New EasySet™ onstruction Procedure · 2013. 2. 28. · Panel leaning 26. Page 3. onstruction...
Transcript of New EasySet™ onstruction Procedure · 2013. 2. 28. · Panel leaning 26. Page 3. onstruction...
EasySet™ Construction Procedure
Page 2
Construction Procedure
CONTENTS
General Construction Process 3
General Panel Handling 4
Preparation of Base Slab 5
Fixing of Wall Rebar 6
Fixing Service Fittings 7
Initial Equipment Organization 8
Panel Treatment Prior to use 10
Erection of EasySet Wallform 13
Erection of EasySet Slab Form 15
Erection of EasySet Stair Form 16
Erection of EasySet Steel Accessories 17
Fixing Slab Rebar & Installation of Service Equipment 19
Pouring Concrete 20
After Concreting 21
Stripping EasySet Panels 22
Flat Tie Removal 24
Removal of Slab Form 25
Panel Cleaning 26
Page 3
Construction Procedure
General Construction Process
In order to ensure that the EasySet™ system can be used to achieve a one day cycle, it is im-
portant to follow the standard construction sequence provided. Aluma suggests the follow work-
ing procedure:
Step 1 Preparation of foundation – (not critical to achieving the cycling time.
This step can be completed before using of forms for typical floors
and slab)
Step 2 Fixing of Wall Rebar
Step 3 Installation of Electric and Plumbing Fittings inside wall
Step 4 Initial Panel Organization
Step 5 Panel Treatment
Step 6 Panel Installation
i) EasySet™ Wall Panels Set Up
ii) EasySet™ Stairs Set Up
iii) EasySet™ Slab Panels Set Up
iv) EasySet™ Steel Accessories Set Up
Step 7 Fixing of Slab Rebar &Installation of Electric and Plumbing
Fittings inside slab
Step 8 Pouring Concrete
Step 9 Stripping of EasySet™ Form
Step 10 Panel Cleaning
Page 4
Construction Procedure
Introduction
Similar to all other all aluminum panel system, EasySet™ panels should be handled with care
and should be used only by trained workers. Failure to do so will lead to unnecessary damage
thus shorten the life the panel.
General Handling
1. Panels should be moved by lifting the complete panel off ground. It should never be
dragged, nor tossed.
2. Never drop panel from a height more than 75mm.
3. Panels should only be used as concrete mold and follow design drawing. They should nev-
er be used as support, stair, bridge or any other uses.
4. Never stand or walk on the panel.
5. Do not land the panel over hard surface. If it cannot be avoided, land the panel lightly
with care.
6. Do not use iron hammer or steel bar to strike panel directly.
7. Always use proper tools to erect and strip the panels.
8. The horizontals and Integrated Pins are designed for their intended use only and should
not be used as stepping ladder or struck with a hammer to facilitate removal of the wedge
or pin.
9. Any concrete accumulated on the panel, whether is on the panel face, at the side rails or
at the back of the panel, should be cleaned immediately.
10. Apply form releasing agent to panel after cleaning but before concreting.
Panel General Handling
Page 5
Construction Procedure
Preparation of Base Slab Preparation of the base is the first thing that must be done prior to installation of form-work. It is important to have a firm and level base for the structure to be built on top. There are different kinds of foundation, the contractor should follow the engineer’s instruc-tions to contract the foundation accordingly.
However, the following is the most important for the work to carry out afterwards.
> The completed slab must be firm and with required strength.
> The finished slab must be level.
> The starter rebar must be at their correct position and alignment.
Setting Out Method
For each line of wall, mark 4 lines on top of the
completed slab, two lines showing both sides
of the wall and the other two lines 60 mm off
showing outside edge of EasySet™ Form.
Mark all turning points at the wall with trian-
gular solid marks. These are the control
points, and erection of EasySet™ wall panels
should start from these points.
