6750 Method Statement - HV Panel - Ischebeck Titan ME LLC

HV Panel SystemMethodstatement

Ischebeck Titan | Method statement | HV Panel March 2009MethodstatementHV PanelSystemContentsPageIntroduction 2Disclaimer 2Site safety 3Your responsibilities 3Safe working practice 4Personal protective equipment 4Description 5Technical specifications 5Components 6Component details 7Standard erection procedure 17Checklist 21Standard striking procedure 21IntroductionIschebeck Titan is renowned as one of theleading manufacturers and suppliers ofequipment to the construction and civilengineering industries.Our commitment to safety and site efficiencyis evident in the design performance andquality of our products, which offer safeaccess and secure working platforms for anenormous variety of applications.The enclosed method statement underlinesour devotion to site safety by providingrecommendations, based on tried andtrusted methods, for the proper use andapplication of Ischebeck Titan’s HV Panelsystem.Please take time to read and understand theinformation presented before using theproducts covered. If you need further adviceor assistance consult a suitably qualifiedperson within your own company or contactIschebeck Titan.DisclaimerThe methods presented in this document aresolely for the use of Ischebeck Titanequipment and are intended for guidanceonly. When familiarity has been gained withthe equipment preferred methods may beadopted, provided they do not contravenehealth and safety regulations or acceptedsafe working practices. The information iscorrect at time of publication, but IschebeckTitan reserves the right to change, withoutprior notice, the specifications and methodsmentioned. No responsibility whatsoever canbe accepted for any errors or omissions in,or misrepresentation of, the contents. Forspecific information refer to Ischebeck TitanLimited.Copyright reserved.Page 2 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Site safety is yourresponsibilityThe importance of site safety cannot be overemphasized. You have a responsibility toyourself, your colleagues, site visitors, family,friends and others to ensure you do notinjure yourself or take actions, which put thelives and health of other people at risk.Site safety rules will form part of every site’shealth and safety plan. You should familiariseyourself with these rules and make sure thatyou and fellow workers do not contravenetheir requirements. A prominent notice willidentify personnel with overall responsibilityfor site safety.You will have contractual and legal obligationto follow these rules and adhere to relevantlegislation, such as the Health and Safety atWork Act, which place specificresponsibilities on you and your employer toprevent accidents.Site safety is the responsibility of everyoneon site. If you have a reason to believe thatsafety is being compromised, you shouldreport it to the appropriate personnel.Your responsibilitiesFollowing are a few suggestions to help youwork safely and contribute to safety on yoursite:• Make sure you fully understand the safeand proper way to do any job.• If in doubt, ask your supervisor – do notguess.• Always conduct yourself in a responsibleand safe manner.• Do not expose others to danger throughyour actions.• Always use the correct tools and equipmentfor the job.• Always use the appropriate safetyequipment and protective clothing.• Report ALL defects in plant and equipment.• Observe and comply with warning andhazard notices.• Advise newcomers of safe workingpractices.• Make sure you know where to go for firstaid treatment.• Report any injury and ensure it is enteredin the accident book.• Never indulge in horseplay or practicaljokes at work.• Never attempt to work whilst under theinfluence of alcohol or drugs.• Make sure you have read and understoodthe sites health and safety requirements.• Report any situation which mightcompromise site safety to the sites safetyofficer.Page 3 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Safe working practicePersonal protectiveequipment• Consider health and safety first. If you arenot sure of procedures ask.• Do not take shortcuts – use the accessprovided.• Do not remove handrails or ladders fromscaffolds unless instructed to do so andreplace them as soon as possible.• Play your part in keeping the site tidy andsafe.• Look out for hazard warning notices andobey them.• Never attempt to operate machinery unlessyou have been trained and authorized to doso.• Attempting to lift heavy objects or materialscan cause injury – obtain assistance wherenecessary.• Study you company’s policy.• Remember you have a legal duty to takereasonable care of your own health andsafety and to avoid placing other people atrisk. Such as those who work with you andmembers of the public.• If in doubt about your job, ask yourimmediate supervisor for guidance.• Your co-operation in discouraging childrenfrom entering the site will help to reducethe risk of accidents to them and others.• Remember that entering an unsafe areacould render you liable to prosecution. If itlooks or feels unsafe, report it. If you areunsure, ask site supervision for advice.For your protection, always use the safetyhelmets, ear protectors, face masks,goggles, gloves, safety harness and otheritems of personal protective equipmentappropriate to tasks you are undertaking.When protective clothing and/or equipment isissued to you:-• Wear or use the equipment when requiredand when there is any possibility ofpersonal injury in the course of your work.• Look after the equipment.• If the equipment is on personal issue, storeit carefully and ensure that it is available foruse when needed.• Make sure that equipment is properlymaintained.• Replace defective equipment immediately.• If you have any doubts about the correctuse, adjustment or maintenance of theequipment, ask your supervisor.Page 4 of 24

