2/2011 technicalmanual mesa - ertf · tools 68 . general remarks ertf – modular tunnel form...

2/2011� � � � � � � � � � � ��Technical�Manual�

MESA - ERTF Modular Tunnel Form System�

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Contents

Introduction System Description 1

Comparisons 2 Scope of Applications 4 Simple Procedure 5 System Overview 11 Dimensions and Physical Properties 13

Technical Information Parts in Detail 16

Complementary Equipments 36 Types of Connection 37 Permanent Assemblies 38 Temporary Connections 45

Part List Panels 48 Supports 51 Jacks and Driving Units 54 Safety Componenets 55 Lifting & Transporting 57 Kicker Forms 58 Stopends 61 Intermediate Components 63 Tie-Rod Accessories 66 Tools 68

� General Remarks�

ERTF – Modular Tunnel Form System TECHNICAL MANUAL – 2/2011 www.mesaimalat.com.tr�

Important Note

�

Sight-Check

�

Information

�

Warning

� All products of MESA should be used according to the relevant safety regulations of the state or country in which they are operated.

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

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

� Any MESA products could not be combined with the products of other manufacturers.

� 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

Remarks

Symbols Used�

� Warranty�

ERTF – Modular Tunnel Form System TECHNICAL MANUAL – 2/2011 www.mesaimalat.com.tr�

Warranty Period

� Limited Warranty for two (2) years is promissed by Mesa �malat San.ve Tic. A.�. for Steel Face Formworks and Slab Formworks unless the Operational Conditions described below are violated.

� This warranty covers defects of steel material, welding and painting.

� For Hydraulic Cylinders and Hydraulic Power Units, the limited warranty period is one (1) year.

Service Life

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

Operational Conditions

� Instruction or User’s Manuals must be used while Formwork assemblies, accessory attachements and concrete casting. � It is not allowed to use hummer, sedgehummer, cranka and vs that cause physical demage on Formworks, and also applications of extra welding, cutting and drilling without permission of authorities. � It is not allowed to exceed the Max Concrete Pressure described in Technical or User’s Manuals. � Formwork should be used between + 50 °C and – 30 °C. � Formworks should be cleaned after each application to remove the concrete residues and active faces should be lubricated with suitable concrete/metal seperation oil. � After 250 applications, maintenance should be done at site. � This maintenance covers the flatning of active surface, repainting, welding and rust control. � After 500 applications, maintenance should be done at work shop where the necessary equipments exist. � During the storage period, all active surfaces should be lubricated with suitable oil to prevent rusting. � Stock area should be closed area; if it is not possible, formworks and accessories should be stocked in open areas by covering them with water resistant materials. � Maitenance procedure should be repeated for each 250 usages after first 500 usages are exceeded. �� For HCP-hydraulic system, the allowable working pressure must not be exceeded ( 250 bar ).�� All connections between hydraulic cylinders, hydraulic power units and hydraulic pipes and must be checked against leakage before each usage. � Electrical power supply and connections must be suitable as written in the ınstruction or User’s Manuals given by MESA.

Introduction� System Description

ERTF – Modular Tunnel Form System1

TECHNICAL MANUAL – 2/2011 www.mesaimalat.com.tr

Tunnel form system contruction is a method that the wall and the slab are cast in a single operation.

Half Tunnel System is composed of two half shells which are placed together to form a room or cell, while several cells making an apartment.

Once reinforcement is placed, concrete for walls and slabs can be poured in a single operation.

The Half tunnel design makes possible to remove one whole side of a tunnel, then to prop the slab near the joint before removing the other half, permitting a faster rotation of the equipment.

By using a heating system during night ( only in countries where the air temperature is comperatively low ) , the concrete has a sufficient strength to allow the early stripping of the forms in the next morning.

Tunnel Formwork system which offers a complete solution is:

� Ergonomic to save time � Professionally designed to solve every request � Safe enough to offer fool-proof workplace safety

When using tunnel form system the construction time is much shorter than that of conventional method. Many studies showed that almost 50% of the time is cut compared to traditional methods.

A crew of 10 people can achieve a daily cycle of casting 1-2 apartments per day depending on the type of structure. Once you catch this daily cycle economy comes by itself.

Installation of electrical conduits, water and gas pipes in the shell reduces the internal finishing work, internal finishing proceeds in accordance with the concrete shell construction resulting in reduced total building time.

The dimensional accuracy of the concrete structure allows the placement of partition walls and fixing of all other finishing material such as joinery right after casting.

Much of the finishing work like plastering is eliminated through a perfectly flat concrete surface. Paint, wall paper or any decoration can be applied directly to the surface.

SYSTEM DESCRIPTION

Basic Introduction Advantages

Half-Tunnel Formwork System provides ;

Fast construction fits to tight construction schedules:

In the high temperature zones and/or by thermal treatment, with the use of ordinary cement, the normal pace is one day per cycle.

Reduction in total construction time:

Installation of all utility conduits in the shell reduces the internal finishing work.

Economy through reduced construction times:

Not to get beaten by price increases.

A perfect daily rhythm for other works at site.

A monolithic structure with simultaneous casting of walls/cross-walls and slab

A nice concrete surface that eliminates much of the finishing works:

The obtained surface allow direct application of paint or wall paper after sanding off the fins at the joints connecting two forms and smoothing with paint filler.

Dimensional accuracy

Standardisation of finishing works such as joinery, partition walls, etc.

Last three means quality

Complete workplace safety

�The simultaneous casting of walls, slabs and cross walls results in a monolithic structure which meets the requirements of building codes of countries located in earthquake zones.

Introduction� Comparisons



With Other Systems

Generally, Half-Tunnel Formwork System gains ;

Less Construction Items :

Less masonry, no plastering, no formwork timber, no nails,less tie bars, etc. 15% less steel in weight and less Labor; By using ST IV instead of ST in.

Higher Net Ffloor Area to Gross:

86-88% compared to 82-84% in conventional systems

Advantageous over Industrial Timber Forms :

After building of 140 housing units.

Advantageous over Conventional System :

After building of 90 housing units.

Average Cost Advantage :

45% in projects of over 100 houses.

Advantageous on Eartquake Zones :

Area of load bearing walls to the total area is 2% more than compared to 0.5% in conventional systems. For low-rise buildings e.g. 5 storey, total weight of the building can be designed 1.10 – 1.20 tons/m2 lighter than compared to 1,30 in conventional method. No buildings built by tunnel form system reported as demolished or damaged. Only minor cracks have been observed.

COMPARISONS�

Introduction� Comparisons



With Classic Tunnel Form Systems �

Modular Vertical Pannel with Extension :

Vertical panels are produced in standard heights. It can be used for half-tunnels and also for end-walls which reduces different types of panels on site. Vertical panels are used with upper extension panels to reach different floor heights easily. In this way panels can easily be reused at new projects.

ERTF Telescopic Push Pull Prop :

Standard push-pull props can easily be used at any tunnel span by the help of its telescopic design. It eliminates the need for several different types of props. ERTF Push-Pull Props makes it very easy to adjust the height & level deck panels of tunnel form. Lifting up the the control arm will simply move the deck panel down. The arm is locked once the panel is adjusted properly.

Modular Deck Pannel with Extension :

Deck panels are produced in standard width and can be used at any span dimension with extension adapter panels. In this way panels can easily be reused at new projects. It eliminates the need for deck-panels with special dimensions. Provides better concrete finish at joints of extension panels.

Roller for Stripping the Tunnels :

Half-tunnels can easily be moved and stripped on platforms by the help of rollers which are used instead of wheels. It is placed under vertical panel of half-tunnels above the slab. It reduces vertical panel price by cancelling the wheels and also simplify storage of vertical panels. Formwork weight will not affect stripping platform as the tunnel forms are carried by the rollers during their movement.

90% Less Labor Cost During Horizontal Alignments of Deck Panels :

Foldable Inclined Props are adjusted at the beginning only. Locking Arm of the Prop will provide the required alignment of Deck Panel when it is locked. Separation of the Panels from the concrete will become unlaboured also.

75% Less Labor Cost During Setting Up and Striking Operations:

Portable Rollers which enable to drive the Tunnels easily, reduce the setting up and striking times considerably.

65% Less Labor Cost During Plumbing Operation :

Newly installed Jacks on Tunnel Wheels will make simple the plumbing of the Tunnel while reducing the labor cost.

Higher Kicker means Easier Level Control :

High kicker makes it easier to adjust tunnel heights which eliminate levelling mistakes of the foundation.

Easy use with elevated level of lowest Tie-rod position:

The Elevation of the lowest level of tie-rod position to 290mm eliminates the problem arisen with the concurrenge of kicker and tie-rod cones.

Advantages on the Next Project :

Since Vertical Panels have standart heights, it will be easy to adopt all vertical panels to new projects by changing the extension panels only. The same procedure is also valid for the Deck Panels.

Allows to application on higher concrete pressure by means of powered lowest and highest Stiffeners:

More strength and rigidity obtained by powered stiffeners located on the same level of the lowest and highest tie-rods allows the increased concrete pressure caused by higher rate of placing. Since the rate of placing of concrete increases, total concreting period will be decreases.

ERTF Modular Half-Tunnel Formwork System has a lot of significant advantages according to the Classical Tunnel Formwork Systems. These are;

Introduction� Scope of Application



SCOPE of APPLICATION

Introduction� Simple Procedure



Stripping Platform Landing Platform Gable End Frame

For product, installation and operation details of Stripping Platforms, Landing Platforms and Gable End Frames to be used, refer to relevant booklets given by MESA.

On Layout

Concrete Structure to be built will determine the quantity of Tunnel Formwork.

Straight walls and slab ends must be preferred, because otherwise will increase the floor cycle time which is not the logic of Tunnel Formwork Operations.

Symmetric layout plans make easy the application of Tunnel Formwork if more than one concrete phase for one floor is to be planned.

Platforms should be located all around the building.

Full set of Platform of one floor give safer working area and easier application stage.

R.C.Wall to be cast Slab End Door Opening

Lift & Stair Shafts

SIMPLE PROCEDURE




The lengths of Half Tunnel Sets should be determined so that, the weight of the one which has the maximum weight should not exceed maximum allowable load of the Tower Crane.

Since transferring of both Tunnel Formworks and Platforms have to be evaluated; generally, full set of Tunnel Formwork of one full floor should be avoided. Because, before transferring of all Tunnel Formworks to the next phase, one should transfer the Platforms also. In order to transfer a full set of tunnels of a floor, one must transfer them to the ground first, then transfer the platforms to the next floor and then transfer the tunnels on the ground onto the platforms. This procedure will repeated in each floor.

Approximately, 300 m2 Formwork Area on Layout Plan is suitable for everyday concreting cycle. This area gives approximately 1000 m2 total formwork area (total area of all Vertical and Horizontal Panels)

Figure shows the first day application: erecting the Formwork, Concreting and Stripping the Formwork for the next phase.

Second day is started with the transferring and erecting of Tunnel Formworks and Outside Wallforms to their next locations and continue with concreting.

At the same time, Platforms left behind the First Concreting Phase is transferred to the next locations (generally to the next floor)

Cycle has to be completed and next day will be started with the transferring and erecting of Tunnel Formworks to the First Concreting Phase of the next floor.

Stripping Direction

Outside Wallform

Length of a Half Tunnel

Back Panel

Tunnel Number

Length of a Half Tunnel Set

Deck Panel Extension

Slab casted in 1st. Phase of Concreting

R.C.Wall casted in 1st. Phase of Concreting

Half Tunnel Sets kept in previous positions

Half Tunnel Sets transferred to location of 2.nd Phase of Concreting

Outside Wallforms transferred to location of 2.nd Phase of Concreting

Slab casted in half in 1st. Phase of Concreting




Once the Tunnel Formworks and Outside Wallforms are erected to the locations on the First Concreting Phase, the Platforms left behind the Second Concreting Phase will be transferred to the next locations (generally to the next floor)

Slab cast in 1st. Phase of Concreting

R.C.Wall cast in 1st. Phase of Concreting

Slab cast in 2nd. Phase of Concreting

R.C.Wall cast in 2nd. Phase of Concreting

Slab completed in 2nd. Phase of Concreting




On Site

Foundation is completed as per construction drawings.

