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Version3– 07/2016

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The Formwork Experts.

DokaRex alignment strut

User Information

Instructions for assembly and use (Method statement)

Copyright User Information DokaRex alignment strut

© by Doka Danmark, DK-4621 Gadstrup

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User Information DokaRex alignment strut Contents

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Contents

Introduction 5

Elementary safety warnings 5

Eurocodes at Doka 9

Product description 10

Declaration of conformity 15

Instructions for assembly and use 16

Structural design 21

Possible incorrect usages 23

Technical conditions 24

Transport, stacking and storing 25

Component overview 27

Introduction User Information DokaRex alignment strut

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Introduction

Elementary safety warnings

User target groups

▪ This manual is aimed at all persons who will be working 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 utilization 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 laws, Standards and 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, documenting, 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 formwork (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.

Remarks on this document

▪ This manual can also be used as a generic method 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.

User Information DokaRex alignment strut Introduction

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▪ Further safety instructions, especially warnings, will be found in the individual sections of this

document!

Regulations; industrial safety

▪ All laws, Standards, industrial safety regulations and other safety rules applying to the utilization of our

products in the county and/or region in which you are operating must be observed at all times.

▪ If a person of object falls against, or into, the side guard 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.

Rules applying during all phases of the assignment:

▪ The customer must ensure that this product is erected and dismantled, reset and generally used for its

intended purpose in accordance with the applicable laws, Standards and rules, under the direction and

supervision of suitably skilled persons. 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.

▪ It is strictly forbidden to weld Doka products – in par-ticular anchoring/tying components, suspension

components, connector components and castings etc. – or otherwise subject them to heating. Welding causes

serious change in the microstruc-ture of the materials from which these components are made. This leads to a

dramatic drop in the failure load, representing a very great risk to safety. The only articles which are allowed to

be welded are those for which the Doka literature expressly points out that welding is permitted.

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 equipment/system must be assembled and erected in accordance with the applicable laws, Standards and

rules by suitably skilled personnel of the customer's, having regard to any and all required safety inspections.


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▪ It is not permitted to modify Doka products; any such modifications constitute a safety risk.

Closing the formwork

▪ Doka products and systems must be set up in such a way that all loads acting upon them are safely transferred!

Pouring

▪ Do not exceed the permitted fresh-concrete pressures. Excessively high pouring rates lead to formwork

overload, cause greater deflection and risk causing breakage.

Stripping out the formwork

▪ Do not strip out the formwork until the concrete has reached sufficient strength and the person in charge has

given the order for the formwork to be stripped out!

▪ When stripping out 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 stripping out 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!

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.

User Information DokaRex alignment strut Introduction

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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.

Sight-check

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

out.

► Instruction

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

Tip

Points out useful practical tips.

Reference

Refers to other documents and material


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Eurocodes at Doka

User Information DokaRex alignment strut Product description

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Product description

The fast, lightweight and precise DokaRex alignment strut

The new DokaRex alignment strut for precast elements and columns is quick to install and easy to adjust.

Ergonomic

Weights up to 20% less than similar products on the market.

Lightweight and ergonomically design enables easy and ergonomically convenient working, easy to handle

and superbly adaptable to and building-construction project.

Fast

With only 4 different strut types a length range of 1.80m to 10.20m is covered. A turn-prevention and a pin-

insertion guarantees an easy and fast length adjustment.

The low weight and precise adjustment enables a quick installment and easy adjustment, which contributes

to high productivity and less crane-costs.

Highly engineered

The high quality galvanization of the DokaRex alignment strut 305 provides the basis for a long life span of

this steel strut.

The three longer strut types are made from Aluminum. The extruded alu-profile offers a great durability

against damages and weather. The powder coating guarantees fast cleaning and prevents adherence of

concrete.

Highly engineered, DokaRex features a handle for exact adjustments.

DokaRex alignment strut 305 DokaRex alignment strut 450

Product description User Information DokaRex alignment strut

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DokaRex alignment strut 305 IB

First rough adjustment will be done by fixing the strut with it’s length adjustment pin.

Afterwards, the fine adjustment will be obtained by the threaded spindles. The top and bottom spindle have to

have the same extension length. The length adjustment pin may only be used when in closed position.

Permissible Loads (Tests results processed in compliance with EN norms, calculation methods and safety factors)

25,00

18,00

25,00

0,00

5,00

10,00

15,00

20,00

25,00

30,00

1,80 1,90 2,00 2,10 2,20 2,30 2,40 2,50 2,60 2,70 2,80 2,85 2,90 2,95 3,00 3,05

Pe

rmis

sib

le L

oad

s [k

N]

Length [m]

Loadability


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Afterwards, the fine adjustment will be obtained by the final threaded spindles, which must be extracted at the

same length. All pins have to be always secured with the linch pins.