Ischebeck Titan | Method statement | HV Panel March 2009DescriptionTechnical specificationThe Titan HV panel decking system providesa rapid, versatile and efficient means ofcasting in-situ concrete decks in a widevariety of applications.Lightweight and easy to use, Titan HVcomprises just 3 main components and canbe erected and dismantled by a team of twooperatives without the need for special tools,making it one of the least labour intensivesystems on the market.With all erection and dismantling undertakenfrom beneath the deck itself, Titan HVminimises requirements for working at heightand makes a major contribution to site safety.The system’s modular nature simplifies theentire process, naturally creating a 1.8m gridthat self-sets. This simplicity in use,combined with the system’s drop-head,allows for early stripping and re-use ofbeams and panels, thus enhancing siteproductivity whilst maintaining automaticbackpropping.Primary beams1.15m, 1.50m, 1.70m, 3.50m 2.30mIxx Moment of Inertia 559cm 4 1027cm 4Zxx Section Modulus 60.8cm 3 94.5cm 3E.I. Bending Stiffness 391kNm 2 719kNm 2M Resistance Moment 6.89kNm 10.8kNmS Allowable Shear Force 27kN 27kNSecondary beams1.15m, 1.50m, 1.70mIxx Moment of Inertia 175cm 4Zxx Section Modulus 29cm 3E.I. Bending Stiffness 122.5kNm 2M Resistance Moment 3.3kNmS Allowable Shear Force 9.25kNDropheadSafe Working LoadConcrete Slab50kNMaximum allowable slab thickness = 0.4mConcrete = 24.5kN/m 3Live Load + Impact = 1.8kN/m 2Maximum Leg Load 1.8m x 1.8m Grid = 37.58kNSee relevant prop loading graphs for permissible legloads.Page 5 of 24

Ischebeck Titan | Method statement | HV Panel March 2009ComponentsDrophead – Galvanised steel componentthat is bolted to the support prop by meansof 2 No. speed thread bolts and nuts. Thecam action mechanism of the dropheadallows for 100mm strike distance for theremoval of beams and panels.Primary Beams – Lightweight high strengthaluminium profile of durable construction foreasy, fast and safe handling. Primary beamsare located on to the support plate of thedrophead.HV Panel – Lightweight panel of aluminiumconstruction with Iflon GRP decking panel.Panel size of 1.8m x 0.45m with a weight of16.5kg, incorporating a quick release handlelocator, allows for one man to safely erectand dismantle the panel from below. Panelsare located into the support channels of theprimary beams.Iflon Filler Strip – Closes gap betweenpanels over the primary beam.Secondary Beams – Lightweight aluminiumprofiles that are used for infill areas aroundcolumns or for make up bays within the floorslab area. Beams are located into thesupport channel of the primary beam.Support Props – System can be supportedby either aluminium Titan HV Props or TitanLegs. Legs/props are stabilised by Titanledger frames at predetermined intervals.Steel props can also be used for support.Panel Storage Rack – Used for the safedelivery and return of HV Panels. Amaximum of 30 panels are stored in the rackgiving an overall weight of 615kg.Safety Catch - Used to secure PrimaryBeams when cantilevered beyond slab edge.Quick release handle on one sideof panel allows erection andstripping from beneath deck.Page 6 of 24

Ischebeck Titan | Method statement | HV Panel March 2009HV beam detailsPage 7 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Titan HV IFLON-GRP panelHigh re-use IFLON-GRP deckingAluminium frameHinged locator(can be moved up and down)Fixed locator121Bearing profile for locator180045011016921630450Weight: 16.5kgMaximum slab thickness: 400mmPage 8 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Iflon filler stripThe gap between the panels over the main beam is closed by a filler strip.21170170112590021Iflon filler stripWeight:1125mm = 3.80kg900mm = 3.04kgPage 9 of 24

