999804102 - 03/2013

en-GB

The Formwork Experts.

Composite formwork beams

User information
Instructions for assembly and use (Method statement)

User information Composite formwork beams

by Doka Industrie GmbH, A-3300 Amstetten

2|

999804102 - 03/2013

User information Composite formwork beams

Contents
4
4
6
8

Introduction
Elementary safety warnings
Doka services
Eurocodes at Doka

9
9
10
12
15

Product description
Instructions for assembly and use
Technical condition
Transporting, stacking and storing

16

Component overview

999804102 - 03/2013

|3

Introduction

User information Composite formwork beams

Elementary safety warnings

Introduction

User target groups

Remarks on this document

This manual is aimed at all persons who will be work-

This manual can also be used as a generic method

ing with the Doka product or system that it describes.

It contains information on the standard design for
setting up this system, and on correct, compliant utilisation of the system.
All persons working with the product described
herein must be familiar with the contents of this manual and with all the safety instructions it contains.
Persons who are incapable of reading and understanding this booklet, or who can do so only with difficulty, must be instructed and trained by the customer.
The customer is to ensure that the information materials provided by Doka (e.g. User Information booklets, Instructions for Assembly and Use, Operating
Instruction manuals, plans etc.) are available to all
users, and that they have been made aware of them
and have easy access to them at the usage location.
In the relevant technical documentation and formwork utilisation plans, Doka shows the workplace
safety precautions that are necessary in order to use
the Doka products safely in the usage situations
shown.
In all cases, users are obliged to ensure compliance
with national OH&S (occupational health and safety)
rules throughout the entire project and to take appropriate additional or alternative workplace safety precautions where necessary.

Hazard assessment
The customer is responsible for drawing up, docu-

menting, implementing and continually updating a

hazard assessment at every job-site.
This document serves as the basis for the site-specific hazard assessment, and for the instructions
given to users on how to prepare and utilise the system. It does not substitute for these, however.

Planning
Provide safe workplaces for those using the form-

4|

work (e.g. for when it is being erected/dismantled,

modified or repositioned etc). It must be possible to
get to and from these workplaces via safe access
routes!
If you are considering any deviation from the
details and instructions given in this booklet, or
any application which goes beyond those
described in the booklet, then revised static calculations must be produced for checking, as well
as supplementary assembly instructions.

statement or incorporated with a site-specific

method statement.
Many of the illustrations in this booklet show the
situation during formwork assembly and are
therefore not always complete from the safety
point of view.
Any safety accessories not shown in these illustrations must still be used by the customer, in accordance with the applicable rules and regulations.
Further safety instructions, especially warnings,
will be found in the individual sections of this
document!

Symbols used
The following symbols are used in this booklet:

Important note
Failure to observe this may lead to malfunction or damage.

CAUTION / WARNING / DANGER

Failure to observe this may lead to material
damage, and to injury to health which may
range up to the severe or even life-threatening.

Instruction
This symbol indicates that actions need to be
taken by the user.

Sight-check
Indicates that you need to do a sight-check
to make sure that necessary actions have
been carried out.

Tip
Points out useful practical tips.

Reference
Refers to other documents and materials.

999804102 - 03/2013

User information Composite formwork beams

Rules applying during all phases of

the assignment:

Introduction

Pouring
Do not exceed the permitted fresh-concrete pres-

sures. Excessively high pouring rates lead to formwork overload, cause greater deflection and risk
causing breakage.

The customer must ensure that this product is

erected and dismantled, reset and generally used for

its intended purpose under the direction and supervision of suitably skilled persons with the authority to
issue instructions.
These persons' mental and physical capacity must
not in any way be impaired by alcohol, medicines or
drugs.
Doka products are technical working appliances
which are intended for industrial/commercial use
only, always in accordance with the respective Doka
User Information booklets or other technical documentation authored by Doka.
The stability of all components and units must be
ensured during all phases of the construction work!
The functional/technical instructions, safety warnings and loading data must all be strictly observed
and complied with. Failure to do so can cause accidents and severe (even life-threatening) damage to
health, as well as very great material damage.
Fire-sources are not permitted anywhere near the
formwork. Heating appliances are only allowed if
properly and expertly used, and set up a safe distance away from the formwork.
The work must take account of the weather conditions (e.g. risk of slippage). In extreme weather,
steps must be taken in good time to safeguard the
equipment, and the immediate vicinity of the equipment, and to protect employees.
All connections must be checked regularly to ensure
that they still fit properly and are functioning correctly.
It is very important to check all screw-type connections and wedge-clamped joins whenever the construction operations require (particularly after exceptional events such as storms), and to tighten them if
necessary.

