Jasco Fly Form Manual 1 PDF

F LY F ORM MANUAL S ECTION I
HI - LIT E GENERAL INFORMATION

JASCO SALES INC.
FLY FORM
MANUAL
SECTION I
(GENERAL INFORMATION)
* See Section II for Assembly and Instructions

1680 Bonhill Rd., Mississauga
Ontario, Canada, L5T 1C8
Phone: (905) 677-4032
Fax: (905) 677-4542
e-mail: hilite@hi-lite -systems.com
This information is subject to change. Latest information may be obtained from Copyright © 2002 by JASCO Sales Inc. All rights reserved. No part of this manual may
November 2004 be used or reproduced in any manner whatsoever without prior written permission.
HI-LITE Systems’ web site at www.hi-lite-systems.com
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JASCO SALES INC.
Table of Contents
INTRODUCTION ...................................................................... 3 BOTTOM CHORD H-SECTION.......................................... 19
STRUT INNER LEG / OUTER LEG.................................... 20
BENEFITS OF HI-LITE'S TELESCOPIC FLY FORMS .... 4
BOLTS & NUTS 9MM × 127MM (3/4" × 5") ...................... 21
GENERAL INFORMATION ................................................... 6 STRUT SAFETY LOCK PIN C/W CABLE OR CHAIN ..... 21
COMPLETE BASIC UNIT ..................................................... 6 WEDGE UNITS ..................................................................... 22
TRUSS LENGTH IDENTIFICATION ................................... 7 WEDGE UNIT HOOK .......................................................... 22
Fly Form Size Configurations ..............................................8 WEDGE UNIT BLOCK ........................................................ 22
FLY FORM STRUT RANGE CONFIGURATIONS ............. 9 PICK BRACKET C/W BOLTS ............................................. 23
FLY FORM TRUSS HEIGHT ADJUSTMENT ................... 10 GUARD RAIL POST / GUARD RAIL POST HOLDER /
GUARD RAIL TUBE............................................................ 23
PRODUCT PART NUMBERS AND DESCRIPTIONS ...... 11 CLAMPS ................................................................................ 24
TRUSS UNITS ....................................................................... 11 FORM STABILIZER............................................................. 24
TRUSS UNIT COMPONENTS............................................. 12 TELESCOPIC HORIZONTAL AND DIAGONAL STRUT
FLY FORM ACCESSORIES ................................................ 13 BRACE................................................................................... 25
FLY FORM MOVING EQUIPMENT .................................. 14 HINGE BRACKET ASSEM BLY ........................................ 25
TOP CHORD SCREW JACK................................................ 26
PARTS DETAILS .................................................................... 15 T-BOLT / WING NUT .......................................................... 26
TRUSS UNIT (SINGLE TRUSS).......................................... 15 BEAM CLIP C/W HI-LITE T-BOLT.................................... 27
TRUSS CONNECTING PARTS ........................................... 15 JET LOCK.............................................................................. 27
1.52M (5') TRUSS UNIT EXTENSION C/W TCP............... 16 CROSS BRACES ................................................................... 28
3.04M (10') TRUSS UNIT C/W TCP .................................... 16 ALUMINUM BEAMS........................................................... 29
TRUSS EXTENSION............................................................ 17 FORM MOVING DOLLY C/W CASTORS ......................... 30
TOP CHORD SPACER ......................................................... 17 LOWERING JACK................................................................ 30
TOP CHORD CHANNELS ................................................... 18 FORM ROLLOUT ROLLER ................................................ 31
TOP CHORD SPLICE CHANNEL....................................... 18 FORM MOVER ..................................................................... 31
BOTTOM CHORD................................................................ 19 HYDRAULIC JACK DOLLY............................................... 32
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JASCO SALES INC.
Introduction
This edition of the HI-LITE Telescopic Fly Form Manual is the SHOULD BE USED IN CONJUNCTION WITH
latest update of technical data on the most advanced flying truss GENERALLY ACCEPTED SHORING DESIGN AND
shoring system on the market today. THE SAFETY REGULATIONS IN EFFECT WITHIN
THE AREA AND COUNTRY OF USE.
The HI- LITE Telescopic Fly Form is primarily a flying truss
that is to be rolled out and lifted from one floor after the ALL DRAWINGS FOR CONSTRUCTION PURPOSES
concrete is set, on top of the slab for the next pour with a crane, SHOULD BE APPROVED BY A LOCALLY
and may also be used quite successfully as a rolling system. REGISTERED PROFESSIONAL ENGINEER.
The purpose of this manual is to simplify the understanding and Our engineering department is available to answer any
use of the system. Each component of the system is described engineering questions to help you to make use of every
and illustrated in Section I (General Information) advantage of this versatile, time-saving fly form system.
Section II (Assembly and Instructions) of the manual covers Additional information including sample drawings, photos of
various setups for the correct use and handling of the system the product in use in the field and information on our entire
product line can be seen on our web site: www.hi- lite-
THIS MANUAL IS PUBLISHED PRIMARILY FOR OUR systems.com
CUSTOMERS, SHORING DESIGNERS AND
ERECTORS. IT IS INTENDED ONLY AS A GUIDE AND
George W. Jackson
CEO & Founder
JASCO Sales Inc.
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JASCO SALES INC.
Benefits of HI-LITE's Telescopic Fly Forms