Ischebeck Titan | Method statement | HV Panel March 2009ErectionSystem can be positioned directly against existing R.C. walls1701800Iflon filler strip1701800Panel positioneddirectly against wall180011251800Middle of dropheadMax. 1501125450 450Main beamsare positionedwith wallspacers, thegap is coveredby filler strips170 1630Main beamDropheadPage 10 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Wall positioningThe gap between the panel and the wall can be closed with filler strips.The wall-spacers give the required distance to the wall.86.5Wall spacerWeight:0.60kgPage 11 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Panel storage rack (Collapsible)Detail: ADetail: BDetail: BDetail: AWeight:134kg (excluding panels)Once emptied storage racks can be collapsed and stored on top of each other.Hinged JointPage 12 of 24

Ischebeck Titan | Method statement | HV Panel March 2009HV drophead and safety catch120Weight:4.8kgPage 13 of 24

Ischebeck Titan | Method statement | HV Panel March 2009HV drophead positionsStage 1Drophead in lowered positionPrimary beam directionLocating plateSupport pin• HV drophead bolted to prop by meansof 2 No. M12x35 speed thread bolts andnuts• Ensure support pins run parallel withHV primary beamsHV beam support plateFront viewDrophead locking collarPage 14 of 24

Ischebeck Titan | Method statement | HV Panel March 2009HV drophead positionsStage 2Support plate in positionLocating plateHV beam support plate• Lift support plate vertically.• Position and guide slot into locatingplate.Support pinDrophead locking collarFront viewPage 15 of 24

Ischebeck Titan | Method statement | HV Panel March 2009HV drophead positionsStage 3Position and rotate locking collarLocked positionLocating plateHV beam support plateDrophead locking collarSupport pin• Lift drophead locking collar oversupport pin and rotate 90°• Collar tightens against pin by means ofcam action• Once rotated, tap with hammer tosecureFront viewPage 16 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Standard erectionprocedure• Fix drophead to Titan leg by means of 2No. M12 x 35 Nuts and bolts or 2 No.speed thread bolts. Bolts to be fitteddiagonally opposite each other.• Introduce exclusion zone around area ofwork• Extend prop to the approximate heightrequired.• Erect first tower of props and link by meansof ledger frames. Ensure support pins ofdrophead are facing in the primary beamdirection.• Further props may now be added in thesame fashion on the primary beam lines.• As primary beams proceed position and fixpanels between aligned beams.• Introduce Titan ledger frames in every 5bays in each direction to form stabilisingtowers.• For heights greater than 3.5m introduceledger frames in every 3 bays in eachdirection. For heights greater than 4.5mintroduce ledger frames every other bay ineach direction.• Place one end of primary beam ontosupport plate of locked drophead withopposite end hanging down.• Lift opposite end of beam and position onnext drophead.• Fix adjacent primary beam in a similarmanner.• Lift and position panels between primarybeams. We now have a stabletower/column to proceed from.• Panels can be fixed from ground level up toa maximum propping height of 2.5m. Forheights greater than 2.5m a suitable accessplatform is required.• Position one end of primary beam ontodrophead with opposite end hanging down.• Place prop with locked drophead into theopposite end of primary beam and lift intothe vertical position.Page 17 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Recommended erection procedure for slab perimeterStage 1 Stage 2Erect 6/8 no. Titan legs on 1.8m x 1.2m grid.Erect additional legs and ledger frames to allow forbeam and panel installation. Deck out with boardsand install temporary handrail system.Stage 3Install primary beams and panels as per standard erectionprocedure. Fix prop positioners to primary beam to helplocate beam into Titan legs. Props on underside of primarybeam fixed by means of 2 no. Titan clamps per leg.Page 18 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Erection procedure for slab perimeter (Continued)Stage 4Install remaining panels as per standard erection procedure.Access by mobile tower or MEWP.Lock primary beam to drophead by means of HV safety catch.Install edge protection system.Stage 5Remove temporary handrail system and decking boards.Position 4 No. Titan trolleys on outside frames.Stage 6Trolley tower to slab edge and then remove trolleys.Once tower is in position internal decking/supportcan be erected by standard procedure.Page 19 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Erection procedure for slab perimeterat column infill areaExisting edge protectionPanels/infill beams betweentowers put in position by meansof mobile tower/MEWPTemporary edge protection to beinstalled around opening beforeinstalling infill panelEdge protection panel to be installedby suitably harnessed operativesInfill secondary beamsExisting edge protectionAll operatives working on panel deck must be suitablyharnessed and anchored to a suitable point until fullperimeter edge protection is installed.Page 20 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Checklist before pouring• Ensure plumbness of props• Ensure system is erected as per the designdrawing• Ensure that infill beams are at the correctspacing to suit ply spans• Ensure any damaged parts are removedand replaced immediately• Ensure dropheads are locked correctly• Ensure the safety procedures are adopted,such as handrails to match the constructionand health working regulations• Ensure the whole slab form is stabilisedagainst overturning from either wind forcesor horizontal loading due to constructionloads.• Final height adjustment for pouring is nowapplied.Standard striking procedure• Before striking introduce exclusion zonearound area of work• With a hammer stroke the drophead will bereleased, and the whole slabform grid willcome down 100mm• Now the panels and infill beams can beremoved.• Titan jack may require re-tightening afterdrophead release. Strike jack nut withhammer and ensure drophead is centraland square on infill filler strip. (see page22)• Remove primary beams.• To avoid the inefficient and uneconomicallabour costs put all the components inpallets/storage racks to lift them to the nextarea/level.• Ensure suitable release agent is applied topanel deck before fixing of steel reinforcing.Page 21 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Incorrect Position – Prop/Drophead off centre and not square to infill stripCorrect Position – Prop/Drophead on centre and square to infill stripPage 22 of 24

