Operating Manual - August 2009

OPERATING MANUAL

October 2009 COFFOR SERVICES S.A. 21, rue de Chantepoulet 1201 Geneva, Switzerland tel. +41 22 716 1616 - fax +41 22 716 1610 www.coffor.com - [email protected]

Operating manual – October 2009

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BUILDING WITH COFFOR

TABLE OF CONTENT

1. TRACING AND PREPARING ..............................................................................3!!"!#$%&'()*+$,*$%-.$/0'1 """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""2!

!"3#$*')0)*+$4,,5.*$1,'&5/"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""2!

!"2#$60'()*+$6&,6/$'*5$/766,&%/"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""8!

2. PLACING PANELS..............................................................................................6!3"!#$/%'&%)*+$9&,:$%-.$'*+0./$'*5$%-.$,6.*)*+/""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""";!

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3"2#$4-.*$(,99,&$6'*.0/$)/$*,%$4)5.$.*,7+- """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""<!

3"8#$9'/%.*)*+$,9$6'*.0/$%,$.'(-$,%-.& """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""=!

3. FIXING COFFOR PANELS..................................................................................9!2"!#$/,07%),*$4)%-$4,,5.*$1,'&5"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""">!

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4. FINAL ADJUSTMENT .......................................................................................13!5. OPENINGS.........................................................................................................14!?"!#$5,,&/ """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""!8!

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6. INSERTING REBAR ..........................................................................................18!;"!#$&.1'&$)*$(7&&.*%$6,&%),*$,9$%-.$4'00""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""!=!

;"3#$&.1'&$9,&$'*+0.$4'00$'*5$(&,//)*+$4'00"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""3@!

;"2#$&.1'&$9,&$0)*%.0$'*5$1.': """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""3@!

;"8#$&.1'&$9,&$(,99,&$&,,9 """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""3@!

;"?#$(,**.(%)*+$4'00$'*5$90,,& """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""3@!

7.USING SINGLE COFFOR PANELS FOR HIGHLY RENFORCED WALLS ......21!8. FRAMING OF COLUMNS AND BEAMS...........................................................23!9. EDGE CLOSING ................................................................................................24!>"!#$,6.*)*+/ """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""38!

>"3#$4'00$.5+."""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""38!

10. CONDUITS.......................................................................................................25!11. CHECKING BEFORE CONCRETING .............................................................26!12. CONCRETING .................................................................................................27!!3"!#$9&,:$%-.$90,,&$1.)*+$(,*/%&7(%.5"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""3<!

!3"3#$$9&,:$%-.$766.&$90,,& """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""3=!

!3"2#$$A)1&'%)*+ """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""3>!

!3"8#$$/:,,%-.*$%-.$/7&9'(."""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""3>!

!3"?#$$(,*(&.%)*+$%-.$4'00/$'*5$%-.$766.&$/0'1$)*$,*.$6'// """""""""""""""""""""""""""""""""""""""2@!

13. WALL FINISHING ............................................................................................30!EXHIBIT 1: CONSTRUCTIVE INSTRUCTIONS....................................................32!EXHIBIT 2: LINTEL AND BEAM ..........................................................................33!EXHIBIT 3: COFFOR TO BUILD ROOFS .............................................................34!EXHIBIT 4: WALL/FLOOR CONNECTION ...........................................................35!


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1. TRACING AND PREPARING

1.1) TRACING ON THE SLAB

WITH A CHALK BOTH SIDES OF THE WALL

1.2) NAILING WOODEN BOARDS Interior Walls Exterior Walls

Nails One board required

2nd board optional


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1.3) PLACING PROPS AND SUPPORTS

Maximum distance between props or supports is 3 m

Anchoring screws or use reserves wires from the floor in a secure manner (4 mm

diameter wire

Anchoring screws or use reserves wires from the floor in a secure

manner

Adjustable support


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THESE SUPPORTS ARE MULTIFUNCTIONAL. THEY SERVE AS VERTICAL ALIGNMENT, STABILIZER FOR THE PANELS AND THEY ALSO SERVE AS WORKING PLATFORM. ANY KIND OF SUPPORT CAN BE USED WITH COFFOR PROVIDED SECURITY IS MAINTAINED.