Before the first casting with Tunnel Form, kicker should be cast in order to position the load bearing concrete walls.

Reinforcement wire mesh and bars of the concrete walls are installed.

First Half-Tunnel set is taken to place by crane in accordance to the formwork layout. Bottom of Tunnel Form is set levelled with the line on the kickers by the help of the jacks mounted on the Vertical Panels.

Block-outs for door/window openings are assembled on vertical surface.

Electrical Conduits are installed.

Cones and tie-rods are placed.

Second Half Tunnel Unit is taken to place. Block-outs are assembled. The verticalities of Half Tunnel Units are set using the Wheeled Supports.

After providing adverse deflection of deck panels, two Half-Tunnel Units are locked by the roof locks on the Deck Panels.

Cones and tie-rods are placed.




All Tunnel Form Units for the first casting phase are located in a same manner. Outside Wall Formworks for endwalls are positioned.

After adjusting the verticalities of all Tunnel Forms, tie-rods are fastened and Horizontal surfaces are oiled.

Electrical Conduits are installed. Block-outs for openings on slab are installed. Wall and Slab stopends are set in place.

Reinforcement wire mesh and bars on slab are installed and the Kicker forms for next level are fixed on the Tunnels.

Final checks are performed before concreting and Insulation curtains are placed for night-time heating at cold weathers.

Concreting procedure is started from the inside walls towards the end walls firstly. Then the slab concrete is cast.

Each tunnel room is heated by simple heaters throughout the night for curing purpose at cold weather.

Next morning is started with dismantling of tie-rods.

Half Tunnel Sets are dismantled to each other. Block-outs are also dismantled from Half Tunnel Units.

Half Tunnels are moved on the rollers and pulled-out by crane to the next place of concreting by the help of lifting triangle.

Reinforcement wire mesh and bars are installed for the next level.




Surfaces of Vertical panels are cleaned and oiled while stripping the Half Tunnel Sets.

At every span, the slab is back propped after the first Half Tunnel Unit is stripped.

Second Half Tunnel Unit is removed after back propping.

Stripping-Platforms and Gable-end-Platforms are introduced to the building on the ground level where the Half Tunnels are in the first level. These platforms are all around the perimeter of the building.

Tunnel Form Sets are stripped out on Stripping-Platforms.

Introduction� System Overview



For product, installation and operation details of Stripping Platforms, Landing Platforms and Gable End Frames to be used, refer to relevant booklets given by MESA.

SYSTEM OVERVIEW

ABCDEFGHIJKLMNP

J E GC

N D M H A

Half Tunnel Back Panel Outside Wallform Lifting Beam Lifting Device RollerKicker Form Slab Stopend Wall Stopend Slab Boxout Door Boxout Window Boxout Stripping Platform Gable End Frame Tie-rod & Cone Set

Main Parts B

F

Introduction� System Overview



I P K B L

Only the bottom edges of Vertical Panels are made of 15x120mm steel plates.

The end of the deck panel, built of an 80x80-mm. steel angle section carries the key locks permitting the assembly of two units face to face. Generally the turn of the deck panels to verticals is 63 mm. The turns on the back panels are 93 mm. to vertical and deck panels. The connection between the panels is done with U-shaped alignments and bolts.

The surfaces of panels which are forming the tunnel form are made from THRU 3244 3-mm. steel plate (equal to St.44). They are stiffened by 50x60mm square tubes, welded at every 178 mm. Panels are assembled rigidly one to the other by special U-shaped centering pieces and bolts which enable only slight deformations of the dihedral.

The lateral ends of the panels are made of 60x30x4mm cold rolled U-profiles, in which the connecting equipment is employed to ensure the correct fit of the consecutive units. Assembly is carried out using

i

Basic Materials

Introduction� Dimensions & Physical Properties



As a feature of ERTF – Modular Tunnel Formwork System, Inside and Outside Panels are same and they are called as “Vertical Panels”.

v

h : Floor Height s : Slab Thickness w : Wall Thickness g : Span between Walls a : Kicker Height v : Gap between two panels (=2mm)

w g

WD2WD1 a

s

h

concrete already poured

concrete to be poured

HV

HT :Tunnel Height WD :Deck Panel Width WDE :Deck Panel Extension Width HV :Inside Panel Height HVE :Inside Panel Extension Height HB :Back Panel Height

HQ

h = K + HV + TD + s g = ( WD1 + WDE1 ) + ( WD2 + WDE2 ) + v

Detail A

HT

HT = HV + TH

HQ + HQE = h + a - K HB = HT

TD = 63mm

System Section

hnet (Net Floor Height) = h (Floor Height) - s (Slab Thickness)

DIMENSIONS & PHYSICAL PROPERTIES�

HQ :Outside Panel Height HQE :Outside Panel Extension Height TD :Deck Panel Turn TB :Back Panel Turn K :Jack Height t :Height of Panel Touch to Kicker

WDE2WDE1

TD HVE

K

HQE

a K

t

Detail A

�

t = a - K

Floor Height (from Slab to Slab)

Total Outside Panel Height

Net Floor Height (From Slab to Ceiling)

Span between Two Adjacent Walls

Tunnel Height

Back Panel Height Total Inside Panel Height

HV + HVE = hnet - K - TDHQ= HV

ERTF Feature

TB = 93mm a = 120mm

K = 87 mm t = 33 mm




Larger spans “g” than 5700 mm can be achieved by introducing table forms between two half tunnels.

Other Span dimensions are provided by additional filler forms called as “Exensions” installed to Deck and Back Panels or introducing new Panels having required dimensions.

Other Floor Height dimensions are provided by additional filler forms called as “Exensions” installed to Vertical Panels or introducing new Vertical Panels having required dimensions.

WD Combinations for Span “g”

Frequently Used Tunnel Heights

Standard Span & Floor Height

1049 1349 1649 1949 2249 2549 2849

1049 2100 2400 2700 3000

1349 2400 2700 3000 3300 3600

1649 2700 3000 3300 3600 3900 4200

1949 3000 3300 3600 3900 4200 4500 4800 Best

2249 3600 3900 4200 4500 4800 5100 Better

2549 4200 4500 4800 5100 5400 Rarely

2849 4800 5100 5400 5700 Never

Preference Table for Standard Spans "g" (mm) (including v = 2 mm)

WD

2 + W

DE2

WD1 + WDE1

Preference Order

hnet HT HB HV HVE HQ HQE

2650 2563 2563 2500 0 2,500 183 + s

2700 2613 2613 2500 50 2500 233 + s

2750 2663 2663 2500 100 2500 283 + s

2800 2713 2713 2500 150 2500 333 + s

2850 2763 2763 2500 200 2500 383 + s

2850 2763 2763 2700 0 2700 183 + s

2900 2813 2813 2700 50 2700 233 + s

2950 2863 2863 2700 100 2700 283 + s

3000 2913 2913 2700 150 2700 333 + s

3050 2963 2963 2700 200 2700 383 + s

Tunnel and Panel Heights (mm)

g (mm)

2100

2400

2700

3000

3300

3600

3900

4200

4500

4800

5100

5400

5700

Standard Spans

hnet = h-s (mm)

2650

2700

2750

2800

2850

2900

2950

3000

3050

Standard Floor Heights




If HV = 2500 mm then b=1000 mm If HV = 2700 mm then b=1200 mm

�

Stress Diagram �

Deflection Diagram �

Physical Properties

Inside, Outside and Back Panels are fitted to each other by three tie-rods located vertically.

Maximum horizontal distance between tie-rods is 1250 mm.

Allowable load on Tie-Rods is 90 kN.

Allowable hydrostatic pressure of concrete to be applied on Vertical Panels having maximum height of 2700 mm is 67.5 kN/m2.

Maximum deflection on Vertical Panels under allowable concrete pressure is 1.45 mm.

260

290

950

b

HV

Technical�Information� Parts in Detail

ERTF – Modular Tunnel Form System 16


For wider spans, Table Forms are placed between the Deck Panels to ensure not to exceed the allowable deflection of the slab.

A – Half Tunnel �

1

The standard form (half-shell) take the form of a right hand dihedral, whose vertical plane “HT” is made up of a floor-height panel, less the slab thickness “s” and less “K (= 87 mm)” (or more if the kicker is high) for jacking down.

“WD” is the width and “TD” is the turn of Deck Panel. Turn is generally equal to 63 mm. It could also be 33 or 93 mm. “WDE” is the width of Deck Panel Extension. The sum of the widths of Deck Panels and their Extensions for a certain span is 2mm less than the span width “g”.

“HV” is the height of Vertical Panel. “HVE” is the height of Vertical Panel Extension.

The-standard lengths “L” of the dihedrals are 2.50 m. and 1.25 m. According to the length of the bay, special panels can also be provided.

PARTS in DETAIL�

WDE

g L

HT

WDL

HV

HVE

TD

2

5

78

4

3

6

9

Legend Pcs.

1 Deck Panel 1

2 Deck Panel Extension 1

3 Vertical Panel 1

4 Vertical Panel Extension 1

5 Foldable Prop 2

6 Wheel Support 2

7 Wheel Connector 1

8 Tunnel Driving Wheel 1

9 Vertical Panel Jack 2




1 – Deck Panel

The surfaces of Deck Panels are made from THRU 3244 3-mm. steel plate. They are stiffened by 50x60 mm square tubes, welded at every 178 mm. They are assembled rigidly one to the other and to the Inside Panels by U-Alignments and bolts which enable only slight deformations of the dihedral.

The one end of the deck panel is built of a 60x60x4 mm. cold rolled U-profiles permitting the assembly of inside panel and/or inside panel extension. Generally turn of the deck panels to verticals is 63 mm. The connection between the panels is done with U-Alignments and bolts.

The opposite end which is connected to the Extension Panel is made of 60x30x4mm cold rolled U-profile.

2 – Deck Panel Extension

WD

TD

L

850 1150 1450 1750 2050 2350 2650

1250 (850 + 63 ) x 1250 (1150 + 63 ) x 1250 (1450 + 63 ) x 1250 (1750 + 63 ) x 1250 (2050 + 63 ) x 1250 (2350 + 63 ) x 1250 (2650 + 63 ) x 1250

2500 (850 + 63 ) x 2500 (1150 + 63 ) x 2500 (1450 + 63 ) x 2500 (1750 + 63 ) x 2500 (2050 + 63 ) x 2500 (2350 + 63 ) x 2500 (2650 + 63 ) x 2500

Standard Dimension of Deck Panels ( W D + T D ) x L (mm) ( T D = 63 mm)

WD

L

The surfaces of Deck Panel Extensions are made from THRU 3244 3-mm. steel plate. They are stiffened by 50x60 mm square tubes in a reduced quantity.

The other two reciprocal ends which are connected to the other Deck Panels are also made of 60x30x4mm cold rolled U-profiles in which the connecting equipment is employed to ensure the correct fit of the consecutive units.

WDE

L

149 199 249 299 349

850 999 1049 1099 1149 1199

1150 1299 1349 1399 1449 1499

1450 1599 1649 1699 1749 1799

1750 1899 1949 1999 2049 2099

2050 2199 2249 2299 2349 2399

2350 2499 2549 2599 2649 2699

2650 2799 2849 2899 2949 2999

WDE

WD

Total Dimensions with Std.Deck Panels and Std.Deck Panel Extensions ( W D + W DE ) (mm) Three ends which are to be connected to Deck Panels or Extensions permanently are made of 60x30x4mm cold rolled U-profiles.

The remaining end built of an 80x80-mm. steel angle section carries the key locks permitting the assembly of two units face to face.

Extensions are connected to Vertical Panels with Centering U and bolts.

Standard Openings

The alignments of two panels are provided by the adjustment of Hinge Bolts.

Standard lengths “L” are 1250 and 2500 mm.




