variokit heavy duty tower vst assembly instructions

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Assembly Instructions Edition 04/2011

VARIOKIT Heavy Duty Tower VST

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Heavy Duty Tower VST 4 Features .........................................................................................................................................................................4 Intended use ..................................................................................................................................................................4 Work safety ....................................................................................................................................................................5

1) General safety instructions ..............................................................................................................................................5 2) Storage and transport ......................................................................................................................................................5 3) System-specific safety instructions ..................................................................................................................................5

Overview ........................................................................................................................................................................7 Overview Modules VST................................................................................................................................................................7

Positioning of the Brace Connector VST........................................................................................................................8 Module VST 125 ........................................................................................................................................................................10 Module VST 175 ........................................................................................................................................................................12 Module VST 275 ........................................................................................................................................................................14 Module VST 375 ........................................................................................................................................................................16 Module VST 525 ........................................................................................................................................................................18 Module VST 775 ........................................................................................................................................................................20 Module VST 1025 ......................................................................................................................................................................22 Head Spindle Frame VST ..........................................................................................................................................................24 Head Spindle VST 100...............................................................................................................................................................25 VST-Tower Configuration 2,0 x 2,0m (Configuration 1) ..............................................................................................................26 VST-Tower Configuration 2,0 x 1,0-4,5m (Configuration 2) ........................................................................................................28 VST-Tower Configuration 2,0 x 4,5-14,0m (Configuration 3) ......................................................................................................29 VST-Tower Configuration 1,25-4,5 x 1,0-4,5 m (Configuration 4) ...............................................................................................30 VST-Frame with Assembly Platform...........................................................................................................................................31 Connector UP-VST (Component 5.1) .........................................................................................................................................32 VST-Frame with additional Legs.................................................................................................................................................33

Part A Work Preparation 35 A1 Operation status and loads ..................................................................................................................................35

Operating status: working...........................................................................................................................................................35 Operating status: lowering and striking.......................................................................................................................................35

A2 Pre - design of the Heavy Duty Tower VST .........................................................................................................36 A2.1 Combination Table for Tower Heights from 125 to 1225 cm...........................................................................................36 A2.2 Combination Table 1250-1925.......................................................................................................................................37 A2.3 Combination Table 1950-2525.......................................................................................................................................38 A2.4 Combination Table 2550-3125.......................................................................................................................................39 A2.5 Combination Table 3250-3725.......................................................................................................................................40 A2.6 Approx. permissible Leg Load on Top............................................................................................................................41

A3 Preparing and Assembling a single frame ...........................................................................................................42 A3.1 Element assembly sequence for a single leg .................................................................................................................43 A3.2 Assembly of a Frame.....................................................................................................................................................46

A4 Preparing and Assembling the head frame..........................................................................................................48 A4.1 Width Adjustment of Head Spindle VST 100..................................................................................................................48 A4.2 Assembly of Head Spindle Frame..................................................................................................................................49

A5 Pre-assembly of Tower segments .......................................................................................................................50 A5.1 Assembly of Tower with VST Parts ................................................................................................................................50 A5.2 Assembly of Tower with SLS-Spindles...........................................................................................................................52

A6 Assembly Platforms .............................................................................................................................................54 A6.1 Assembly of Assembly Platform on single Frame...........................................................................................................54

Part B Assembly 56 B1 Assembly of Tower with VST Parts......................................................................................................................56 B2 Assembly of Tower with SLS-Spindles ................................................................................................................58 B3 Assembly of single Frame....................................................................................................................................60 B4 Anchoring.............................................................................................................................................................64 Part C Application 66 C1 Height Adjustment (+/- 140 mm)..........................................................................................................................66 C2 Lowering Procedure.............................................................................................................................................67 Part D Disassembly 68

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Part E General Information 69 E1 Cleaning and Maintenance ..................................................................................................................................69 E2 Transport .............................................................................................................................................................69 E3 Storage ................................................................................................................................................................69 E4 Hydraulic System.................................................................................................................................................69 Part F Appendix 70 F1 Instruction of use for the Hydraulic Jack ..............................................................................................................70 Part G Component Catalogue 71

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Heavy Duty Tower VST Features The PERI Heavy Duty Tower VST is designed to carry high loads from shoring systems for cast in-situ bridges as well as to support all temporary situations with structural elements. The system can be flexibly used for any kind of shoring construction up to heights of 40 m with a bearing capacity up to 700 kN per leg. The main components consist of standardised PERI parts taken from the "VARIOKIT" engineering construction kit. The basis of the structure is formed by 2 parallel legs comprised of RCS Climbing Rails connected with Horizontal Ledgers VST 200 and several Diagonal Struts VST with a distance of 2 m. The RCS Climbing Rail is additionally stiffened by the Bracing Connector VST between the U-profiles in a distance of max. 1.5 m to increase the bending stiffness in weak direction. The connection of the frame in vertical direction is realized with the Prop Connector VST 48 and the Prop Base VST 48. The frames can be connected with the Horizontal Ledger VST 200 and the Diagonal Struts VST to get a tower of 2 by 2 m. For other distances between the frames, VARIOKIT standard components are used. Optimal adjustment to the necessary height in steps of 25 cm could be done by the combination of the Modules VST 125 up to VST 1025. (See Combination Table page 33 ff.) The fine adjustment is possible with the VST Spindle Head within +/- 140 mm. The PERI Heavy Duty Tower VST is a complete system to support bridge formwork on beams and trusses, pre-casted (bridge-) elements and all temporary load situations. It extends the product-range of PERI to the heavy duty segment and provides a simple and comfortable possibility to adjust and lower the construction in height.

Intended use 1. PERI products have been exclusively designed as technical work equipment for use in the industrial

and commercial sectors by suitably trained personnel.

2. These assembly instructions serve as a basis for the building-related risk assessment and the instructions for the provision and use of the system by the contractor (user). However, this document does not replace the building related risk assessment.

3. Only PERI original components may be used. The use of other products and spare parts represent a misapplication with associated safety risks.