Assembly
The equipment/system must be inspected by the

customer before use, to ensure that it is in suitable

condition. Steps must be taken to rule out the use of
any components that are damaged, deformed, or
weakened due to wear, corrosion or rot.
Combining our formwork systems with those of other
manufacturers could be dangerous, risking damage
to both health and property. If you intend to combine
different systems, please contact Doka for advice
first.
The assembly work must be carried out by suitably
qualified employees of the client's.
It is not permitted to modify Doka products; any such
modifications constitute a safety risk.

Striking the formwork

Do not strike the formwork until the concrete has

reached sufficient strength and the person in charge

has given the order for the formwork to be struck!
When striking the formwork, never use the crane to
break concrete cohesion. Use suitable tools such as
timber wedges, special pry-bars or system features
such as Framax stripping corners.
When striking the formwork, do not endanger the
stability of any part of the structure, or of any scaffolding, platforms or formwork that is still in place!

Transporting, stacking and storing

Observe all regulations applying to the handling of

formwork and scaffolding. In addition, the Doka

slinging means must be used - this is a mandatory
requirement.
Remove any loose parts or fix them in place so that
they cannot be dislodged or fall free!
All components must be stored safely, following all
the special Doka instructions given in the relevant
sections of this manual!

Regulations; industrial safety

Always observe all industrial safety regulations and

other safety rules applying to the application and utilisation of our products in the country and/or region
in which you are operating.
If a person or object falls against, or into, the sideguard component and/or any of its accessories, the
component affected may only continue in use after it
has been inspected and passed by an expert.

Maintenance
Only original Doka components may be used as

spare parts. Repairs may only be carried out by the

manufacturer or authorised facilities.

Miscellaneous
We reserve the right to make alterations in the interests
of technical progress.

Erecting the formwork

Doka products and systems must be set up in such
a way that all loads acting upon them are safely
transferred!
999804102 - 03/2013

|5

Introduction

User information Composite formwork beams

Doka services
Support in every stage of the project
Doka offers a broad spectrum of services, all with a single aim: to help you succeed on the site.
Every project is unique. Nevertheless, there is one
thing that all construction projects have in common
and that is a basic structure with five stages. We at
Doka know our clients' varying requirements. With our
consulting, planning and other services, we help you
achieve effective implementation of your formwork
assignment using our formwork products in every one
of these stages.

1
Project Development Stage

2
Bidding Stage

3
Project Management Planning
Stage

Taking well-founded decisions

thanks to professional advice and
consulting

Optimising the preliminary work

with Doka as an experienced partner

Controlled, regular forming operations, for greater efficiency

resulting from realistically calculated
formwork concepts

Find precisely the right formwork

solutions, with the aid of
help with the bid invitation
in-depth analysis of the initial situation
objective evaluation of the planning, execution, and time-risks

Draw up potentially winning bids, by

basing them on realistically calculated guideline prices
making the right formwork
choices
having an optimum time-calculation basis

Plan cost-effectively right from the

outset, thanks to
detailed offers
determination of the commissioning quantities
co-ordination of lead-times and
handover deadlines

6|

999804102 - 03/2013

User information Composite formwork beams

4
Concrete Construction Stage

Introduction

5
Project Close-out Stage

The advantages for you

thanks to professional advice and
consulting

Cost savings and time gains

When we advise and support you

right from the word "go", we can
make sure that the right formwork
systems are chosen and then
used as planned. This lets you
achieve optimum utilisation of the
formwork equipment, and effective forming operations because
your workflows will be correct.

Maximised workplace safety

The advice and support we can

give you in how to use the equipment correctly, and as planned,
leads to greater safety on the job.

Transparency
Optimum resource utilisation
with assistance from the Doka
Formwork Experts

Seeing things through to a positive conclusion

with professional support

Workflow optimisation, thanks to

thorough utilisation planning
internationally experienced project technicians
appropriate transport logistics
on-site support

Doka Services are a byword for

transparency and efficiency here,
offering
jointly handled return of rented
formwork
professional dismantling
efficient cleaning and reconditioning using special equipment

999804102 - 03/2013

Because our services and costs

are completely transparent, there
is no need for improvisation during the project and no unpleasant surprises at the end of it.

