Mesa Logica Design Calculation - Mesa İmalat

01/2011

MESA – Logica

Modular Wallform System

Logica (MRWF)

Modular Wallform System

Design Calculation

Contents

Introduction

System Overview 1

Technical Features

Connection Variation 4

Loading Limits

Concrete Pressure 11

Tie-Rods 15

Formwork Connection 16

Push-Pull Props 17

Lifting Device 18

Platform Bracket 19

Test Results 20

General Remarks

Logica Wall Formwork System –MRWF

DESIGN CALCULATION – 01/2011 www.mesaimalat.com.tr

Important Note

Sight-Check

Information

Warning

Remarks

Symbols Used

� 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

Warranty



Warranty Period

� Limited Warranty for two (2) years is

promissed by Mesa İmalat San.ve Tic. A.Ş. 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 İMALAT San.ve

Tic.A.Ş., 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 + 40 °C

and – 30 °C.

� Formworks should be cleaned after each

application to remove the concrete residues and

active faces should be lubricated with suitable

concrete/metal seperation oil.

� After 250 applications, maintenance should

be done at site.

� This maintenance covers the flatning of

active surface, repainting, welding and rust

control.

� After 500 applications, maintenance should

be done at work shop where the necessary

equipments exist.

� During the storage period, all active

surfaces should be lubricated with suitable oil to

prevent rusting.

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

possible, formworks and accessories should be

stocked in open areas by covering them with water

resistant materials.

� Maitenance procedure should be

repeated for each 250 usages after first 500

usages are exceeded.

� 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 Overview


1


SYSTEM OVERVIEW

Wall Formwork

Parts

Platform Bracket

Working Platform

Main Panel

Extension Panel

Lifting Device

Steel Waler

Fixing Tie and Flange Nut

Adjustable Filler

Tension Device

Inside Corner

Panel Lock

Tie Rod and Flange Nut

Corner Tie and Flange Nut



2


Parts

Adjustable Lock

Corner Tie and Flange Nut

Universal Panel

Easy Filler

Upper Prop

Prop Connector

Lower Prop

Prop Base

Tie-Rod and Flange Nut

Main Panel

Working Platform

Guardrail Post

Ladder Connector

Access Ladder

Outside Corner

Access Platform



3


Column Formwork

Parts

Ladder Connector

Ladder

Access Platform

Flange Tie

Universal Main Panel

Platform Bracket

Prop Connector

Lower Prop

Upper Prop

Prop Base

Working Platform

Panel Lock

Universal Extension Panel

Guardrail Post

Lifting Device

Technical Features Connection Variation


4


CONNECTION VARIATION

MESA – Logica Wall Formworks are designed

so that vertically placed two sets of Tie-rods

will be satisfied up to the concrete height of

2,700 mm.

Main Panels could also be superposed to

achieve bigger heights.

Level of Tie-rod Holes

The tie-rod holes on each panel frames are

positioned so that the arranging all the panels to

different height combinations will be possible,

Wiith 300 mm increments, concrete height could

be arranged up to 4,500 mm.

Maximum horizontal distance between two

adjacent tie-rods is 1,200 mm.

Each Width Set of Panels (1200 – 900 – 750 –

600 – 450 and 300mm) have two different

heights for vertical adjustment ; 600 and

1,200mm

Number of Tie - Rods



5


Up to Concrete Height of 270 cm



Active Tie-rod Level

Max.Concrete Height

Panel Combinations for Walls



6





7





8





9





10


For the column sizes greater than 1,100 mm;

Extra Tie-Rod should connect the reciprocal

panels.

Adjustment on Column Formwork

MESA – Logica Column Formworks are made up

of Logica Universal Panels with three different

widths of 1,200 – 900 – 600 mm.

Each edge of the columns are sized by adjusting

the connection points with the holes on the panels.

Adjusting Holes allow to adjust the size of the

column with 50mm incrementation (d).

1 4 2 3 7 6 5 10 9 8 11 12 13 14 15 16 17 18 19 20 21

Detail A

Detail A

Wmax

Wmax

Wmax

Wmax

d

Wmin

Wmin

Wmin

Wmin

W

Hole No.

Column Tie

Embedded Nut

If the size of the column is greater than 1,100 mm

then it is possible to use two or more Universal

Panels which are connected to each other side by

side.

1200 900 600

1 1,100 (Wmax) 800 (Wmax) 500 (Wmax)

2 1,050 750 450

3 1,000 700 400

4 950 650 350

5 900 600 300

6 850 550 250

7 800 500 200 (Wmin)

8 750 450 150

9 700 400 100

10 650 350

11 600 300

12 550 250

13 500 200 (Wmin)

14 450 150

15 400 100

16 350

17 300

18 250

19 200 (Wmin)

20 150

21 100

W distance (mm) for Different Widths

of Column formworks

Hole No.sPanel Widths

Loading Limits Concrete Pressure


11


According to Standard DIN 18202, table 3, line 5 to 7;

Admissible deformation values for the concrete are listed by means of the relation to the distance between the

measuring points.