Ischebeck Titan | Method statement | HV Panel March 2009Striking procedure for slab perimeterStage 1Exclusion zone to be formed below work area.External edge protection to be removed by suitableharnessed operative.Fix edge protection system to poured slab.External HV panel also removed at this stage.Stage 2Re-install handrails and decking.Strike dropheads and lower adjustable jacks. Removepanels within decked area. Slide external panel intodecked area and remove.Undo Titan clamps then lift and lower 3.5m primary beamto deck level.Internal panels and beam components to be removed byoperative on MEWP or mobile tower.All material to be palletised and moved to next location.Note:Alternative to above would be to remove all ledger framesand then remove panels and beams by means of MEWPor mobile tower.Back proppingStage 3Remove temporary handrail system and decking boards.Remove Titan ledger frames.Reinstate external back propping.Page 23 of 24

Ischebeck Titan GroupFounded in Germany over 120 years ago Ischebeck isrenowned internationally for it’s aluminium formwork andfalse work systems, trench support systems and groundengineering products.Ischebeck Titan LtdThe company operates from headquarters centrally locatedin the heart of the UK.Product AvailabilitySubstantial stocks of equipment are available ex-stock fromthe company’s strategically located 4-acre distribution site,with most main product lines available nationwide on a 48-hour delivery. Products are available for both hire andoutright purchase.Technical SupportWe will participate in concept stage development. Providinginput on applications, production rates, budget design,programming and costings. Active for on site support andtraining. We can provide guidance on industry specialEuropean and national standards.HEAD OFFICEJohn Dean HouseWellington RoadBurton upon TrentStaffordshire DE14 2TGTel: 01283 515677 Fax: 01283 516126www.ischebeck-titan.co.ukE-mail: sales@ischebeck-titan.co.ukNORTHERN REGIONAL OFFICE& DESIGN OFFICEHollinwood Business CentreAlbert Mills Albert StreetHollinwood Oldham OL8 3QPTel: 0161 682 4732 Fax: 0161 684 3603E-mail: technical@ischebeck-titan.co.ukSince our policy is one of continuous improvement we reserve the right tochange without prior notice the specifications and methods of constructionmentioned in this document. No responsibility whatsoever can be accepted forany errors or omissions in, or misinterpretation of the contents. Products mustbe used in conformity with safe practices and applicable codes andregulations. Photos and details shown are for general guidance only and mayvary according to circumstances. For specific information refer to IschebeckTitan Limited. Copyright reserved.