons for
o Climatic conditions should allow to operation. - Rebar Working
Persons in the Operation Crew should Min.4 persons for

have been educated on necessary safety - Plumbing
regulations. - Installation of electrical conduits
Alignment of Tunnel Formworks

WD+WDE
In order to adjust the alignment of a Tunnel
Formwork;
90°
Firstly it is necessary to provide the
perpendicularity of “Deck Panel” and “Vertical Panel”.
This is obtained by adjusting either the length of “Foldable
Prop” or the height of “Tunnel Driving Wheel” or both. HT
LP
Secondly, it will be needed to adjust the reverse
deflection of “Deck Panels”, which is described below.
WD + WDE :Deck Panel Width HTD

HT :Tunnel Height
HTD :Height of Tunnel Driving Wheel

43
Symbols Used
,ĞŝŐŚƚŽĨtŚĞĞůĞĚWƌŽƉ ŶŐůĞďĞƚǁĞĞŶĞĐŬWĂŶĞůĂŶĚ/ŶƐŝĚĞWĂŶĞů
ZŝŐŚƚŶŐůĞ;сϵϬ ° )
ĞĐƌĞĂƐĞ /ŶĐƌĞĂƐĞ
ĐƵƚĞŽƌKďƚƵƐĞŶŐůĞ; тϵϬΣͿ
>ĞŶŐƚŚŽĨ/ŶĐůŝŶĞĚWƌŽƉ sĞƌƚŝĐĂůDŽǀĞŵĞŶƚŽĨ,ĂůĨdƵŶŶĞů;ƐͿ
ZĞĂĐƚŝŽŶƐ
ĐƚŝŽŶƐ
hƉ
ŽǁŶ
,ĞŝŐŚƚŽĨ/ŶƐŝĚĞWĂŶĞů:ĂĐŬ WŽƐŝƚŝŽŶŽĨ/ŶƐŝĚĞWĂŶĞů ,ŽƌŝǌŽŶƚĂůDŽǀĞŵĞŶƚŽĨ,ĂůĨdƵŶŶĞů;ƐͿ
ĞĐƌĞĂƐĞ >ĞǀĞƌƚŽůĞĨƚ ƚŽƚŚĞ>ĞĨƚ
/ŶĐƌĞĂƐĞ >ĞǀĞƌƚŽZŝŐŚƚ ƚŽƚŚĞZŝŐŚƚ
Alignment of a Half Tunnel
After providing the right angle between “Deck

90°
and Vertical Panels”, increase or decrease the height of 90°
“Tunnel Driving Wheel” to obtain the verticality of “Vertical

Panel”.
If Vertical Panel is in vertical position then;
o If the angle between “Deck and Vertical Panel” is >90°

<90°
less than 90°, then increase both the length of “Foldable
Prop” and the height of “Tunnel Driving Wheel” properly.
o If the angle is greater than 90°, then decrease

both the length of “Foldable Prop” and the height of
“Tunnel Driving Wheel” properly.
If “Deck Panel” is in horizontal position then;
o If the angle between “Deck and Inside Panel” is

>90° <90°
less than 90°, then increase the length of “Foldable Prop”
only.
o If the angle is greater than 90°, then decrease

the length of “Foldable Prop” only.

44
Preperation of Foundation
Before starting the casting of first

kicer, provide the flatness of the foundation.
Ensure the surface of the

foundation is smooth and clear.

It is recommenended that
Preperation of Foundation
should be realised in the
daytime.
Reinforcement bars embedded on

the slab must be in correct
positions.
Offset the main centerlines and draw

chalk line.
Overlapping of Reinforcement
Bars and the centerlines drawn
could not be allowed.
Oil the surfaces of Kicker Forms with

suitable Formwork Separation Oil.
Place and Install Kicker Forms as

given in the Kicker Plan.
Ensure the distance between

Kicker Forms are correct.

Connect straight kicker forms by

M14x50 bolt&nut.
Connect corner and ønner kicker

forms by Key Locks and M14 nuts.
Maximum dimensional
tolerance for kicker is ±3mm.

45
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.
Measure the starting and ending

points of wall boxouts and locate concrete
stoppers to each ends.
On the corners; cones and clamps

are located on all directions.

Ensure that, construction site is

ready for concreting.

Realise the concreting procedure

properly.
Clean the construction site form

concrete particles and dust.
Wait for concrete setting about 12

hours.
Concrete setting period changes

with the weather conditions.

Firstly remove the clamps and then

concrete stopers from the concrete by using
lever.