4. The components are to be inspected before each use to ensure that they are in perfect condition as well as being able to function properly.

5. Changes to PERI components are not permitted and represent a misapplication with associated safety risks.

6. Safety instructions and permissible loads must be observed at all times.

7. Components provided by the contractor must conform to the characteristics required in these assembly instructions as well as all valid construction guidelines and standards. In particular, the following apply if nothing else is specified:

Timber components: Strength Class C24 for Solid Wood EN 338.

Scaffold tubes: galvanized steel tubing with minimum dimensions 48.3 x 3.2 mm according to EN 12811-1:2003 4.2.1.2.

Scaffold tube couplings according to EN 74.

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8. Any deviations from the standard configuration may only be carried out after a separate risk assessment has been done by the contractor (user). On this basis, appropriate measures for the working safety and stability are to be implemented.

Work safety The structures shown in these assembly instructions are examples and feature only one component size. They are valid accordingly for all component sizes contained in the standard configuration.

1) General safety instructions 1. Deviations from the standard configuration and/or intended use present a potential safety risk. 2. All country-specific laws, standards and other safety regulations are to be taken into account whenever

our products are used. 3. During unfavourable weather conditions, suitable precautions and measures are to be taken in order to

ensure both working safety and stability. 4. The contractor (user) must ensure the stability during all stages of construction. He must ensure and

verify that all loads which occur are safely transferred. 5. The contractor (user) has to provide safe and secure working areas which can be safely accessed.

Areas of risk must be cordoned off and clearly marked. Hatches and openings on accessible working areas must be kept closed during working operations.

6. For better comprehensibility, detailed drawings are partly incomplete. The safety installations which have possibly not been featured in these detailed drawings must nevertheless be available.

2) Storage and transport 1. Do not drop the components. 2. Store and transport components so that no unintentional change in their position is possible. Detach

lifting gear from the lowered units only if these are in a stable position and no unintentional change is possible.

3. When moving the components, make sure they are lifted and set down so that any unintentional tilting over, falling apart, sliding or rolling away is avoided.

4. Use only suitable load-carrying equipment to move the components as well as using the designated load-bearing points.

5. During the lifting and moving procedure, ensure all loose parts are removed or secured. 6. During the moving procedure, always use a guide rope. 7. Move components on clean, flat and sufficiently load-bearing surfaces only.

3) System-specific safety instructions 1. The contractor must ensure that assembly, modification and dismantling, moving, as well as the use

and handling of the product is directed and supervised by technically qualified and authorised personnel.

2. All persons who work with the product must be familiar with the working instructions and safety information.

3. The contractor must ensure that the assembly instructions, other instructions required for operations or assembly, relevant planning documents, parts lists and other data are available for the user.

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Assembly work 4. The contractor must ensure that appropriate and sufficient number of tools, lifting and load-securing

means, suitable and sufficient place for assembly work and storage, as well as sufficient crane capacity is available for the user.

5. During assembly work, there is always the possibility that unforeseen risks may arise. The degree of risk is to be assessed in each individual case and, if necessary, measures are to be taken in order to avoid or at least minimize the danger.

6. If it is not possible to use guardrails due to operational reasons, or if these have to be removed, suitable safety equipment must be installed in their place to catch falling persons. Should the use of fall arrest equipment be inappropriate, then rope protection (personal protection equipment) can also be used if suitable fastening points are available.

7. Use a guide rope for controlled guidance of the assembly units which are suspended on the crane. 8. Site personnel should avoid remaining under loads being lifted. If working under suspended loads

cannot be avoided, suitable measures are to be determined and implemented. Persons should also avoid being between suspended loads and the building.

9. It is forbidden for site personnel to enter the area below where assembly work is taking place so long as the danger area has not been provided with protection against falling, sliding and rolling objects and materials. The danger area is to be cordoned off.

Maintenance and repairs 10. VST components are to be inspected before each use to ensure that they are in perfect condition. As a

basic principle, only fully-functional materials may be used. 11. The VST components are to be inspected for signs of damage at regular intervals by expert and

authorized persons. Any dirt which could impair the functionality is to be removed immediately. Damaged components are to be identified, removed and replaced.

12. If the maximum permissible wind speed is exceeded, with temperatures outside of the range of application or after an unusual event such as fire or an earthquake, all safety-related components and the supporting structure are to be examined with regard to the functionality and load-carrying capacity before further use.

Safety-related components: A visual inspection is to be carried out at regular intervals by authorized personnel A functional check is to be carried out before loading and/or assembly each time by an

empowered person Only PERI original components are to be used when replacing parts Repairs are to be carried out by qualified PERI personnel only Work on and under the supported construction must stop if overloading or recurring damage

7occurs - then determine the cause and eliminate the problem. Supporting structure: A visual inspection is to be carried out by authorized personnel before the initial use Only PERI original components are to be used for repairs or as replacement parts Work on and under the supported construction must stop if overloading or recurring damage

occurs - then determine the cause and eliminate the problem.

Other components: Repairs are to be carried out by qualified personnel and the authorized person(s) must be

informed If any recurring damage occurs, determine the cause and eliminate the problem.

