DG7 Gass Design Guide

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 1

 Index

Page number Contents

3-5 Main components
6-7 Gass platforms
8 Moving devices etc
9 Gass Leg Safety Catch
10-11 Lateral restraint
12-18 Gass table forms
19-29 Strip & Re-erect
30-31 Stability
32 Buildability
33-36 Wind uplift
37-41 Data sheets
42-43 Ledger Frame positions
44-45 Design brief requirements
46-53 Appendix A
54 Design guide notes and feedback sheet

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 2

 2.80m Inner
*check availability

Frame
(Ext = 2.200m)

Frame
1.2m Ledger
T150
S150

T225

1.8m Ledger
1.68m Inner

Dual Beams
(Ext = 1.314m)

1.4m Outer 1.45m Inner

*check availability
(Ext = 1.1m)

Frame
2.49m Outer 0.78m Inner

Frame
3.0m Ledger
(Ext = 0.414m)

2.4m Ledger
Main Components

3.58m Outer 0.5m Ext'n

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G

Leg

4.67m Outer

3
DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 4
 Adjustable
height

Gass Single Guardrail.

(Used on Gass outer leg)

Adjustable
height

Gass Single Guardrail +

Jack Guardrail Collar.
(Used on Gass inner leg)

Note: Sizes available (centre to centre of Gass leg) 1200, 1800,

2400, 3000mm
ONLY to be used as a guardrail during erection phase, NOT
for use as fall erest. Must be positioned in accordance with
current standards.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 5

Gass Platforms

Sizes available
(centre to centre of
ledger) 1800, 2400,
3000mm
Handrail detail not
shown for clarity.
See relevant details.

Gass Access
Platforms
(positioned on top of Toeboard clip detail
ledger)

Sizes available
(centre to centre of
ledger)
1800,2400,3000mm

Gass Access Platforms Toeboard clip detail

(positioned on bottom
of ledger)

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 6

 Gass Advanced Guardrail. (Sizes available 1065, 1650mm)
For Gass structures with two or more ledgers in height.

Gass infills - Sizes available 1.2m, 1.8m, 2.4m and 3.0m.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 7

 Gass Castor Gass Twin Castor

Gass Lift Lowering Trolley Gass Trolley Unit

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 8

Gass Leg Safety Catch
Designers to ensure that ONE leg safety catch is quantified per Gass leg
(Units to be craned only – ie Tables) to prevent inner dropping out of
outer.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 9

Lateral restaint
GASS is a partially braced aluminium falsework system and requires columns and walls
for laterally restraint. In order to understand this statement we need to evaluate the
forces that are applied to a Gass falsework structure.

Vertical forces.

Vertical forces include concrete, self weight of falsework, imposed loads, permanent
works loads and construction operation loads. Refer to Appendix A example for typical
calculation.

Horizontal forces.

• Wind
• Erection tolerances – The magnitude of the horizontal force depends upon the
amount of out-of-plumb of the particular member. Note the structure could be
out of vertical by design giving horizontal forces that need to be resisted.
• Concrete pressures – Horizontal forces occur at slab edge formwork etc.
• Dynamic and impact forces – e.g. rolling vehicles, braking forces etc (See BS5975
Section 4.4)
• Bow imperfections (straightness of legs and ledger frames).

Top restraint from permanent works

The designer should, where possible, butt the formwork against walls and columns and
use the note shown below on the drawing.

Within BS 5975: 2008 the code states that where the design assumes top restraint, the
connection to the permanent works should be designed to resist the applied forces. The
forces required should be set down on the drawings in order that the adequacy of the
permanent works can be verified.

This includes loads being transferred through the surrounding permanent works eg
columns, lift cores, shear walls etc.
Within section 19.3.2.4 of the new code various examples are detailed showing how the
restraint should be catered for.

The restraint to the plate may comprise tension, compression and shear connections to
the permanent works. The plate will be required to resist internal forces, the extent of
which is dependant upon the degree of restraint that exists. In order to transfer loads it
is essential that adequate contact is provided between the plate and the restraining
structure.
Note: Top restraint must act as a plate providing lateral restraint in all directions and
plan rotation.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 10

In most examples it is difficult to assess how the forces are split into the permanent
works components. To avoid over complicated calculations please state the horizontal
load (2.5% AVL) for a ‘worst case’ metre square of slab and put the emphasis on to the
customer to split the forces. See notes below:

Free standing towers

Where top restraint can not be provided it will be necessary to design the Gass structure
as free standing un-braced, partially braced or fully braced. This will greatly reduce the
safe working load of the Gass leg. Please see the data sheet section for a typical
example.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 11

GASS Table forms

A Gass table form is a pre-

assembled, crane-handled falsework
structure for multistorey
construction (as shown in the photo
opposite).