46
Secondly remove the straight kicker

forms and then inner and corner kicker forms
from the concrete by using lever.
Check whether the kicker is

cracked or damaged and the
required kicker height is achieved.
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.
Uneven level on kicker is not

allowed for next operations.
90° 90°
<90° <90°
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.

47
Cleannig and Oiling of Formworks
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.
Marking the Boxouts and Stopends
Positions of Wall and Slab

Stopends and Boxouts are defined
on relevant drawings.
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.
øn a same manner, mark and drill te

connection holes for Slab Stopends and Wall
Boxouts.
Provide the vertical alignment of

Wall Stopends.

48
Lifting the Tunnel Formwork Set
Close the “Lifting Triangle” to the

“Tunnel Formwork Set” which will be lifted and
transferred to its location for the first
concreting operation.
Pass the Lifting Rod of the “Lifting

Triangle” through the Lifting Hole on the “Deck
Panel”.
Screw the Lifting Beam Nut from

under the Lifting Beam tightly.
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.
Lift the “Tunnel Formwork Set” and

transfer it.
Pull down it to the location of the first

concreting operation.
Ensure the boom length of the

crane is sufficient for this
operation.

49
Daily Cycle
DAILY CYCLE
Time Schedule
This time schedule is prepared for a Tunnel Formwork application which has a 550-600 m2 construction area for one
floor
o Concreting Phases for One Floor : 2
o Formwork area : 1/2 of a floor (800 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
No.s of ϬϲŚ ϬϳŚ ϬϴŚ ϬϵŚ ϭϬŚ ϭϭŚ ϭϮŚ ϭϯŚ ϭϰŚ ϭϱŚ ϭϲŚ ϭϳŚ ĨƌŽŵϭϴŚƚŽϬϲŚ
STRIKING
Persons
Wall Reinforcement of Next Phase ϰ
Installation of Plumbing/Electrical Conduits on Wall ϯ
Removing the Curtains and the Heaters ϭ
Removing the Kicker Forms Ϯ
Removing the Slab Boxouts Ϯ
Removing the Slab Stopends ϭ
Uninstallation of the Wall Boxouts ϭ
Loosening the Roof Keys ϭ
Removing Tie-Rods Ϯ
Marking the Half Tunnel levels on Kicker ϮƐƵƌǀĞǇŽƌƐ
Striking the Outside Wallforms ϯ
Lowering and Striking the First Half Tunnel Sets ϯ
Cleaning and Oiling the First Half Tunnel Sets ϭ
Back Propping ϭ
Striking the Wall Boxouts ϭ
Lowering and Striking the Second Half Tunnel Sets Ϯ
Cleaning and Oiling the Second Half Tunnel Sets ϭ
Removing the Cones ϭ
dƵŶŶĞůƌĞǁ ZĞďĂƌƌĞǁ WůƵŵďŝŶŐƌĞǁ ŽŶĐƌĞƚŝŶŐƌĞǁ ƌĂŶĞĂƚǁŽƌŬ

50
Daily Cycle
Setting of Formwork
No.s of ϲŚ ϳŚ ϴŚ ϵŚ ϭϬŚ ϭϭŚ ϭϮŚ ϭϯŚ ϭϰŚ ϭϱŚ ϭϲŚ ϭϳŚ ĨƌŽŵϭϴŚƚŽϮϯŚ
SETTING
Persons
Moving and Setting the First Half Tunnel Sets ϯ
Leveling the First Half Tunnel Sets ϭ
Installation of Tie-Rods and Cones ϭ
Carrying and Installation of Wall Boxouts Ϯ
Installation of Plumbing/Electrical Conduits on Wall ϯ
Moving and Setting the Second Half Tunnel Sets Ϯ
Leveling the Second Half Tunnel Sets ϭ
Installation of Slab Stopends ϭ
Tightening of Roof Keys ϭ
Tightening of Bottom and Mid Tie-Rods ϯ
Cleaning and Oiling the Deck Panels ϭ
Slab Reinforcement (lowest level) ϰ
Installation of Plumbing/Electrical Conduits on Slab ϯ
Slab Reinforcement (highest level) ϰ
Moving and Setting the Outside Wallforms Ϯ
Installation of Slab Boxouts ϭ
Installation of Kicker Spacers ϯ
Installation of Kicker Forms and Clamps ϯ
Tightening of Top Tie-Rods Ϯ
Alignment of Half Tunnels Ϯ
Adjustment of Opposite Deflection Ϯ
Moving the idle Stripping Platforms Ϯ
Moving the idle Gable Platforms Ϯ
Moving the idle Landing Platforms Ϯ
Concreting Operation
No.s of ϲŚ ϳŚ ϴŚ ϵŚ ϭϬŚ ϭϭŚ ϭϮŚ ϭϯŚ ϭϰŚ ϭϱŚ ϭϲŚ ϭϳŚ ĨƌŽŵϭϴŚƚŽϮϯŚ
CONCRETING
Persons
Last Check before Concreting ϭ
Installation of Heaters ϭ
Closing the Tunnel Curtains ϭ
Concreting ϱ
Curing
See details of each operations scheduled Time Schedules and capacity of crew
above on the following pages. 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.