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Overview Overview Modules VST

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Positioning of the Brace Connector VST

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Components for the Modules VST

Name Item no. 1. The VST Leg is given by 1.1 Climbing Rail Profile RCS 98 117585 1.2 Climbing Rail RCS 148 114166 1.3 Climbing Rail RCS 248 109469 1.4 Climbing Rail RCS 348 109470 1.5 Climbing Rail RCS 498 109471 1.6 Climbing Rail RCS 748 109472 1.7 Climbing Rail RCS 998 109610 2. VST Frame consisting of 2 VST legs plus 2.1 Bracing Connector VST 117411 2.1.1 Bolt 21 x 120 104031 2.1.2 Bolt 26 x 120 111567 2.1.3 Cotter Pin 4/1 018060 2.2 Cross Connector VST 117425 2.2.1 Bolt ISO 4014 M20 x 140-8.8 113994 2.2.2 Nut ISO 7042 M20-8 781053 2.2.3 Sleeve 25x2,3 l=97mm 117492 2.3 Prop Base VST 48 117453 2.3.1 Bolt ISO 4014 M20 x 130-10.9 117452 2.3.2 Nut ISO 7042 M20-8 781053 2.3.3 Bolt ISO 4014 M24 x 140-10.9 114563 2.3.4 Nut ISO 7042 M24-8 105032 2.4 Prop Connector VST 48 117454 2.4.1 Bolt ISO 4014 M20 x 130-10.9 117452 2.4.2 Nut ISO 7042 M20-8 781053 2.4.3 Bolt ISO 4014 M24 x 140-10.9 114563 2.4.4 Nut ISO 7042 M24-8 105032 2.4.5 Bolt ISO 4014 M24 x 80-8.8 105416 2.5 Horizontal Ledger VST 200 117371 2.5.1 Bolt 21 x 120 104031 2.5.2 Cotter Pin 4/1 018060 2.6 Diagonal VST 200/150 117379 2.7 Diagonal VST 200/100 117382 2.8 Diagonal VST 200/112,5 117385 2.9 Diagonal VST 200/62,5 117388

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Module VST 125 Isometric View of Frame VST 125

1.1

2.5

2.4

2.8

2.3

2.4

2.3

2.5

1.1

2.8

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Components for the Module VST 125 Name Item no. Quantity 1. The VST Leg is given by 1.1 Climbing Rail Profile RCS 98 117585 4 2. VST Frame consisting of 2 VST legs plus 2.3 Prop Base VST 48 117453 2 2.3.1 Bolt ISO 4014 M20 x 130-10,9 117452 6 2.3.2 Nut ISO 7042 M20-8 781053 6 2.3.3 Bolt ISO 4014 M24 x 140-10.9 114563 6 2.3.4 Nut ISO 7042 M24-8 105032 6 2.4 Prop Connector VST 48 117454 2 2.4.1 Bolt ISO 4014 M20 x 130-10,9 117452 6 2.4.2 Nut ISO 7042 M20-8 781053 6 2.4.3 Bolt ISO 4014 M24 x 140-10.9 114563 6 2.4.4 Nut ISO 7042 M24-8 105032 6 2.5 Horizontal Ledger VST 200 117371 2 2.5.1 Bolt 21 x 120 104031 8 2.5.2 Cotter Pin 4/1 018060 8 2.8 Diagonal VST 200/112,5 117385 2

! Bolts and Nuts for all VST-Parts are pre-assembled ! The total weight for the Module VST 125 amounts to 370,20 kg.

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1.22.5

2.1

2.4

2.5 2.7

2.7

2.9

2.3

2.4

2.3

2.2

2.5

1.2

2.9

2.1 2.2

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Components for the Module VST 175 Name Item no. Quantity 1. The VST Leg is given by 1.2 Climbing Rail RCS 148 114166 2 2. VST Frame consisting of 2 VST legs plus 2.1 Bracing Connector VST 117411 2 2.1.1 Bolt 21 x 120 104031 4 2.1.2 Bolt 26 x 120 111567 4 2.1.3 Cotter Pin 4/1 018060 8 2.2 Cross Connector VST 117425 2 2.2.1 Bolt ISO 4014 M20 x 140-8.8 113994 4 2.2.2 Nut ISO 7042 M20-8 781053 4 2.2.3 Sleeve 25x2,3 l=97mm 117492 2 2.3 Prop Base VST 48 117453 2 2.3.1 Bolt ISO 4014 M20 x 130-10,9 117452 6 2.3.2 Nut ISO 7042 M20-8 781053 6 2.3.3 Bolt ISO 4014 M24 x 140-10.9 114563 6 2.3.4 Nut ISO 7042 M24-8 105032 6 2.4 Prop Connector VST 48 117454 2 2.4.1 Bolt ISO 4014 M20 x 130-10,9 117452 6 2.4.2 Nut ISO 7042 M20-8 781053 6 2.4.3 Bolt ISO 4014 M24 x 140-10.9 114563 6 2.4.4 Nut ISO 7042 M24-8 105032 6 2.5 Horizontal Ledger VST 200 117371 3 2.5.1 Bolt 21 x 120 104031 14 2.5.2 Cotter Pin 4/1 018060 14 2.7 Diagonal VST 200/100 117382 2 2.9 Diagonal VST 200/62,5 117388 2


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1.3

2.5

2.1

2.4

2.5

2.8

2.3

2.4

2.3

2.2

2.5

1.3

2.8

2.1 2.2

2.6 2.6

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Components for the Module VST 275 Name Item no. Quantity 1. The VST Leg is given by 1.3 Climbing Rail RCS 248 109469 2 2. VST Frame consisting of 2 VST legs plus 2.1 Bracing Connector VST 117411 2 2.1.1 Bolt 21 x 120 104031 4 2.1.2 Bolt 26 x 120 111567 4 2.1.3 Cotter Pin 4/1 018060 8 2.2 Cross Connector VST 117425 2 2.2.1 Bolt ISO 4014 M20 x 140-8.8 113994 4 2.2.2 Nut ISO 7042 M20-8 781053 4 2.2.3 Sleeve 25x2,3 l=97mm 117492 2 2.3 Prop Base VST 48 117453 2 2.3.1 Bolt ISO 4014 M20 x 130-10,9 117452 6 2.3.2 Nut ISO 7042 M20-8 781053 6 2.3.3 Bolt ISO 4014 M24 x 140-10.9 114563 6 2.3.4 Nut ISO 7042 M24-8 105032 6 2.4 Prop Connector VST 48 117454 2 2.4.1 Bolt ISO 4014 M20 x 130-10,9 117452 6 2.4.2 Nut ISO 7042 M20-8 781053 6 2.4.3 Bolt ISO 4014 M24 x 140-10.9 114563 6 2.4.4 Nut ISO 7042 M24-8 105032 6 2.5 Horizontal Ledger VST 200 117371 3 2.5.1 Bolt 21 x 120 104031 14 2.5.2 Cotter Pin 4/1 018060 14 2.6 Diagonal VST 200/150 117379 2 2.8 Diagonal VST 200/112,5 117385 2