Flatness Tolerances for Walls and Slabs Under-Faces

(line values according to DIN 18202, table 3)

m

mm

tole

rances

distance between measuring points

Concrete Pressure Deflection

CONCRETE PRESSURE

Pressure of Fresh Concrete on

Vertical Formwork (DIN 18218)



12


Basic Formwork Design

Dimensions : 1,200mm x 2,700mm

Materials :

Primary Sections on Frames : S315MC (δall = 315kg/mm2)

Secondary Sections ; St-37 (δall = 235 kg/mm2)

Concrete Facing ; Plywood (15mm thickness)

Calculation Method

Finite Element Analysis by "Cosmos-simulation V.2010" Software program was executed.

This type of analysis depends on the “Matrix displacement” method.

On the analysis, the principle of “linear static elastic analysis” was taken into consideration.



13


Limit State Design factored

Load Combination

Fresh Concrete Pressure ; 1) 6500 kg/m2 (as uniform distributed load) (H = 2700 mm)

2) 6750 kg/m2 max (as hydrostatic pressure) (H = 2700 mm)

Density of Fresh Concrete ; 2,500 kg/m3

δhd = γf . δhk

δhd ; Nominal horizontal value of fresh concrete pressure

δhk ; characteristic horizontal value of fresh concrete pressure

γf ; concrete pressure load factor

With a favorable effect of the fresh concrete was to be a safety factor used by УF= 1,0 according to DIN

18218 “clause 4.2”

Result of Analysis

Max. von Mises stress;

1) On Uniform Distributed Load

285 N/mm2 (H = 2700mm)

Factor of safety =

315 / 285 = 1,1 > 1 => OK!

2) On Hydrostatic Pressure

233 N/mm2 (H = 2700mm)

Factor of safety =

315 / 233 = 1,35 > 1 => OK!

Max. Deflection ;

1) 3.80 mm , between two support

2) 2.47 mm , between two support

3.8 mm is under the range of

Table 3, line 7 on DIN 18218

Maximum Tension Forces of tie-rods

5,792 kg (for 1st

and 4th

Tie-Rods

4,579 kg (for 2nd

and 3rd

Tie-Rods

1200

27

00

Tie-Rod

Supports

Pressure Value =

1- Uniform Distributed Load

0.65 kgf/cm2

2- Hydrostatic Pressure

Max. 0.675 kgf/cm2 at the bottom

15

00

75

0

45

0



14


With h=2700mm Logica

Panel;

It is possible to pour the

concrete up to concrete

height of 2.7m without

taking care of the rate of

placing.

For the Concrete Heights

greater than 2.7 m,

Concrete Rate of Placing

must not be greater than

2.75 m/h

Conclusion

DEFLECTION

DIAGRAM

1 ) Limit under Uniform Distributed Load

2) Limit under Hydrostatic Pressure

Logica Formwork Panel

(h = 2700mm) meets the maximum bending

limits on DIN 18202 “Flatness Tolerances”

for hydrostatic fresh concrete pressures.

Pb =6,500 kg = 63.77 kN

hs

hf

5Vb =h

According to DIN 18218 clause 5.4;

h = hs + hf = 5Vb

hs = 6.5 tons / 2.5 tons/m3

hs = 2.6 m

Where ;

Vb ; Concrete Rate of Placing

2.5 tons/m3 ; Density of Fresh Concrete

hs ; Hydrostatic Pressure Deep

hf ; Vibration Deep

P = 17.Vb + 17

63.77 = 17.Vb + 17 �� Vb = 2.75 m/h

Pb =6,750 kg = 68.81 kN

h

DEFLECTION

DIAGRAM

Loading Limits Tie-Rods


15


Tension Forces of tie-rods ; 5,792 kg (for 1st

and 4th

Tie-Rods

4,579 kg (for 2nd

and 3rd

Tie-Rods

5,792 kg = 56.820 kN < 90 kN

(working load of Ø15mm Tie-rod “SAS 900 /1100- Type FA”

TIE-RODS

Optimum Rate of Concrete Placing

With15FA Tie-Rod and 15Fx55 Flange Nut

Permissible Rate of Concrete placing will be ;

Temperature

Air / Concrete HOZ / L-NW PZ 35F PZ 45F / PZ 55

ºC m/h m/h m/h

15 - 20 2.80 5.00 5.00

12 2.30 4.50 4.50

10 2.00 4.50 4.50

8 2.00 4.00 4.00

5 1.50 4.00 4.00

Kind of Concrete

Loading Limits Formwork Connection


16


For Vertical Connections of Panels,

at least 2 number of Panel Locks

must be used.

FORMWORK CONNECTION

Working Load of a Panel

Lock= Buckling Load / 1.7

= 50,30 kN / 1.74

= 28.93 kN

= 2,949 kg.