51
Daily Cycle
Striking
ϬϲŚ ϬϳŚ ϬϴŚ ϬϵŚ ϭϬŚ ϭϭŚ ϭϮŚ ϭϯŚ
Wall Reinforcement of Next Phase
Prepare the rebars on the area

reserved for rebar-working.
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.
Place the rebars on the slab

whose span “g” is the
smallest.
Place the rebars properly.
Ensure that rebars are vertical and

corners are properly installed.
Wire-mesh usage as the

reinforcement bar is
recommended.

52
Daily Cycle

Installation of Plumbing and Electrical
Conduits on Walls

Carry and distribute required

materials and equipments to the slab properly.
Start the installation of plumbing and

electrical circuits on walls properly.
Finish all lifting and carrying

operations before striking the
formworks since The Lifting
Triangle will be installed to the
Crane Hook.

Removing the Curtains and the Heaters
Open the Tunnel Curtains and fold

them properly.
Remove LPG tubes (if exist) on the

Stripping Platforms.
LPG tubes must be securely

closed and hoses must be
separated form the Heaters.
In order not to became dangerous

during the carrying of Tunnel
formworks, ensure that the
Curtains are not swung.

53
Daily Cycle

Removing the Kicker Forms
Remove Kicker Clamps
Remove Kicker Stopers
Loosen the nuts on the Roof Keys

which connect the Inner and Corner Kicker
K
Forms.
Remove the Kicker Forms from

m the
concrete by using lever.
Remove the Kicker Spacers from

m the
concrete by using lever.
Fill concrete to the cleara

ances
caused from Kicker Spacers.
Check the height of Kickers.
Collect all Spacers, Clamps and

Stopers on the Accessory Box.
Ensure that the Kickers are

ssary
smooth and provide neces
alignments.

54
Daily Cycle

Removing the Slab Boxouts
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
If the boxout consist only one part,

remove it from the concrete by using lever.
Connect the parts in order to use the

boxout in the next concreting phase.
Keep the boxouts securely.

Removing the Slab Stopends
Remove only Stopend Locks.
Collect all Locks for the next

concreting phase.

55
Daily Cycle

Removing the Wall Boxouts
Loosen and remove all Wall Boxout

Bolts.
Collect all Bolts for the next

concreting phase.

Loosening the Roof Keys and Spring Arms
On “Deck Panels”, by using “Deck ϭ Ϯ

Panel Wrench”,
o Loosen all “Roof Key Bolts” on the left

side (figure 1).
o Loosen all “Roof Key Bolts” on the right

side (figure 2).
ϯ
o Turn the “Roof Key” to the right side

(figure 3).
Do not remove the Roof Keys

from Panels. They should still
be on the Panels.
Samely for “Back Panels”, by using ϰ ϱ

“Back Panel Wrench”,
o Loosen all “Roof Key Bolts” on the left

and right sides (figure 4).
o Turn the “Roof Key” to the right side

(figure 5).
Open Spring Arms which connect ϲ ϳ ϴ

Vertical and Deck Panels on two adjacent
Tunnel Formwork Sets (figures 6 - 7 and 8).

56
Daily Cycle

Removing Tie-Rods
Unscrew the “Wing Nuts” (figure 1). ϭ
Since 2010, Flange Nuts have been

used instead of Notched Nuts.
From the other side, unscrew and

remove the Notched Nuts (figure 2).
Keep “Notched Nuts” inside the Mid- Ϯ

Stiffeners of the “Vertical Panel” (figure 3).
Withdraw the set of “Tie-Rod and

Wing Nut” together (figure 4).
Keep the set of “Tie-Rod and Wing

Nut” inside the Mid-Stiffeners of the “Vertical
Panel” (figure 5).
ϰ
Ensure that the sets of “Tie-Rod

and Wing Nut” have been
withdrawn towards the Half
Tunnels on the connections of
Wall Formwork and Half Tunnel
Set.

Marking the Half Tunnel levels on Kicker
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.
Refer to system section for

application given by MESA to take
the Jack Height “K”.