• Manufactured in HI-Strength & LITE-Weight aluminum.
• Engineered with unique telescopic features for superior flexibility of use.
• Ideally suited for any multiple re-use application.
• Average weight of 8 lbs per sq. foot permit larger surface areas compared to steel.
• Rapid and simple telescopic truss height adjustment for different floor heights.
• Unique mobile accessories eliminating positioning by crane. Fly and drop reducing crane time.
• No costly lowering on flat slab structures.
• Wedges replace time-consuming flip screw jacks.
• Can be telescopically lowered hydraulically in minutes to go under edge beams.
• Modular components for simple, quick assembly and disassembly for storage or transport.
• Uses standard Aluminum Beams.
• HI-LITE Systems supplies engineering and layout drawings.
HI-LITE Aluminum Fly Forms are ideally suited for any multiple-storey
application. Condominiums, apartments, townhouses, large bay shopping malls,
below grade structures and tunnels can also be constructed faster.
The HI-LITE Aluminum Fly Form is the most efficient Fly Forming System
available today. The telescopic modular concept reduces the skilled labour required
for assembly and use. It also reduces the cost of filler strips and minimizes material
wastage by being able to easily move the form up against one wall and only use
filler strips on the other side. Crane time is also reduced significantly.
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JASCO SALES INC.
Flip jacks are replaced with fast acting wedge units, cutting set up, leveling
and stripping time. To clear edge beams fast, light hydraulic lowering
jacks make it advisable to telescope the truss rather than use long,
awkward extension legs and large heavy lowering jacks.
The small initial assembly costs make it practical to fly

when as few as 3 floors are to be shored. The crane time
saved during the flying operation is considerable. This
performance speeds up the entire construction process, thus
increasing productivity and profits.
The Fly Form is a modular component system assembled into

rugged adjustable aluminum trusses, using standard aluminum
beams and a range of compatible custom designed accessories.
HI-LITE Aluminum Fly Forms average panel weight is approximately 39 kgs/m2 (8 lbs/ft 2 ).
The HI-LITE Telescopic Fly Form requires minimal maintenance. Uses standard aluminum
beams or our special hollow beams that provide for extension up to 2ft (600 mm) using
standard 50 ´ 100 mm (2 " ´ 4" lumber) Eliminates staggering of beams. Versatile and
economical to use. Eliminates the loss of Crane time in placement. Designed to get the
most out of 17.5 mm (11/16") plywood.
Saving crane time is most important. With a HI-LITE Fly Form you set the form down on
blocks anywhere near the desired location and immediately release the crane, then position
the form exactly in only a few minutes using our hydraulic jack dollies.
Good accessories are very important in cutting costs. We invite you to check ours out.
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JASCO SALES INC.
General Information
This section of Telescopic Fly Form manual is intended to show the component parts of the form with part numbers and weights.
Pictures or drawings are included as appropriate for easy identification
Complete Basic Unit

The HI-LITE Telescopic Fly Form is designed to be very versatile. The components are built to complement each other as well as being
able to adjust to accommodate future projects. The components necessary for a basic fly form are
A. 2 - 3 truss units (product part code FFTU##-NN)

B. 1 - 2 cross brace(s) for every strut (depending on height) plus
1 or 2 across the bottom chords for squaring the form
(depending on length)
C. wedge unit (product part code FFWDG) & wedge hook
(product part code FFWDGH) for every “v” intersection on
each truss unit
D. pick brackets (product part code FFPICK)
E. guard rail post holders (product part code FFGRPH) for every
truss end that extends outside the building
F. guard rail post for every guard rail post holder- 48mm (1.9”)
tubes or 38mm×89mm (2”×4”) lumber
G. guard rails the width of the truss
H. 48mm x 48mm (1.9”×1.9”) aluminum right angle clamps (product part code CL##) for each guard rail post.
I. #HI-LITE aluminum beams (product part code ALBM##) (for quantity see the Beam Manual)
A more in-depth description of the components follows.
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JASCO SALES INC.
Truss Length Identification

Trusses from 15 to 55 ft long are built up from four basic configurations of truss components, a 15ft stand-alone unit and a 20 ft. stand
alone basis truss unit as well as two truss extensions of 5 ft. and 10 ft. as illustrated below. Longer units are made up by joining 15
and/or 20 ft sections with appropriate lengths of extensions.
15 ft. Basic Truss 10 ft. Truss Extension
20 ft. Basic Truss 5 ft Truss Extension
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JASCO SALES INC.
Description Composed of
Part # Note 5.6 ft truss
other heights Fly Form Size Configurations 15 ft 20 ft 5 ft 10 ft
available truss truss extension extension
FFTU56-15 FF 15' Truss - 5'6" Strut 1
FFTU56-20 FF 20' Truss - 5'6" Strut 1
FFTU56-25 FF 25' Truss - 5'6" Strut 1 1
FFTU56-35 FF 35' Truss - 5'6" Strut 1 1 1
FFTU56-45 FF 45' Truss - 5'6" Strut 1 1 2
1 1 3
FFTU56-55 FF 55' Trus - 5'6" Strut
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JASCO SALES INC.
Fly Form Strut Range Configurations