Reduced close-out costs

Our professional advice on the

selection, quality and correct use
of the equipment helps you avoid
damage, and minimise wear-andtear.

|7

Introduction

User information Composite formwork beams

Eurocodes at Doka
In Europe, a uniform series of Standards known as
Eurocodes (EC) was developed for the construction
field by the end of 2007. These are intended to provide
a uniform basis, valid throughout Europe, for product
specifications, tenders and mathematical verification.
The EC are the world's most highly developed Standards in the construction field.
In the Doka Group, the EC are to be used as standard
from the end of 2008. They will thus supersede the DIN
norms as the "Doka standard" for product design.

Ed
Ed

Fd

Fk

Design value of effect of actions

(E ... effect; d ... design)
Internal forces from action Fd
(VEd, NEd, MEd)
Design value of an action
Fd = F Fk
(F ... force)
Characteristic value of an action
"actual load", service load
(k ... characteristic)
e.g. dead weight, live load, concrete pressure,
wind
Partial factor for actions
(in terms of load; F ... force)
e.g. for dead weight, live load, concrete pressure, wind
Values from EN 12812

Comparison of the safety concepts (example)

Permissible stress design
115.5 [kN]

Fyield

EC/DIN concept
Rk

115.5 [kN]

Rd gM = 1.1

90<105 [kN]
n ~ 1.65

Factual

98013-100

60 [kN]

gF = 1.5

Fpermissible

Factual Fpermissible

98013-102

60<70 [kN]

Ed

90 [kN]

The widely used "Permissible stress design" (comparing the actual stresses with the permissible stresses)
has been superseded by a new safety concept in the
EC.
The EC contrast the actions (loads) with the resistance
(capacity). The previous safety factor in the permissible
stresses is now divided into several partial factors. The
safety level remains the same!

Rd
Rd

Design value of the resistance

(R ... resistance; d ... design)
Design capacity of cross-section
(VRd, NRd, MRd)
Rk
Rk
Steel: Rd =
Timber: Rd = kmod
M
M

Rk

Characteristic value of the resistance

e.g. moment resistance to yield stress

Partial factor for a material property

(in terms of material; M...material)
e.g. for steel or timber
Values from EN 12812

kmod

Modification factor (only for timber to take

account of the moisture and the duration of load
action)
e.g. for Doka beam H20
Values as given in EN 1995-1-1 and EN 13377
The "permissible values" communicated in
Doka documents (e.g.: Qpermissible = 70 kN)
do not correspond to the design values
(e.g.: VRd = 105 kN)!
Avoid any confusion between the two!
Our documents will continue to state the permissible values.
Allowance has been made for the following partial factors:
F = 1.5
M, timber = 1.3
M, steel = 1.1
kmod = 0.9
In this way, all the design values needed in an
EC design calculation can be ascertained from
the permissible values.

Ed Rd

A Utilisation factor

8|

999804102 - 03/2013

User information Composite formwork beams

Product description
Doka beam I tec 20
Doka beams I tec 20 are solid-web beams made of
wood and derived timber products. They are intended
for use in wall and floor-slab formwork only.
Other features include:
Timber-plastic composite formwork beam
Long service life ensured by the 'Top' beam-end
reinforcement and the plastic sheet on the broadside
of the flange.
Increases load-bearing capacity by approx. 80 %
compared to the Doka beam H20
Reduces equipment quantities in both floor and wall
formwork
Beam-flange markings in a 50 cm grid for the Dokaflex and Dokaflex 30 tec systems
Same overall height and width as Doka beams H20,
so compatible with existing Doka systems

8.0

4.0

20.0

I tec 20

Approval Number
Z-9.1-773
Overall height tolerance 1.0 mm, assuming 12% timber moisture
content.

A
C
G
D

A
B
C
D
E
F
G

Web
Flange
Distance-marks on beam-flanges, for Dokaflex system
System holes
End-reinforcement
Notch for chalk line
I tec sheet

The innovative end-reinforcement on the Doka

beam I tec 20 greatly reduces damage to the
beam-ends.