57
Daily Cycle

Striking the Outside Wallforms
By unscrewing the bolts on the

connections between Outside Panels,
Į
separate the Outside Wallform Sets from each
other.
Install the lifting rope to the Lifting

Hooks welded on the Outside Panels properly.
Angle between the Lifting

Ropes “Į” must not greater
than 60°.
Lift and transport the Outside

Wallform Set properly to the place which is
already prepared for stocking.
Ground the Outside Wallform Set

properly.
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.
Ensure the stocking area is safe

and smooth.
Laying down the Outside Wallform

Set in horizontal position sholud
be preferred.
Clean the surface of Vertical Panels

from any rust and concrete particles with
spatula or suitable tools.

in the Section “Formwork Separator Oil” of this
Manual.
Complete all lifting and

carrying operations before
striking the formworks since
The Lifting Triangle will be
installed to the Crane Hook.

58
Daily Cycle

Lowering and Striking the First Half Tunnel Sets
Seperate longitudionally connected

Half Tunnel Sets from each other by
unscrewing the bolts which connect two Deck ĞƚĂŝů
Panels and two Vertical Panels.

In order to lower and strike the First
Half Tunnel Set (A), lower the “Tunnel Driving

Wheel” of the Second Half Tunnel Set (B) by
using the jack on it, so that the Tunnel Driving
ĞƚĂŝů
Wheel is touch to the slab.
Striking Operation should start ĞƚĂŝů ĞƚĂŝů

with the Half Tunnel Set which was
located on the place where
concreting operation was started.
Security Net of the Stripping

Platform must be lowered.
Refer to the “User Manual” of

Stripping Platform given by MESA.
Since the striking and carrying Roller (h=53mm)

1 2
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.
Turn up the Arms of the Foldable

Props of the first Half Tunnel Set (A) (figure1).
3 4
Locate at least two of Rollers
(h=53mm) under Vertical Panels (figure2).
Lower the Vertical Panels by turning

the Vertical Panel Jacks until Panels will put
on the Rollers (figure3).
Drive the Half Tunnel Set towards the

Lifting Hole 5
Stripping Platform whose surface was already
cleaned (figure4).
When the Lifting Hole on the Deck

Panel appears, pass the Lifting Rod of the
Lifting Triangle through the Lifting Hole
(figure5-6).
Screw the Lifting Beam Nut from

under the Lifting Beam tightly (figure7). 7 6

59
Daily Cycle

Cleaning and Oiling the First Half Tunnels
Clean the surface of the Vertical

Pannels from any rust and concrete particles
with spatula or suitable tools.

in the Section “Formwork Separator Oil” of this
Manual.
Before starting to carry the

Formworks, Landing and
Stripping Platforms and Gable
End Frames have to be set.
Refer to “User Manual”s of
those platforms provided by
MESA.

Back Propping
Since Propping will start just after the

Stripping of the Fist Half Tunnel Formwork
L
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.
Longitudinal distance “L”

between two adjacent props
could not be greater than 1500 g < 4500 mm
g > 4500 mm
mm.
Make double Prop row, if the

span “g” is greater than
4500mm.

60
Daily Cycle

Striking the Wall Boxouts
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.
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
Seperate longitudionally connected

Second Half Tunnel Sets from each other by
unscrewing the bolts which connect two Deck
Panels and two Vertical Panels.
Turn up the Arms of the Foldable

Props and locate at least two of Rollers
(h=53mm) under Vertical Panels.
Lower the Half Tunnel Set by using

the Jacks both on the Vertical Panels and on
the Tunnel driving Wheel until the Vertical
Panel will put on the Rollers.
Drive the Half Tunnel Set towards the

Stripping Platform until the Lifting Hole
appears.
When the Lifting Hole on the Deck

Panel appears, pass the Lifting Rod of the
Lifting Triangle through the Lifting Hole, screw
the Lifting Beam Nut from under the Lifting
Beam tightly.
Comply with the descriptions and

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

61
Daily Cycle

Cleaning and Oiling the Second Half Tunnels
Clean the surface of the Vertical

Panels from any rust and concrete particles
with spatula or suitable tools.

this Manual.

Removing the Cones
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.

62
Daily Cycle
Formwork Setting
ϴŚ ϵŚ ϭϬŚ ϭϭŚ ϭϮŚ ϭϯŚ ϭϰŚ ϭϱŚ

Moving and Setting the First Half Tunnel Sets
Put at least two of Rollers (h=73mm)

to the place where the First Half Tunnel Set
will be located (figure 1).
Carry the Half Tunnel Set and leave

it on the place where it will be located on the
next concreting phase (figure 2-3).
ϭ Ϯ ϯ
Draw up the Half tunnel Set by lever
until it touches the kicker (figure 4).
Unscrew the Lifting Nut and remove

the Lifting Triangle from the Half Tunnel.
Screw down the Panel Jacks until

Panels touch to the Rollers (figure 5).
Screw down the Jack on the Tunnel ϰ ϱ

Driving Wheel until it touches to the slab
(figure 6).
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.
Use Levelling instrument.