The Telescopic height range
of a Fly Form shown in the
Strut Ranges
chart and table below
permits users to use the 250
same product to deal with a
wide range of finished floor
heights by varying the 200
height of the adjustable
Range in Inches
struts., a key benefit to
150
minimizing costs and
speeding cycle time.
100
Maximum and minimum
heights of the Fly Form are
measured from the bottom 50
of the bottom chord to the

top of the top chord, 0
excluding wedge units, 3.0 4.0
aluminum joist beams and 5.0
5.5
Extended Fly Form Height
6.0
plywood. The choice of Nominal Strut Length in feet
6.5
7.0
Closed Fly Form height
8.0
strut for the product is 10.0
determined by the range of
3.0 4.0 5.0 5.5 6.0 6.5 7.0 8.0 10.0
floor heights that are
Closed Fly Form height 32.6 50.2 64.8 71.7 78.5 85.2 91.6 104.4 129.5
proposed for the project. Extended Fly Form Height 59.5 85.0 109.7 121.9 134.1 146.2 158.4 182.6 230.9
Note that these are multiple
combinations that can be
chosen as the ranges
overlap. See the chart on pg. 10.
Consult HI-LITE Engineering with the specifics of your project.
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JASCO SALES INC.
Fly Form Truss Height Adjustment

MAXIMUM AND MINIMUM TRUSS HEIGHT
(NOMINAL)
STRUT SIZE MINIMUM HEIGHT MAXIMUM HEIGHT
m ft m ft m ft
0.90 3 0.827 32.6” (2’ 8”) 1.512 59.5” (4’ 11”)
1.20 4 1.274 50.2” (4’ 2”) 2.158 85” (7’ 1”)
1.50 5 1.646 64.8” (5’ 5”) 2.785 109.7” (9’ 2”)
1.60 5’ 6” 1.521 71.7” (5’ 11”) 3.096 121.9” (10’ 2”)
1.80 6 1.992 78.4” (6’ 6”) 3.406 134.1” (11’ 2”)
2.40 8 2.651 104.4” (8’ 10”) 4.637 182.6” (15’ 2”)
3.0 10 3.28 129.5(10’ 10”) 5.86 230.9(19’ 3”)
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JASCO SALES INC.
Product Part Numbers and Descriptions

Part numbers and generic descriptions follow.For more details on individual lpart see the parts detail section starting pg. 15
Truss Units
FFTU## NNTruss Unit (shipped unassembled) See pg 15 for details
FFTUA## NNTruss Unit (shipped fully assembled)
Note: ## refers to nominal strut length in feet and NN refers to Form length in feet and A refers to assembled-see table below
Nominal Strut Extended Fly Form Closed Fly Form 10 15 20 25 30 40 45 50 55

length Height height
ft. mm. inches mm. inches mm.
3.0 900 59.5 1512 32.6 827 FFTU30-10 FFTU30-15 FFTU30-20 FFTU30-25 FFTU30-30 FFTU30-40 FFTU30-45 FFTU30-50 FFTU30-55
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JASCO SALES INC.
Truss Unit Components

FFTCLEXT FF Top Chord Extension 91m (3') c/w Splice (pair) See pg 17L for details
FFTCP Truss Connecting Parts (TCP) for Joining 2 Trusses See pg 15 for details
FFTCU5 FF Truss Unit (1.52m, 5') used to add 5 feet of length to an existing Form See pg 16 for details
FFTCUA5 FFTCU5 shipped assembled
FFTCU10 FF Truss Unit (3.04m (10') used to add 10 feet of length to an existing Form See pg 16for details
FFTCL# Top Chord Channels(pairs) See pg 18 for details
FFTCLSP Top Chord Splice Channels(pairs) See pg 18 for details
FFBC# Bottom Chord See pg 19for details
FFH# Bottom Chord H Sections See pg 19for details
FFSOL# / FFSIL# Strut Outer Leg / Strut Inner Leg See pg 20 for details
HDSHC3/4NC Hex Cap Screw 3/4x5-1/2in. NC See pg21for details
HDNH3/4NC Hex Nut 3/4in NC
HDFW34SAE Flat Washer 3/4in. (S.A.E.)
FFSLP Strut Safety Lock Pin c/w Cable See pg 21 for details
FFSPCR Top Chord Spacer See pg 17 for details
FFTHSB FF Telescopic Horizontal/Diagonal Strut Brace package See pg 25 for details
FFSTUD FF Strut Stud c/w 2 Jam Nuts & Hex Nut
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JASCO SALES INC.
FFTCSJ FF Top Chord Screw Jack c/w Nuts and Plates See pg 26for details
FFHINGE FF Beam Hinge Bracket Assembly See pg 25 for details
Fly Form Accessories

FFWDG Wedge Units See pg 22 for details
FFWDGH Wedge Unit Hook
FFWDGB368 Wedge Unit Block 368mm High
FFPICK Pick Bracket See pg 23 for details
FFGPH-FF FF Guard Rail Post Holder See pg 23 for details
CLGRP Aluminum Guard Rail Post 1.5mm (5’)
FFSTB## FF Form Stabilizer) See pg 24 for details
CL4848SS Clamp-48x48mm (1.9x1.9) Swivel Stl See pg 24for details
CL4860SS Clamp- 48x60mm Swivel Stl,
CL4870SS Clamp-48x70mm Swivel Clamp Stl
CL60JL Alum Half Clamp - 60mm (2.36in)
CL70JL Alum Half Clamp - 70mm (2.75in)
FFTHSB Telescopic Horizontal Strut Brace See pg 25 for details
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JASCO SALES INC.
FFHA Hinge Bracket Assembly See pg 25 for details
T-BOLT / W-NUT T-Bolt / Wing Nut See pg 26 for details
BM-CLPC Beam Clip c/w HI-LITE T-Bolt See pg 27 for details
CB-# Cross Braces See pg 28 for details
AL-BM## Aluminum Beam See pg 29 for details
Fly Form Moving Equipment