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1.4

2.5

2.1

2.4

2.5

2.7 2.7

2.8

2.3

2.4

2.3

2.2

2.5

2.8

2.1 2.2

1.4

2.6 2.6

2.5

2.1

2.2

2.1 2.2

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Components for the Module VST 375 Name Item no. Quantity 1. The VST Leg is given by 1.4 Climbing Rail RCS 348 109470 2 2. VST Frame consisting of 2 VST legs plus 2.1 Bracing Connector VST 117411 4 2.1.1 Bolt 21 x 120 104031 8 2.1.2 Bolt 26 x 120 111567 8 2.1.3 Cotter Pin 4/1 018060 16 2.2 Cross Connector VST 117425 4 2.2.1 Bolt ISO 4014 M20 x 140-8.8 113994 8 2.2.2 Nut ISO 7042 M20-8 781053 8 2.2.3 Sleeve 25x2,3 l=97mm 117492 4 2.3 Prop Base VST 48 117453 2 2.3.1 Bolt ISO 4014 M20 x 130-10,9 117452 6 2.3.2 Nut ISO 7042 M20-8 781053 6 2.3.3 Bolt ISO 4014 M24 x 140-10.9 114563 6 2.3.4 Nut ISO 7042 M24-8 105032 6 2.4 Prop Connector VST 48 117454 2 2.4.1 Bolt ISO 4014 M20 x 130-10,9 117452 6 2.4.2 Nut ISO 7042 M20-8 781053 6 2.4.3 Bolt ISO 4014 M24 x 140-10.9 114563 6 2.4.4 Nut ISO 7042 M24-8 105032 6 2.5 Horizontal Ledger VST 200 117371 4 2.5.1 Bolt 21 x 120 104031 20 2.5.2 Cotter Pin 4/1 018060 20 2.6 Diagonal VST 200/150 117379 2 2.7 Diagonal VST 200/100 117382 2 2.8 Diagonal VST 200/112,5 117385 2


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1.5

2.5

2.1

2.4

2.5

2.8

2.3

2.4

2.3

2.2

2.5

2.8

2.1 2.2

1.5

2.5

2.1

2.7

2.2

2.7

2.1 2.2

2.1

2.2

2.1

2.2

2.6 2.6

2.6 2.6

2.5

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1.6 2.1

2.4

2.5

2.2

2.8

2.3

2.4

2.3

2.2

2.8

2.1

1.6

2.5

2.7

2.7

2.1

2.5

2.2 2.1

2.7

2.7

2.1

2.5

2.2

2.2

2.1

2.6

2.6

2.1

2.5

2.2

2.2

2.1

2.6

2.6

2.1

2.5

2.2

2.2

2.1

2.6 2.6

2.5

2.2

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1.7 2.1

2.4

2.5

2.2

2.8

2.4

2.2

2.8

2.1

1.7

2.6 2.6

2.5

2.5

2.1

2.2

2.2

2.1

2.6 2.6

2.5

2.1

2.2

2.2

2.1

2.6 2.6

2.5

2.1

2.2

2.2

2.1

2.7 2.7

2.5

2.1

2.2

2.2

2.1

2.6 2.6

2.5

2.1

2.2

2.2

2.1

2.6 2.6

2.5

2.3

2.3

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Head Spindle Frame VST Isometric View of Head Frame VST 100

Name Item no. Quantity 3. VST Spindle Head Frame consisting of 3.1 Head Spindle VST 100 117465 2 2.5 Horizontal Ledger VST 200 117371 2 2.9 Diagonal VST 200/62,5 117388 2


2.5

2.9

3.1

2.5

3.1

2.9

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Head Spindle VST 100 Isometric View of Head Spindle VST 100

Name Item no. 3.1 VST Spindle Head vonsisting of 117465 3.1.1 Fork Head 3.1.2 Spindle Nut 3.1.3 Spindle Sleeve Associated Tools 3.1.4 Assembly Handhold VST 117377 7.1.1 Hydraulic Jack

3.1.4

3.1.3

3.1.2

7.1.1

3.1.1

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VST-Tower Configuration 2,0 x 2,0m (Configuration 1) Isometric View VST-Tower with Ledgers and Braces VST

Name Item no. 4a. Tower Configuration 2,0 x 2,0 m 2.5 Horizontal Ledger VST 200 117371 2.6 Diagonal VST 200/150 117379 2.7 Diagonal VST 200/100 117382 2.8 Diagonal VST 200/112,5 117385 2.9 Diagonal VST 200/62,5 117388 4.4 Horizontal Brace VST 200/200 117504

2.5

4

2.6

7.6

2.7

2.8

2.9

4.4

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Total Weight for one VST-Tower (Configuration 1):

VST-Tower 2,0 x 2,0 m Total Weight kg Tower 125 912,80 Tower 175 1.324,52 Tower 275 1.579,64 Tower 375 2.103,28 Tower 525 2.764,52 Tower 775 3.945,4 Tower 1025 4.861,84 Tower Spindle Head 998,48

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VST-Tower Configuration 2,0 x 1,0-4,5m (Configuration 2) Isometric View VST-Tower with SLS-Spindles

Name Item no. 4b. Tower Configuration 2,0 x 1,0-4,5 m 4.1 Heavy Duty Spindle SLS - depending on the length

4.1

4

7.1

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VST-Tower Configuration 2,0 x 4,5-14,0m (Configuration 3) Isometric View VST-Tower with RS 1000 (RS 1400)