ϲ ϳ

Leveling the First Half Tunnel Sets
Adjust the bottom level of the Vertical

Panel with Panel Jack so that the line marked
on the Kicker will be conisided with the bottom
edge of the Panel (figure 7-8).
If there are two or more Half

Tunnel sets to be located
longitudionally, connect them with
proper bolts explained in “ERTF-
Technical Manual” provided by
MESA. ϴ

63
Daily Cycle

Installation of Tie-Rods and Cones
Check the Tunnel Number is the

same with that of the Half Tunnel
Set given in the Formwork Layout
provided by MESA.
Pass the Tie-Rod and Wing Nut set

through the tie-rod holes on the Vertical
Panels starting from
• the bottom holes (figure 1)
ϭ
• the middle holes (figure 2)
• and to top holes (figure 3).
Ϯ ϯ
Install Cones through the Tie-Rods.
The side of the Cone which has

small diameter must be on the
Wall Formwork side.
Ensure that Tie-Rods did not go

out of the Cones.

At the rebar side, if Tie-Rod

collides with rebar, cut that part of
rebar properly.

64
Daily Cycle

Installation of Wall Boxouts
Carry the Wall Boxout as an

assembly and close to the place where it will
be installed (figure 1).
Draw up the Boxout by lever until it

touches the kicker (figure 2).
Adjust the bottom level of the Boxout

ϭ
with the Jack located at the bottom so that the
connection hole on it will coinside with the
hole on the Vertical Panel (figure 3).
Check if the dimensions of

Boxouts is true.
Ϯ
From inside of the Half Tunnel, screw

the Boxout Bolt to connect it to the Inside
Panel (figure 4).
ϯ ϰ

Installation of Plumbing and Electrical
Conduits on Wall
Complete the plumbing connections

and installation of conduits box on the wall.
Before carrying the First Half

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

65
Daily Cycle

Moving and Setting 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.
If there are two or more Half Tunnel

sets to be located longitudionally, connect ϭ
them with proper bolts explained in “ERTF-
Technical Manual” provided by MESA.
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. Ϯ ϯ

Leveling the Second Half Tunnel Sets
As described in the “Leveling the

First Half Tunnel Sets”, adjust the bottom
level of the Vertical Panel with Panel Jack so
that the line marked on the Kicker will be
conisided with the bottom edgee of the Panel.
Check the Tunnel Driving Wheel

touches to the slab by adjusting the height of
the Jack on it.
Make ready all components and

spare parts for connections
described in “ERTF-Technical
Manual”.

66
Daily Cycle

Completing the Half Tunnel Setting (Total)
Carry the Half Tunnel Sets starting

from the first one to the second one for each
room.
Install wall boxouts before setting of

the second half tunnels.
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.
Ensure that all accessories, spare

parts and components are already
collected on accessory boxes and
they are ready to transfer.

Installation of Slab Stopends
Install Slab Stopend Lock between

two adjacent Stopends.
Check the space between two

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

67
Daily Cycle

Tightening the Roof Keys and Spring Arms
Equalize the level of two resiprocal ϭ Ϯ

Deck Panels so that the roof Keys should
easily connect them.
Turn the Roof Key so that the slote

on it will locate on the Key Bolt properly
(figure 1).
Tighten the nuts on the Key Bolts

(figures 2 and 3).
Repeat the same procedure for Back ϯ ϰ

Panels and Outside Panels if exist (figure 4).
Check the alignment of Deck

Panels (figure 5).

ϱ
Close Spring Arms to connect ϲ ϳ ϴ

Vertical and Deck Panels on two adjacent
Tunnel Formwork Sets (figures 6 - 7 and 8).
In some applications, Inside

Panels could also be connected
with each other by Roof Keys.

68
Daily Cycle

Tightening of Bottom and Mid Tie-Rods
Pass the Tie-rod through the tie-rod

Hole on Back and Vertical Panels located at
the other side (figure 1).
Screw the Notched Nut loosely until it

just touches to the stiffener (figure 2-3).
ϭ Ϯ
Starting with Back Panels, screw the
Wing Nuts on the Tie-rod at the bottom tightly
(figure 4).
Screw the Wing Nut on the Tie-rod at

the middle loosely.
ϯ ϰ
The notch should be placed in dZh &>^
the space between two parts of
the stiffener (figure 5).
Otherwise after tightening the
Wing Nut, it will squeeze the
stiffener (figure 6).
EŽƚĐŚďĞƚǁĞĞŶ^ƚŝĨĨĞŶĞƌƐ EŽƚĐŚŽŶƚŚĞ^ƚŝĨĨĞŶĞƌ
Do not use any tie-rods or nuts
which are damaged or rusty.
ϱ ϲ
ϲ

Cleaning and Oiling the Deck Panels
Clean the surface of Deck Pannels

from any rust and concrete particles with
spatula or suitable tools.

this Manual.