FFMD Form Moving Dolly See pg 30 for details
FFLJ Lowering Jack
FFFR Form Rollout Roller See pg 31 for details
FF2x4FR 2x4 Form Mover
FF4x4FR 4x4 Form Mover
FFHJD Hydraulic Jack - Dolly See pg 32 for details
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JASCO SALES INC.
PARTS DETAILS
TRUSS UNIT (Single Truss)
Part No.: (FFTU##-NN)
DESCRIPTION : The truss unit is a single truss consisting of top chords, bottom
chords, H-sections, top chord splice channels, inner and outer struts (5’6” -
standard strut length), strut connecting pins, top chord spacers and all necessary
hardware. Truss units are available in lengths varying from 4.5m (15’) to 20m
(60’) in increments of 1.5m (5’).
APPLICATIONS: The single truss unit is to be used in conjunction with 1 or 2

additional single truss units, connected with cross braces and topped with
aluminum beam to form a double or triple truss table form. This resulting table
form can be used as a fly form in commercial or residential towers, or as a rolling
table form in warehouses, shopping centers or other commercial building. Other
applications include parking garages, tunnels and culverts.
TRUSS CONNECTING PARTS

Part No.: (FFTCP)
Weight: 30 kgs (66.4 lbs)
DESCRIPTION: The parts necessary to join two truss units together to produce
a longer truss unit. One pair of top chord splice channels, c/w bolts, washers, nuts
and spacers and one 3048mm (10’) bottom chord section.
Note: These are only required when joining two existing trusses.
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JASCO SALES INC.
1.52m (5') TRUSS UNIT EXTENSION C/W TCP

Part No.: (FFTCU5)
Weight: 53.8 kgs (118.5 lbs)
DESCRIPTION: The parts necessary to add 1.52m (5’) to an existing 3048mm

(10’) truss unit. Note: the 1.52m (5’) truss unit can not be added onto the end of
another 1.52m (5’) truss unit section. They are priced complete with all necessary
hardware including 1.6m (5’6”) standard struts.
3.04m (10') TRUSS UNIT C/W TCP

Part No.: (FFTCU10)
DESCRIPTION: The parts necessary to add 3048mm (10’) to an existing truss

units. Note the 3048mm (10’) truss unit can not be added onto the end of a truss
unit that has a 1.52m (5’) section. They are priced complete with all necessary
hardware including 1.6m (5’6”) standard struts.
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JASCO SALES INC.
TRUSS EXTENSION
Part No.: (FFTCLEXT)
Length: 914mm (3’)
Weight: 3.5kgs (29.8 lbs)
DESCRIPTION : Pairs of 914mm (3’) top chords complete with top chord splice
channels and hardware.
APPLICATIONS: To extend the length of top chord of the fly form table by
914mm (3’), in order to provide a working platform or walkway at the edge of the
building. Not designed to support any concrete load unless it is posted at the end.
TOP CHORD SPACER

Part No.: (FFSPCR)
Length: 67mm (2 5/8”)
Weight: 0.2 Kgs (0.5 lbs)
APPLICATIONS: Top chord spacers are used to maintain the correct spacing
between the top chords. This space allows for the insertion of the inner within the
top chords without force, and without damage to either section.
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JASCO SALES INC.
TOP CHORD CHANNELS

Part No.: (FFTCL#)
Depth: 512mm (6”)
Weight: 7.5 kgs/m (5.1 lbs/ft )
DESCRIPTION: The top chord is designed to be very versatile. As well as being

used on the fly form it can also be used as a strongback for aluminum gang wall
forms. The top chord is used in pairs of either 914mm, 1524mm or 3048mm (3’,
5' or 10') lengths. They can be easily joined together to assemble fly forms of
different lengths. The top chord features a t-bolt slot on the top and bottom which
is very useful for attaching, pick brackets, top chord jacks, aluminum beams, etc.
TOP CHORD SPLICE CHANNEL

Part No.: (FFTCLSP)
Depth: 127mm (5”)
DESCRIPTION: The top chord splice is a pair of channels used to join together
two top chords.
APPLICATIONS: The splice is used to assemble standard lengths of truss units.

It can also be used to extend the length of a truss by splicing a 914mm (3’) length
of top chord to either end of the truss.
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JASCO SALES INC.
BOTTOM CHORD
Part No.: (FFBC#)
Weight: 8.0 kgs/m (5.4 lbs/ft)
DESCRIPTION: The HI-LITE bottom chord is primarily designed for strength and
moveability. The top of the bottom chord features a T-bolt slot for attaching cross braces,
form stabilizers, HI-LITE post shores etc. The bottom of the bottom chord has two
rounded grooves that complement the design of the form movers. Note there is no left or
right, top chord or bottom chord.
BOTTOM CHORD H-SECTION

Part No.: (FFH#)
Length: 457mm (18”), 990mm (39”)
Weight: 3.9 kgs (8.5 lbs), 7.9 kgs (17.4 lbs)
APPLICATIONS: The ‘H’ sections are used as a splice for the bottom chord as well as
a support of the outer leg of the vertical struts. The ‘H’ section is available in two lengths:
457mm (18”), and 990mm (39”). The 990mm (39”) has two sets of 6 holes (symmetrical
@ Center) to accept two vertical struts. The holes are numbered from the center out 1 to 6
(as shown). This “H” section is commonly used with 3048mm (10’) top chords. The
457mm (18”) ‘H’ section has one set of holes (1 to 6), and is used when a 1524mm (5’)
top chord is used at an end of the truss. The “H” section are connected to the bottom
chord using 19mm (3/4”) bolts.
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JASCO SALES INC.
STRUT INNER LEG / OUTER LEG