20,00 20,00

11,00

0,00

5,00

10,00

15,00

20,00

25,00

3,05 3,10 3,20 3,30 3,40 3,50 3,60 3,70 3,80 3,90 4,00 4,10 4,20 4,30 4,40 4,50

Pe

rmis

sib

le L

oad

s [k

N]

Length [m]

Loadability

Product description User Information DokaRex alignment strut

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25,00 25,00

16,00

0,00

5,00

10,00

15,00

20,00

25,00

30,00

4,45 5,00 5,50 6,00 6,10 6,20 6,30 6,40 6,50 6,60 6,70 6,80 6,90 7,00 7,10 7,20 7,30 7,40 7,50

Pe

rmis

sib

le L

oad

s [k

N]

Length [m]

Loadability


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First rough adjustment will be done by fixing the strut with it’s length adjustment pins.




30,00 30,00

24,00

0,00

5,00

10,00

15,00

20,00

25,00

30,00

35,00

7,08 7,50 8,20 8,30 8,40 8,60 8,80 9,00 9,20 9,40 9,60 9,80 10,00 10,20

Pe

rmis

sib

le L

oad

s [k

N]

Length [m]

Loadability

Declaration of Conformity User Information DokaRex alignment strut

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Declaration of Conformity

The DokaRex alignment struts, as described in these instructions for assembly and use, in association

with the Doka brand name are products of TheFormwork.

The table below sets out the corresponding products and declares the conformity, confirmed by the

manufacturer, of those products having different designations and article numbers.

857508001 DokaRex alignment strut 305 IB 857508001 TF Strut Ste 180-305

857508002 DokaRex alignment strut 450 IB 857508002 TF Strut Alu 305-450



857508005 DokaRex docking head M20 857508005 Self locking head

857508006 DokaRex strut shoe EB M16 857508006 Standard shoe

857508007 DokaRex strut shoe EB M16/M20 857508007 Heavy shoe

857508008 DokaRex strut head EB M20 857508008 Fixing head

857508009 DokaRex-strut head EB M20 weldable 857508009 Fixing head

Article n

o Article desciption Article n

o Article description

User Information DokaRex alignment strut Instructions for assembly and use

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Sight-check:

Always make sure that the DokaRex docking head M20 is correctly closed

As an additional precaution when in use

on the site, the DokaRex docking head

M20 can be secured with a spring cotter

5mm to prevent accidental opening

Instructions for assembly and use

Connection of DokaRex docking head M20

The DokaRex docking head M20 will be secured and ready to work, only when the red latch area isn’t

visible anymore! To remove the DokaRex alignment strut push down the latch of the DokaRex docking

head M20. Do not remove the pin.

The DokaRex docking head M20 works only in connection with the DokaRex alignment struts 450, 750 and

1020.

Security latch

DokaRex docking head M20




Precasted wall Precasted wall

Instructions for assembly and use User Information DokaRex alignment strut

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Connection of DokaRex strut head EB M20 weldable

The DokaRex strut head EB M20 weldable will be secured and ready to work, only when the Pin and Linch

pin are properly fixed!

The DokaRex docking head EB M20 weldable works only in connection with the DokaRex alignment struts 450,

750 and 1020.

DokaRex strut head EB M20 weldable

Pin

Linch pin



DokaRex strut head EB M20 weldable

Pin

Linch pin


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Connections in detail

DokaRex strut shoe EB M16

The DokaRex strut shoe EB M16 works in connection with the DokaRex alignment struts 305, 450 and 750 as shoe.

The transfer of loads to be checked by user.

For the DokaRex alignment strut 305, the Strut Shoe EB M16 works also as head. The same loading charts apply.

DokaRex strut head EB M20

The DokaRex strut head EB M20 weldable can get used as alternative option to the DokaRex docking head M20

for the DokaRex alignment struts 450, 750 and 1020.


The DokaRex docking head M20 works in connection with the DokaRex aligment struts 450, 750 and 1020.


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DokaRex strut shoe EB M16/20

The DokaRex strut shoe EB M16/M20 works in connection with the DokaRex alignment struts 1020 as shoe. It can

be used also for DokaRex alignment struts 450 and 750 when the loads are bigger than the ones DojaRex strut

shoe M16 can bear (fixing bolt loadability). The transfer of loads to be checked by user.