Advantages:-

• Reduced project costs from

faster floor-by-floor cycle-
times. Reduction in time-
consuming “fix & strike”
areas.

• If designed correctly and

adequately supervised,
Tableforms can be safely
lifted by crane without the
need for a loading platform
at building edge.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 12

Table shapes & Infills.

TABLE 1 TABLE 2

TABLE E
TABLE F TABLE F TABLE G
(modified)

The sketch above shows various table configurations in use on a typical scheme.

Table F is a typical Gass table utilizing Mk2 primary beams and S150 secondarys. MK2
and Aluminium primary beams can be used in tables, however MK2 Soldiers are
predominantly used when larger table sizes are required (up to 15m long). ‘Infill’ plywood
panels will be required to bridge the gap to adjacent tables. Infills must be designed and
care should be taken to ensure the plywood is orientated in its strong direction (See
infill section later).

Table G is a variation on the standard table, often referred to as a ‘hammer head’ table.
It is designed to omit the need for infills, where possible, whilst still ensuring the table
can be flown.

Table E is designed to ensure safe access around a corner of a structure. Care must be
taken in the design process to ensure there is sufficient room to fly the table. The
adjacent table (Table F) must be flown first, Table E can then move into the void before
being flown out of the structure.

NOTE: Handrails on table E must be safely removed prior to the table moving into the
structure. Customer must operate separate safety system during this operation.
DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 13
 Infills
Ply infill panel with ply (face
100mm x 50mm Timber runner grain) running in strong Timber secondary beams
by Customer. direction. (225mm x 75mm)

Note: This dimension allows

50mm clearance between
column and table. Customer to
check and confirm this is
acceptable.

All timber work to be designed

Timber Secondary infill detail
supplied and fixed by Customer.

150mm x 50mm end timber screwed Ply infill panel with ply (face grain) running
into S150 / T150 timber insert by in strong direction.
Customer.

Aluminium Secondary infill detail

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 14

 Ply infill panel with ply (face grain) T150 & Gass leg prop line.
running in strong direction.

Propped infill detail

Infill notes

• See appendix A for typical infill calculation.

• Timber runner prevents ply from spanning in two directions.
• Direction of the infill ply face grain must be indicated on drawing.
• Splice channels etc can be fixed beneath a T150 secondary to increase support if
required.
• Design standard infill as SINGLE SPAN case NOT load case 58 in formwork
guide.
• Design propped infill as TWO SPAN case NOT load case 58 in formwork guide.
• If required the clear span can be taken when calculation Deflection ONLY.
• If required live load can be removed when calculating Deflection ONLY.
• Use the note below on drawings for health and safety reasons.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 15

Adequate Strike?

The sketches opposite highlight problems that

600
can occur when striking and moving tables.
These issues should be avoided at all costs.

Sketch 1 – The Concrete has been poured to a

typical slab and spine beam. The slab has
1.40 out

1.2 Frame

reached sufficient strength and the table can be

struck.

Sketch 2 – Table struck, Note position of timber

600

side shutters.
1.40 out

1.2 Frame

600

Sketch 3 – Castors have now been added

but the side shutter must be removed to
allow the table to move.
1.40 out

NOTE- The long 1.68m jack could NOT 1.2 Frame

be used in this case as it would clash with

the primary beam (Gass outer = 1.4m).

Sketch 4 – Up to this point the scheme

600

was still workable, all be it with the

increased labour cost of
removing/replacing the timber side
shutter. However if we introduce a 1.0m
1.40 out

1.2 Frame
drop beam round the perimeter of the
building it becomes impossible to
remove the table!!

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 16

 Flying Table sequence

1. TABLE SHOWN IN FIXED POSITION 4. PUSH OUT TABLE KEEPING CRANE HOOK
VERTICALLY ABOVE ATTACHMENT POINTS.

2. TABLE SHOWN IN STRUCK POSITION 5. ATTACH REAR SLINGS

3. TABLE WITH CASTOR WHEELS ATTACHED 6. CONTINUE TO PUSH OUT TABLE. MOVING CRANE
HOOK & SHORTENING REAR SLINGS IN UNISON
TO ENSURE TABLE IS FLOWN HORIZONTAL.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 17

GASS TABLEFORMS DO'S & DON'TS

DO'S

DON'TS

ANY COSTS ARISING FROM DAMAGE CAUSED BY

NON-COMPLIANCE WITH ANY OF THE ABOVE
WILL BE MET BY THE CUSTOMER

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 18

Strip and re-erect
Strip and re-erect GASS as the name
implies is erected, concrete poured
and the dismantled. In can then be re-
used else where on the site.