Part No.: (FFSIL#) / (FFSOL#)
O.D.: Inner 60mm / Outer 70mm
Length: Varies 914mm (3’) - 3048mm (10’)
DESCRIPTION: The Outer Strut features holes every 152mm (6”) which allows for a
wide range of telescoping strut lengths. There are also 2 jet locks which allow cross
bracing to be attached easily. There is also a jet lock to be installed at the top end to
accommodate the telescopic horizontal strut brace
The Inner Strut is made from a special high-strength heavy gauge aluminum extrusion.
It readily slides into the outer strut to give additional height to the telescopic fly form in
152mm (6”) increments.
The telescopic struts come in standard sizes of 3’, 4’, 5’, 5’6”, 6’, and 8’ with the 5’6”
strut being the most common. (Trusses are priced using 5’6” inner and outer struts. When
using other struts the prices will vary.)
There are two holes and a half hole in each inner strut. One hole and the half hole are
spaced 152mm (6”) apart to match with the holes in the outer strut, for securing the inner
strut into the outer strut. The half hole ensures correct alignment of the struts. One pin of
the inner strut support pin set is installed completely into the outer strut, at the required
level of the bottom of the lower strut.
The inner strut is placed into the outer strut until it rests on the pin. Then the inner strut is rotated until the half hole slips down onto the
pin. This automatically aligns the inner strut in the outer strut so that the holes line up, and the second pin can be installed without
looking or "fishing". (another of HI-LITE's patented innovations.)
The single hole at the other end of the tube is intended to be used for attaching the inner strut to the top chord, using the 19mm (3/4”)
bolt, washers and nut.
Note: the load must be carried by both the 1/2 hole and the full hole in the extension tube, transferring the load through both sides of the
support pin set, whether the two legs of the support pins are separated, or in the form of a u-pin.
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JASCO SALES INC.
Bolts & Nuts 9mm × 127mm (3/4" × 5")

Part No.: (HDSHC3/4NC)
Hex Cap Screw 3/4x5-1/2in. NC
Part No.: (HDNH3/4NC)

Hex Nut 3/4in NC
Part No.: (HDFW34SAE)

Flat Washer 3/4in. (S.A.E.)
Bolt Length: 127mm (5”)
APPLICATIONS: The nuts, bolts and washers are made from high tensile steel. Remember to keep the bolts pointed towards the
center of the fly form. Note: the thread of the bolt must protrude through the chords and “H” sections so that no vertical load is carried
on the threaded portion of the bolt. Use washers to achieve the correct length.
Strut Safety Lock Pin c/w Cable or Chain

Part No.: (FFSLP)
O.D.: 13mm (1/2”)
DESCRIPTION : The Safety lock pin set is a pair of self- locking pins, joined together with a length of chain
or cable. The support pins have a special self- locking feature to prevent them from falling out or being
accidentally removed and/or lost. Turn the handles up to remove or place.
APPLICATIONS: The pins are used to secure the inner struts in the outer struts
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JASCO SALES INC.
WEDGE UNITS
Part No.: (FFWDG)
Adjustments: 130mm (5”) to 200mm (8”) / Weight: 7.7 kgs (17 lbs)
APPLICATIONS: Wedge unit are used to provide fine height adjustment to the fly form
truss, in place of flip jacks. The wedge has an adjustable height from 130mm (5”) up to
200mm (8”). However with the telescopic feature of the HI- LITE truss, normally very little
adjustment of the wedge is required.
WEDGE UNIT HOOK

Part No.: (FFWDGH)
APPLICATIONS: The small loop of the wedge hook is placed between jet locks and cross
braces on the vertical struts of the truss unit. After the wedge unit is removed, in preparation for
flying, the wedge unit is hung on the hook so that it can be flown with the truss.
WEDGE UNIT BLOCK

Part No.: (FFWB)
Height: Standard - 370mm (14.5”)
DESCRIPTION : The standard wedge unit block consists of four 185mm (7.25”) aluminum beams 305mm
(12”) long, 2 beams on the bottom and 2 beams perpendicular on top. They are secured together by 4 beam
clips. The wedge unit block is priced separately.
NOTE: Only HI-LITE 184 mm (7 1/4”) beams must be used as blocking.
APPLICATIONS: Blocking is used when there are small drop beams, less than 648mm (25 1/2”) below
ceiling height; when the fly form needs to be higher than the truss can telescope, or, if there is an up turn on the
slab. If the drop required is greater than 660mm (26”) then usually advisable to telescope the fly form.
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JASCO SALES INC.
PICK BRACKET C/W BOLTS

Part No.: (FFPICK)
Weight: 4.5 kgs (10 lbs)
APPLICATIONS: Pick brackets bolt to the underside of the top chord (in the T-bolt
slot) and provide a hook up location for the crane. They can be moved along the top
chord to allow for level flying.
NOTE: pick brackets should be spaced no further than 5m (16’). On a 9.144m (30’)
truss 3m (10’) is a good spacing.
GUARD RAIL POST / GUARD RAIL POST HOLDER / GUARD RAIL TUBE
Part No.: (FFGPH-FF) / (CLGRP) / (GR-GRT)
OD: Post / Tube - 48mm (1.9”)
Length: Post - 1524mm (5’)
APPLICATIONS: The guard rail post holder is bolted to either end of the truss unit at
the end of the top chord. It is designed to accept either a 48mm (1.9”) tube or 38mm x
98mm (2”x4”) wood as guard rail posts.
The guard rail post are 48mm (1.9”) diameter aluminum tubes 1525mm (5’) long.
The guard rails are connected to the guard rail posts using 48mm x 48mm swivel or
right angle aluminum wedge clamps.
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JASCO SALES INC.
CLAMPS
WEDGE CLAMP SIZES FOR EXTERNAL AUXILIARY B RACING
Part No. Description Metric Size Function
CL4848SR 1.9”x1.9” Right Angle Clamp Stl 48mm x 48mm Tube-to-Tube