3 – Vertical Panel

ERTF - Vertical Panels are used as both Inside Panels of The Half Tunnels and Panels of the Outside Wallforms. Therefore, Outside Panel height “HQ” is equal to the height of Inside Panel “HV” on the Half Tunnel.

Same with the Deck Panels, the surfaces of Vertical Panels are also made from THRU 3244 3-mm. steel plate. They are stiffened by 50x60 mm square tubes, welded at every 178 mm. Three Main Stiffeners which are welded to the panels on the levels of Tie-Rods are made up of 50x100x5 mm Cold Rolled U-Profiles. These stiffeners are also used for connections of Wheel Supports, Foldable Props.

All edges except the lower edge, are made of 60x30x4mm cold rolled U-profile. Vertical Panels are connected to each other or Extension Panels or Deck Panels by these edges with Centering U and bolts. The lower edge is made up of Steel Plate having 15x60mm section. This Plate increases the strength of the Panel against any impacts or buckling which might be occurred during striking from concrete with lever arms.

There are two standard heights of Vertical Panels which are 2500 and 2700mm.

L

HV = HQ

4 – Vertical Panel Extension (Inside)

2500 2700

1250 1250 x 2500 1250 x 2700

2500 2500 x 2500 2500 x 2700

HV=HQ

Standard Dimensions (mm)

L

Inside Vertical Panel ExtensionHV

L

All materials used in Vertical Panel Extension are same with that of Vertical Panels.

The edges of Panel Extensions are made from 60x30x4mm cold rolled U-profile. Extensions are connected to Vertical Panels by this edge with Centering U and bolts.

The alignments of two panels are provided by the adjustment of Hinge Bolts. 150 160 170 190 200 210

2500 2650 2660 2670 2690 2700 2710

2700 2850 2860 2870 2890 2900 2910

Total Vertical Panel Height in Tunnel Formwork

Sum of Vertical Panel and Vertical Panel Extension ( H V + H VE ) (mm)

HVE

HV




For Vertical Panel Height “HV” as 2500 mm, Deck Panel Width “WD” as 1150 mm and Vertical Panel Extension Height “HVE” as 100 mm ,

Then select ; Foldable Prop as #1, and take ; LJ = 350 mm & LK = 167 mm

Two Foldable PropTypes described as; Prop #1 : Foldable Prop – 2500 Prop #2 : Foldable Prop – 2700

HV HVE # LJ LK # LJ LK # LJ LK # LJ LK # LJ LK # LJ LK # LJ LK

2500 0 1 200 128 1 250 173 1 400 155 1 550 163 1 600 158 1 750 153 1 800 147

2500 50 1 200 175 1 300 171 1 450 149 1 600 156 1 650 149 1 750 190 1 850 181

2500 100 1 250 175 1 350 167 1 500 143 1 650 147 1 700 140 1 800 179 1 900 169

2500 150 1 300 173 1 400 164 1 500 187 1 700 139 1 750 131 1 850 168 1 900 157

2500 200 1 350 172 1 450 161 1 550 182 1 700 181 1 750 172 1 900 157 1 950 145

2700 0 1 350 172 2 400 210 2 600 132 2 700 181 2 700 222 2 900 157 2 900 195

2700 50 2 400 170 2 500 157 2 600 176 2 700 223 2 800 163 2 900 197 2 1000 133

2700 100 2 400 219 2 500 204 2 600 221 2 800 166 2 800 206 2 1000 137 2 1000 172

2700 150 2 500 168 2 600 151 2 700 166 2 800 208 2 900 148 2 1000 177 2 1000 210

2700 200 2 500 216 2 600 199 2 700 211 2 900 151 2 900 190 2 1000 217 2 1100 149

Vertical Panel

Vertical Panel

Extension850 1150 1450 1750 2050 2350 2650

Height ( mm ) Standard Deck Panel Widths (W D) ( mm )

Foldable Prop Adjustment on Tunnel Formworks"Standard Vertical Panel Extensions" versus "Standard Deck Panel Widths"

5 – Telescopic Foldable Prop�

Inclined prop made of two nested tubes having Ø76 mm and Ø60 mm diameter (as outside and inside tubes) makes easy to adjust the nominal length of inclination to ensure the perpendicularity of vertical and deck panels by a screw jack. Telescopic feature of the prop provides the usage of it for all standard span lengths of Deck Panels.

Required reverse deflection of the Deck Panel before concreting is easily adjusted and the Prop is fixed with the counter nut. After concreting, in order to draw down Deck Panel from the concrete the Folding Arm is turned on. Then Deck Panel will be dropped. By superposing the holes both on Inside and Outside tubes, The Length “LJ” could be adjusted with 50 mm incrementation.

Table below shows the adjustments of Variable Lengths on Telescopic Foldable Props according to the selected Vertical and Deck Panels. Reverse deflection of Deck Panel before concreting operation will be provided by additional adjustment of the dimension “LK” of the Jack which will be described in the Booklet of “User’s Manual” supplied by MESA.

LF

LK

LJ

Folding Arm is open

Lprop

Lprop = LF + LJ + LK

LF

min max min max min max

#1 1821 200 950 78 330 2099 3101

#2 1821 200 1300 78 330 2099 3451

Types of

Props

LJ LK Lprop

Folding Arm is closed

Te

ER

TE

6

aS

gao

D“

7

a

op

2

2

echnical�Info

RTF – Modular T

ECHNICAL M

Wheethe H2500

Wheethe H1250m

(2500

6 – Wheel S

ERTFa Special WhSupports.

Wheegalvanised tuband the Wheeof it.

LengtDeck Panel w“HV”.

7 – Wheel C

Wheeand the Tunne

Rigid of Ø48mm tubplates.

HV

Whee2700

Whee2500

HV

WheL

2500or

2700

formation�

Tunnel Form S

MANUAL – 2

el SupportsHalf Tunnel

0mm or 1250

el ConnectorHalf Tunnel mm) or the Ve0mm or 2700mm

Support

F Modular Halfheel unit sup

el Support is mbe. This suppl Unit with bo

th of Wheel Swidth “WD” a

Connector

el Connector jol Driving Whe

body of the Wbes and spec

"Deck Panel

850 � WD � 1150

el Support 85-115 (27L S=2040

el Support 85-115 (25L S=1857

eel Connector (85L C=717 L D=108

Ty"Deck Panel Wi

850 � WD � 115

System

2/2011

s do not dil Length “L0mm.

rs do not dLength “L”

ertical Panel m) .

f Tunnel is drivpported by a

made up of Øport is connecolts via the ho

Support “LS” nd the Vertic

oins the Paneel.

Wheel Connecially shaped

Types of Whel Width W D " versu

145

700) Wheel Su

500) Wheel Su

5-115)88

W

L C=

ypes of Wheeidth W D" versus

50 14

ww

iffers whethL” is equal

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Height “HV”

ven by means pair of Wh

Ø48mm hot dected to the Pales at both en

varies with cal Panel hei

l, Wheel Supp

ector is made 8mm thick st

eel Supports us "Vertical Panel

50 � WD � 1750

upport 145-175 (270L S=2289

upport 145-175 (250L S=2123

Wheel Connector (145-175)

=1317 L D=1088

l Connectorss "Vertical Pane

450 � WD � 1750

20 ww.mesaimala

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ver or

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Height H V "

2050

Wheel SuppL

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L C=161

el Height H V "

2050

t.com.tr

� WD � 2650

port 205-265 (2700)L S=2478

port 205-265 (2500)L S=2357

el Connector205-265)17 L D=1088

� WD � 2650

“LC” andwidth “W

Refer to secon this MinformationWheel Suppo

Dimensions od “LD” vary w

WD” only.

Parts

ction of “PartManual for

about typeort.�

LS

LD

LC

of Wheel Conwith the Deck

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t List”more

es of

nector Panel




8 – Tunnel Driving Wheel

9 – Vertical Panel Jack

By connecting directly to the Wheel Connector and Wheel Supports, Tunnel Driving Wheel provides horizontal movement of ERTF-Modular Tunnel Formwork during erecting or stripping operations, as well as the vertical alignment of the Tunnel because of the included Jack on it.

5,000 kg loading capacity of the Wheel assembly has a long life of working period.

Whatever the length “LS” (1250mm or 2500mm) of the Half Tunnel Formwork is, each Vertical Panel is supplied with two Panel Jacks which are uninstalled.

These Dismountable Jacks gives great versatility to the system when transporting of Vertical Panels or if maintenance or repairment is required.




According to the width of the span, special back panels can also be provided but must be avoided for the sake of non-diversified inventory items and for future use.

B – Back Panel

The surfaces of Back Panels are made from THRU 3244 3-mm. steel plate. They are stiffened by 50x60 mm square tubes, welded at every 178 mm.

The one vertical end of the Back Panel is built of an 60x30x4 mm. cold rolled U-profiles so that the direction of it permits the assembly of Inside Panel and/or Inside Panel Extension. The turn of the Back Panels to verticals is 93 mm. The connection between the panels is done with Centering–U pieces and bolts. If the side which has a turn of 93mm is on left, The Back Panel is called as Left Back Panel, otherwise The Panel is called as Right Back Panel.

The upper end of the Back Panel is built of an 60x30x4 mm. cold rolled U-profiles also. This turn permits the assembly of Deck Panel and/or Deck Panel Extension. The turn of the Back Panels to horizontal is also 93 mm. The connection between the panels is done with Centering –U pieces and bolts.

As in the half tunnel, vertical height of the Back Panel “HB” is the floor-height, less the slab thickness “s” and less the jack height “K” which is nominally equal to 87 mm (or more if the kicker is high) for jacking down.

“HB” is the height of Back Panel which is equal to height of Vertical Panel “HV” plus the turn of Deck Panel “TD”.

TB

HB

WD

1

2

Legend

1 – Back Panel 2 - Back Panel Wheeled Jack

hnet HT HB

2650 2563 2563

2700 2613 2613

2750 2663 2663

2800 2713 2713

2850 2763 2763

2850 2763 2763

2900 2813 2813

2950 2863 2863

3000 2913 2913

3050 2963 2963

Tunnel and Back Panel Heights (mm)

93 mm Left Turn 93 mm Right Turn

1049 (1049 x HB).L93 (1049 x HB).R93

1349 (1349 x HB).L93 (1349 x HB).R93

1649 (1649 x HB).L93 (1649 x HB).R93

1949 (1949 x HB).L93 (1949 x HB).R93

2249 (2249 x HB).L93 (2249 x HB).R93

2549 (2549 x HB).L93 (2549 x HB).R93

2849 (2849 x HB).L93 (2849 x HB).R93

WD

Standard Dimension (mm) Width (mm)




Legend pcs pcs

a – b a – b

According to the width of the span, special vertical panels can also be provided but must be avoided for the sake of non-diversified inventory items and for future use.

C – Outside Wallform

1250 1250 x HQ

2500 2500 x HQ

Standard Dimension (mm)

L

6 – Platform Connector 2 - 2 7 – Guardrail Post 2 - 1 8 – Guardrail Connector 0 - 1 9 – Ladder (optional) 1 - 110 – Ladder Connector(opt) 1 - 1

1

2

3

45

7

9

10

1 – Vertical Panel 1 - 1 2 – Vertical Panel Ext. 1 - 1 3 – Panel Support 2 - 1 4 – Platform Support 2 - 1 5 – Working Platform 1 - 1

HQ

HQE

L

ERTF - Vertical Panels are used as both Inside Panels of The Half Tunnels and Outside Panels as described in Section “Vertical Panels on Half Tunnels” of this Manual. Therefore, the height of Vertical Panel “HQ” used in Outside Wallform is equal to the height “HV” of the Inside Panel on the Half Tunnel .

Three Main Stiffeners which are welded to the panels on the levels of Tie-Rods, are made up of 50x100x5 mm Cold Rolled U-Profiles. These stiffeners are also used for connections of Platform Supports, Panel Supports and Ladder Connectors.