Advantages:-

• Large grids can be possible

hence fully utilising the SWL of
the Gass.
• Equipment erected in 4 leg
towers (in most cases) hence
reducing the number of ledger
frames and consequently
hire/sale price.
• Ply infills become redundant.
• High floor to soffits can be
achieved.

Disadvantages

• Labour cost in strip and re-

erect procedure.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 19

Gass design principals and best practice

Estimate a grid size before drawing anything in AutoCAD

For the first estimate of grid size, calculate the allowable leg load from the data sheets.
For example, a 3.58m Outer with 600mm jack extension gives a SWL=117kN. Using
T225 primary beams this would be reduced to 100kN (Allowable reaction)

Note: Within BS 5975: 2008, the code states that different values for live load should be
taken depending on the slab depth (see section 17.4.3.1 of BS 5975: 2008). The rules are
as follows:

Hence, if we had a 300 slab, Load = 9.35 kN/m2 ((0.300 x 24.5) + (0.75+0.75) + 0.5)

A grid of 1.8m x2.4m would give an actual leg load of 44.43kN which is too low.
(9.35 kN/m2 (Loading)x 1.8m x 2.4m x 1.1 (allowance for continuity**))

A grid of 2.4m x 3.0m would give an actual leg load of 74.05 kN which is OK !
(9.35 kN/m2 (Loading)x 2.4m x 3.0m x 1.1 (allowance for continuity**))

Further increasing the grid to 3.0m x 3.0m may be possible but continuity would more
than likely be increased to 25% and T150 beams used as secondary’s (to omit excessive
deflection)

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 20

Sketch out by hand first before committing to AutoCAD

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 21

Use the continuity rules to achieve an economic layout
Continuity is a term that relates to beams that are continual across their support
positions. The effects of this are to cause bending moments over the support position
and redistribute the resultant reactions. Note that the applied load must equal the
reacted load for equilibrium and hence increasing the centre reactions has a relieving
effect n the end ones.

NO
CONTINUITY
A B

25%
CONTINUITY
A B C

10%
CONTINUITY
A B C D

Note: From the above it can be seen that it is preferable to design falsework avoiding
the use of two span beams. This is not always practical, especially it the case of Gass and
Dual where due to large ledger frames (i.e. 3.0m) two span cases are the norm (no
aluminium beams greater than 7.2m). Where using single span beams take special care
to ensure the deflection criteria is not exceeded.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 22

Balance the main spans

2400
2400

2400

2400
1800 3000 3000 2400

2400
2400

2400
2400 1800 2400

Avoid layouts consisting of vastly different grid sizes. The poor example above may
results in large deflections and a greater leg load, leading to an un-economical design.

Balance the cantilevers.

Primary cantilevers should only be 1/3 of

the adjacent span as a rule of thumb. If
possible avoid using a single span primary in
2400

the last bay of a Gass grid. Both of these

issues can lead to overturning problems and
excessive bending, shear and deflection.
1800

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 23

Eccentrically loaded legs

It is unacceptable and bad practice to

eccentrically load any falsework leg. The
load from the beam MUST go down the
centre of the leg. Any deviation from this
principal will result in a large reduction in
allowable leg load. Please refer to the
following examples of good and bad
practice and the sub primary section later in
this document.

T225-3.0
2400 2400 T225-4.2 T225-3.0
2400
2400

2400

2400

2400

2400
T225-3.0
2400 2400 T225-4.2 T225-3.0
2400

T225-3.0
1800
T225-3.6 1800 T225-4.2
1800
1800

1800

1800

1800
2400

2400

T225-3.0
1800 T225-3.0
1800

T225-3.6
1800

1800 1800 1800

3.6m T225 Sub Primary
1800

1800

1800

1800

1800

1800

1800

1800 1800 1800

T225-4.8 T225-2.4 T225-4.2

1800 1800 1800

T225-4.8 T225-2.4 T225-4.2

1800

1800

1800

1800
2400

2400

1800 1800

T225-3.6 Twin 2.5m T150 Twin 2.5m T150

1800

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 24

 2xT225-3
.0 1800
T22518-3.0

@610 CRS
S150-2.7
00

1800

1800

S150-2.7

S150-2.7
1800
1800 T225-4
.8
T225-3.6
2400
@610 CRS
S150-2.7

T225-3.6
2400 T225-4.2
1800
2400

2400

2400

2400
@610 CRS
S150-3.6

T225-3.6
2400 T225-4.2
1800

2 no props to be laced back into

2xT225-3 Gass structure. Customer must
1800.0
T22518-3.0
00
position using a suitable safety
system.
@610 CRS
S150-2.7