69
Daily Cycle

el)
Slab Reinforcement (lowest leve
Carry slab rebars and place them

onto the Deck Panels where the span “g”
“ is
smaller.
Place the concrete covers on Deck

Panels.
Proceed the slab rebar working

g for
the lowest level properly.

Installation of Plumbing an
nd Electrical
Conduits on Slab
Mark the Deck Panel accordin

ng to
the Conduit Drawing properly.
Carry all neceesary materials and

place them onto the Deck Panels where e the
span “g” is smaller.
Install the electrical conduits and

pipes, plumbings on the slab.

vel)
Slab Reinforcement (highest lev
Proceed the slab rebar working

g for
the highest level properly.
Slab is now ready for installa

ation
of boxouts and kicker forms.


70
Daily Cycle

Moving and Setting the Outside Wallforms
Ensure the wall where the Outside

Wallform Set will be located is ready so that
Tunnel Formwork was set, rebar working is
completed and wall stopend was installed
(figure 1).
Carry the Outside Wallform Set and

leave it on the place where it will be located
on the next concreting phase (figure 2-3-4-5). ϭ Ϯ
Draw up the Outside Wallform Set by

lever until it touches the kicker (figure 6).
Comply with the operation

rules, load and wind limits
given by the Crane
Manufacturer. ϯ ϰ
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 explained in
“ERTF-Technical Manual” provided by MESA. ϱ ϲ

Manual”.
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.

71
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.

Installation of Kicker Spacers

Manual”.
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.
Distance between the Kicker

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.

72
Daily Cycle

d Clamps
Installation of Kicker Forms and
Before installation, oil Kicker Fo

orms
properly (figure 1).

spare parts for connecttions
described in “ERTF-Tech
hnical
Manual”.
ϭ Ϯ
Transfer all Kicker Forms and Kicker
K
Clamps near to the working area (figure 2).
2
Put Corner Kicker Forms f

firstly
(figure 3).
Connect them with the Inner Kicker

K ϯ
Forms with Roof Keys (figure 4).
Join the Straight Kicker Forms to

o the
end of Corner Kicker forms by bolts described
in the Section “Assembly of Kicker Formms” of
“ERTF-Technical Manual” provided by MESA
M
(figure 5).
Install double sided Kicker Cla amps ϰ ϲ

close to the Kicker Spacers (figure 6) and
d put
Kicker Stopers to the ends of the walls.
Similarly, install single sided Kicker

K
Clamps close to the single sided Kicker K
Spacers which are located between the
Outside Wallforms and the Tunnel Formw works
just near them.
ϱ
Kicker Forms now supported by

Kicker Spacers and Slab
Stopends.

73
Daily Cycle

Tightening of Top Tie-Rods
Pass the top Tie-rod through the tie-

rod Hole on the Vertical Panel located at the
other side (figure 1-2).
Screw the Notched Nut loosely until

it just touches to the stiffener (figure 4).
Screw the Wing Nut on the top Tie-

ϭ Ϯ
rod loosely (figure 3).
Tighten the Wing Nuts on the mid

Tie-rod firstly. Tighten the Wing Nuts on the
top Tie-rod secondly.
ϯ ϰ
The notch should be placed in dZh &>^

the space between two parts of
the stiffener (figure 5).
Otherwise after tightening the
Wing Nut, it will squeeze the
stiffener (figure 6).
ϱ EŽƚĐŚďĞƚǁĞĞŶ^ƚŝĨĨĞŶĞƌƐ ϲ EŽƚĐŚŽŶƚŚĞ^ƚŝĨĨĞŶĞƌ