On the inside of the two lines showing location
of wall, install a guide at all corners and at eve-
ry 1.2 m following the wall run. The guide can
be used as a guide for EasySet™ form to main-
tain correct thickness and alignment of the
completed wall.
These guides can be inform of concrete nail,
steel pin installed in predrilled holes, plastic
spacer (shown right) fixed to the slab, or any
other alternative method to serve this pur-
pose.
Page 6
Construction Procedure
Fixing of Wall Rebar
Rebar
Next step is installation of wall reinforce-ment usually in form of wire mesh. When installing the rebar, make sure they are vertically plumb and securely fixed to the starter bars.
EasySet™ Flat Ties are 40 mm deep and placed at 150 mm from the bottom, thereafter spacing at 300 mm. Make sure the wire mesh is arranged so that it will not interfere with the flat ties. A stencil will help ensure that this is done properly.
Spacers
After the wall rebar is completed, install concrete spacers to prevent steel wire mesh touch the EasySet™ panel face dur-ing concreting. The same spacer can be used to control the thickness of wall as well. The spacer can be in plastic rings purchased from third party suppliers or any other method that serves the same function.
Page 7
Construction Procedure
Fixing of Service Fittings
After the rebar work is completed,
electrical, sanitary and gas fittings can
be installed.
All electrical, sanitary and gas con-
duits should be carefully fix to the re-
bar securely to avoid dislocation dur-
ing concreting.
All electrical boxes should be firmly
anchored to the steel mesh, using ad-
ditional steel bars when necessary.
All electrical boxes should be filled or
covered to prevent concrete from en-
tering it during concreting. Do not
rely on the Easy Panel face to cover
these openings as the conduit may
move slightly during concreting allow-
ing concrete to enter the opening.
Page 8
Construction Procedure
Initial Equipment Organization:
Aluma EasySet is one of the fastest monolithic form to erect and cycle through the construction process. However, the deployment of the equipment from its shipping packages can present unique challenges. While the equipment is generally packaged by zone or area, the panels are packaged to maximize container space and not to facilitate initial deployment. This means that the panels are not packaged in sequence, and the first panel you may need might be at the bottom of the package. That being said, with proper organization many of the issues with initially deploying the formwork can be eliminated. Below are a number of steps that can be taken to speed up deployment and erection of the form: 1) Review material lists and installation drawings prior to opening any of the shipping packages to
become familiar with what each package contains and where each package is supposed to be assembled.
2) Take stock of all packages and ensure that all packages and boxes are easily accessible.
3) Distribute a copy of the Assembly drawings for the area to be installed to the workers so that the workers have a clear idea of their task and the material required.
4) Plan assembly of the form by zone and identify the appropriate packages required for each zone. Packages should be staged near or in the zones they will be deployed.
5) Only open the packages corresponding to the zone being installed. DO NOT open any other packages. Opening multiple packages at the same time can lead to panels being mixed up be-tween zones making finding panels difficult during erection.
6) If space is available lay out the panels on the ground near the zone to be installed with the in-stallation marks facing up to facilitate panel identification. Laying the panels out will also allow for easy application of any panel treatment prior to first use. If space is not available, panels should be at least regrouped by type and sequence or roughly positioned against the standing rebar.
7) Steel components and accessories should remain in their packages or boxes until they are need-ed to prevent loss and damage.
8) Occasionally, panels will be found that are missing the appropriate installation mark. These pan-els should be segregated from the rest of the formwork and set aside in the same zone. During erection the proper location of these unmarked panels usually becomes obvious and they can be installed and remarked.
Page 9
Construction Procedure
Initial Equipment Organization (Cont’d)
Preparation of Flat Tie It is recommended to wrap the tie with polyethylene glove cover (tie sleeve) or any alternative product to ease the removal of the flat tie after concreting. Ensure that there are enough tie-sleeves for the equipment to be erected prior to the installa-tion of panels. Tie sleeves will be consumed during each cast. Check local suppliers for purchasing details.