1800

1800

1800
1200
T225 - 4.
2
1200

1200

1800
1200

T225 - 4.2 1800

1200
T225-3.6
@610 CRS
S150-2.7

T225-3.6
2400 T225-4.2
1800
2400

2400

2400

2400
@610 CRS
S150-3.6

T225-3.6
2400 T225-4.2
1800

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 25

Dual beam typical maximum cantilevers under concrete.

T225 Primary T150 / S150

Typical plywood maximum cantilevers under concrete.

Slab depth Ply cantilever

Up to 200mm 75mm
200-500mm 50mm
500-750mm 25mm
750 - Ask!!!

Under slung beams

Under slung beams can be
used to omit excessive ply
spans around columns. This
will occur where the
column’s plan dimensions
are larger than the
permissible secondary/ply
span.
Note: each intersection is
fixed using 2 number
Universal clamps.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 26

The under slung beam should be sufficiently long that it can be attached to 2 secondary
beams, either side of the column.

Under slung beams may also be used to provide safe access around the more complex
buildings, however care should be taken and the design discussed with your design
manager.
Note- Gass structure is box tied around Columns to provide stability. Even though the
equipment is strip and re-erect no ledger frames are omitted to provide additional
rigidity. All beams must be fully fixed prior to loading the cantilever.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 27

Sub primarys

Sub primarys are used when the standard beam

sizes can not fit between walls, circular formwork
and other applications where the length of the
primary beam needs some flexibility.
In the application shown opposite concentric
loading is maintained as the load in the short
primary is transferred through the sub-primary
into the Gass leg.
NOTE- On low floor to soffits the introduction of
a sub primary may at best limit strike or at worst
cause the inner to clash with the deck. This needs
to be checked.
A

A A

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 28

IMPORTANT NOTE – Please use Universal clamps for all decking beam connections.
Wedge clamps are still available but may be phased out at a later stage.

Strip & re-erect and

Tableform

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 29

Stability: Part 1

All types of free standing structures depend

for their stability either on their self weight or
on additional anchors / kentledge.

Even where there are no environmental loads

or live loads, such as wind, a free standing
tower may show some tendency to overturn,
perhaps due to its centre of gravity being
outside the base or a force being applied at
the top/deck level. The following guidance is
taken from BS5973 clause 28.11.1 (now
withdrawn but still represents good practice).

Maximum height to width ratio’s for free standing towers.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 30

Stability: Part 2

Where environmental loads or live loads occur on towers a more detailed design should
be undertaken to prevent any instability. The designer should ensure there is sufficient
self weight in the structure or introduce kentledge / anchors. See example below:-

Stability: Example

Consider the tower opposite with a LIVE

load of ONE MAN (0.75kN) every 500mm
acting at up against the handrail. The frame
centres are 1.8m. The tower is shielded
against wind.

Hence

Point load onto 2.5m T150 = 0.75kN x 1800

500

= 2.7kN

Overturning about B = 2.7kN x 1.0m

= 2.7kNm

Uplift at A (ignoring self weight of deck) = 2.7kNm / 1.2m (leverarm)

= 2.25kN

SWL T bolt clamp = 3.0kN (Tension). 2 No = 6.0kN. Hence connection OK!

By inspection a 2.49 Gass outer and Gass inner (approx 2.29kN but this does not allow
for a factor of safety against overturning OF 2:1) will NOT provide enough self weight
to resist uplift force. Additional restraint in the form of box ties around columns and/or
lace tubes back to existing structure will be required.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 31

Buildability

The sketch opposite will be, in most cases,

acceptable from a structural point of view having a
SWL of 117kN* (3.58m outer, 600mm extension,
restrained at deck level). However building the
structure would be very difficult, if not impossible.

* Remember this would not be the design criteria

as the SWL of the T225 beam would limit the
allowable leg load to 100kN.

Moving the ledger frame to the centre of the

leg is NOT an acceptable solution (due to the
associated reduction in leg load – See ledger
position section of this document).

The sketch opposite shows the correct solution,

enabling the ledger frames to be decked out etc
to provide a safe working platform for fixing
the top ledger frame and beams / ply.