All edges except the lower edge are made of 60x30x4mm cold rolled U-profile. Outside Panels are connected to each other or to Inside Panels of Half Tunnels by these edges with Centering U and bolts. The lower edge is made up of Steel Plate having 15x60mm section. This Plate increases the strength of the Panel against any impacts or buckling which might be occurred during striking from concrete with lever arms.

hnet HT HQ HQE

2650 2563 2500 183 + s

2700 2613 2500 233 + s

2750 2663 2500 283 + s

2800 2713 2500 333 + s

2850 2763 2500 383 + s

2850 2763 2700 183 + s

2900 2813 2700 233 + s

2950 2863 2700 283 + s

3000 2913 2700 333 + s

3050 2963 2700 383 + s

Tunnel and Panel Heights (mm)

1 – Vertical Panel

6

Total vertical height of the Outside Panels which is “HQ + HQE” is the floor height “h” plus the kicker height “a (= 120 mm)” and less “K (= 87 mm)” for jacking down.

10

2

3

4

5

7

9

9HQ

HQE

L

6

L=2500 mm

L=1250 mm

a

b

1

8




HQE

L

333 383 433 483 533 583

2500 2833 2883 2933 2983 3033 3083

2700 3033 3083 3133 3183 3233 3283HQ

Sum of Vertical Panel and Vertical Panel Extensions ( H Q + H QE )(mm)

Total Vertical Panel Height in Outside Wallform

HQE

All materials used in Vertical Panel Extension are same with that of Vertical Panels.

The edges of Panel Extensions are made from 60x30x4mm cold rolled U-profile. Extensions are connected to Vertical Panels with Centering U and bolts.

Lifting Hooks welded on Outside Panel Extensions are the only difference between Inside and Outside Panel Extensions.

2 – Vertical Panel Extension (Outside)

3 – Panel Support

4 – Platform Support

Simplified Panel Support is easily connected to the Vertical Panel through the bottom and middle stiffeners on it.

There is only one type of Panel Supports used on Vertical Panels having the height “HQ”of 2500 and 2700 mm.

Platform Supports are also connected to the Vertical Panels through the middle stiffeners on them.

2500 Platform Support-2500

2700 Platform Support-2700HV=

HQ

Types of Platform Supports

1250 1 piece

2500 2 pieces

L

Quantities of Panel Supports

1250 1 piece

2500 2 pieces

Quantities of Platform Supports

L

The alignments of two panels are provided by the adjustment of Hinge Bolts.

On the Outside Panel whose length is greater than 1250mm, always 2 pieces of Panel Supports must be connected.

On the Outside Panel whose length is greater than 1250mm, always 2 pieces of Platform Supports must be connected.

There are two standard Platform Supports according to the Vertical Panel heights “HQ” of 2500 and 2700 mm.




Walking Platforms with Shutter have only two different Lengths “LPL” which are 1200 and 2400 mm.

5&6 – Working Platform & Platform Connector

7&8 – Guardrail Post & Connector

9&10 – Ladder & Ladder Connectors�

MESA-Universal Working Platforms are suitable for Outside Wallforms used in ERTF-Modular Tunnel Formwork System.

Each Walking Platform is connected to the Vertical Panel by two pieces of Platform Connectors.

Working Platform

Working Platform with Shutter

LPL

Two pieces of Guardrail Post are installed to the Working Platforms whatever the Platform Length “LPL” is.

On the Working Platforms whose “LPL” is smaller than 1500mm, Guardrail Post is installed to the Platform with a Post Connector.

The nominal height of the MESA-Universal Guardrail Post used in ERTF-Outside Wallforms is 1200mm.

Ladders are designed for maximum safety.

In order to install the Ladder, “Working Platform with Shutter” must be selected as the Working Platform.

The Ladder Connector provides rigid connection of the Ladder and the Vertical Panel.

Platform Connector

Guardrail Post (1200)Guardrail Connector

Guardrail Post Post Connector

600 2 2800 2 2

1000 2 21200 2 21500 2 01700 2 02000 2 02400 2 0

Platform Length "LPL"

Quantities

Panel Length "L" Platform Length "LPL"

800 > L � 625 6001000 > L � 800 800

1200 > L � 1000 10001500 > L � 1200 12001700 > L � 1500 15002000 > L � 1700 17002400 > L � 2000 20002500 � L � 2400 2400




Summary of Quantities varying with the Panel Length “L”�

800 > L � 625 600 1 pc 1 pc 2 pcs. 2 pcs. 2 pcs.1000 > L � 800 800 1 pc. 1 pc. 2 pcs. 2 pcs. 2 pcs.

1200 > L � 1000 1000 1 pc. 1 pc. 2 pcs. 2 pcs. 2 pcs.1500 > L � 1200 1200 1 pc. 1 pc. 2 pcs. 2 pcs. 2 pcs.1700 > L � 1500 1500 2 pcs. 2 pcs. 2 pcs. 2 pcs. 02000 > L � 1700 1700 2 pcs. 2 pcs. 2 pcs. 2 pcs. 02400 > L � 2000 2000 2 pcs. 2 pcs. 2 pcs. 2 pcs. 02500 � L � 2400 2400 2 pcs. 2 pcs. 2 pcs. 2 pcs. 0

Post ConnectorPanelSupportPanel Length "L" Platform Length

"LPL" Platform Support Platform Connector Guardrail Post




In non-standard total lenght of half tunnels units which are not listed above, Length of the Lifting Beam should be choosen from the standard values regarding the below formula ;

500 mm < ( LT – LL ) < 1500 mm�

D – Lifting Beam

E

D

A

L =2500mm L =2500mm L =1250mm

L=2500 mm L=1250 mm

1

1

1 1

2

2 1

3 7500

1000

2000

3000

4000

5000

5000

1250

2500

3750

5000

6250

Number of Half Tunnels Total Length of Tunnel

LT (mm)

Standard Lengths of Lifting Beam

LL (mm)

Determination of Length of Lifting Beam The lifting beams are for hoisting

the tunnel form arrays. The deflection of a tunnel form array is controlled by them.

They increase the strength of Tunnels during stripping and lifting operations.

Length of the Lifting Beam is determined according to the total lengths of Tunnels to be stripped together.

Lifting Beams are installed to the Tunnel Form with special Lifting Beam NPL and special bolts.

For the Tunnels having the total length greater than 7500 mm, Trusssed Lifting Beam should be used, refer to MESA advisory.

LLHalf Tunnel Lifting Beam Lifting Triangle

A D E




For safety regulations, Lifting Triangle should be operated according to the rules described in “ERTF–User Manual”

E – Lifting Devices

1 – Assembly Device�

2 – Lifting Triangle (Classic)�

This is only used for assembly at the beginning.

During this operation some loading may occur which try to bend the Bearing Rod. Frequently this will end by an observed bending on the Bearing Rod.

This apparatus is supplied only to protect the Lifting Triangle from these types of loads and bending as it is not used at this stage.

This is used for lifting and carrying operations of the Tunnel Formworks.

The Cylindrical Bearing minimizes the effect of the bending moments.

The Wing Nut has to be tightened thoroughly for a smooth operation.

Load Test of Classic Lifting Triangle; Nominal load: 4000 kg.s Test load : 6750 kg.s No permanent deformation has been observed under 6750 kg.s.

Test during operation: Satisfactory results have been obtained from a number of accelerated tests applied to the Bearing Rod under mock site conditions.

Hook BedMain Frame

Cylindrical BearingRubber Wedge

Bearing RodWing Nut

Assembly Device cannot be used for carrying the Tunnel Formwork.

Maximum usage of the Bearing Rod could not be greater than 300 times.




Load Test of Asymetrical Lifting Triangle; Nominal load: 4000 kg.s Test load : 6750 kg.s No permanent deformation has been observed under 6750 kg.s.

Test during operation: Satisfactory results have been obtained from a number of accelerated tests applied to the Bearing Rod under mock site conditions.

2 – Lifting Triangle (Asymetrical)�

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.

Platform timber under slab Stripping Half Tunnel

LTOT

LLT

LG

It is easier to handle and transport the Asymetrical Lifting Triangle than the Classic Lifting Triangle.

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.

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

LG > LLT

Maximum usage of the Bearing Rod could not be greater than 300 times .




F – Roller

Half-tunnels can easily be moved and stripped on platforms by the help of rollers which are used instead of wheels. It is placed under vertical panel of half-tunnels above the slab.

It reduces vertical panel price by cancelling the wheels and also simplify storage of vertical panels.

Formwork weight will not affect stripping platform as the tunnel forms are carried by the rollers during their movement.

There are two types of Rollers used for different operations ;

HR = 53mm : for stripping the Tunnel Forms HR = 73mm : for setting up the Tunnel Forms

HR




Concrete Stoper Straight Kicker Form Kicker Clamp (Two Sided) Kicker Spacer (Two Sided) Corner Kicker Form Inner Kicker Form Kicker Spacer (One Sided) Kicker Clamp (One Sided)

12 3 4 5 6 7 8

G – Kicker Form Set

Kicker Forms are 120x80 mm steel angle sections (or larger if necessary) in accordance with the line of the building walls. These angle sections, marked with respect to one another, are assembled at site in accordance with the assembly plan provided.

Tunnel Form segment is set in place using the Kicker Form as a guide.

They are erected by means of steel rests and spacers on the tunnel forms prior to concreting. Their location automatically ensures the correct positioning of the walls�and the door openings.

8 7 K 3 4 K

K

Vertical Panel (outside)

Vertical Panel (inside)

Deck Panel

View A

View B

View A View B

w

s




Dimensions of Spacers and Clamps are determined according to the wall and slab thicknesses.

2

6

5

2, 5, 6 – Kicker Forms�

LS

LI

LC

LCT

1

7

6 4

3

1, 3, 4, 7, 8 – Clamps and Spacers�

w

s

w

s

Standard Kicker Form Lengths (mm)

LC + LCT

2593 + 300 (Right)

2593 + 300 (Left)

LS LI

1250 1498

2500 1798

3750 2098

5000 2398

2698

2998

3298

4198

4498

3598

3898

Kicker Spacers provides the width of the kicker to be same as the wall thickness by preventing the Kicker Forms to close to each other.

Two sided Kicker Spacer fits onto the Deck Panels from two sides.

One sided Kicker Spacer fit onto the Deck Panels from one side only. The other side is in contact with the Outer Vertical Panel.

Conical shaped arms allow the Spacers to extract from the concrete.

In contrast with the Kicker Spacers, Kicker Clamps do not allow the Kicker Forms to apart from each other.

Kicker Forms work such a formwork having 120 mm height.

Straight Kicker Forms are used throughoutly the length of the Half Tunnels.

Onto the Back Panels, two Corner Kicker Forms (left and right) and one Inner Kicker Form between the two are located so that the span “g” between two walls are achieved.

4 - Kicker Spacer (Two Sided) 7 - Kicker Spacer (One Sided) 3 - Kicker Clamp (Two Sided) 8 - Kicker Clamp (One Sided)

1 - Concrete Stoper 2 - Straight Kicker Form 5 - Corner Kicker Form 6 - Inner Kicker Form




H & I – Stopends�

All surfaces of stop-ends are made from the

same steel that panels are made.

The lateral ends of the stop-ends are made of 60x30x4mm. Cold rolled U-profiles.

Slab Stopend Wall Stopend

g

s

WD2 ww

HQ

Slab Stopend�

Wall Stopend�

The thickness of the Slab Stopend is same with

the slab thickness “s”.

Width of the Slab Stopend “WSS” is 4 mm less than the sum of the Deck Panel width “WD” and Deck Panel Extension width “WDE” on which it is located.

The thickness of the Wall Stopend “ww”is 2 mm

less than the wall thickness “w”.

Height of the Wall Stopend is same with the Outer Vertical Wallform height “HQ”.