CL4848SS 1.9”x1.9” Swivel Clamp Stl 48mm x 48mm Tube-to-Tube
CL4860SR 1.9”x2.38” Right Angle Clamp Stl 48mm x 60mm Tube-to-Extension Tube
CL4860SS 1.9”x2.38” Swivel Clamp Stl 48mm x 60mm Tube-to-Extension Tube
CL4870SR 1.9”x2.75” Right Angle Clamp Stl 48mm x 70mm Tube-to-Frame Leg
CL4870SS 1.9”x2.75” Swivel Clamp Stl 48mm x 70mm Tube-to-Frame Leg
RIGHT ANGLE SWIVEL
WEDGE CLAMP WEDGE CLAMP
APPLICATION : Swivel clamps attach 2 tubes and allow a complete 360° rotation.
Right angle clamps hold tubes at 90°. Half clamps with jet locks allow a cross brace to
be attached to a 60mm or 70mm tube, such as a 60mm OD inner strut or a 70mm OD
outer strut.
FORM STABILIZER
Part No.: (FFSTB)
APPLICATION : The form stabilizer is used to allow the telescopic fly form to be raised and lowered straight up
and down without the possibility of the form shifting end ways. The bottom channel is placed over the bottom chord
between two (2) h-sections and is secured with t-bolts. The inner tube is bolted through a bolt hole in the top chord.
On trusses under 12m (40’) one stabilizer per truss is used. On trusses over 12m (40’) use 2 per truss. There is a
special form stabilizer for each length of strut.
Page 24 / 32
JASCO SALES INC.
TELESCOPIC HORIZONTAL AND DIAGONAL STRUT BRACE

Part No.: (FFTHSB) – The Complete package.
DESCRIPTION : The horizontal and diagonal strut brace is adjustable

to accommodate the spacing between the vertical struts (at any angle).
The braces are attached to the outer legs at the upper jet lock location
(perpendicular to the truss).
APPLICATION : The telescopic horizontal and diagonal

strut brace is used to provide lateral bracing to the
vertical struts. Bracing is required when loads on the
struts are high, and when the struts are close to full
extension. For design applications refer to the fly form
design charts “WITH BRACING”.
HINGE BRACKET ASSEMBLY

Part No.: (FFHINGE)
APPLICATION : The hinge bracket assembly is used to attach

a hinge panel to a fly form. The bracket is attached to the
underside of the aluminum beam in the t-bolt slot. An
aluminum ledger beam is attached to the other end of the
bracket. Hinge are designed for hinging under a slab or under a
beam, by adjusting the hinge bracket arm.
Page 25 / 32
JASCO SALES INC.
TOP CHORD SCREW JACK

Part No.: (FFTCSJ)
Extension: 120mm (4.5”) - 700mm( 27.5”)
DESCRIPTION : A steel 48mm (1.9”) screw jack complete with two handle nuts and
plates to secure the jack to the top chord.
APPLICATION : The top chord screw jacks are used to support a stringer/ledger beam
above the top chord. This is required when tables are used for beam/slab design, when
the top chord is below the beam bottom and the ledger are picking up the slab. Screw
jacks can be used in place of packing on the top chord.
T-BOLT / WING NUT

Part No.: (T-BOLT) / (W-NUT)
DESCRIPTION : 12mm (1/2”) diameter course thread, 51mm (2”) long, complete
with wing nut. The threaded end is flattened to indicate the head direction.
APPLICATIONS: Used for connecting cross bracing to t- bolt slot in bottom chord
and in beam clip assembly. Note the course non-jamming acme thread. The new wing
nut is also easily tightened with a hammer or a 22mm (7/8”) spanner wrench.
Page 26 / 32
JASCO SALES INC.
BEAM CLIP C/W HI-LITE T-BOLT

Part No.: (BMCLPC)
Weight: 0.1 kgs (.25 lbs)
DESCRIPTION : Plate steel complete with T-Bolt and Wing Nut
APPLICATIONS: Used to clamp an aluminum beam to other aluminum beams or to

top chords, etc. To secure the beam clips to the aluminum beams or top chord, unwind
the wing nut until it jams against the deformed end of the T-bolt. This provides control
of the T-head bolt and assures that the T-head can enter the slot deeply enough. Push
the bolt all the way into the slot and turn it clock-wise to the locking position. Wind up
the wing nut to tighten. It is very important that the head of the bolt be lodged
crossways in the beam slot for secure attachment (i.e. between the joist beam and the
top chord.) Tighten well by hand or with a 22mm (7/8”) spanner wrench or hammer.
The new wing nut is now virtually indestructible.
JET LOCK
Part No.: (JLTT)
DESCRIPTION : This unique fastener is standard on all HI- LITE struts and shoring
frames. The jet lock is installed at appropriate locations to allow cross braces to be
attached to the struts or frames quickly and securely. Jet locks are easily replaced in
the field (if necessary) as they are held in place by standard hex jam nuts. To install
cross braces on the jet locks, simply open up the braces and position the holes over the
jet locks, then push to snap on. The jet lock spring is made of stainless steel, for a
long, rust- free life.
Page 27 / 32
JASCO SALES INC.
CROSS BRACES
Part No.: Refer to the following table.
DESCRIPTION : Cross Braces are made of galvanized high-
tensile steel tubes. Tube Diameter is 25.4mm (1”) or 31.75
(1-1/4”). Brace sizes are stamped on the flattened ends (one
side only).
APPLICATIONS: Used to brace together trusses to make a

fly form (table form). Use one or two on each strut as detailed. Also use across the lower chords to keep the trusses square. The same
cross braces can be used with frames to make a shoring tower.
DESCRIPTION TUBE IMPERIAL METRIC COLOUR CODE