** PLEASE OBSERVE THE CORRECT FRAME SPACINGS AS PER

THE LATEST GASS DATA SHEETS **

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 32

Wind Uplift

In high wind situations there is a possibility that a Gass table may be uplifted due to the
effects of wind. This effect is magnified if the table is left up against a shear wall where
the wind hits the ‘blockage’ and is deflected upwards. Please note that this is not a
common situation, the following example is for awareness only (extracted from ‘wind
uplift’ spreadsheet) and is designed to highlight situations where uplift may occur. This
example has been calculated to CP3 however the same principles can be used with
BS6399.
Wind Loading to BS6399:Part 2

Basic wind speed (Vb) = 23 m/s Outskirts of Glasgow

Site altitude = 2 m
Altitude factor (Sa) = 1.002

Direction factor (Sd) = 1.0 (Ignored)

Seasonal factor (Ss) = 1.0 (Ignored)
Probability factor (Sp) = 1.0 (Ignored)

Site wind speed (Vs) = Vb x Sa x Sd x Ss x Sp

= 23.05 m/s

Approximate distance to sea = 100 km

Effective height = 10 m

Terrain & building factor (Sb) = 1.62 (In Country)

Effective wind speed (Ve) = Vs x Sb

= 37.33 m/s

Dynamic Pressure (qs) = 0.85 kN/m2

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 33

 Weight of a 9.9m x 5.1m Gass, Mk2 and Dual table

Table Weight Edit only those items shown blue Unit weight Weight

No of Legs 8 1.4m Outer 8.04 kg 64.32 kg

Additional Leg Type (If any) 0 None 0.00 kg 0.00 kg

Ring Bolts (Head to Head) 0 0.00 kg 0.00 kg

Primary Number, Length, Type 2 9.9 m MkII 20.80 kg/m 411.84 kg

Secondary Number, Length, Type 25 5.1 m S150 3.24 kg/m 413.10 kg

Alternative Secondary Number, Length, Type (if any) 0 3.9 m T150 5.81 kg/m 0.00 kg

Alternative Secondary Number, Length, Type (if any) 0 0.0 m S150 3.24 kg/m 0.00 kg

Number of 1200 Frames 9.10 kg 0.00 kg

Number of 1800 Frames 0 10.30 kg 0.00 kg

Number of 2400 Frames 10 13.40 kg 134.00 kg

Number of 3000 Frames 0 15.50 kg 0.00 kg

Inner Type (Bottom) 8 1680 Inner 10.20 kg 81.60 kg

Inner Type (Top) 0 None 0.00 kg 0.00 kg

GASS Leg Safety Catch 8 No per Leg One 0.55 kg 4.40 kg

End Timbers None 0.00 kg/m 0.00 kg

Universal Clamps 50 0.60 kg 30.00 kg

Soldier Ring Bolt 16 0.15 kg 2.40 kg

Edge Protection 0.0 m Tube/Boards 11.50 kg/m 0.00 kg

Plywood Area 49.7 sq.m 11.0 kg/m2 546.70 kg

(Note: Plywood area is based on primary length x maximum secondary length)

Actual Plywood Area (optional) - Set to zero if not required. 49.7 sq.m

Table Weight 1688 kg

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 34

 Smallest table
dimension (Width)
Example 5.1m Windward
edge

Example 3.0m Ledger Frame

WIND
FORCE

Centre of pressure
0.25 Width
Example 1.275m
Overturning
Lever arm restoring TABLE
point
Example 1.5m WEIGHT

Lever arm
overturning
Example 2.775m

Overturning moment

Solidity ratio / Pressure coefficients BS6399 Table 13

Note: A solidity ration of 1.0 represents a fully blocked canopy (i.e. up against a shear
wall). A solidity ratio of 0 represents a canopy with no obstructions (as in the case above
where wind can move freely under the table unit).

Hence Cp=1.2 for a fully blocked canopy and Cp=0.5 for a canopy with no obstructions
(Roof angle = 0 in this case).

Note: The centre of pressure should be taken to act at 0.25 x deck with from the
windward edge. In this case the wind lever arm = 0.25 x 5.1m = 1.275m.
If we consider that the beam cantilevers are equal at 1.05m each we can calculate that
the overturning lever arm (due to the wind) is….