WD1

v

hnet HT HQ

2650 2563 2683 + s

2700 2613 2733 + s

2750 2663 2783 + s

2800 2713 2833 + s

2850 2763 2883 + s

2900 2813 2933 + s

2950 2863 2983 + s

3000 2913 3033 + s (3033 + s ) x ( ww )

(2933 + s ) x ( ww )

(2883 + s ) x ( ww )

(2833 + s ) x ( ww )

(2783 + s ) x ( ww )

(2733 + s ) x ( ww )

Standard Dimensions of Wall Stopends H Q x ( w w ) (mm)

HQ x ( ww )

(2683 + s ) x ( ww )

(2933 + s ) x ( ww )

WDE1 WDE2

WSS = WD + WDE – 4 mm

WD + WDE 1049 1349 1649 1949 2249 2549 2849

(1045 + 93 ) x s (1345 + 93 ) x s (1645 + 93 ) x s (1945 + 93 ) x s (2245 + 93 ) x s (2545 + 93 ) x s (2845 + 93 ) x s

Standard Dimension of Slab Stopends ( W SS + T B ) x s (mm) ( T B = 93 mm)




J – Slab Boxouts ( a x b x s )�

K – Door Boxouts ( a x b x y )�

All surfaces of Slab Boxouts are made from the

same surface material (st-37 steel) that panels are made.

The backs of the surface material are made of 3 mm Cold rolled U-profiles which has the dimension same with the slab thickness “s”.

One set of Slab Boxout consists four pieces of L- shaped units which are connected to each other.

Connection principle of these four units is the same with the connection of two Deck Panels on the Half-Tunnels so that the gap “v” between two units will be 2 mm.

ab

dd

v

c

c

v

d = (b / 2) – 1mm c = (a / 2) – 1mm

s

L – Window Boxouts ( a x b x y )�

b

v

d d

a

y

d = (b / 2) – 1mm y = w – 2mm

Materials are same with that of Door Boxouts.

One set of Window Boxout consists four pieces

of L- shaped units like in Slab Boxouts.

Connection principle of these four units is the same with the connection of four Slab Boxout units.

The thickness of the Window Boxout “y” is 2 mm less than the wall thickness “w”.

c

c

a

bd

d

v y

1

2

3

4

1 2

Materials are same with that of Slab Boxouts.

One set of Door Boxout consists two pieces of

L- shaped units which are connected to each other.

Connection principle of these two units is the same with the connection of four Slab Boxout units.

Jacks at the bottom provides to lower the Door Boxout during stripping operation same as in Half Tunnel operations.

y = w – 2mm

c = (a / 2) – 1mm

d = (b / 2) – 1mm

1

2

3

4




Tie-Rods used on the extension joints or dilatations are different.

Thread standard on Tie-Rod, Wing Nut and Flang Nut is M23 (10mm rounded pitch).

P – Tie Rod & Cone Set�

w - 2

Flange Nut

Composite Cone

Plate 100x100

Wing Nut

Tie-Rod

Tie Rods are horizontally located on each 1250 mm of Vertical Panels.

The number of Tie-rods in vertical position is three.

In each Tie-Rod & Cone set, there are ; One piece of Tie-Rod One piece of Composite Cone One piece of Wing Nut One piece of Steel Plate (100x100mm) One piece of Flange Nut

Wing Nut and Steel Plate are used together on the same side.

Tightening operation is realised on the side where the Wing Nut and Steel Plate exist. Then the Flange Nut is tightened automatically.

Cone length should be 2mm less than the wall thickness.

Tie-Rod length is selected according to the wall thickness.

w Cone length Tie-Rod Length

(mm) (w-2) mm > (w + 326) mm

120 118 700

150 148 700

160 158 700

180 178 700

200 198 700

250 248 800

300 298 900

350 348 900

Tie Rod and Cone Lengths

Technical�Information� Complementary Equipments



Heating Capacity 15,000 kcal/hour

Heating Capacity 28,500 kcal/hour

Heating Equipments�

After concreting (which is completed usually late afternoon), especially in cold weather, it is often necessary to heat the concrete for striking the forms next morning. Heating will decrease the duration for setting of concrete. Heating procedure is not necessary for high temperature zones. But generally, it is recommended.

MESA presents two types of Heaters o In normal temperatures; LPG-Heater (fuel type is

LPG). o In considerably low temperatures; Radiant

Burner (fuel type is diesel oil).

Isolation Equipments�

Curtains covering the open ends of tunnel forms are made from plastic based 1100 dny material. In low temperature zones, double layer curtains with extra insulation between the layers should be preferred.

ERTF-Tools�

Tools given with full Set of Tunnel Formwork are separated into two groups;

ERTF-Tool box�

ERTF-Special Tools�

LPG�Heater� Radiant�Burner�

COMPLEMENTARY EQUIPMENTS�

Socket Wrench 13 (1/2) 1






Hexagon Key Wrench 14 1

Ratchet for Jack Ø38 (31K-20") 2

Ratchet 1/2" w/LOCK 4

Ratchet Arm 5" (1/2) 2

2-Ended Open Jaw Spanner 19-22 3



Open Ended Slogging Spanner Ø 36 1



Drift Punch A350-5 2

Punch Ø16 2

Punch Ø20 5

Punch Ø27 2

Punch Ø35 1

Hammer (1.5 kg) 2

Magnetic Plumb 2

Chalk Line 1

Steel Tape (5 metre) 2

Metal Marker 2

Deck Panel Wrench 1

Back Panel Wrench 1

Punch to Remove Cones 1

Punch to Remove Dilatation Cones 1

Spatula 1

Lever 1

Technical�Information� Types of Connection



Standard types of connections are done between two UPF30x60x4 profiles, and between two NPL80 profiles.

Refer to Section of “Part List” of this Manual to see the details of Connector Parts listed on the following pages.�

TYPES of CONNECTION

o Permanent Assemblies ; Half Tunnels, Formworks or other sets ( Kicker Forms etc.) are connected properly at once. These sets are not disassembled until the job is finished.

o Temporary Connections ; According to the Formwork Layout of the project, Some of the Permanent Assemblies may be connected during erecting, concreting and stripping stages. These assemblies make also easy the lifting and transporting operations as well as the erecting and stripping stages.

Connections for assembly of Tunnel Formwork elements could be collected into two main groups ;

o UPF30x60x4 ; - Both vertical ends of standard Vertical Panels, - Four sides of standard Deck Panels - One vertical end of standard Back Panels have this type of profile.

o NPL 80 ; - One side of standard Deck Panels - One vertical end of standard Back Panels have this type of profile.

Assembly Conditions� Profiles at the Panel Ends�

Connections can also be classified according to the profiles at the end of the standard panels ;

Introduction� Permanent Assemblies



Quantities of Connectors on the connection no’s “1 - 3 and 4” differ according to the Deck Panel length “L”.

Quantities of Connectors “x, y and z” and “p,q and r” on the connections “6 and 7” are tabulated on the next page.

Assembly of a Half Tunnel

Connections

1 – Vertical Panel Extension & Deck Panel 1 set 2 – Back Panel & Vertical Panel Extension 1 set 3 – Vertical Panel & Vertical Panel Extension 1 set 4 – Deck Panel & Deck Panel Extension 1 set 5 – Back Panel & Deck Panel Extension 1 set 6 – Deck Panel & Back Panel 1 set 7 – Vertical Panel & Back Panel 1 set 8 – Deck Panel & Foldable Prop 2 sets 9 – Vertical Panel & Wheel Support 2 sets10 – Vertical Panel & Foldable Prop 2 sets11 – Vertical Panel & Wheel Connector 1 set12 – Vertical Panel & Vertical Panel Jack 2 sets13 – Wheel Support & Wheel Connector 2 sets14 – Back Panel & Back Panel Wheeled Jack 1 set15 – Wheel Connector & Tunnel Driving Wheel 1 set

One Simple ERTF-Modular Half Tunnel includes one Deck Panel and it’s Extension, one Vertical Panel and it’s Extension, two Foldable Props, one Tunnel Driving Wheel, two Wheel Supports and one Wheel Connector as described in the Section “Parts in Detail” of this Manual. In some cases, a Back Panel could also be added on the Assembly.

1 PERMANENT ASSEMBLIES

3

9

10 11

12

8 4 6

7

13

14

15

5

2

Tables below give the quantities of connectors for one set of connection ;

1

L = 1250 mm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

U ALIGNMENT (45mm) 1 1 x p

HINGE BOLT SET 2

HEXAGON BOLT,NUT&WASHER (M14x30) 5 5 5 2 2

HEXAGON BOLT,NUT&WASHER (M14x50) 1 y q

HEXAGON BOLT,NUT&WASHER (M14x80) 1 2 2 1 z r

HEXAGON BOLT,NUT&WASHER (M16x30) 4


L = 2500 mm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

U ALIGNMENT (45mm) 1 1 x p

HINGE BOLT SET 3

HEXAGON BOLT,NUT&WASHER (M8x80)


HEXAGON BOLT,NUT&WASHER (M14x50) 1 y q

HEXAGON BOLT,NUT&WASHER (M14x80) 1 4 4 1 z r



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Connectors

Connectors

Connection No.

Connection No.




Quantities of Connectors “p, qand r” on “Vertical Panel & Back Panel connection (No.7)” depend on the Vertical Panel height “HV”.

Quantities of Connectors “x, yand z” on “Deck Panel & Back Panel connection (No.6)” depend on the Deck Panel width “WD”.

The length of Hinge Bolt is selected according to the height of Vertical Panel Extension “HVE” and width of Deck Panel Extension “WDE”.

One Hinge Bolt Set includes the components listed on right.

x, y and z values�

p, q and r values�

Hinge Bolt Set�


240 < WDE < 299

300 < WDE < 349

350 < WDE < 399

119 < WDE < 169

170 < WDE < 239

"W DE " range ( mm )

Vertical Panel


Nut for Hinge Bolt

Hinge Bolt

Vertical Panel Extension

Deck Panel

WDE

HVE

HINGE BOLT (120)

HINGE BOLT (190)

HINGE BOLT (250)

HINGE BOLT (300)

HINGE BOLT (350)

Length of Hinge Bolts forVertical and Deck Panel Extensions

120 < HVE < 160

161 < HVE < 230

231 < HVE < 290

291 < HVE < 340

341 < HVE < 390

"H VE " range ( mm )

Vertical Panel Extension

Hinge Bolts (L HB)

LHB

LHBM14x80 Hexagon Bolt,Nut & Washer

HINGE BOLT

NUT for HINGE BOLT


Quantities of Connectors in A Hinge Bolt Set

Connectors Quantity

1

1

1

850 1150 1450 1750 2050 2350 2650

x U ALIGNMENT (45mm) 3 4 4 5 5 6 6

y HEXAGON BOLT,NUT&WASHER (M14x50) 3 4 4 5 5 6 6

z HEXAGON BOLT,NUT&WASHER (M14x80) 3 3 4 4 5 5 6

Connectors

Quantities of x , y and zfor Connection no.6 Deck Panel Width "W D " ( mm )

p U ALIGNMENT (45mm)

q HEXAGON BOLT,NUT&WASHER (M14x50)

r HEXAGON BOLT,NUT&WASHER (M14x80)

Quantities of p , q and rfor Connection no.7

Connectors

Vertical Panel Height "H V " ( mm )

2500 2700

7 8

87

5 6




Tables on the next page give the quantities of connectors for one set of connection.�

Detail A on above sketch, shows the connection of Upper Panel Support and the Vertical Panel as well as the Upper Panel Support Set. �

Assembly of an Outside Wallform

Connections No.of Connections L=1250 L=2500

16 – Vertical Panel & Vertical Panel Extension (*) 1 1 17a – Vertical Panel & Platform Connector 2 2 17b – Platform Connector & Working Platform 2 2 18a – Working Platform & Platform Support 1 2 18b – Platform Support & Guardrail Post -- 2 19a – Working Platform & Guardrail Connector 2 -- 19b – Guardrail Connector & Guardrail Post 2 -- 20 – Vertical Panel & Platform Support 1 2 21 – Working Platform & Ladder (optional) 1 1 22 – Vertical Panel & Ladder Connector (optional) 1 123 – Ladder & Ladder Connector (optional) 1 124 – Vertical Panel & Panel Support 1 225 – Vertical Panel & Vertical Panel Jack 2 2

One Simple Outside Wallform includes;

One set of Vertical Panel and Extension One of Working Platform (could be the type which has a shutter), Two of Panel Supports (the quantity of Panel Support is one if the length of the wallform is 1250 mm or less), Two of Platform Supports (the quantity of Platform Support is one if the length of the wallform is 1250 mm or less), One set of Ladder (optional), Two of Guardrail Posts, Two of Vertical Panel Jack.