Page 10
Construction Procedure
Introduction
New aluminum alloy extrusion will react with oxygen in the air and react to create a protective
coating. This coating will minimize the natural reactivity between aluminum and fresh con-
crete, thus reduces concrete build up and sticking.
However, before this process is completed, the chemical reaction will still take place when the
extrusion is in contact with wet concrete, during the first few pours. During concreting, the in-
crease in temperature, due to the heat generated by the reaction between cement and water,
will quicken the chemical reaction at the aluminum form surface, which can potentially lead to
an inconsistent concrete finish. This chemical reaction usually completes after 3 to 5 uses, de-
pending on concrete grade, cement type, temperature and stripping time (see image below).
Once this process is completed, the aluminum panel surface will appear dark and the forming
surface should give a consistent finish on the concrete.
If concrete surface finish is of critical importance, there are a number of options to counteract
this reaction, as outlined in the following pages.
Panel Treatment Prior to Use
First Pour Second Pour Third Pour
Page 11
Construction Procedure
Panel Treatment Prior to Use (Cont’d)
Form Releasing Agent
If the rough concrete surface is not acceptable for the first few
pours, oil base form releasing agent, such as RM Mold Oil or
NKC form releasing agent, can be used to obtain typical con-
crete surface finish from the beginning. Alternatively, a mixture
using three (3) parts of gasoline oil (#2 Diesel) mixed with one
(1) part commercially available water base form releasing agent
such as Alumi-Con can be used.
The releasing agent can be applied manually via sponge roller,
pump sprayer, or as per manufactures instructions.
After several pours with oil base form releasing agent, the alu-
minum oxide protective coating will form on the surface of the
panels and will stop further chemical reaction. This will make
the panel surface appear darkened. Once this point is reached
water based form releasing agent should continue to be used
throughout the life of the project.
Seasoning in Factory
Upon special request— panels can be chemically “Seasoned” at
the factory. A chemical compound is applied at the factory that
initiates the reaction . This seasoning reduces the number of
pours require to use oil base form releasing agent.
Unfortunately, pre-seasoning of the panel can only reduce the
times of using oil base form releasing agent, but cannot elimi-
nate it totally, unless the form is not being used for 6 months
after the application of seasoning agent.
Oxidized Panel
New Panel
Page 12
Construction Procedure
If the panels are not pretreated in the factory, there is a site-applied treatment option that
will also reduce the number of times that an oil base form releasing agent must be used. The
following method can be applied to the aluminum panel surface, before first use:
Clean panel surface to make sure it is free from grease or oil.
Prepare cement mortar with concentration 1:1.
Alternatively, a calcium hydroxide mixture (calc) of 3 parts water—2 parts Calcium Hydrox-
ide *Ca(OH)2+ can be used. Finally, Seasoning compound from generic supplier (e.g. Nox-
crete Seasonox, or similar) can also be used.
Apply the mixture to the panels surface by roller, brush or mop. The application of generic
product should follow the manufacturer’s instructions.
Leave the compound on the panels for at least 16 hours to allow reaction to begin.
Clean the panels with high pressure clear water until the panels are completely free from
compound. The panels should have a slightly darker surface than prior to application.
The panels are ready for mold oil to be applied after completely drying.
Panel Treatment Prior to Use (Cont’d)
Page 13
Construction Procedure
Erection of EasySet™ Wall Form
Wall Form Set Up
1) Locate the desired inside corner panel in
which to begin the panel installation on Installation Drawings.
2) Find the panel with this mark and erect the panel on the control point given from STEP 1. Ensure that the panel is in the cor-rect orientation before continuing.
3) Once the inside corners are erected, con-tinue to erect the inside walls according to the installation drawings.
4) If the Tie-bar system is used, install the panel found on the opposite side of the wall and continue this process until the room is complete (see photo below).
Before erection of wall panels, check to make sure all the rebar, con-duits and electrical boxes are properly installed and secured.