5.1m (beam length) - 1.05m (cantilever) -1.275m (distance from windward edge to centre of pressure) = 2.775m

From wind data above

Wind force uplift = qfull x Cp x Area = 0.85 x 0.5 x (9.9 x 5.1) = 21.46kN

Uplift Moment = 21.46 x 2.775 x 1.2 (factor of safety) = 71.46kNm

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 35

Restoring moment

Weight of table = 1688kg = 16.88kN

Restoring moment = 16.88kN x 1.5m (restoring la) = 25.32kNm

Hence kentledge will be required against uplift.

Due to wind acting in all directions the kentledge would have to be positioned in the
centre of the table. Hence…

Overturning (uplift) = Restoring + kentledge x 1.5

71.46 = 25.32 + (kentledge x 1.5)

Kentledge = 30.76kg

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 36

Data sheets
There are 3 variations on SWL graphs for GASS legs with TOP RESTRAINT in the
current data sheets and 3 other graphs that cover FREE STANDING unbraced,
partially braced and fully braced towers. This section examines how to use the
relevant sheets.

In all cases, unless stated otherwise, use the ‘without differential support settlement’
graphs as we can usually assume the ground will be of uniform strength (concrete
slab).

Note that the graphs state the maximum SWL of a Gass leg is 140kN. This will not
normally be the limiting factor as the primary beam reaction usually dictates the max load
(Reaction T225 = 100kN, Mk2 = 115kN)

A) One ledger frame + one jack. (See Data sheet page 204, Included)

Consider a 3.58m Outer with 600mm jack extension, using the correct graph we can
read up from 600mm to the 3.58m leg line. Reading across the SWL=117kN (The
vertical axis is calibrated in 5kN increments).

B) Two ledger frames + one jack. (See Data sheet page 206, Included)

Consider a 3.58m Outer with 900mm jack extension. Firstly estimate a graph
between the 3.0m Outer and 4.0m Outer. Using the new graph we can read up from
900mm to the 3.58m leg line. Reading across the SWL=102kN

C) One ledger frame + two jack. (See Data sheet page 216, Included)

For simple cases these graphs are relatively straight forward to use, however more
complex scenarios may need to be analysed using Robot.

Consider a 2.49m Outer with 600mm base jack extension, 900mm top jack extension.
Reading up from the correct case the SWL=75kN

However if we consider a 2.49m Outer with 450mm base jack extension, 900mm top
jack extension we would need to interpolate between the cases shown (See data
sheet extract). Reading up from this line the SWL=92kN

D) Three ledger frame + one jack, free standing, un-braced. (See Data sheet page
269, Included)

These graphs must be used when we can not assume any top restraint. Consider
6.0m Outer with 400mm base jack extension. SWL = 41kN

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 37

 Loadings
GASS SYSTEM Date 06/07/2003 Page: 204
Issue: ‘C’

Gass Tower (1 Jack) Loading Charts - 2 of 12

117

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 38

 Loadings
GASS SYSTEM Date 06/07/2003 Page: 206
Issue: ‘C’

Gass Tower (1 Jack) Loading Charts - 4 of 12

102

3.58m
Outer

900

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 39

 Loadings
GASS SYSTEM Date 06/07/2003 Page: 216
Issue: ‘C’

Gass Tower (2 Jacks) Loading Charts - 2 of 34

91

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 40

 41

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 41

Ledger frame position

The simplest way to explain the 'phenomenon' is by looking at what exactly ledger
frames do, and explain it in terms that will reach the minds of 'all' ‘engineers’, 'effective
lengths'.

Buckling of the legs is inhibited by the shear capacity of the ledger frames and as shear
is introduced it breaks a long strut into smaller bits; that is, as long as it is given a chance
to work. The more load in the ledger frame the greater its impact on the system.

The examples below shows two cases of a 3580 leg, restrained at the top, with 300 mm
jacks.

Case A. shows the ledger frame in the middle. In that position ledger frame has little
benefit. 'Effective length' of the leg is virtually it's total length.

Case B. shows the ledger frame 150 mm from the bottom of the leg. Here the ledger
frame does work and breaks the long column into shorter lengths. Although the top
cantilever is larger, the maximum 'effective length' is still substantially reduced and this
reflects in the higher collapse load.