L

16

24

18a-18b 21

20 22

17a-17b

24 23

25

Detail A

Detail A

M14x80 Bolt, Nut & Washer Nut for Hinge Bolt

Hinge Bolt Upper Panel Support

Vertical Panel Extension M14x80 Bolt, Nut & Washer

Vertical Panel

LUS

16

24

18a21

20

22

17a – 17b

24

23

25

Detail A

19a – 19b

L L=2500 mm L=1250 mm

As the Length “L” of Outside Wallform varies, both the number of components and connectors varies also.

LHB = 120mm

LHB

(*) See details on the next page




One Upper Panel Support Set includes the components listed on right. The Length “LHB” of Hinge bolt is 120 mm.

Length “LUS” of Upper Panel Support Set is 55 mm longer than the height “HVE” of Vertical Panel Extension.

Upper Panel Support Set�

UPPER PANEL SUPPORT

HINGE BOLT (120)

NUT for HINGE BOLT


Connectors

1

1

3

Quantity

1

Quantities of Connectors in An Upper Panel Support Set

L = 1250 mm

16 17a 17b 18a 19a 19b 20 21 22 23 24 25

U ALIGNMENT (45mm)

UPPER PANEL SUPPORT SET 2

HEXAGON BOLT,NUT&WASHER (M14x30) 5 2 1 2 2 2




L = 2500 mm

16 17a 17b 18a 18b 20 21 22 23 24 25

U ALIGNMENT (45mm)

UPPER PANEL SUPPORT SET 2





Connectors

Connectors

Connection No.

Connection No.

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Connections

26 – Vertical Panel & Vertical Panel 1 set 27 – Vertical Panel Extension & Vertical Panel Extension 1 set 28 – Deck Panel & Deck Panel 1 set 29 – Deck Panel Extension & Deck Panel Extension 1 set 30 – Deck Panel & Lifting Beam 1 set

Profiles on Connection No.26,27,28 and 29 are UPF30x60x4.

Quantities of Connectors “k,ly and m”, “p, q and r” “t, u and v” and “xand y” on the connections “26, 27, 28 and 29” are tabulated on the next page.

Assembly of a Half Tunnel Set�

These Sets are assembled at once and they are used during the all concrete operations of site until the whole job is finished.

“Half Tunnel Set” consists of two or more “Half Tunnel”s and/or a Back Pannel.

In some cases one or more Outside Wallforms might be added to the Set.

The quantity of “Half Tunnel”s determines the connection quantities.

Figure shows the connection of two sets of Half Tunnel (L1=2500mm, L2=2500mm).

27

29

26

2830

Tables below give the quantities of connectors for one set of connection ;

L1

L2

26 27 28 29 30

U ALIGNMENT (45mm) k p t x

LIFTING BEAM NPL 2

U ALIGNMENT (89) 6

HEXAGON BOLT,NUT&WASHER (M14x50) l q u

HEXAGON BOLT,NUT&WASHER (M14x80) m r v y


Connectors

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Connection No.




Quantities of connectors “k, l and m” between Vertical Panels (No.26) depends on the height of Vertical Panel “Hv”.

Quantities of connectors “p, q and r” between Vertical Panel Extensions (No.27) depends on the height of Vertical Panel Extensions“HVE”.

Quantities of connectors “t, u and v” between Deck Panels (No.28) depends on the width of Deck Panels “WD”.

Quantities of connectors “x and y” between Deck Panel Extensions (No.29) depends on the width of Deck Panel Extensions“WDE”.

k, l and m values�

p, q and r values�

t, u and v values�

x and y values�

If HVE is greater than 360mm ,then Upper Panel Support Sets are used as the following quantities ; 2 sets for L=1250mm, 3 sets for L=2500mm as per in the Outside Wallforms.

k U ALIGNMENT (45mm)

l HEXAGON BOLT,NUT&WASHER (M14x50)

m HEXAGON BOLT,NUT&WASHER (M14x80)

Connectors 2500 2700

5 6

Quantities of k , l and mfor Connection no.26


5 6

19 20

p U ALIGNMENT (45mm)

q HEXAGON BOLT,NUT&WASHER (M14x80)

r HEXAGON BOLT,NUT&WASHER (M14x80)

2

1

Connectors 0 < H VE < 150 150 < H VE < 250 250 < H VE < 400 400 < H VE < 600

Quantities of p , q and rfor Connection no.27

Range of Vertical Panel Extension Height "H VE " ( mm )

1 2 2

1 1 2 2

0 1 0

850 1150 1450 1750 2050 2350 2650

t U ALIGNMENT (45mm) 3 4 4 5 5 6 6

u HEXAGON BOLT,NUT&WASHER (M14x50) 3 4 4 5 5 6 6

v HEXAGON BOLT,NUT&WASHER (M14x80) 3 3 4 4 5 5 6

Quantities of t , u and vfor Connection no.28 Deck Panel Width "W D" ( mm )

Connectors

x U ALIGNMENT (45mm)

y HEXAGON BOLT,NUT&WASHER (M14x80) 2 3

Range of Deck Panel Extension Width"W DE" ( mm )

300 < W DE < 450 450 < W DE < 600

2 30 1

0 1

Quantities of x and yfor Connection no.29

Connectors 0 < W DE < 150 150 < W DE < 300




Profiles on Connections No.31 and 32 are UPF30x60x4.

Tables below give the quantities of connectors for one set of connection.�

Qquantities of Connectors do not depend on the Vertical Panel Lengths “L”.�

Assembly of an Outside Wallform Set

These sets are assembled at once and they are used during the all concrete operations on site until the whole job is finished as in Half Tunnel Sets.

“Outside Wallform Set” consist two or more “Outside Wallform”s.

As in the assembly of “Half Tunnel Set’s”, quantities of connectors depend on the height of Vertical Panel “HV” and height of Vertical Panel Extension “HVE”.

Figure shows the connection of one set of Outside Wallform (L1=2500mm) and one set of Outside Wallform (L2=1250mm).

32

31

L1

L2

Hv

Hve

Connections

31 – Vertical Panel & Vertical Panel 1 set 32 – Vertical Panel Extension & Vertical Panel Extension 1 set

U ALIGNMENT (45mm)



U ALIGNMENT (89)

5

5

6 6



Quantities of Connectorsfor Connection no.31

6

6

19 20

U ALIGNMENT (45mm)



1

Connectors 0 < H VE < 150 150 < H VE < 250 250 < H VE < 400 400 < H VE < 600


1 2 2

0 1 0 2

1 1 2 2

Range of Vertical Panel Extension Height "H VE " ( mm )

Introduction� Temporary Connections



Profiles on Connection No.21 are UPF30x60x4.

Longitudinal Connection of Half Tunnel Sets and/or Outside Wallform Sets�

TEMPORARY CONNECTIONS

Permanently assembled two or more “Half Tunnel Set”s are sometimes to be connected temporarily during concreting. These two sets will be dismantled from each other before striking operation.

Longitudinal connections provide more strength to the concrete pressure.

The quantity of “Set”s determines the connector quantities.

The quantities of Connectors do not differ with the Tunnel Height “HT”.

Figure shows the connection of the Half Tunnel Set “A” (L1=2500mm, L2=2500mm) and another Half Tunnel Set “B” (L1=2500mm, L2=2500mm).

Set “A” and Set “B” could be a “Half Tunnel Set” or an “Outside Wallform Set”.

LA

LB

LA + LB

Half Tunnel Set - A Half Tunnel Set - B

2

1

33

Connection

33 – Half Tunnel Set & Half Tunnel Set 1 set

SPRING and ARM

U ALIGNMENT (89)



4

12

Connection No.

26Connectors

4

6





Profiles on Connection No.34 & 35 are NPL80.

Reciprocal Connection of Two Half Tunnel Sets �

Permanently assembled two resiprocal “Half Tunnel Sets” are connected temporarily during concreting. These two Sets will be dismantled from each other before striking operation.

The Deck Panel Length “L” and Back Panel Height “HB” of “Set”s determines the connection quantities.

Principle of this type of connection based on the joining of two resiprocal “Roof Key Bolts” welded on each Panels with a “Roof Key”, so that 2mm gap between two panels is obtained. This gap makes easy the removing of panels from concrete during dismantling.

Figure shows the connection of the Half Tunnel “A” (L=2500mm) and another Half Tunnel “B” (L=2500mm).

Reciprocal Connection is also realised between Back Panels if exist (connection no.35) in the same manner.

Same connection principle is also operative between two Outside Wallforms if 2mm gap is required in order to remove the Outside Wallforms from concrete (such as in Lift Shafts or Stair Shafts).

AConnections

34 – Deck Panel & Deck Panel 1 set 35 – Back Panel & Back Panel 1 set

B

Roof KeyBolt (welded)

Roof Key

M18 Nut & Washer

34

35

34

ROOF KEY

HEXAGON NUT&WASHER (M18)


Deck Panel Length"L" ( mm )


2 4

4 8

ROOF KEY

HEXAGON NUT&WASHER (M18)

4 5

8 10


Back Panel Height"H B " ( mm )

Connectors H B < 2763 mm H B > 2763 mm




Assembly of Kicker Forms�

Connections

36 – Inner Kicker & Corner Kicker 1 set 37 – Straight Kicker & Corner Kicker 1 set 38 – Straight Kicker & Straight Kicker 1 set

37 or 38 36

Connection No.36 Connection No.37 & 38

Kicker Forms are assembled similarly as in the assembly of “Half Tunnel Set”s.

Straight Kicker Forms could be permanently connected to each other with two sets of M14x30 bolt and nuts, if it is not to be disasembled after concreting.

Corner Kickers and Inner Kickers are always temporarily connected to each other so that the same principle of “reciprocal connection of two Deck Panels or two Back Panels” could be realised. Therefore, 2mm gap between each part is obtained.

Figure shows the basic connection of Kicker Forms in a Room of an Half Tunnel. As increasing the length, the length of Straight Kicker Forms will increase.

In each 1250 mm, one piece of Kicker Spacer and one piece of Kicker Clamp is located.

On each open ends of the Kicker Forms, one piece of Kicker Stoper is required.

Quantities in One Connection

36 37 38

ROOF KEY 1

HEXAGON NUT&WASHER (M18) 2

HEXAGON BOLT,NUT&WASHER (M14x30) 2 2

Connectors

Connection No.

Part�List� Panels



PANELS�MESA IDPART NO PART NAME

Unit Weight (kg)

Back Panels�

Vertical Panels�

As an example, Heights of Back Panels listed above are taken as 2563 mm. For other heights, part numbers and names of panels are given in a similar way.