Name Item no. 4c. Tower Configuration 2,0 x 4,5-14,0 m 4.2 RS 1000 028990 4.2.1 Bolt 21 x 120 104031 4.2.2 Cotter Pin 4/1 018060 4.2.3 Bolt ISO 4014 M16 x 100-10.9 4.2.4 2 x Sleeve 21x2 L=29mm 4.3 RS 1400 103800

4.2 or 4.3

4.2.3+4.2.4

4.2.1+4.2.2

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VST-Tower Configuration 1,25-4,5 x 1,0-4,5 m (Configuration 4) Isometric View VST-Tower with Connector VST-SRU and SLS-Spindles

Name Item no. 4d. Tower Configuration 1,25 x 1,0-4,5-14,0 m 4.4 Connector VST-SRU 123823 4.4.1 Bolt 21 x 120 104031 4.4.2 Cotter Pin 4/1 018060 4.5 SRU 0,72-5,97 4.1 Heavy Duty Spindle SLS - depending on the length

4.5

4.1

4.4

4.4.1+4.4.2

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VST-Frame with Assembly Platform Isometric View VST Frame with Assembly Platform PERI UP Rosett Flex

Name Item no. 5. Assembly Platform 5.1 Connector UP-VST 117707 5.1.1 Bolt 21 x 120 104031 5.1.2 Bolt 20 x 140 105400 5.1.3 Cotter Pin 4/1 018060 5.2 All Parts of PERI UP Rosett Flex

5.2

5.1.1

5.1

5.1

5.1.3

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Connector UP-VST (Component 5.1) Isometric View Connector UP-VST

Name Item no. 5. Assembly Aids 5.1 Connector UP-VST 117707 5.1.1 Bolt 21 x 120 104031 5.1.2 Bolt 20 x 140 105400 5.1.3 Cotter Pin 4/1 018060 5.1.4 Connector Strap 117701 5.1.5 Wedge K 024250

5.1.4

5.1.5

5.1

5.1.1 5.1.3

5.1.2

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VST-Frame with additional Legs Isometric View VST with Leg-Connector VST

Name Item no. 6. Reinforced with additional VST-Leg 6.1 Leg-Connector VST 117712 6.1.1 Bolt 21 x 120 104031 6.1.2 Cotter Pin 4/1 018060 6.2 Horizontal Connector VST 117696 6.2.1 Bolt 21 x 120 104031 6.2.2 Cotter Pin 4/1 018060

6.1.1+6.1.2

6.2

6.1

5.1

6.2

6.1

6.2

6.2.1+6.2.2

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Hydraulic Unit VST 70

Name Item no. 7. Lowering and Lifting Work 7.1 Hydraulic Unit VST 70 117678 7.1.1 Hydraulic Jack 7.1.2 Hydraulic Hose 7.1.3 Hand Pump

7.1.1

7.1.3

7.1.2

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Part A Work Preparation

A1 Operation status and loads

Operating status: working Assembling Main Beams, Longitudinal Beams and Formwork Reinforcing the Superstructure, closing the formwork and concreting The height of the formwork has to be accurately adjusted with the Head Spindle VST 100 The assembling platforms will not be used as a storage area.

Operating status: lowering and striking After the concrete has its required strength, the VST has to be lowered according to the

statical calculation of the superstructure. The formwork is struck. The longitudinal and main beams are to be removed. The assembling platforms must not be used as a storage area.

The PERI Heavy Duty Shoring System VST has to be verified through a static calculation on the basis of PERI product information for each use. The basis of the verification is provided by the following standards: DIN EN 12812:2008 Falsework Requirements, Dimensioning and Design DIN 1055-4 Influences on Load-Bearing Structures Wind Loads DIN 18800 Steel Constructions DIN 1052:2004 Timber Construction

Head Spindle VST 100

Longitudinal Beam

Main Beam

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A2 Pre - design of the Heavy Duty Tower VST A2.1 Combination Table for Tower Heights from 125 to 1225 cm

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A2.2 Combination Table 1250-1925

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A2.6 Approx. permissible Leg Load on Top (according to the height considering 2,5 % of vertical Load as horizontal Load)

Spindle Load

0,0

100,0

200,0

300,0

400,0

500,0

600,0

700,0

800,0

1 4 7 10 13 16 19 22 25 28 31 34 37 40

Height

perm

. Loa

d

zulV

For every use, a detailed static analysis has to be done.

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A3 Preparing and Assembling a single frame

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A3.1 Element assembly sequence for a single leg Assembly of Leg

Step 1 Preparing RCS-Rail to build a Module Support the RCS-Rail with

spacer h>= 10 cm on plain surface.

Remove the first and last pair of bolts (M20 and M24).

Put in the Prop Connector VST 48 2.4 on the Top side of the RCS (after removing the bolts must there be 6 pairs of holes).

Put in the Prop Base VST 48 2.3 on the Base side of the RCS (5 pairs of holes).

Top

2.3

Bolts RCS

2.4

Base

1.5

- 44 -

Assembly of Leg

Step 2 Connecting Prop Connector VST 48 2.4 and to the Climbing Rail RCS 1.5 Insert one Bolt ISO 4014 M20

2.3.1 from the left side and two Bolts from the right

Insert two Bolts ISO 4014 M24 2.3.3 from the left side and one Bolt from the right.

Put on the Nuts 2.3.2 and 2.3.4 and tighten the Connection

Connecting Prop Base VST 48 2.3 to the Climbing Rail RCS 1.5 Insert one Bolt ISO 4014 M20

2.3.1 from the left side and two Bolts from the right

Insert two Bolts ISO 4014 M24 2.3.3 from the left side and one Bolt from the right.

Put on the Nuts 2.3.2 and 2.3.4 and tighten the Connection

2.5

2.4 Top

Base

2.3.1

2.3.3

2.3.4

2.3.2

2.3.3

2.3.4

2.3.2

2.3.1

1.5

- 45 -

Assembly of Leg

Step 3 Connecting Bracing Connector VST 2.1 to the Climbing Rail RCS 1.5 The Brace Connector VST 2.1

must be installed in the positions of the Horizontal Ledger VST 2.5. The Position is given by the Dimensions shown with the Overview on page 6+7. For this use the sleeve 2.2.3 of the Cross Connector VST 2.2 to center the Bracing Connector VST 2.1, before entering the Bolts 21 2.1.1 und 26 2.1.2 (greasing the Bolts makes it easier). After entering the Bolts, dont forget to secure them with Cotter Pin 4/1 2.1.3.