Check to make sure all the panel face are clean and treated with form
releasing agent and all the tie bars are covered with plastic wrap.
Use of Pins & Wedges
Pins & Wedges are used to lock the Form Pan-els together and to connect accessories. First align the panels, then put the Pin through both holes of the adjacent panels and then drop in the Wedge to lock the two pan-els together. Do not tighten the Wedge by hitting the Wedge hard during this stage. Wedges should be tightened with a hammer only when the complete wall is erected, the tie bars are installed, and all the Pins are in position.
Page 14
Construction Procedure
Note on pin installation:
Due to a number of factors, including un-level base slab, and the panelized nature of the system, some
pins will be more difficult than others to install, and some hole may appear not to be aligned. In these
cases the Torbar provided with the system can be used to help align the holes and facilitate pin instal-
lation.
Also, due to the standardized manufacturing of the system there will occasionally be pin holes that
obviously do not line up with any adjacent hole. This is especially common along the stripping corner
or SC panels or in areas of complex geometry. This does not represent a defect of the form.
Exterior wall form installation:
Exterior wall form installation should also begin on a
corner of a structure and proceed in the same method
as the interior panels.
On multi-level structures the exterior wall form will
have starter (STA or K) panels along the top of the
form . If the starter panel methodology utilizes the
Cast-in Anchor system then the anchors should be in-
stalled at all pre-drilled hole locations after the entire
form is erected and prior to rebar installation.
Erection of EasySet™ Wall Form (Cont’d)
Page 15
Construction Procedure
Erection of EasySet™ Slab Form
Slab Form Set Up
1) Install the stripping corners (SC) on top
of the erected wall panels around the
room according to the Deck portion of
the Installation drawings. Check the ori-
entation of the SC corners to ensure
that holes line up against the wall pan-
els below.
2) Install the 3-way Stripping Corner (SCU)
corners located at the corners of each
room. The walls below will not be in-
stalled orthogonally so if the corner
does not fit perfectly, do not worry!
With the assistance of a provided Torbar
you can insert the pins through the
aligned holes easily.
3) Install the deck panel shown on the in-
stallation drawing next to the corner.
Remember to orient the panels so that
the beveled part of the deck panel faces
the stripping corner (SC).
4) Install the remainder of the deck panels
(D) and Ledger panels as shown on the
Installation drawing. Panels spanning
greater than 1.2 m should be support-
ed. DO NOT tighten the pins until all
panels are installed between 2 corners,
or else it would be difficult to install the
final deck panel.
Page 16
Construction Procedure
Erection of EasySet™ Stair Form
There is nothing difficult about the assembly of the
EasySet™ stairs! The most challenging part is locating
the panels because of its irregular shape so go over
the installation drawings to familiarize yourself with
the shapes and follow the instructions below.
All staircases will be packaged separate from the rest
of the form.
Step 1: Open Stair package and organize material as
discussed earlier.
Step 2: Ensure the opposing wall or walls of the stair-
case is completely erected, all tie bars installed and
pins tightened.
Step 3: Begin erection of the wall (W) panels below
the staircase.
Step 4: Install the stripping corner (SC) panel along
the top of the panels below the staircase.
Step 5: Erect W panels above the staircase. Panels
should be secured to the tie bars from the adjacent
wall.
Step 6: Install the stair riser interface (CH) panel.
Step 7: Install the stair soffit panel. Install support
posts as required.
Step 8: If staircase is open on one side and only mon-
olithic with one adjacent wall then install the Stair
bulkhead (CF) panel as required.
Step 9: Install stair runner and riser forms.
Page 17
Construction Procedure
Erection of EasySet™ Steel Accessories
Installation of Recoverable Cast-In Anchor
Cast-In Anchors are installed on the panel face of
the Outside Edge formwork (K panels) and are con-
nected via supplied bolt. Bolt should be hand tight-
ened using an ordinary spanner.