PART
No. Dia. A B C Weight A B C Weight
(A) x (B) HI-LITE USER
in mm Feet Feet Inches Lbs mm mm mm Kg
CB42 4’ x 2’ 1 25 4 2 53 5/8 6.0 1220 610 1361 2.72 Orange
CB44 4’ x 4’ 1 25 4 4 67 13/16 7.5 1220 1220 1722 3.40 Yellow
CB52 5’ x 2’ 1 25 5 2 64 9/16 7.2 1524 610 1641 3.27 White
CB54 5’ x 4’ 1 25 5 4 76 13/16 8.5 1524 1220 1951 3.86 Silver
CB62 6’ x 2’ 1 25 6 2 75 7/8 8.4 1828 610 1928 3.81 Black
CB64 6’ x 4’ 1 25 6 4 86 1/2 9.5 1828 1220 2197 4.31 Red
CB72 7’ x 2’ 1 25 7 2 87 5/16 9.6 2134 610 2218 4.35 Blue
CB74 7’ x 4’ 1 25 7 4 96 3/4 10.6 2134 1220 2456 4.81 Grey
CB82 8’ x 2’ 1 25 8 2 98 15/16 10.9 2438 610 2512 4.94 Green
CB84 8’ x 4’ 1 25 8 4 107 5/16 11.8 2438 1220 2725 5.35 Orange
CB102 10’ x 2’ 1 25 10 2 122 3/8 13.4 3048 610 3109 6.08 Yellow
CB104 10’ x 4’ 1 25 10 4 129 1/4 14.1 3048 1220 3282 6.40 Grey
CB104B 10’ x 4’ 1¼ 32 10 4 129 1/4 17.9 3048 1220 3282 8.12 Grey
CB114B 11’ x 4’ 1¼ 32 11 4 140 7/16 19.5 3353 1220 3568 8.85
CB124B 12’ x 4’ 1¼ 32 12 4 151 13/16 21.0 3658 1220 3709 9.53
NOTE: Crossbraces in metric sizes or any other length may be custom- made on request.
Page 28 / 32
JASCO SALES INC.
Aluminum Beams
Part No.: Refer to the front picture.
DESCRIPTION : All aluminum beams have reasonably

wide bottom flanges to minimize any overturning action.
Every beam has a continuous 13mm (1/2”) slot to allow
attachment of beam clips, hinge panels, etc. Most of the
beams also have a wood nailer on top to secure plywood.
Our 165mm (6.5”) hollow beam is ideal for fly form joists
where you might wish to extend either end to accommodate
slab areas between columns or a change in bay width. The
hollow beam receives a standard 38mm x 89mm (2x4) timber
in the hollow section. This provides for a 38mm x 89mm
(2x4) or wider timber to lie flat on top of the inserted timber
to make the top of the 2x4 level with the top of the beam so
that the plywood can be kept level across the beam and
extension. Nail the 2x4 to the filler strip
On thinner slabs or narrower fly forms our 114mm (4.5”) or

140mm (5.5”) aluminum beams can be used. This will save
money and allow for a lighter fly form.
Page 29 / 32
JASCO SALES INC.
FORM MOVING DOLLY C/W CASTORS

Part No.: (FFMD)
DESCRIPTION : The form moving dolly has two independent 200mm (8”) swivel
castors that are connected to an arm which is easily connected with T-bolts to the bottom
chord.
APPLICATION : Four form moving dollies are used to roll the fly form over relatively
rough surfaces, whether level or slightly sloped. They are very useful in large buildings
where there is more than 1 pour per floor. With these dollies two men can easily move
most forms in any direction.
LOWERING JACK
Part No.: (FFLJ)
Adjustment: 1.54m (60.5”) - 3.13m (123”)
DESCRIPTION : Specially designed hydraulic lowering jack.
APPLICATION : Used in groups of four to lower or raise telescopic truss tables.
Page 30 / 32
JASCO SALES INC.
FORM ROLLOUT ROLLER

Part No.: (FFFR)
Height: 45mm (1 3/4”)
DESCRIPTION : Small light weight roll out rollers with special side guides that keep the
fly form moving straight.
APPLICATION : Form rollout rollers are placed under the bottom chord of the fly form
and are used to roll the fly form out of a bay to the pick up position for flying.
FORM MOVER
Part No.: (FF2X4FR) / (FF4X4FR)
Weight: 3.9kgs (8.5 lbs)
DESCRIPTION : Form movers are basically crowbars with wheels that are specially
designed to compliment the grooves on the underside of the bottom chord.
APPLICATION : Used to lift the form off wood blocks and either lower on to the rollout
rollers or move the form sideways, away from walls and/or columns. When 38mm x
89mm (2x4) blocks are used you need a 2x4 form mover. When 89mm x 89mm (4x4)
blocks are used, a 4x4 form mover is required. 38mm x 89mm (2x4) blocks should be
used when the wedge units are set at 150mm (6”), to allow for sufficient distance to break
the form from the slab, allowing 40mm (1.5”) to 115mm (4.5”) of drop. When the wedge
unit can be extended 175mm (7”) to 200mm (8”), it is then better to use 75mm (3” ) to
89mm (3.5”) blocks and use the 4x4 form mover. Note, we prefer the higher wedge unit
settings when ever possible.
Page 31 / 32
JASCO SALES INC.
HYDRAULIC JACK DOLLY