Step 4 Assembling Cross Connector VST 2.2 to Climbing Rail RCS 1.5. Insert the Cross Connector VST

2.2 in the axis of the Bracing Connector VST 2.1. Insert the Bolts M24 2.2.1 in the free holes.

Put on the Nuts 2.2.2 and tighten the Connection

2.2.1 2.1

2.2

Top

Base

2.2.3

2.2

2.2

2.1

2.1

2.2.2

2.2.1

2.1.2

2.1.1

2.2.2

2.3.1

2.1

2.2.3

2.2.3

2.1.3 2.2.3

2.1.2

2.1.1

2.2.1 2.2.1

1.5

- 46 -

A3.2 Assembly of a Frame Assembly of Ledger

Step 1 Connect the legs with Ledger Lay two VST-Legs in a distance

to each other of 2,0 m. Insert first the Horizontal Ledger

VST 200 on top and bottom using the first hole in the Prop Connector VST 48 2.3 or Prop Base VST 48 2.4 to get the right distance

Hold the Horizontal Ledger VST 200 2.5 over the Legs and move it down to the level of the axis.

Move one end of the Ledger to the Connection Point of the Prop Connector VST 48 and insert the Bolt 21 2.5.1.

Turn the Ledger to the Connection Point of the second Leg and insert the second Bolt.

After entering the Bolts, dont forget to secure them with Cotter Pin 4/1 2.5.2.

Repeat this procedure with all the necessary Ledgers.

!!Use always the middle hole when the Ledger is connected with the Cross Connector VST!!

2.5

2.5

2.4

Top

Base

2.5.1

2.5.1

2.5

2.5

- 47 -

Assembly of Bracing

Step 2 Connect the Bracing to the Frame To get the right angle, insert one

Diagonal Strut VST 200/150 2.6 on Base side first and fix it with one bolt 21 2.5.1 to the Prop Base VST 48 2.4.

Turn the Diagonal in direction to the connected Leg.

Insert the second Diagonal Strut VST 200/150 and fix it to the Prop Base VST 48.

Then fix the first Diagonal to the Horizontal Ledger VST 200. To make the hole fit, move one leg in axial direction, till you can insert the Bolt.

Fix the second Diagonal to the Ledger. After entering the Bolts, dont forget to

secure them with Cotter Pin 4/1 2.5.2. Insert all Diagonals in this way and

secure all bolts. !!Use the right Diagonals according to

the Overview!! Now the module is ready to be erected or to build a complete tower module.

2.4 2.4

2.5

2.6

2.5.1

2.6

2.5

2.5 2.5.1

2.6

2.6

- 48 -

A4 Preparing and Assembling the head frame

A4.1 Width Adjustment of Head Spindle VST 100

Width Adjustment The Head Spindle VST 100 is able to support main beams with a width of 20 up to 32 cm. To guarantee the centric position of the main beam, the distance between the centering plates has to be adjusted. That is, it must be installed the same number of plates on both sides to get no eccentricities on the spindle!! Loosen the Bolts on both sides of the fork

3.1.1. Put out the distance plates 3.1.2. Put the distance plates not needed for the

width to the outside. Move the centering plates 3.1.3 to its new

position Insert the Bolts and fix the centering plates. Now the main beam can be installed in a

centric position over the spindle to avoid additional loads.

3.1 3.1.1

3.1.2

3.1.3

Main Beam

- 49 -

A4.2 Assembly of Head Spindle Frame

Assembly Head Spindle Frame The Head Spindle VST 100 must be assembled to a frame before connected to a VST-Frame. Step 1 Position two Head

Spindles VST 100 with a distance of about 2050 mm.

Put in the lower Horizontal Ledger VST 200 3.2 first.

Fix the Ledger to one Head spindle and move the other Head Spindle 50 mm towards the first one, to get the Ledger Connection in the right position.

Fix the Ledger to the second Head Spindle.

Step 2 Slip in the second Ledger

and fix it to the Head Spindles.

Step 3 Slip in the Diagonal Strut

VST 200/62,5 3.3. Step 4 Fix the Strut to the Head

Spindle first. Step 5 Swivel the Diagonal Strut

and fix it to the Ledger with the Bolt 21 2.5.1

Step 6 Slip in the second Strut Step 7 Fix the Strut to the Head

Spindle first. Step 8 Swivel the Strut and fix it

to the Ledger with the Bolt 21 2.5.1

After entering the Bolts, dont forget to secure them with Cotter Pin 4/1 2.5.2.

3.2

3.3 2.5.1

3.1

- 50 -

A5 Pre-assembly of Tower segments A5.1 Assembly of Tower with VST Parts

Preparing Assembly Step 1 Pick one Frame by crane using

the Connection Bolts of the RCS as suspension

Move the Module over another Module considering the direction.

Insert the 4 Horizontal Ledgers VST 200 2.5 in the Bracing Connector of the Prop Base VST 48 2.4 and Prop Connector VST 48 2.3 of the upper Module

Fix them with Bolts 21 2.5.1 Secure the Bolts

Installing first Diagonal Strut Step 2 Lower the upper Module until the

Bolts 21 2.5.1 can be inserted.

Secure the Bolts. Insert the Diagonal Strut VST

200/112,5 2.8 to the topside ledger.

Fix the Diagonal to Bracing Connector VST 2.1 with Bolt 21 2.5.1.

Move the upper Module in axial direction until the Bolt 21 can be fixed to the topside Ledger

The crane can be released For Modules longer than 5 m,

insert a third Ledger to avoid deflection.