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Connection of DokaRex docking head M20

PH Pv ANGLE (α)0,97 0,71 45°

0,82 0,77 50°

0,50 0,87 60°

EXAMPLE of DokaRex docking head M20 Fixing Bolt dimensioning: As an example, the force F, applied on the considered DokaRex alignment strut, is fixed to 11 kN, (always refere to the loadabilty graphs previously showed for each DokaRex alignment strut model, in order to determine the admissible loadability given a certain extraction); it’s assumed that the shear force RV, will be equal to FV (resulting from vectorial composition of the force F), so only FH vector component have to be parameterized, by the PH values indicate in related tables from above.

With above mentioned premises, proceed as following:

Force F assumed value 11,00 kN

Angle between DokaRex alignment strut and bearing basement 50°

RH = F x PH = 11,0 kN x 0,82 = 9,02 kN

RV = F x PV = 11,0 kN x 0,77 = 8,47 kN

Be sure to use DokaRex alignment strut ONLY on vertical (90°) precast elements; any different application have to be accurately verified before any works, based on this User Manual indicated loadabilities


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Connection of DokaRex strut head EB M20

PH Pv ANGLE (α)0,87 0,71 45°

0,73 0,77 50°

0,50 0,87 60°

EXAMPLE of DokaRex strut head EB M20 Fixing Bolt dimensioning:

As an example, the force F, applied on the considered DokaRex alignment strut, is fixed to 11 kN (always refere to the loadabilty graphs previously showed for each DokaRex alignment strut model, in order to determine the admissible loadability given a certain extraction); it’s assumed that the shear force RV, will be equal to FV (resulting from vectorial composition of the force F), so only FH vector component have to be parameterized, by the PH values indicate in related tables from above.




RH = F x PH = 11,0 kN x 0,73 = 8,03 kN

RV = F x PV = 11,0 kN x 0,77 = 8,47 kN

Be sure to use DokaRex alignment struts ONLY on vertical (90°) precast elements; any different application have to be accurately verified before any works, based on this User Manual indicated loadabilities


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Connection of DokaRex strut shoe EB M16

PH Pv ANGLE (α)0,71 0,79 45°

0,64 0,91 50°

0,50 1,13 60°

EXAMPLE of DokaRex strut shoe EB M16 Fixing Bolt dimensioning:

As an example, the force F, applied on the considered DokaRex alignment strut, is fixed to 11 kN (always refere to the loadabilty graphs previously showed for each DokaRex alignment strut model, in order to determine the admissible loadability given a certain extraction); it’s assumed that the shear force RH, will be equal to FH (resulting from vectorial composition of the force F), so only FV vector component have to be parameterized, by the PV values indicate in related tables from above.




RH = F x PH = 11,0 kN x 0,64 = 7,04 kN

RV = F x PV = 11,0 kN x 0,91 = 10,01 kN



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Connection of DokaRex strut shoe EB M16/M20

PH Pv ANGLE (α)0,71 0,70 45°

0,64 0,86 50°

0,50 1,14 60°

EXAMPLE of DokaRex strut shoe EB M16/M20 Fixing Bolt dimensioning:

As an example, the force F, applied on the considered DokaRex alignment strut, is fixed to 11 kN, (always refere to the loadabilty graphs previously showed for each DokaRex alignment strut model, in order to determine the admissible loadability given a certain extraction); it’s assumed that the shear force RH, will be equal to FH (resulting from vectorial composition of the force F), so only FV vector component have to be parameterized, by the PV values indicate in related tables from above.




RH = F x PH = 11,0 kN x 0,64 = 7,04 kN

RV = F x PV = 11,0 kN x 0,86 = 9,46 kN


User Information DokaRex alignment strut /Structural design

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Structural design

Important note!

It is the customers responsibility to calculate, which forces will appear from erecting the wall element –

based on the weight of the element, height (wind), area factor, year factor, etc…

After the choice of the right strut (length) and the amount of struts the reaction force have to get calculated

by the customer to decide on the according inserts.

The max. allowable loads of the struts as mentioned before have to get considered.

The2/3 of H anchoring point height indication is a “general rule”, to be followed as the easiest way to work safely;

different positions could be chosen only by a previous verification and calculation, based on this User Manual

prescriptions and indications.

DokaRex alignment struts to be used only on Vertical Precast Elements (90°). Any different application

to be previously carefully verified, statically and operatively, strictly following all prescriptions,

indications and loadabilities indicated and contained in this User Manual.