Alignment of Half Tunnels
,ĞŝŐŚƚŽĨtŚĞĞůĞĚWƌŽƉ ŶŐůĞďĞƚǁĞĞŶĞĐŬWĂŶĞůĂŶĚ/ŶƐŝĚĞWĂŶĞů
ZŝŐŚƚŶŐůĞ;сϵϬ ° )
ĐƵƚĞŽƌKďƚƵƐĞŶŐůĞ; тϵϬΣͿ
>ĞŶŐƚŚŽĨ/ŶĐůŝŶĞĚWƌŽƉ sĞƌƚŝĐĂůDŽǀĞŵĞŶƚŽĨ,ĂůĨdƵŶŶĞů;ƐͿ
ZĞĂĐƚŝŽŶƐ
ĐƚŝŽŶƐ
hƉ
ŽǁŶ
,ĞŝŐŚƚŽĨ/ŶƐŝĚĞWĂŶĞů:ĂĐŬ WŽƐŝƚŝŽŶŽĨ/ŶƐŝĚĞWĂŶĞů ,ŽƌŝǌŽŶƚĂůDŽǀĞŵĞŶƚŽĨ,ĂůĨdƵŶŶĞů;ƐͿ
ĞĐƌĞĂƐĞ >ĞǀĞƌƚŽůĞĨƚ ƚŽƚŚĞ>ĞĨƚ
/ŶĐƌĞĂƐĞ >ĞǀĞƌƚŽZŝŐŚƚ ƚŽƚŚĞZŝŐŚƚ

74
Daily Cycle
z
If desired alignment is not provided or failed
y
somehow after assembling of Half Tunnel Set, it will be x
needed to adjust the alignment similarly.
>90°
If Deck Panel is in horizontal position, then;
2 1
3
5 4
6
o Start to adjust the length of Foldable Prop from
one end of Half Tunnel Set (from no.1 to no.6 as shown in
the figure).
z
If the perpendicularity of Deck and Vertical Panel y
is already provided, then;
x
o Start to adjust the height of Tunnel Driving

Wheel from one end of Half Tunnel Set (from no.1 to no.6 90°
as shown in the figure).
1
2
3
If Vertical Panel is in vertical position, then; z

y
x
o Start to adjust the length of Foldable Prop and
the height of Tunnel Driving Wheel from one end of Half
Tunnel Set (from no.1 to no.6 as shown in the figure). <90°
1
3 2
4
5
6
1
3 2
Before starting the concreting, be

sure that the Wheeled Prop does not touch
the slab.

75
Daily Cycle

Adjustment of Opposite Deflection
Before concreting, it is necessary to change the

setting of perpendicular angle between Deck and Vertical
Panels, so that the horizonrtal alignment of slab will be
obtained without being affected by dead load of concrete d
itself.
Below formulae give satisfactory opposite

deflections “d” changing with the range of span “g”.
2100mm g 3900 mm ĺ d = 2 mm
3900mm < g 5700 mm ĺ d = 4 mm
5700mm < g ĺ d = 8-20 mm g
Experienced results are listed above. The

measure of Opposite Deflection “d” differ by
the slab thickness, site conditions and
<90° <90° >90° >90°
experience of the Operation Crew itself.
Check the kicker level of Vertical Panel Jack

is in proper position. <90° >90° 90° 90°
Adjust the length of Foldable Prop and the height

of Tunnel Driving Wheel properly in such a way that the
vertical alignment of Vertical Panels are satisfied.
Figures show different cases which requires

necessary adjustments. 90° <90° <90° 90°
Provide required dimension of the Vertical

Panel height which touches the kicker.
Ensure Vertical Panels are in vertical

positions and the alignment of Deck Panel
give required opposite deflections. 90° 90° <90° >90°
Site is now ready to concreting procedure

with well aligned Formworks and well
prepared working area.

76
Daily Cycle
ϭϮŚ ϭϯŚ ϭϰŚ ϭϱŚ ϭϲŚ ϭϳŚ ĨƌŽŵϭϴŚƚŽϮϯŚ

Moving the Idle Stripping Platforms
Transfer the Stripping platforms

which are in idle position to the places for next
concreting phase.
Refer to the “User Manual” of the

Stripping Platform provided by
MESA.

Moving Idle Gable Platforms
Transfer the Gable End Frames

which are in idle position to the places for
next concreting phase.

Gable End Frame provided by
MESA.

77
Daily Cycle

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.

Landing Platform provided by
MESA.

78
Daily Cycle
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.
Comply with all safety

regulations and conditions.

79
Daily Cycle

Installation of Heaters
Carry the heaters and required

componenets near to the Tunnel Formworks.
Place them inside Tunnel Formworks

and make necessary installations as shown.
Place LPG-Tanks of LPG-Heaters

onto the Stripping Platforms.
Operate the Heaters properly.
Ensure that all safety

requirements are provided.
Technical documents should be

reviewed in the Section
“Construction Materials” of this
Manual.

Closing the Tunnel Curtains
Close all Tunnel Curtains and tie two

parts.
If necessary, Outside Wallform Sets

could also be isolated.
Ensure that air leakage at the

bottom is prevented.