Installation of Guardrail Post
Guardrail Post are installed on the Outside Edge Form Panel. Prior to any working activities taking place on the completed slab deck, all Guardrail posts as well as guardrails should be installed and secured (by contrac-tor). When working close to the edge of the building, workers should have proper fall arrest protection. Guardrail posts are installed via pin and wedge connec-
tion. Some guardrail post types have pre-welded pins
already in position for installation.
Installation of Catwalk Bracket
For multi-storey buildings, catwalk brackets need to
be installed and all guardrails need to be installed
and secured (by contractor) prior to working on
there.
Catwalk brackets are installed over the top level of
existing tie bars and connected via pin and wedge.
Page 18
Construction Procedure
Installation of Aligners & Aligner Brackets
Follow the installation drawings provided to install
the aligner brackets. Make sure that aligner is in
contact with all the EasySet panels. If the aligners do
not make contact with the panels, the aligners are
installed incorrectly. This also applies to corner
aligner brackets.
Aligner brackets must be perpendicular to the align-
ers and not slack.
Erection of EasySet™ Steel Accessories
Installation of Post Shores
Install post shores properly. Do not over tighten the
post. Make sure the posts are fastened to the ground
and braced according to the installation drawings.
Page 19
Construction Procedure
Fixing Slab Rebar & Installation of Services Equipment
Installation of Negatives Once the slab form is complete install the form-work for the slab negatives.
Installation of Slab Rebar
Once the slab form is completed, fixing of slab rebar can be started immediately.
Installation of Services Equipment
After the rebar work is completed, electrical, sani-
tary and gas fittings can be installed.
All electrical, sanitary and gas conduits should be
carefully fixed and secured to the rebar to avoid
dislocation during concreting.
All electrical boxes should be firmly anchored to
the steel mesh, using additional steel bars when
necessary.
All electrical boxes should be filled or covered to
prevent concrete from entering it during con-
creting. Do not rely on the Easy Panel face to cov-
er these openings as the conduit may move slight-
ly during concreting allowing concrete to enter
the opening.
Page 20
Construction Procedure
Pouring Concrete
Pouring Wall Start pouring the wall at one of the outside corners and let the concrete run. Use vibrator whenever necessary. But remember, do not over-vibrate, and never let the vibrator to get in contact with the wall panel. Proceed along the wall as level of concrete rises.
Pouring Windows Windows are poured with the walls. When using concrete with low viscosity, it is necessary to open the window bulkhead panels to ensure that the win-dow wall is fully poured before continuing. Lock the bulkhead panel once the check is complete.
Pouring Staircase
Usually staircases are located at center of building. It is recommended that pouring begin in the walls ad-jacent to the staircase until the level of concrete is stable about 1/2 way up the wall. Pour concrete di-rectly into the staircase until the same level is reached. Complete the walls and remainder of the stairs in the same fashion
Pouring of Slab
Once finished concreting of all vertical members, start pouring the slab concrete, again from the out-side to the inside. It is important to make sure the completed slab is level for next pour.
Before pouring concrete, make sure all the rebar, services conduits, and junction boxes, etc. are installed and secured in their correction position. Check that all
panels are installed according to the installation drawings provided. Also, make sure all EasySet™ accessories, such as Flat Ties, Aligners, Plumbing
Braces and Guardrails, are properly installed.
Page 21
Construction Procedure
After Concreting
Immediately after concreting
Use water jet to clean the back of all EasySet™ Panels to ensure there is no concrete accumulated on the horizontal
faces and around the Pin & Wedge.
Also, clean the bottom of all wall panels to avoid concrete build-up which will make the panels difficult to strip and
cause damage to the panel.
Page 22
Construction Procedure
Stripping EasySet™ Panels
Before starting of stripping process, make sure the finish con-crete attained the strength as approved by the Engineer.