Safety Information: The height of anchoring must be coordinated with the deliverer of the pre-fabricated parts or must be noticed in the adequate construction- or part drawings. The length calculation does not give consideration to the arising loads. These must be calculated separately

Warning: Anchor the DokaRex alignment strut so that it is resistant to tensile and compressive forces!

For details regarding “Fixing to the ground”, see the relevant User Information booklets of the chosen supplier. For more information, see the Calculation Guide “Wind loads to the Eurocodes”.

Important note! Every pre-cast member must be secured by at least 2 DokaRex alignment struts.

/ /Possible incorrect usages User Information DokaRex alignment strut

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Possible incorrect usages

WARNING

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

Not to be used as floor prop

Important note!

To set up and shore pre-cast concrete members safely, it is necessary for the DokaRex alignment struts to be fixed both to the prefabricated member and to the floor.

Before the type of anchorage can be decided, the design and load-calculation (wind loads, loads from working platforms etc.) for the strut must be carried out in accordance with the relevant standards.

Only use the DokaRex docking head M20 in the vertical.

Important note!

Handle & length adjustment pin & top fork is forbidden to use as crane attachment point.

User Information DokaRex alignment strut / /Possible incorrect usages

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The DokaRex docking head M20’s red latch area must not be visible any more to operate safely!

Must be checked before any operation!

Technical condition User Information DokaRex alignment strut

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Technical condition

Screw jack

Must be clean and action must be smooth over entire length.

Anti-dropout lock of the screw jack

Must be in full working order.

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.

User Information DokaRex alignment strut Transport, stacking and storing

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Transport, stacking and storing

Doka stacking pallet 1.55x0.85m

Ideal for all sizes of floor props, timber formwork beams, Dokadur panels and formwork sheets.

Galvanized – stackable – safe to lift by crane

Loading capacity of the stacking pallet Follow the directions in the Operating Instructions!

Bolt-on castor set B

The Bolt-on caster set B turns the stacking pallet into a fast and maneuverable transport trolley.

Suitable for drive-through access openings > 90cm.

The Bolt-on caster set B can be mounted to the following multi-trip packaging items:

Doka stacking pallets

Utilise the benefits of Doka multi-trip packaging on your site.

Multi-trip packaging such as containers, stacking pallets and skeleton transport boxes keep everything in place on the site, minimise time wasted searching for parts, and streamline the storage and transport of system components, small items and accessories.

9720-332-01

Max. load: 1100 kg

DokaRex alignment struts DokaRex alignment strut 305 IB tbd

DokaRex alignment strut 450 IB 28 units

DokaRex alignment strut 750 IB 15 units

DokaRex alignment strut 1020 IB tbd

Transport, stacking and storing User Information DokaRex alignment strut

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Doka accessory box

Doka multi-trip transport box 1.20x0.80m

Storage and transport devices for small items: Durable Stackable

Suitable transport appliances: Crane Pallet stacking truck Forklift truck

Important note!

Multi-trip packaging items that each contain very different loads must be stacked with the heaviest ones at the bottom and the lightest ones at the top!

The rating plate must be attached and clearly legible.

Follow the directions in the Operating Instructions!

Max. load: 1500 kg

Permitted imposed load: 7900 kg

User Information DokaRex alignment strut Component Overview

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Component Overview

[kg] Article no [kg] Article n

o


Length: 180-305cm

Steel

galvanised

17,5 857508001 DokaRex docking head M20

galvanised

2,7 857508005


Length: 305-450cm

Aluminum

Outer tube:

Powder coated blue

20,2 857508002 DokaRex strut shoe EB M16

galvanised

1,5 857508006


Length: 445-750cm

Aluminum

Outer tube:

Power coated blue

42,7 857508003 DokaRex strut shoe EB M16/20

galvanised

2,3 857508007


Length: 704-1020cm

Aluminum

Outer tube:

Powder coated blue

93,0 857508004 DokaRex strut head EB M20

galvanised

1,3 857508008

Component Overview User Information DokaRex alignment strut

30 Version3 07/2016

DokaRex strut head EB M20

weldable

untreated

1,3 857508009

Doka stacking pallet 1.55x0.85m

Galvanised

height: 77cm

follow the directions in

the Operating instrutctions

41,0 586151000

Doka multi-trip transport box

1.20x0.80m

Galvanised

Height: 78cm

follow the directions in

the Operating instrutctions

70,0 583011000

Bolt-on castor set B

Painted blue

33,6 583168000

User Information DokaRex alignment strut Component Overview

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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.

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