80
Daily Cycle

Concreting
Starting point for pouring the

concrete will be clarified according to
o the
below parameters;
o Concreting should start from the

inside walls (or core walls) to
o the
outside walls.
o The walls which have the largest

boxout areas have the first prioritty.
o Concreting should start from the area

whose Tunnel Formwork will be
transferred firstly for the next
concreting phase.
Continue to place the concrete with

slab.
Trowel by means of Kicker Fo

orms,
Slab Stopends and Slab Boxouts.
At junction points on slabs

where the concrete will be
completed on the next phas se;
pour concrete having a widdth
of 1/5 of the span “g”.
Comply with rules and

conditions for the rate of
placing of concrete explaine
ed
in the Section “Construction
Material” of this Manual.

81
Daily Cycle

Curing
Curing could be continued all night

long.
Check the fuel quantity periodically.
Ensure that the hourly increase in

temperature inside the room
should not be greater than 20 °C.
Maximum inside temperature

should be 70 °C.

Provide required wetness of

concrete.
Take required precautions for

different climatic conditions.

Periodic checking of the Heaters

during night against any unwanted
situation and fire is strongly
recommended.

82
Non-standard Applications
NON-STANDARD APPLICATIONS
Storeys with higher floor height
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 phases.
Then install the Special Tunnel

Extension Sets to the Half Tunnle Sets and
follow the instructions provided by MESA.
Rooms with greater spans than

Standards
In some buildings, some of the spans

could 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.

83



ERTF User Man - Eng

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

ERTF User Man - Eng

Caricato da

Copyright:

Formati disponibili

ϭϮͬϮϬϭϬ hƐĞƌDĂŶƵĂů

Tools and Consumables

Before Arrival of MESA-Supervisor 17

Assembly of Tunnel Formwork

Assembly of a Tunnel Formwork Set

General Remarks Safety Remarks

• Users working with MESA products and

ERTF-Modular Tunnel Formwork System

Operational Conditions Warranty Period

 Formwork should be used between + 40 °C and

 Formworks should be cleaned after each Service Life

 This maintenance covers the flatning of

 After 500 applications, maintenance should be

 During the storage period, all active surfaces

 Stock area should be closed area; if it is not

• MESA will issue a “OPERATION

• If a person who do not have this

ERTF-Modular Tunnel Formwork System

 Mesa Imalat reserves the right to make

© Copyright by MESA Imalat San. ve Tic

ERTF-Modular Tunnel Formwork System

o Setting Plan of Tunnel Formworks

Setting Plan of Tunnel Formworks

ERTF – Modular Tunnel Formwork System

Assembly codes and Tie-rod Positions

S+SB R15 L15 R12A ERA L13

S+SA V2L+VA V1+VA L15 R15 L17 R13

S+SA V2R+VA V3+VA

Position of Tie-Rod and Cone

Assembly Code of Back Panel R3 L3 L

Assembly Code of Inside Panel and Inside Panel Extension

Assembly Code of Deck Panel H1 H1

Assembly Code of Deck Panel Extension

Assembly Code of Outside Panel and Outside Panel Extension

ERTF – Modular Tunnel Formwork System

Setting Plan of Kicker Forms

Assembly Code of Corner Kicker Form LA BA RA LA

Assembly Code of Inner Kicker Form

Assembly Code of Straight Kicker Form 1A 1A

ERTF – Modular Tunnel Formwork System

Setting Plan of Slab and Wall Stopends

Assembly Code of Slab Stop-end

Assembly Code of Wall Stop-end P1

ERTF – Modular Tunnel Formwork System

Setting Plan of Lifting Beams

Rough Position of Lifting Beam

Assembly Code of Lifting Beam

ERTF – Modular Tunnel Formwork System

Setting Plan of Slab and Wall Boxouts

ERTF – Modular Tunnel Formwork System

Setting Plan of Platforms

Assembly Code of Assembly Code of Assembly Code of

ERTF – Modular Tunnel Formwork System

Assembly Charts of Tunnel Formworks

TUNNEL NO : 3 WITHOUT WITH WITH WITH

POSITION of LIFTING HOLE

ERTF – Modular Tunnel Formwork System

Rate of Placing of Concrete

tİ ; total time for end of setting of concrete

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

As described in the booklet “ERTF-

• For earthquake zones, concrete and rebar

o Concrete : 0.34 – 0.45 m3/m2 in plan

Formwork should be used between + 40 °C and

Formworks should be cleaned after each Service Life

This maintenance covers the flatning of

After 500 applications, maintenance should be

During the storage period, all active surfaces

Stock area should be closed area; if it is not

Mesa Imalat reserves the right to make

• Formwork separation oil should provide ƉƉĞƌĞĂŶĐĞ DŝŶĞƌĂůĂƐĞĚ