999804102 - 03/2013

All standard and custom lengths, from 1.80m

to 5.90m, come fitted with the 'Top' beamend reinforcement.
Doka beams I tec 20 of over 5.90m and up to
12.00m in length are square-cut and treated
with I tec 20 beam-end sealant.
If the ends of beams are square-cut at Doka
branches or at jobsites, they must be treated
with I tec 20 beam-end sealant in order to
ensure the full lifespan of the beam.

|9

User information Composite formwork beams

Instructions for assembly and use

Doka beams I tec 20 are formwork beams made of
wood and derived timber products. They are intended
for use in load-bearing towers and formwork and are
loaded in the direction of the height of the beam.

In order to maximise durability, it is important to handle

the components with due care; this applies particularly
when stripping out floor-slab formwork.
Technical data:
Permitted bending moment: 9 kNm
Permitted shear force: 20 kN
Rigidity: 640 kNm2
Weight: 5.6 kg/lin.m

Practical example

These values allow for a F = 1.5, a kmod of 0.9 and a

M = 1.3.
Based on a residual moisture content of 20 % or less.
The values must be adjusted accordingly if conditions
of use differ.

9768-200-01

Deflection diagram
30

98036-100

p [kN/m]

2.5

3.5
2

4.5

25
L
5
M

1.5

Deflection [mm]

20

7
8

15

10

12.5

10

L/500

15

0.5 kN/m

20
L/250

25
30

0
1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

Support centres L [m]

M ... permitted bending moment
Q ... permitted shear force
p ... actual load (service load)

10 |

999804102 - 03/2013

5.0

User information Composite formwork beams

Possible incorrect usages

WARNING
Always position Doka formwork beams
"upright".

9791-205-01

9791-206-01

Correct "upright" positioning

Incorrect positioning "turned on
(load direction is parallel to web
side" (load direction at right
plane).
angles to web plane).
Wall formwork

9791-220-01

9791-219-01

Floor formwork

WARNING
The uses illustrated below are prohibited, as
are other, similar uses!

9791-200-01

Do not use as scaffold flooring.

9791-201-01

Do not use as traffic-route flooring.

999804102 - 03/2013

| 11

User information Composite formwork beams

Technical condition
The following quality criteria define the extent of damage permissible in terms of load-bearing strength.
Use is prohibited if damage is beyond these limits.

Splintering at side
permissible up to depth a = 10 mm and length b =
500 mm on one side.

Flange
Angled cracks (across the grain)

b
a

Not permissible.
98041-201-01

98041-200-01

98041-201-01

Straight cracks (parallel to the flange)

parallel to flange, permissible up to width a = 2 mm.
If the flange can be parted at the crack the beam is
not in usable condition.

Angled splintering across the edge

permissible up to a = 30 mm across the diagonal and
up length b = 500 mm.

a
98041-200-01
98041-201-01

98041-200-01

98041-201-01

98041-201-01

12 |

999804102 - 03/2013

User information Composite formwork beams

Openings in joints

Flange end

permissible up to a = 1 mm.

Splintering a up to length = 60 mm is permissible.

Damage to the plastic cap has no effect on loadbearing strength, but beams damaged evincing
damage of this kind do not necessarily meet the
quality criteria for Doka rental formwork

98041-207-01

98041-208-01

98041-207-01

Saw cuts

98041-208-01

Superficial saw cuts up to depth a = 2 mm are permissible.

Drilled holes
Not permissible, with the exception of system holes:

9791-207-09

- Waling attachment with beam screw

9791-209-02

98041-203-01

a ... 15 mm
b ... 112 mm
Drilled-hole diameter max. 10 mm

- Attachment of table head with beam screw

a

9791-209-01

98041-203-02

a ... 15 mm
c ... 396 mm
Drilled-hole diameter max. 10 mm

- Attachment of profiled timber formers

d

98041-209-01

d ... 113 mm
Drilled-hole diameter max. 12 mm

999804102 - 03/2013

| 13

User information Composite formwork beams

Web

Drilled holes in web

Damage to web
permissible only if slight and at one side of the beam.

9791-216-01

Permissible drilled holes:

Standard holes
- Each standard beam has 2 drilled holes, dia.
21.5 mm
Additional system holes for:
- Flange claw
- Fastening plate
- Connection splice plate
- Table head 30
- Lifting bracket
- Portal head
One drilled hole of maximum diameter 20 mm per running metre in addition to the system holes is permissible.
If the incidence of drilled holes is frequent the overall
condition of the beam is definitive.