Removal of Aligner and Plumbing Brace
Start the stripping process by removing all the Box Aligners, Aligner Support Brackets and Plumbing Braces.
Stripping of Opening Forms All the Panels forming the openings are complet-ed with stripping slope. The panels can be easily taken out after removing all the Pins and Wedges connecting it. Put the opening forms aside in their correct order, so that they can be easily identified when re-quired for the next use.
Stripping Wall Panels
Locate the Stripping (SL/SR) panel on the interior wall, or the corner panel on the exterior wall, and always start stripping from there.
Remove the Pin and Wedge connected to the Stripping Panel using the correct hand tool and following the correct method. Once all the connecting Pins and Wedges are re-moved, due to the sloping edges at the stripping panel, it should be easily removed. If found nec-essary, the provided Torbar can be used to assist. Once the first panel in the run is removed, the fol-lowing panels should come out easily by following the same procedure.
Page 23
Construction Procedure
Stripping EasySet™ Panels (Cont’d)
Install Tie Filler (Bench) at all Tie Bars that are supporting the Starter Panels immediately after removal of inside form.
Tie Bar Supporting Starter Panel For Tie Bars supporting Starter Panels, they should be fixed in position by installing Packers with Pin & Wedge immediately after stripping of the inside form.
Starter Panels Usually an extra set of starter panels are provid-ed. DO NOT Strip the starter panels., they are required for the assembly of the floor above. This includes starter panels found beside the stairs. Removal of starter panels will compromise the orthogonality and the overall geometry of exter-nal walls.
Page 24
Construction Procedure
Removal of Flat Tie
Removal of Flat Tie Once the panels are removed, the Flat Ties can be easily removed by hand. Most ties will come out easily if tie-sleeves are used properly and if the ties are not bent out of shape. Taping the tie lightly with a hammer can assist in loosing the tie if it is tight. Do not use excessive force on the tie or strike it forcefully with the ham-mer—this can damage or warp the tie and make it unusable in the future. In the rare occasion where the tie is diffi-cult to remove, special tie removal tool can be purchased (see photo on the right, below).
Page 25
Construction Procedure
Removal of Slab Form
EasySet™ Post Head system allow the stripping of slab panels without dis-turbing the Support Post. This permit early stripping, thus speeding up the process and saves equipment .
Stripping Slab Form EasySet™ slab form comes with Strip-ping Panels which make stripping a re-ally easy job. Always start stripping at the Stripping Panels. Locate the Stripping Panels from the drawing before start stripping work. Once the first panel is removed, follow-ing the same procedure, the rest of the panels can be stripped easily. After the slab soffit panels are re-moved, then the corner pieces and ledger panels can come down. Ensure the Posts & Post Heads are left in place until deemed safe to remove by the site engineer. This includes all short posts under the stair form. If it is absolutely necessary to remove the posts under the stairs to strip the pan-els the project structural engineer should be consulted and appropriate reshoring installed.
Page 26
Construction Procedure
Panel Cleaning
Clean Panels
Clean all dirt stuck to panel surface or edges with a
scraper or fine steel wool pad. Do not apply exces-
sive force or it will damage the aluminum surface.
If there are stains that cannot come out, use gener-
ic product provided by concrete chemical specialist
and follow their instructions.
Clean panel with spray of fresh water and carry out
visual check for any damage of panel. Report im-
mediately if any structural damage occurred and
the panel should be put aside for further investiga-
tion.
Let panel dry completely before applying a thin lay-
er of form releasing agent to their surface.
The panel is now ready for its next use.
Clean Tie-Bars
Clean the tie with scraper if any concrete stick on it, and apply releasing agent to it, if necessary. Wrap the tie with polyethylene glove cover, or any alternative product. The tie is now ready for its next use
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Aluma Systems International, Inc.
55 Costa Road, Concord, Ontario
L4K 1M8
Canada
Tel.: +1 (905) 669-5282 Fax.: +1 (416) 736-2924