2.4

2.5

2.5.1

2.8

1.5

2.1

2.5

2.5.1

2.5.1

2.3

- 51 -

Installing Ledger Insert the second Diagonal Strut

VST 200/112,5 2.8 to RCS and topside Ledger

Insert the necessary Ledgers.

Installing Diagonal Struts Insert the necessary Diagonals in

the same way like for the assembly of Module.

2.5

2.1a

4.3

2.6

4.3

2.6

2.7 2.8

2.8

- 52 -

A5.2 Assembly of Tower with SLS-Spindles

Preparing Assembly Step 1 Pick one Frame by crane

using the Connection Bolts of the RCS as suspension.

Move the Module over another Module considering the direction.

Insert the 4 SLS-Spindles 4.1 with the right length (according to the distance between the legs) in the Bracing Connector of the Prop Base VST 48 2.4 and Prop Connector VST 48 2.3 of the upper Module

Fix them with Bolts 21 2.5.1

Secure the Bolts

Installing first diagonal SLS Step 2 Lower the upper Module until

the Bolts 21 2.5.1 can be inserted.

Secure the Bolts. Insert the first diagonal SLS-

Spindle 4.1 with the right length to the Bracing Connection of the Prop Base VST 48 2.4.

Fix the Diagonal to Bracing Connector VST 2.1 with Bolt 21 2.5.1.

Move the upper Module in axial direction until the Bolt 21 can be fixed to the topside Ledger

The crane can be released

2.1

4.1

2.4

2.5.1

2.1a

2.2

4.3

4.1

2.3

2.3

- 53 -

Installing SLS-Spindles Insert all other SLS-Spindles

one after each other and fix them with Bolts 21 2.5.1 to the Bracing Connections of the legs.

4.1

2.1a

2.5.1

2.8

- 54 -

A6 Assembly Platforms A6.1 Assembly of Assembly Platform on single Frame

Installation Connector UP-VST Step 1 Installing the upper Connector

UP-VST 5.1 as horizontal bearing point from downside in top Ledger 2.5. Fix it with Bolt 21 5.1.1 and secure Bolt with Cotter Pin. Alternatively use the wedge to be flexible in positioning the Connector.

Installing the lower Connector UP-VST from beside as vertical bearing point. Fix it.

Installing UVR Step 2 Pick the UVR (minimum UVR

150) and put a Rosett on the lower Connector UP-VST 5.1.

Install the Connection Strap 5.1.4 to the lower Connector and fix it with Bolt 5.1.2.

Install the Connection Strap 5.1.4 to the upper Connector and fix it with Bolt 5.1.2.

5.1

UVR

5.1.2 2.5

5.1.4 5.1

2.5

5.1.2

5.1.4

2.5

5.1.1

- 55 -

Installing UH Insert the UH 150 Ledger

between the UVR in the level between top and second Ledger VST 200 2.5

Insert the other necessary UH-Ledgers.

Installing Platform Insert the necessary console

brackets. UH-Ledgers and Standards 5.2.

The vertical bearing load is able to bear 5 kN vertical load. Please check the dimension of the area of influence to avoid overload.

The maximum load considered is 0,75 kN/m according to DIN EN 12812

UH 150

UVR

5.2

5.1

- 56 -

Part B Assembly Note: For assembly, a crane or other lifting equipment as well as a level assembly area are required, intermediate states to be secured by means of temporary supports to prevent any tipping over. Furthermore, sufficient space is available for temporary storage. In general, additional assembly plans are required! For assembly, the use of lifting platforms or mobile scaffold is recommended. In individual cases, the use of safety ropes might be necessary.

B1 Assembly of Tower with VST Parts

Suspension for crane Step 1 Connect Crane cable to

Horizontal Ledgers VST 200 2.5 on topside

Tilt the tower segment with crane over the Prop Base VST 48 2.4

2.5

- 57 -

Tilt Tower Tilt the construction slowly,

until it is vertical.

Moving Tower Lift the construction up and

move it to the place where it is needed.

If the construction is put on a foundation, use the anchors to secure the construction. The foundation must be even, unevenness must have to be equalized by mortar of the same quality as the concrete of the foundation.

For assembly on an existing tower the construction will center itself by the Pivot of the Prop Connector VST 48. The Construction is secured by the Bolts of the Connector.

The construction then can be released from the crane

2.1b

4.4

4.1

- 58 -

B2 Assembly of Tower with SLS-Spindles

Suspension for crane Step 1 Connect Crane cable to

Horizontal Ledgers VST 200 2.5 on topside

Tilt the tower segment with crane over the Prop Base VST 48 2.4

Tilt Tower Tilt the construction

slowly, until it is vertical.

4.4

- 59 -

Moving Tower Lift the construction up and


If the construction is put on a foundation, use the anchors to secure the construction. The foundation must be even, unevenness must have to be equalized by mortar of the same quality as the concrete of the foundation.

For assembly on an existing tower the construction will center itself by the Pivot of the Prop Connector VST 48. The Construction is secured by the Bolts of the Connector.

The construction then can be released from the crane

- 60 -

B3 Assembly of single Frame

Connecting to crane Step 1 Pick the Frame by crane using

the Horizontal Ledger VST 200 as suspension.

Tilt the Frame over the Prop Base VST 48.

Tilt by crane Tilt the Frame until it is vertical. Lift the construction up and


2.5

2.4

- 61 -

Assembly in Front of Abutment/Pillar Fix the Frame to the Foundation

if necessary. Use anchoring points in the

abutment/pillar to secure the Frame horizontally, for example with SRZ and Kicker Braces.

Securing to Foundation Fix the Frame to the Foundation

if necessary. Secure the frame with an SLS-

Spindle to the foundation. Use the Bracing Connector VST

in the upper third of the Frame, if no anchoring to the foundation existing.

If the Connection to the foundation can be used, an SLS-Spindle in the first third is sufficient.

Kicker Brace

SRZ

4.1

A

Cam Nut

SLS-Spindle

4.3

2.3

- 62 -

Adding second Frame Move the next Frame to the

place of installation. Fix Frame to the Foundation if

necessary.