Part No.: (FFHJD)
Weight: 25 kgs (55 lbs)
Lifting Capacity: 2800 LBS.
DESCRIPTION : Hydraulic jack dollies raise or lower the truss from 533mm (21”) down
to 90mm (3.5”). The jack dollies enable the form to be easily moved in any direction for
exact positioning and quick leveling. The jack is rolled around the slab and, when
necessary, it can be carried by one man. Adapters are also available which will extend the
lifting or lowering heights to 900mm (35”), but this has to be done in two steps. First,
lower the form onto blocks that are between 375mm (15”) and 533mm (21”) high,
remove the adapter and lower to 90mm (3.5”). Note, this is rarely required because if you
wish to lower the form more than 600mm (24”) it is easier to use the lowering jacks.
APPLICATION : Positioning and leveling the truss.
NOTE: Shipped without breather in position. Breather is to be installed on site.
Page 32 / 32

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F LY F ORM MANUAL S ECTION I

HI - LIT E GENERAL INFORMATION

* See Section II for Assembly and Instructions

Benefits of HI-LITE's Telescopic Fly Forms

The small initial assembly costs make it practical to fly

The Fly Form is a modular component system assembled into

Complete Basic Unit

A. 2 - 3 truss units (product part code FFTU##-NN)

Truss Length Identification

15 ft. Basic Truss 10 ft. Truss Extension

20 ft. Basic Truss 5 ft Truss Extension

FFTU56-20 FF 20' Truss - 5'6" Strut 1

FFTU56-25 FF 25' Truss - 5'6" Strut 1 1

FFTU56-30 FF 30' Truss - 5'6" Strut 1 1

FFTU56-35 FF 35' Truss - 5'6" Strut 1 1 1

FFTU56-40 FF 40' Truss - 5'6" Strut 1 2

FFTU56-45 FF 45' Truss - 5'6" Strut 1 1 2

FFTU56-50 FF 50' Truss - 5'6" Strut 1 3

Fly Form Strut Range Configurations

height of the adjustable

of the bottom chord to the

Consult HI-LITE Engineering with the specifics of your project.

Fly Form Truss Height Adjustment

1.20 4 1.274 50.2” (4’ 2”) 2.158 85” (7’ 1”)

1.50 5 1.646 64.8” (5’ 5”) 2.785 109.7” (9’ 2”)

1.60 5’ 6” 1.521 71.7” (5’ 11”) 3.096 121.9” (10’ 2”)

1.80 6 1.992 78.4” (6’ 6”) 3.406 134.1” (11’ 2”)

2.40 8 2.651 104.4” (8’ 10”) 4.637 182.6” (15’ 2”)

3.0 10 3.28 129.5(10’ 10”) 5.86 230.9(19’ 3”)

Product Part Numbers and Descriptions

FFTUA## NNTruss Unit (shipped fully assembled)

Nominal Strut Extended Fly Form Closed Fly Form 10 15 20 25 30 40 45 50 55

Truss Unit Components

FFTCUA5 FFTCU5 shipped assembled

FFTCL# Top Chord Channels(pairs) See pg 18 for details

FFTCLSP Top Chord Splice Channels(pairs) See pg 18 for details

FFBC# Bottom Chord See pg 19for details

FFH# Bottom Chord H Sections See pg 19for details

HDSHC3/4NC Hex Cap Screw 3/4x5-1/2in. NC See pg21for details

HDNH3/4NC Hex Nut 3/4in NC

HDFW34SAE Flat Washer 3/4in. (S.A.E.)

FFSPCR Top Chord Spacer See pg 17 for details

FFTHSB FF Telescopic Horizontal/Diagonal Strut Brace package See pg 25 for details

FFSTUD FF Strut Stud c/w 2 Jam Nuts & Hex Nut

FFHINGE FF Beam Hinge Bracket Assembly See pg 25 for details

Fly Form Accessories

FFWDGH Wedge Unit Hook

FFWDGB368 Wedge Unit Block 368mm High

FFPICK Pick Bracket See pg 23 for details

FFGPH-FF FF Guard Rail Post Holder See pg 23 for details

CLGRP Aluminum Guard Rail Post 1.5mm (5’)

FFSTB## FF Form Stabilizer) See pg 24 for details

CL4848SS Clamp-48x48mm (1.9x1.9) Swivel Stl See pg 24for details

CL4860SS Clamp- 48x60mm Swivel Stl,

CL4870SS Clamp-48x70mm Swivel Clamp Stl

CL60JL Alum Half Clamp - 60mm (2.36in)

CL70JL Alum Half Clamp - 70mm (2.75in)

FFTHSB Telescopic Horizontal Strut Brace See pg 25 for details

FFHA Hinge Bracket Assembly See pg 25 for details

T-BOLT / W-NUT T-Bolt / Wing Nut See pg 26 for details

BM-CLPC Beam Clip c/w HI-LITE T-Bolt See pg 27 for details

CB-# Cross Braces See pg 28 for details

AL-BM## Aluminum Beam See pg 29 for details