HÖRMANN BFT3 Casting Frame Installation Guide

1. About This Manual

This manual is valid for the BFT3 casting frame. Dimensions are in millimeters.

2. Safety

2.1 Intended Use

The product is used in commercial areas and serves the following purposes:

• Mounting at loading points for trucks
• Use for the installation of a HÖRMANN loading bridge HTL3-C

2.2 Suitable Personnel

Only allow trained personnel to work on the product, provided they are authorized and instructed by the operator. The assembly includes:

• Mechanical work
• Welding and concrete work

Special assembly work must only be carried out by qualified personnel from specialized companies. This includes work on the building's structural integrity or ventilation system.

3. Scope of Delivery

The scope of delivery for the casting frame includes:

• Casting frame, in individual parts
• Fastening material

A visual representation of the frame components is provided.

4. Installation Requirements

4.1 Pit Forms

Depending on the door guide, various pit forms are possible:

• Door guide up to the loading bridge: The door closes at the front of the loading bridge platform. This door guide has no impact on the pit design.
• Door guide before the loading bridge: The door guide requires a longer pit with a recess for the door. The casting frame is installed further back in the pit. The door closes on the insulation panel (customer's responsibility) below the loading bridge. For loading ramps without underfloor access, the door closes on the concrete floor.

4.2 Pit Requirements

For permanently flawless functioning, the pit must be designed as follows:

• According to the manufacturer's design drawings
• Dimensionally accurate and square on all sides
• Sufficiently stable to safely accommodate all forces that occur regularly or rarely.

CAUTION: Danger of breakout due to insufficient anchoring

If the pit cannot withstand the load, the loading bridge will break out. In case of an emergency stop, the load is particularly high. Example: a truck drives away while the loading bridge is still in operation. Ensure sufficient connection to the building structure, especially in areas where load forces occur.

NOTE: The reinforcement must extend laterally to the edge of the pit. Alternatively, install posts according to the manufacturer's pit drawings.

4.2.1 Checking Pit Dimensions

Check the dimensional accuracy (in mm):

• Pit length PL / PL1 = Order length NL-5 (Tolerance +5/-0)
• Pit width PW = Order width NW + 70 (Tolerance ±10)
• Pit height PH > Installation height NH +5

The lengths of the diagonals (C) must not differ by more than 10 mm.

NOTE: A gradient of maximum 2% towards the door opening is acceptable for the casting frame. The casting frame must be installed precisely horizontally in width. Otherwise, the functionality of the loading bridge may be impaired, especially when loading below the ramp level.

Pit dimensions:

• PH: Pit height
• PL: Pit length
• PL1: Pit length from the rear to the recess (pit with recess for door guide)
• PW: Pit width
• C1/2: Diagonals

5. Assembly

The assembly of the loading bridge may only be carried out if the requirements for the installation site are met.

NOTE: Deviations from the depicted pit shape are possible. The illustrations do not account for the extension and adaptation of the pit for the door guide before the loading bridge.

5.1 Safety Instructions for Assembly

Assembly only by qualified personnel. Ensure that the following conditions are met during assembly:

• The work area is cordoned off.

5.2 Required Tools

Gather the required tools. We recommend performing the assembly with 2 people.

Lifting aids are required for assembly. If ordered accordingly, they are included.

5.3 Unloading

• In case of deformation or damage, contact your supplier.
• Touch up minor damage to the paint or galvanization only after assembly.

CAUTION: Damage from impact

The casting frame must not deform, as this can impair its functionality.

• Always keep the casting frame horizontal.
• Ensure that the casting frame does not hit anything or fall.

5.4 Assembly

Assemble the casting frame in the specified order.

Figure 1: Positioning components

Place the components near the pit according to the illustration.

Figures 2 and 3: Mounting the front beams

Align a side panel and screw it firmly to the front beam. Ensure that all edges are flush.

Repeat the process on the other side.

Figure 4: Mounting the rear edge angle

Screw the rear edge angle to the two side panels.

Figure 5: Mounting positioning aids

Screw the four positioning aids to the casting frame.

Figure 6: Mounting the back plate

Screw the back plate to the casting frame.

Figure 7: Mounting lifting aids

Screw the lifting aids to the specified points on the casting frame. Brace the frame with a wooden beam parallel to the front beam as required. Remove the lifting aids.

IMPORTANT! The lifting aids must be attached exactly at right angles to the side panels. Otherwise, the frame will deform. Use the same holes on both sides for fastening.

5.5 Installation

The welding symbols correspond to ISO 2553 (E). The BFT3 casting frame is either cast with prefabricated concrete parts (A) or cast into a pit with a sufficiently wide casting joint (B).

5.5.1 Setting Up

Position the casting frame.

A:

• Use lifting aids if necessary for mounting further BFT3 casting frames. Align the frame horizontally.

B:

• Ensure the frame is aligned horizontally.

5.5.2 Welding

WARNING: Health hazard when welding galvanized components

Zinc fumes are released during welding of galvanized parts, which can cause health impairments if inhaled. Grind off the zinc layer at the welding points.

The frame has anchors on the sides and rear.

IMPORTANT! All rear anchors must be welded! You do not have to weld all side anchors if the following conditions are met:

• The pit corresponds to the manufacturer's plans.
• The pit has side posts.
• All anchors are bent.

In this case, weld the following anchors:

• the two outer anchors
• all anchors at the posts
• at least half of all side anchors

Bend all anchors. Connect the anchors to the posts or the reinforcement. Weld the anchors to the reinforcement or the posts.

5.5.3 Casting

Concrete quality: at least C20/25.

Before casting, ensure that the positioning and anchoring of the casting frame are still intact. Pour the concrete casting compound.

5.6 Removing Aids

Remove and dispose of the aids for assembly.

CAUTION: Damage due to deformation

The casting frame must not deform, as this can impair its functionality. Ensure that the lateral pressure during pouring and compacting does not become too high.

CAUTION: Danger due to insufficient anchoring

If the anchoring is insufficient, the pit cannot withstand the load. The loading bridge will break out. Ensure sufficient connection to the building structure, especially in areas where load forces occur.

The edge angle must be completely backfilled. You can check this through the opening in the edge angle.

5.7 Final Inspection

Check if any frame deformations have occurred during installation.