The above explanation is rather simplistic; it does not take into account for example the
moment changes within the effective length or what the effects are
if there is no true point of contra flexure; but without complicating the argument, I hope
it is adequately convincing.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 42

 Effective length

Displacement diagram Bending moment diagram

SWL 43.5 kN
CASE A

Effective length

Displacement diagram Bending moment diagram

SWL 115.5 kN

CASE B

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 43

Design Brief Requirements
Tables

1. Is the ground you are building off adequate to support 100kN leg loads?
(If not sleepers/spreaders may be required especially if the base is not cast.)
2. Is the slab you are supporting Post Tensioned or traditional?
(Extra access will be required for the post tensioning operation.)
3. Are full structural drawings available?
4. What is the slab thickness and does it change as the building progresses?
(The tables will need to be designed for the worst case slab depth.)
5. What is the floor to soffit dimension?
6. What is the crane capacity?
(This will directly affect the size of the table that can be designed.)
7. Where is the crane positioned?
(This will effect the direction in which tables can be flown.)
8. Are there any live roads/railways or any other issue that will affect the flying
direction of tables?
9. Is there a restriction on maximum table size?
(There may be obstacles inside the building or a small site lay down area that
dictates this.)
10. What type and thickness of plywood will the customer be using?
(This will have an effect on secondary beam centres and permissible infill sizes.)
11. Will perimeter screens be used?
(This may affect the table cantilevers and access requirements.)
12. What is the customer’s preference regards primary beams?
(Longer tables can be made using Mk2 primary beams but they are heavier to
man handle.)
13. Will up stands be poured at a later stage once the falsework has been removed?
(Otherwise the design will have to incorporate the additional load.)
14. Are there any obstacles in the structure such as benching or pipe work that will
need to be avoided?
15. Are there any additional deflection criteria other than SPAN/270?
16. Can column’s/walls transfer horizontal forces from the Gass into the permanent
works. (Additional propping of the columns or falsework may be needed if
lateral restraint is not adequate.)

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 44

Design Brief Requirements
Fix and strike

1. Is the ground you are building off adequate to support 100kN leg loads?
(If not sleepers/spreaders may be required especially if the base is not cast.)
2. Is the slab you are supporting Post Tensioned or traditional?
(Extra access will be required for the post tensioning operation.)
3. Are full structural drawings available?
4. What is the slab thickness and does it change as the building progresses?
(The Gass will need to be designed for the worst case slab depth.)
5. What is the floor to soffit dimension?
6. Where is the crane positioned?
(This will affect the design of the falsework grid, particularly if the crane is with
in the building footprint.)
7. What type and thickness of plywood will the customer be using?
(This will have an effect on secondary beam centres and permissible infill sizes.
Consider that some customers may wish to reduce centres to ensure re-use of
ply.)
8. Will perimeter screens be used?
(This will affect the decking cantilevers and access requirements.)
9. What is the customer’s preference regards primary beams?
(Usually dual T225 beams will be used with fix and strike.)
10. Will up stands be poured at a later stage once the falsework has been removed?
(Otherwise the design will have to incorporate the additional load.)
11. Are there any obstacles in the structure such as benching or pipe work that will
need to be avoided?
12. Are there any additional deflection criteria other than SPAN/270?
13. Can column’s/walls transfer horizontal forces from the Gass into the permanent
works. (Additional propping of the columns or falsework may be needed if
lateral restraint is not adequate.)
14. Will some areas of the falsework remain in place (as propping) and hence have
to carry multiple slab loads?
15. Will areas of the building with many ‘drop down’ beams be ‘flat decked’.
(This will save on falsework materials but will require extra decking work to be
carried out.)
16. Will an erection deck need to be built into the falsework?

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 45

Appendix A: Gass Table Design Example

A A

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 46

 REF. CALCULATIONS OUTPUT

Introduction

Proposed Gass/Mk2 and Timber support to Roof Slab.

For details see Harsco drawing :- Sketch provided

Loadings:-

BS 5975,
Self weight of Concrete = 24.5 kN/m3
Section 4 Self weight of Formwork = 0.5 kN/m2
Live Loading = 1.5 kN/m2
Access Loading = (0,75+0.75) kN/m2

Self weight of Timber = 6.50 kN/m3

BS 5973, Self weight of Plywood = 0.10 kN/m2
Table 9

Slab Loads:-
Slab thickness = 225 mm
BS Loading (Inc live) = (Slab depth x concrete density) + live + self weight formwork
5975:2008,

(0.225 x 24.5) + (0.75+0.75) + 0.5 = 7.51 kN/m2

Loading (Exc live) = (Slab depth x concrete density) + self weight formwork

For
deflection
Purpose
(0.225 x 24.5) + 0.5 = 6.01 kN/m2
only

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 47

REF. CALCULATIONS OUTPUT

Plywood
17.5mm Pourform (Cofi-form Plus)

Properties

EI = 3.93 kN.m2
Formwork
MoR = 0.602 kN.m
Guide, qA = 8.12 kN
Table G-S,
appendix G
Note : Face grain Parallel to span in all cases