M.T.EIUU.DK2DS53H ER-INSIDE PANEL-UU (1250x2500) 222,80

M.T.EIUU.DK53H53H ER-INSIDE PANEL-UU (2500x2500) 423,90

M.T.ERDS.0K21250 ER-VERTICAL PANEL-UU (1250x2700) 236,00

M.T.ERDS.0K22500 ER-VERTICAL PANEL-UU (2500x2700) 445,70

M.T.EA2L.DK23N56B ER-BACK PANEL-UL (1049+2563)L93 197,40

M.T.EA2L.DK2R856B ER-BACK PANEL-UL (1349+2563)L93 257,60

M.T.EA2L.DK39056B ER-BACK PANEL-UL (1649+2563)L93 308,60

M.T.EA2L.DK40H56B ER-BACK PANEL-UL (1949+2563)L93 350,80

M.T.EA2L.DK4H656B ER-BACK PANEL-UL (2249+2563)L93 394,50

M.T.EA2L.DK55Y56B ER-BACK PANEL-UL (2549+2563)L93 438,20

M.T.EA2L.DK5TD56B ER-BACK PANEL-UL (2849+2563)L93 480,80

M.T.EA2R.DK23N56B ER-BACK PANEL-UL (1049+2563)R93 197,70

M.T.EA2R.DK2R856B ER-BACK PANEL-UL (1349+2563)R93 257,60

M.T.EA2R.DK39056B ER-BACK PANEL-UL (1649+2563)R93 308,70

M.T.EA2R.DK40H56B ER-BACK PANEL-UL (1949+2563)R93 350,80

M.T.EA2R.DK4H656B ER-BACK PANEL-UL (2249+2563)R93 394,50

M.T.EA2R.DK55Y56B ER-BACK PANEL-UL (2549+2563)R93 438,20

M.T.EA2R.DK5TD56B ER-BACK PANEL-UL (2849+2563)R93 480,80




Vertical Panel Extensions (Inside)

MESA IDPART NO PART NAME

Unit Weight (kg)

Vertical Panel Extensions (Outside)�

M.T.EIUA.DK53H04D ER-INSIDE PANEL ADAPTER (2500x100) 25,30

M.T.EIUA.DK53H05A ER-INSIDE PANEL ADAPTER (2500x120) 30,80

M.T.EIUA.DK53H05Y ER-INSIDE PANEL ADAPTER (2500x130) 32,10

M.T.EIUA.DK53H06S ER-INSIDE PANEL ADAPTER (2500x150) 34,50

M.T.EIUA.DK53H076 ER-INSIDE PANEL ADAPTER (2500x160) 35,30

M.T.EIUA.DK53H07N ER-INSIDE PANEL ADAPTER (2500x170) 36,10


M.T.EIUA.DK53H08H ER-INSIDE PANEL ADAPTER (2500x190) 37,70


M.T.EIUA.DK53H09D ER-INSIDE PANEL ADAPTER (2500x210) 39,30

M.T.EIUA.DK53H0B8 ER-INSIDE PANEL ADAPTER (2500x250) 42,60

M.T.EIUA.DK53H0EH ER-INSIDE PANEL ADAPTER (2500x300) 46,70

M.T.EIUA.DK53H0KY ER-INSIDE PANEL ADAPTER (2500x350) 50,80

M.T.EIUA.DK2DS04D ER-INSIDE PANEL ADAPTER (1250x100) 13,00

M.T.EIUA.DK2DS05A ER-INSIDE PANEL ADAPTER (1250x120) 16,10

M.T.EIUA.DK2DS05Y ER-INSIDE PANEL ADAPTER (1250x130) 16,90

M.T.EIUA.DK2DS06S ER-INSIDE PANEL ADAPTER (1250x150) 18,20

M.T.EIUA.DK2DS076 ER-INSIDE PANEL ADAPTER (1250x160) 18,60

M.T.EIUA.DK2DS07N ER-INSIDE PANEL ADAPTER (1250x170) 19,00


M.T.EIUA.DK2DS08H ER-INSIDE PANEL ADAPTER (1250x190) 19,90


M.T.EIUA.DK2DS09D ER-INSIDE PANEL ADAPTER (1250x210) 20,70

M.T.EIUA.DK2DS0B8 ER-INSIDE PANEL ADAPTER (1250x250) 22,50

M.T.EIUA.DK2DS0EH ER-INSIDE PANEL ADAPTER (1250x300) 24,60

M.T.EIUA.DK2DS0KY ER-INSIDE PANEL ADAPTER (1250x350) 26,70

M.T.ERUA.DK2DS0HK ER-OUTSIDE PANEL ADAPTER (1250x323) 30,10

M.T.ERUA.DK2DS0K3 ER-OUTSIDE PANEL ADAPTER (1250x333) 30,60

M.T.ERUA.DK2DS0KE ER-OUTSIDE PANEL ADAPTER (1250x343) 31,20

M.T.ERUA.DK2DS0N1 ER-OUTSIDE PANEL ADAPTER (1250x353) 31,80

M.T.ERUA.DK2DS0NB ER-OUTSIDE PANEL ADAPTER (1250x363) 32,30

M.T.ERUA.DK2DS0R9 ER-OUTSIDE PANEL ADAPTER (1250x383) 33,40

M.T.ERUA.DK2DS0TK ER-OUTSIDE PANEL ADAPTER (1250x433) 36,20

M.T.ERUA.DK2DS0ZZ ER-OUTSIDE PANEL ADAPTER (1250x483) 39,00

M.T.ERUA.DK2DS109 ER-OUTSIDE PANEL ADAPTER (1250x493) 39,50

M.T.ERUA.DK2DS125 ER-OUTSIDE PANEL ADAPTER (1250x533) 41,80

M.T.ERUA.DK2DS14B ER-OUTSIDE PANEL ADAPTER (1250x583) 44,50

M.T.ERUA.DK53H0HK ER-OUTSIDE PANEL ADAPTER (2500x323) 56,60

M.T.ERUA.DK53H0K3 ER-OUTSIDE PANEL ADAPTER (2500x333) 57,70

M.T.ERUA.DK53H0KE ER-OUTSIDE PANEL ADAPTER (2500x343) 58,80

M.T.ERUA.DK53H0N1 ER-OUTSIDE PANEL ADAPTER (2500x353) 59,90

M.T.ERUA.DK53H0NB ER-OUTSIDE PANEL ADAPTER (2500x363) 60,90

M.T.ERUA.DK53H0R9 ER-OUTSIDE PANEL ADAPTER (2500x383) 63,10

M.T.ERUA.DK53H0TK ER-OUTSIDE PANEL ADAPTER (2500x433) 68,50

M.T.ERUA.DK53H0ZZ ER-OUTSIDE PANEL ADAPTER (2500x483) 73,90

M.T.ERUA.DK53H109 ER-OUTSIDE PANEL ADAPTER (2500x493) 74,90

M.T.ERUA.DK53H125 ER-OUTSIDE PANEL ADAPTER (2500x533) 79,20

M.T.ERUA.DK53H14B ER-OUTSIDE PANEL ADAPTER (2500x583) 84,60




Deck Panels�


Unit Weight (kg)

Deck Panel Extensions�

All types of Panels which have special dimensions are taken part numbers and part names in a similar way as above.

M.Y.ERUL.DK1NH2DS ER-DECK PANEL (850+63)x1250 65,80

M.Y.ERUL.DK2862DS ER-DECK PANEL (1150+63)x1250 83,60

M.Y.ERUL.DK2ZY2DS ER-DECK PANEL (1450+63)x1250 100,30

M.Y.ERUL.DK3ED2DS ER-DECK PANEL (1750+63)x1250 117,00

M.Y.ERUL.DK4542DS ER-DECK PANEL (2050+63)x1250 144,00

M.Y.ERUL.DK4SS2DS ER-DECK PANEL (2350+63)x1250 161,80

M.Y.ERUL.DK5AA2DS ER-DECK PANEL (2650+63)x1250 193,10

M.Y.ERUL.DK1NH53H ER-DECK PANEL (850+63)x2500 124,00

M.Y.ERUL.DK28653H ER-DECK PANEL (1150+63)x2500 157,40

M.Y.ERUL.DK2ZY53H ER-DECK PANEL (1450+63)x2500 189,50

M.Y.ERUL.DK3ED53H ER-DECK PANEL (1750+63)x2500 221,80

M.Y.ERUL.DK45453H ER-DECK PANEL (2050+63)x2500 277,20

M.Y.ERUL.DK4SS53H ER-DECK PANEL (2350+63)x2500 310,60

M.Y.ERUL.DK5AA53H ER-DECK PANEL (2650+63)x2500 374,40

M.Y.ERAL.0K0EE53H ER-DECK PANEL ADAPTER 299x2500 52,20

M.Y.ERAL.0K0KT53H ER-DECK PANEL ADAPTER 349x2500 56,00

M.Y.ERAL.1K06R53H ER-DECK PANEL ADAPTER 149x2500 39,00

M.Y.ERAL.1K09153H ER-DECK PANEL ADAPTER 199x2500 44,20

M.Y.ERAL.1K0B753H ER-DECK PANEL ADAPTER 249x2500 49,40

M.Y.ERAL.0K0EE2DS ER-DECK PANEL ADAPTER 299x1250 27,50

M.Y.ERAL.0K0KT2DS ER-DECK PANEL ADAPTER 349x1250 29,60

M.Y.ERAL.1K06R2DS ER-DECK PANEL ADAPTER 149x1250 19,80

M.Y.ERAL.1K0912DS ER-DECK PANEL ADAPTER 199x1250 22,90

M.Y.ERAL.1K0B72DS ER-DECK PANEL ADAPTER 249x1250 26,00

Part�List� Supports



Foldable Props�

Wheel Connector�


Unit Weight (kg)

SUPPORTS�

Wheel Support�

M.C.KER1.2K ER-FOLDABLE PROP-2500 33,70

M.C.KER2.2K ER-FOLDABLE PROP-2700 35,30

M.C.CEYC.0K096 ER-WHEEL CONNECTOR (666-965) 16,50




M.C.CEDB.0G125 ER-WHEEL SUPPORT 85-115 (2500)-G 6,40











Lifting Beam�

Outside Panel Support�


Unit Weight (kg)

M.V.TTR1.0K100 TR/ER-LIFTING BEAM (1000) 19.00





M.C.FER1.0K ER-OUTSIDE PANEL SUPPORT 27.50

Vertical Panel Upper Support� M.E.EDU1.0K388 ER-UPPER PANEL SUPPORT (388) 2.80

M.E.EDU1.0K438 ER-UPPER PANEL SUPPORT (438) 3.10




Narrow Tunnel Support Connector� Z.E.TER1.0K ER-NARROW TUNNEL SUPPORT CONNECTOR 2.30




Tunnel Extension Set�


Unit Weight (kg)

M.G.AERY.1KTA0700 ER-TUNNEL EXTENSION LEG w/JACK (700) 17.40

M.G.AERY.2KTA1700 ER-TUNNEL EXTENSION LEG w/JACK (1700) 16.00

M.G.AEYP.0K0700 ER-WHEELED PROP EXTENSION w/JACK 10.30

M.G.AEYP.0K1700 ER-TUNNEL EXTENSION PLATE 10.90

M.G.AEYY.0K0700 ER-TUNNEL EXTENSION UNIT (700) 9.30

M.G.AEYY.0K1700 ER-TUNNEL EXTENSION UNIT (1700) 15.50

Part�List� Jacks and Driving Units




Unit Weight (kg)

M.G.YERS.0K ER-SWIVEL TUNNEL WHEEL 15.80

JACKS and DRIVING UNITS

M.G.YERT.0K ER-TUNNEL DRIVING WHEEL 23,80

M.G.AED1.0K ER-PANEL JACK 8,00

M.G.AEA1.0K ER-BACK PANEL JACK AND WHEEL 12,80

M.G.AES1.0K ER-PANEL JACK (for SWIVEL TUNNEL) 7,30

M.G.YERP.1K ER-PANEL WHEEL (for SWIVEL TUNNEL) 13,10

M.G.YERR.1K053 ER-ROLLER (53) 8,90

M.G.YERR.1L073 ER-ROLLER (73) 10,80

Part�List� Safety Componenets



Guardrail Post�

SAFETY COMPONENTS

Working Platforms�


Unit Weight (kg)

M.D.P23Y.0K060 23-WORKING PLATFORM (600) 14,90








M.D.P23Y.0KB120 23-WORKING PLT.w/COMP.SHUTTER (1200) 34,00



M.D.H401.1K120 401-GUARDRAIL POST (1200) 5,20



Part�List� Safety Componenets



Platform Support�

Ladder�


Unit Weight (kg)

M.D.KER1.0K250 ER-PLATFORM BRACKET (2500) 6,30

M.D.KER1.0K270 ER-PLATFORM BRACKET (2700) 6,80

M.D.MERM.1E01 ER/TR- ACCESS PLATFORM LADDER-E 13,40

Part�List� Lifting & Transporting



LIFTING & TRANSPORTING

Assembly Device�

Lifting Triangles�


Unit Weight (kg)