9791-216-01

Damage to web end

permissible up to max. a = 20 mm
98041-207-01

98041-202-01
98041-207-01

Detachment of flange from web

Not permissible.
98041-202-01

9791-207-05

14 |

999804102 - 03/2013

User information Composite formwork beams

Transporting, stacking and storing

Protect stacked beams from extreme climatic

influences such as exposure to sunshine or
moisture by covering them (with breathable tarpaulins). This reduces cracking. Only cover
them never envelope them completely.

Always use edge protectors when strapping beams

together. Edge protectors can be padding made of
plastic, wood or cardboard.

Transport
Always use strap slings to lift stacked beams - do not
use chains.

Packets of 60 beams

Packets of 40 beams

98041-204-02

98041-204-01

When moving beams not securely strapped

together, take care that loose beams cannot
slip.

Stacked beams
max. 3000 kg per stack
98041-205-01

Max. 2 packets on top of one

another

98041-206-01

Max. 4 packets on top of one

another

Ground conditions for stacking

a

Maximum angle of inclination of ground 3%.

The ground on which the stack is to be placed must

98041-204-03

Max. n of beams per stack

Minimum n of timber supports
(min. 10 x 8 x 109 cm)
Dimension 'a'
Dimension 'b'

Lengths of beam
Up to 6.50 m
Over 6.50 m
60
40
2

3
108 cm

78 cm

56 cm

be adequately firm and level. Best-case conditions

are concreted or paved storage areas.
Storage on asphalt:
Depending on the parts stored, place wooden battens, strips of formwork sheeting or metal sheet
between the parts and the asphalt surface to ensure
that the weight is adequately spread.
Storage on other surfaces (sand, gravel...):
Adopt suitable measures for storage (e.g. place thick
plywood sheets underneath the loads).

Reprocessing scrap material

Doka formwork beams contain no wood preservatives
and, consequently, they can be deposited for reprocessing.
Reprocessing by incineration in suitable incineration
plants is recommended. It is advisable not to attempt to
burn scrap material in open fires or domestic woodburners.
Always comply with the applicable local or national regulations.

999804102 - 03/2013

| 15

Component overview

User information Composite formwork beams

[kg]

Article n

10.1
13.7
14.8
16.2
18.5
20.2
21.8
25.2
27.4
30.0
33.0
5.6

188001000
188002000
188003000
188004000
188005000
188006000
188007000
188008000
188009000
188013000
188010000
188011000

[kg]

Component
Article
[kg]
Doka
Beam
System
In
tec 20
overview
Components

Doka beam I tec 20 1.80m

Doka beam I tec 20 2.45m
Doka beam I tec 20 2.65m
Doka beam I tec 20 2.90m
Doka beam I tec 20 3.30m
Doka beam I tec 20 3.60m
Doka beam I tec 20 3.90m
Doka beam I tec 20 4.50m
Doka beam I tec 20 4.90m
Doka beam I tec 20 5.35m
Doka beam I tec 20 5.90m
Doka beam I tec 20 .....m
Doka-Trger I tec 20

Varnished yellow
Grey

Doka beam I tec 20 12.00m

67.2 188012000

Doka-Trger I tec 20 12,00m

Varnished yellow
Grey

I tec 20 beam-end sealant 2.5l

I tec 20-Endenversiegelung 2,5l

2.5 188014000

Yellow

16 |

999804102 - 03/2013

Article n

User information Composite formwork beams

999804102 - 03/2013

Component overview

| 17

Component overview

18 |

User information Composite formwork beams

999804102 - 03/2013

User information Composite formwork beams

999804102 - 03/2013

Component overview

| 19

Near to you, worldwide

Doka is one of the world leaders in developing, manufacturing and distributing formwork technology for use in
all fields of the construction sector.
With more than 160 sales and logistics facilities in over
70 countries, the Doka Group has a highly efficient distribution network which ensures that equipment and

technical support are provided swiftly and professionally.

An enterprise forming part of the Umdasch Group, the
Doka Group employs a worldwide workforce of more
than 5600.

Doka GmbH | Josef Umdasch Platz 1 | 3300 Amstetten | Austria | T +43 7472 605-0 | F +43 7472 66430 | oesterreich@doka.com | www.doka.com

999804102 - 03/2013