Loading (Inc live) Slab depth x concrete density) + live + selfweight ply only

(0.225 x 24.5) + (0.75+0.75) + 0.1 = 7.11 kN/m2

For Loading (Exc live) Slab depth x concrete density) + selfweight ply only
deflection
Purpose
only (0.225 x 24.5) + 0.1 = 5.61 kN/m2

Main Table Ply Secondary beams centres = 610 mm

Based on
Load case
58,
Bending :-
Appendix M = 0.095WL = 0.095 x ( P x L ) x L
B, = 0.25 kNm
Formwork
guide,
Shear :-
qA= 0.525(L-B-t) W = 0.525 (610-75-17.5) x 7.11 x 0.61 = 1.93 kN
L 610

Deflection :-
d = 0.0066 WL3 = 0.0066 x (5.61 x 0.61) x 0.613 x 1000 = 1.3mm
EI 3.93

Allowable = 610/270 = 2.2mm

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 48

Ply Infill Between Tables

Bending :-
M = 0.125WL= 0.125 x ( 7.11 x 0.625 ) x 0.625
= 0.35 kNm

Shear :-
qA= 0.5 W = 0.5 x 7.11 x 0.625 = 2.22 kN

Deflection :-

d = 5/384 x WL3 = 5/384 x (5.61 x 0.575) x 0.5753 x 1000 = 2.03mm

EI 3.93

Allowable = 575/270 = 2.13mm

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 49

 REF. CALCULATIONS OUTPUT

Timber
100 x 50mm timber runner, 610mm spans.

Properties

Formwork EI = 27.14 kN.m2

guide, MoR = 0.575 kN.m
Table 6.
qA = 4.40 kN

Load = 0.675/2 x 7.51 = 2.54 kN/m

Based on Bending :-
Load case 1,
21
Appendix M = 0.125WL= 0.125 x ( 2.54 x 0.61 ) x 0.61
B, = 0.12 kNm
Formwork
guide,

Shear :-

qA= 0.625 W = 0.625 x 2.54 x 0.61 = 0.97 kN

Deflection :-

d = 5/384 x WL3 = 5/384 x (2.54 x 0.61) x 0.613 x 1000 = 0.2mm

EI 27.14

Allowable = 610/270 = 2.2mm

Note – Due to the unknown span cases, Bending and Deflection are
single span, Shear is two span ** Worst Case **

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 50

 REF. CALCULATIONS OUTPUT

Timber
225 x 75mm timber secondary at 610mm centres.

Properties

Formwork I = 6300 cm4

guide,
Table 4 + 6.
E = 7603 N/mm2
MoR = 4.114 kN.m
qA = 15.23 kN

UDL Load = 7.51 x 0.61 = 4.58 kN/m

Point Load = 4.58 x 0.575/2 = 1.32 kN

See CAD analysis

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 51

REF. CALCULATIONS OUTPUT

Primary Beam

For calculation purposes Primary beams have been

analysed with ‘Solid’ supports to find estimated deflection
of beam.
Leg shortening (elastically) can then be found from each
leg load using the stiffness ratio.

Stiffness ratio = AE/L where A=16.0 cm2

E=68900 N/mm2
L=5033mm (5500-17.5-225-225)
Therefore Stiffness = 1600 x 68900
5033 x 1000

= 21.9 kN/mm

Eg, for 61kN leg load shortening = 61/21.9 = 2.79mm

Load applied to Primary = 7.51 x 2.55 = 19.15 kN/m

See CAD analysis (Standard pour)

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 52

 REF. CALCULATIONS OUTPUT

Summary

Max leg load = 60.7 kN

SWL Gass Leg = 79 kN (3.6m leg, 900 ext base,500 ext top, 2 Ledger Frames)
Gass data
sheets

Max deflections

Secondary = 3.52mm
Primary = 1.76mm
5.28mm

Notes :

1) See individual Primary beam analysis for

estimated elastic shortening (generally
between 1 and 3mm)
2) No allowance has been made for joint or
ground settlement.
3) Customer to make any necessary allowance
for the above 2 conditions.
4) Customer to check all Deflections are within
acceptable limits.

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 53

 DESIGN GUIDE NOTES & FEEDBACK

On completion please return this form to:

Harsco Infrastructure - Technical Support
Crabtree Lane
Clayton Industrial Estate
Openshaw
Manchester
M11 1BR
Fax No 0161 223 2829
E-mail Akenmare@harsco.com

DG7 Gass Design Guide – Dec 2009 - By AK/RA Rev G 54