M.G.TNLA.0K NL-ASYMMETRIC LIFTING TRINGLE 156.10

M.G.TTRM.0K TR/ER-ASSEMBLY DEVICE 18,70

M.G.TTRU.0K TR/ER-LIFTING TRIANGLE 66,40

Part�List� Kicker Forms



KICKER FORMS�

Straight Kicker Forms�

Inner Kicker Forms�

Corner Kicker Forms�


Unit Weight (kg)

M.A.L12D.0Y062 L12-KICKER FORM STRAIGHT (625) 11.60





M.A.L12A.0Y150 L12-KICKER FORM INNER (1498) 22,60











M.A.L12G.0YL30 L12-KICKER FORM CORNER (2593x299 L) 43,30

M.A.L12G.0YR30 L12-KICKER FORM CORNER (2593x299 R) 43,30




Kicker Spacers�


Unit Weight (kg)

M.A.L12M.0KC1514 L12-KICKER SPACER (TWO SIDED) w:148 s:140 4,10

























M.A.L12M.0KC3020 L12 KICKER SPACER (TWO SIDED) w:298 s:200 6,90

M.A.L12M.0KT1514 L12-KICKER SPACER (ONE SIDED) w:148 s:140 3,20




























M.A.L12M.0KT3020 L12 KICKER SPACER (ONE SIDED) w:298 s:200 5,70




Kicker Clamps�

Concrete Stoper�


Unit Weight (kg)

M.A.L12K.0KC15 L12-KICKER CLAMP (TWO SIDED) (148) 2,90




M.A.L12K.0KC25 L12 KICKER CLAMP (TWO SIDED) (248) 3,40


M.A.L12K.0KT15 L12-KICKER CLAMP (ONE SIDED) (148) 3,20






M.A.L12U.0K15 L12-CONCRETE STOPER w:148 1,90






Part�List� Stopends



STOPENDS�

Slab Stopends�


Unit Weight (kg)

M.S.DTR1.0K23B068 TR/ER-SLAB STOPEND (1045+93)x140 17,50

M.S.DTR1.0K23B06S TR/ER-SLAB STOPEND (1045+93)x150 18,00

M.S.DTR1.0K23B092 TR/ER-SLAB STOPEND (1045+93)x200 20,60

M.S.DTR1.0K2R3068 TR/ER-SLAB STOPEND (1345+93)x140 20,50

M.S.DTR1.0K2R306S TR/ER-SLAB STOPEND (1345+93)x150 21,10



M.S.DTR1.0K38R06S TR/ER-SLAB STOPEND (1645+93)x150 24,20


M.S.DTR1.0K409068 TR/ER-SLAB STOPEND (1945+93)x140 26,60

M.S.DTR1.0K40906S TR/ER-SLAB STOPEND (1945+93)x150 27,30

M.S.DTR1.0K409092 TR/ER-SLAB STOPEND (1945+93)x200 31,00

M.S.DTR1.0K4H1068 TR/ER-SLAB STOPEND (2245+93)x140 32,60

M.S.DTR1.0K4H106S TR/ER-SLAB STOPEND (2245+93)x150 33,50

M.S.DTR1.0K4H1092 TR/ER-SLAB STOPEND (2245+93)x200 37,90

M.S.DTR1.0K55K068 TR/ER-SLAB STOPEND (2545+93)x140 35,70

M.S.DTR1.0K55K06S TR/ER-SLAB STOPEND (2545+93)x150 36,60

M.S.DTR1.0K55K092 TR/ER-SLAB STOPEND (2545+93)x200 41,40

M.S.DTR1.0K5T7068 TR/ER-SLAB STOPEND (2845+93)x140 38,70

M.S.DTR1.0K5T706S TR/ER-SLAB STOPEND (2845+93)x150 39,70

M.S.DTR1.0K5T7092 TR/ER-SLAB STOPEND (2845+93)x200 44,80

Part�List� Stopends



Wall Stopends�


Unit Weight (kg)

M.S.PTR1.0K06S5S7 TR/ER-WALL STOPEND 148x2823 53,70

M.S.PTR1.0K06S5SR TR/ER-WALL STOPEND 148x2833 53,80

M.S.PTR1.0K06S5T5 TR/ER-WALL STOPEND 148x2843 53,90

M.S.PTR1.0K06S617 TR/ER-WALL STOPEND 148x2933 54,80

M.S.PTR1.0K06S65T TR/ER-WALL STOPEND 148x3033 55,90


M.S.PTR1.0K0845SR TR/ER-WALL STOPEND 178x2833 57,40

M.S.PTR1.0K0845T5 TR/ER-WALL STOPEND 178x2843 57,50

M.S.PTR1.0K084617 TR/ER-WALL STOPEND 178x2933 58,50

M.S.PTR1.0K08465T TR/ER-WALL STOPEND 178x3033 59,60


M.S.PTR1.0K0925SR TR/ER-WALL STOPEND 198x2833 59,70

M.S.PTR1.0K0925T5 TR/ER-WALL STOPEND 198x2843 59,80

M.S.PTR1.0K092617 TR/ER-WALL STOPEND 198x2933 60,90

M.S.PTR1.0K09265T TR/ER-WALL STOPEND 198x3033 62,00

M.S.PTR1.0K0B85S7 TR/ER-WALL STOPEND 248x2823 65,50

M.S.PTR1.0K0B85SR TR/ER-WALL STOPEND 248x2833 65,60

M.S.PTR1.0K0B85T5 TR/ER-WALL STOPEND 248x2843 65,80

M.S.PTR1.0K0B8617 TR/ER-WALL STOPEND 248x2933 66,90

M.S.PTR1.0K0B865T TR/ER-WALL STOPEND 248x3033 68,20

M.S.PTR1.0K0EH5S7 TR/ER-WALL STOPEND 298x2823 71,40

M.S.PTR1.0K0EH5SR TR/ER-WALL STOPEND 298x2833 71,60

M.S.PTR1.0K0EH5T5 TR/ER-WALL STOPEND 298x2843 71,70

M.S.PTR1.0K0EH617 TR/ER-WALL STOPEND 298x2933 72,90

M.S.PTR1.0K0EH65T TR/ER-WALL STOPEND 298x3033 74,30

Part�List� Intermediate Components



INTERMEDIATE COMPONENTSMESA IDPART NO PART NAME

Unit Weight (kg)

M.S.DTR1.2KK TR-SLAB STOPEND LOCK 1.15

Z.B.GER1.0K ER-PLATFORM CONNECTOR 0.80

Z.B.MERK.0K ER/TR-LADDER CONNECTION 1.39

Z.B.TTR9.1E TR/ER-PANEL DRIVE LEVER-E 1.42

Z.B.TTRA.0E TR/ER-POCKET TUNNEL ROOF KEY-E 0.71

Z.L.KTR1.0E TR/ER-NPL for LIFTING BEAM 1.86





Unit Weight (kg)

Z.B.TTR2.0E TR/ER-SPRING and ARM-E 0.62

Z.B.TTR5.0E TR/ER-ROOF KEY-E 0.67

Z.B.KBTR.0K01 TR/ER-PACKAGE TUNNEL CONT.SPC 0.57

Z.B.TTR7.0K TR/ER-VERT.PANEL VERTICAL CONNECTOR 0.63

Z.B.TTR8.0K TR/ER-DECK PANEL VERTICAL CONNECTOR 1.27

Z.B.TTR1.0E TR/ER-U ALIGNMENT (45x60)-E 0.28

K.M.CCER.0E100 ER-DRIVER LEVER BOLT (100)-E 0.30

K.M.CCER.0E300 ER-DRIVER LEVER BOLT (300)-E 0.70





Unit Weight (kg)

Z.C.CERM.0E120 ER-HINGE BOLT (120)-E 0.44





Z.B.TTR6.0G TR/ER-U ALIGNMENT (51)-G 1.40

Z.B.TTR3.0G TR/ER/CK-U ALIGNMENT (89)-G 3.10

Z.B.TTR4.0G TR/ER-ADP.U ALIGNMENT (109)-G 2.87

Z.C.MTR1.00 TR/ER-LIFTING TRIANGLE AXLE 3.51

Z.C.MTR2.00 TR/ER-ASSEMBLY DEVICE AXLE 5.30

Z.S.TQTR.0ER01 TR/ER-BOXOUT TIE (15FAx170)-E 0.39

Z.T.C016.00 TR/ER-STEEL PLUG (Ø16) 0,012





Z.T.P016.00 TR/ER-HOLE PLUG (Ø16) 0,003




Part�List� Tie-Rod Accessories



Tie-Rod ACCESSORIES

Tie-Rods�


Unit Weight (kg)

Cones�

Z.K.CK45.00148 M14x40 DEAD CONE (Steel) 50/40x148 1.80







Z.S.TD23.0E035 TIE ROD Ø23x350 (M23/Y10)-E 1,10














Z.S.TQT1.1E18 ER-DILATATION TIE TYPE1(p:180)-E 2,70









Z.K.KS42.00148 TIE CONE (Composite) Ø42x148 0,20






Z.K.CD56.00148 Ø26 DILATATION TIE CONE 60/50x148 2,10






Part�List� Tie-Rod Accessories



Z.C.STR0.0001 TR/ER-BOXOUT NUT-AA30x30 (15F) 0.14

Nuts�


Unit Weight (kg)

Z.S.PKP1.0E26 PLATE-10x100x100(26)-E 0.74

Z.S.PKP1.0E30 PLATE-DILATATION-10x100x100(30)-E 0.74

Z.C.SER0.0E01 ER-HINGE BOLT CONE (AA36x40)-E 0.20

Z.S.SRV1.0EM23Y10 V-NOTCHED NUT (M23/Y10)-E 0,70

Z.S.SKV1.0E23Y10 V-WING NUT (20F)-E 0,90

Z.S.STV3.0E20F V-FLANGE NUT (20Fx40x120)-E 0,90

Z.S.SDER.0E ER-DILATATION TIE-NUT-E 1,10

Z.C.STR0.0K02 TR/ER-LIFTING NUT (M33/Y6) 3,30

Part�List� Tools



TOOLS� MESA IDPART NO PART NAME

Unit Weight (kg)

Z.E.TSP2.0E SPATULA-E 2.95

Z.E.TSP1.0E SPATULA EXTENSION ARM-E 2.78

T.M.CTRT.TRY TOOL BOX - TRTF (NATIONAL)

T.M.CTRT.INT TOOL BOX - TRTF (INTERNATIONAL)

Z.E.ATRB.0E TR/ER-BACK PANEL WRENCH-E 1.36

Z.E.ATRC.1G TR/ER-PUNCH TO REMOVE CONES-G 2.10

Z.E.ATRD.0E TR/ER-DILATATION CONE REMOVING PUNCH-E 3.00

Z.E.ATRY.0E TR/ER-DECK PANEL WRENCH-E 2.62

T.M.AL13.12 Socket Wrench 13 (1/2) 1






T.M.AA14.0 Hexagon Key Wrench 14 1

T.M.AR38.0 Ratchet for Jack Ø38 (31K-20") 2

T.M.LCKM.12 Ratchet 1/2" w/LOCK 4

T.M.LU12.05 Ratchet Arm 5" (1/2) 2

T.M.AG19.22 2-Ended Open Jaw Spanner 19-22 3



T.M.AC36.0 Open Ended Slogging Spanner Ø 36 1



T.M.ENZ1.A350 Drift Punch A350-5 2

T.M.TMEU.16 Punch Ø16 2




T.M.EC00.015 Hammer (1.5 kg) 2

T.M.EMS1.0 Magnetic Plumb 2

T.M.ECI1.0 Chalk Line 1

T.M.EM05.0 Steel Tape (5 metre) 2

T.M.EMMK.0 Metal Marker 2

Part�List� Tools




Unit Weight (kg)

Suffix “-G” and “-E” at the end of the Part Names refer to Hot Deep Galvanise and Electro Galvanise Coatings respectively. Otherwise the part is paint coated.

Z.V.BB01.00145 CONICAL HOLE FILLER MOULD (145) 9,20





Notes� �

ERTF – Modular Tunnel Form System

TECHNICAL MANUAL – 2/2011 www.mesaimalat.com.tr�

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