Connecting second Frame Insert the first SLS-Spindle on

top and adjust the distance. Release the crane. Insert the first diagonal used

SLS-Spindle to stiffen the Tower.

Remove the temporary Bracing.

DW-Anchor

SLS-Spindle

4.3

4.4

4.1

- 63 -

Bracing Tower Insert the statical neccessary

spindles to complete the tower

Bracing

- 64 -

B4 Anchoring Option 1:

Fixing to Foundation Fix the Frame with a tie rod and

a Cam Nut to the foundation. To get a full-surface contact

between the foundation and the Prop Base VST 48 2.3, the small gap must be filled with non-shrinkable grouting.

Option 2:

Fixing to Foundation First, a Climbing Rail RCS 98

1.1 should insert between the vertical Climbing Rail RCS.

On top of the RCS Rail 98 two SRU Walers are must be applied in the right angle.

Connect the Frame with four Tie Rods and a Wingnut Pivot Plates DW 15 to the foundation

To get a full-surface contact between the foundation and the Prop Base VST 48 2.3, the small gap must be filled with non-shrinkable grouting.

Cam Nut

2.3

2.3

Grouting

Tie Rod DW 15

Climbing Rail RCS

Grouting

Tie Rod DW 15

Climbing Rail RCS Wingnut Pivot Plate DW 15 Steel Waler Universal SRU

1.1

- 65 -

Option 3:

Fixing to Foundation . Connect the Prop Base VST 48

2.3 with a tie rod DW 26, a Counterplate DW 26 and a Hex.Coupler DW 26 in the middle of the Prop Base to the foundation.

To get a full-surface area between the foundation and the Prop Base VST 48 2.3, the small gap must be filled with non-shrinkable grouting.

Grouting

2.3

Tie Rod DW 26

Hex.Coupler DW 26 SW 46/80

Counterplate DW 26 100 x 80 x 20 (123825)

Climbing Rail RCS

- 66 -

Part C Application C1 Height Adjustment (+/- 140 mm)

Height adjustment by hand Insert the Assembly Handhold VST 3.1.4. Turn the Spindle Nut 3.1.2 clockwise to

lift Head up. 1 full turn gives a height adjustment of 12

mm.

Height adjustment with hydraulic jack Insert Hydraulic jack 7.1.1 Turn Spindle sleeve 3.1.3 with the

Assembly Handhold VST 3.1.4 clockwise until it gets contact to the jack in concealed position.

Lift up the Spindle with the Hydraulic jack (max. 16 mm in one step possible).

Turn the Spindle Nut 3.1.2 clockwise, until it gets contact to the top plate.

Release the hydraulic jack Repeat this procedure if necessary !!The maximum Spindle Length of 300

mm must not be exceeded!!

3.1.1

3.1.3

3.1.2

3.1.3

3.1.4

3.1

3.1.4

7.1.1

3.1.2

- 67 -

C2 Lowering Procedure

Lowering with Hydraulic Jack Adjust the Spindle Sleeve

using the Assembly Handhold VST, so that the distance between sleeve base and jack top is 12 mm.

Lift up jack to the maximum. The Spindle Nut must be freely movable.

Turn the Spindle Nut anticlockwise to achieve a gap between top plate and Nut of about 10 mm.

Release jack The Spindle Sleeve must

be movable after the pressure is gone. If not, the distance between Nut and plate was too big. In this case you have to lift up the Spindle a bit and adjust the Nut.

Adjust the Spindle Sleeve to 12 mm.

This procedure repeats, until the maximum lowering degree is reached.

- 68 -

Part D Disassembly Attention! Disassembly is in the other way round to the assembly sequences!

- 69 -

Part E General Information

E1 Cleaning and Maintenance Why? During cleaning, ensure components are

safely stored! Components may not be cleaned whilst still

attached to the crane! Remove any concrete surplus!

Spray (grease if necessary) moving parts regularly with a release agent.

Removes rust, prevents corrosion and keeps parts in good working order.

Ensure that elements and accessories are properly stored.

Prevents damage to the components.

Never use unnecessary force during assembly and dismantling.

Maintains the functionality of the parts as well as faster re-use.

E2 Transport Why? Move components with suitable and secure

transport means and lifting gear. Avoids damage caused by inappropriate transport means.

Dismantle platforms, form storage units, and combine into transportation units.

Small parts are not lost, assembly groups remain together.

Place pieces of timber between the elements. Secure transportation units e.g. with steel bands or scaffold tubes.

Securing parts will be protected; dents, shifting of elements or falling on top of each other must be avoided.

Secure transportation units with suitable load-securing equipment.

Elements remain firmly in position during transportation no shifting or falling.

E3 Storage Why? Store all parts in bundles. Use closed

containers. Parts can be found and used faster. Damageable and smaller components as well as tools are protected.

Avoid direct contact with the ground and water. Storage in an inclined position is possible.

Components are protected from dirt, dampness and corrosion. Storage bundles are supported on timber pieces.

E4 Hydraulic System Climbing device

Hydraulic aggregate

Hydraulic hoses

For additional requirements regarding the cleaning, maintenance, transport and storage refer to document: Operating Manual RCS Climbing Device, Edition 2006-10-31

Maintenance of oil hydraulic equipment See Operating Manual RCS Climbing Device, Section 1

Service of oil hydraulic equipment See Operating Manual RCS Climbing Device, Section 3

- 70 -

Part F Appendix

F1 Instruction of use for the Hydraulic Jack

- 71 -

Part G Component Catalogue

- 72 -

- 73 -

- 74 -

- 75 -

123823 4,160 Connector VST-SRU Complete with Adaptor for connecting SRU as ledger to 3 pc. 104031 Bolt 21 x 120 the VARIOKIT Heavy Duty Shoring Tower 3 pc. 018060 Cotter Pin 4/1, galv.

- 76 -

variokit heavy duty tower vst assembly instructions

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