See Section “Test Results” of this

Manual.

Tb : Buckling Moment on the Frame

Me :Moment from each 2nd Stiffeners

Ta :Buckling Moment between 2 tie-rods

Fc :Total Tension Force on Panel Locks

Fb :Tension Force between 2 tie-rods

c :Total Number of Panel Locks

b :Number of Panel Locks

between 2 tie-rods

Fc Fc

Frame 2nd

Stiffener Tie-Rods Panel Lock

Tb Me Ta Fc Fb c b

kgm kgm kgm kg kg pcs pcs

1.20 539 135 270 5,675 2,838 2 1

1.50 674 135 404 7,094 4,256 3 2

2.70 1,213 135 674 12,769 7,094 5 2

3.00 1,348 135 674 14,188 7,094 6 3

3.30 1,483 135 674 15,607 7,094 6 3

Min.Number of Panel Locks Required for different Panel Heights to be connected

Hmax

Height (m)

Loading Limits Push-Pull Props


17


60° < X° < 70°

Connections of Push-Pull Props

should be close to Vertical Profiles

of Panel Frames.

PUSH-PULL PROPS

K2d

Kv

Kh

Ka

K1d X°

Wind Speed

w = 151 km/h

Wind Pressure

q = 1.43 kN/m2

Up to 100 m above ground

(Cf = 1.3 DIN 1055)

Axial Working Load of

Mesa-Push Pull Prop

Kall = 35.12 kN / 1.7

= 20.65 kN

See Section “Test Results” of this

Manual.

q = 1.43 kN/m2

e : Push Pull Prop Interval

K1d : Axial Load

K2d : Axial Load

Ka : Support Reaction

Kh : Support Reaction

Kv : Support Reaction

L2d : 1.5 m (max.)

H2d

L2d

emax

Wmax

Hmax

2.40 3.00 3.30 3.60 3.90

2.70 11.58 14.48 15.93 17.37 18.82

3.00 12.87 16.09 17.70 19.31 20.91

3.30 14.16 17.70 19.47 21.24 23.01

3.60 15.44 19.31 21.24 23.17 25.10

3.90 16.73 20.91 23.01 25.10 27.19

4.20 18.02 22.52 24.77 27.03 29.28

4.50 19.31 24.13 26.54 28.96 31.37

Maximum Axial Loads for different Panel Areas supported

by Two sets of Push-Pull Prop

Wmax = 2 x emax

Hmax

Height (m)

e - Push-Pull Prop interval (m)

Loading Limits Lifting Device


18


LIFTING DEVICE

Permissible Working Load

= 1,190 kg

Maximum weight of Panels

to be lifted together ;

1,190 kg x 2 Lifting Device

= 2,380 kg

Average Weight of Logica

Panels = 70 kg/m2

Maximum Panel Area to be

lifted together

= 2,380 kg / 70 kg/m2

= 34 m2

Permissible Working Load = 1,190 kg

Panel Width ≤ 6 m.

Pa

ne

l H

eig

ht

≤ 6

m.

α°

α° ≤ 60°

2.40 3.00 3.60 4.80 6.00

2.70 6.48 8.10 9.72 12.96 16.20

3.00 7.20 9.00 10.80 14.40 18.00

3.30 7.92 9.90 11.88 15.84 19.80

3.60 8.64 10.80 12.96 17.28 21.60

3.90 9.36 11.70 14.04 18.72 23.40

4.20 10.08 12.60 15.12 20.16 25.20

4.50 10.80 13.50 16.20 21.60 27.00

4.80 11.52 14.40 17.28 23.04 28.80

5.10 12.24 15.30 18.36 24.48 30.60

5.40 12.96 16.20 19.44 25.92 32.40

5.70 13.68 17.10 20.52 27.36 34.20

6.00 14.40 18.00 21.60 28.80 36.00

Panel Height

(m)

Panel Widths (m)

Maximum Panel Area to be lifted (m2)

Loading Limits Lifting Device


19


Maximum Load acting on Mesa

Platforms in above table should not

be exceeded.

Use Standard Mesa Working

Platforms or 5mm thick timber.

PLATFORM BRACKET

Platform Bracket

Permissible Platform Load;

= 150 kg/m2

Total Load acting on

a 600x2400mm Platform;

0.6m x 2.4m x 150 kg/m2

= 216 kg

Uniform Distributed Load on

Platform Bracket;

= 216 kg / 2 / 0.6m

= 180 kg/m

q

Max.Total Bracket

Load (kg) Load (kg/m)

600 mm 54 45

900 mm 81 68

1,200 mm 108 90

1,500 mm 135 113

2,400 mm 216 180

Platform

Lengths

L

L/4

L/4

L/2

W

Test Results


20


TEST RESULTS

Test Results of Mesa Push-Pull Props

Test Results


21


Test Results of Logica Panel Lock

Buckling Load

80/80 Logica Panel Lock

Notes

Logica Wall Formwork System - MRWF