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2. PLACING PANELS

2.1) STARTING FROM THE ANGLES AND THE OPENINGS

(TEAMS OF 2 PEOPLE) The length of starter bar is increased by 15 cm because they are not necessarily aligned with the C profiles of the panels.

1 2 Temporary fastening

with wire

+15 cm

!


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2.2) GAP BETWEEN COFFOR PANELS

The gap between 2 COFFOR panels should not exceed 1 cm.

2.3) WHEN COFFOR PANELS IS NOT WIDE ENOUGH

- SOLUTION 1: L < 20 cm, place a strip of rib lath

Direction of rib lath

Maxi 1cm

!

Vertical ribs

NO YES

Horizontal ribs

OUI YES

Screws on C profile OR use steel wire

Rib lath


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- SOLUTION 2: 20cm > L > 20 cm, use a wooden boards screwed or fastened with steel wire to the C profile

- SOLUTION 3: Cut the panel to the required size with a circular saw (not recommended as more time consuming).

2.4) FASTENING OF PANELS TO EACH OTHER It is recommended to fastern adjacent panels with wire to one another every 60-80 cm approximately. Preferably it is the C profiles that are fastened to the adjacent panel. During the alignement process, they are already connected to one another.

End of wall

Midle of wall

Pre-cut COFFOR panel


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3. FIXING COFFOR PANELS

3.1) SOLUTION WITH WOODEN BOARD

1° Fixing wooden boards horizontally every 0.80 - 1.20 m, preferably on both sides.

Each panel should be fixed horizontally with screws or steel wire spaced every 0.80 m -1.20 m Overlapping of 2 wooden boards should be minimum 0.50 m

!

Boards are screwed

!

or fastened

O, 80 - 1,20 m

Overlapping min 0,50 m


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2° Final fixing

3° Fix boards on both side of the panel top

Fix props on the board with screw or wire

Ø 4 mm

Boards screwed, fastened with wire or

with clamp


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3.2) SOLUTION WITH L CHANNEL

1° Fixing steel tubes or L channel (with holes) to the COFFOR straightener every 0.80 – 1.20m, preferably on both sides :

Each panel should be fixed with screws or wire spaced every 0.80m -1.20 m Overlapping of 2 L profiles should be minimum 0.50 m

2° Final fixing (Can be done simultaneously while fixing the L channel)

!

L channel is screwed

or fastened

!

1.20 m

Overlapping minimum 0,50 m

Fix the prop to the L channel with screws or fasten with wire


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3° Fixing channels on both side of the panel top to align the panels

ALTERNATIVELY, ROUND TUBES Ø 50 mm CAN REPLACE WOODEN BOARD OR STEEL L CHANNEL

2 L channels screwed or fastened on top

!


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4. FINAL ADJUSTMENT

ADJUSTING VERTICALITY OF THE COFFOR PANEL


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5. OPENINGS

5.1) DOORS

1- Placing panels on both side of the door 2- Placing L channels or

wooden board

3- Placing props


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4- Use a COFFOR panel as lintel

COFFOR panels with special heights can be ordered from the factory or cut on site with a circular saw To adjust the panel length to the required size, see paragraph 2.3 “WHEN PANEL IS NOT WIDE ENOUGH”

4- Use traditional wooden board for lintel

OR

!


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5.2) WINDOWS

SOLUTION 1: PANELS PLACED ON BOTH SIDE OF THE OPENING

1- Place panels on both side of the opening

2- Place L channels or wooden board

Placichannels or wooden board Mise en place des

cornières ou tasseaux

3-Place Apron 4- Place mock-up (leave 1cm on 4 sides)


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See Exhibit 2 for placement of lintel

COFFOR panels with special heights can be ordered from the factory or cut on site with a circular saw. To adjust the panel length to the required size, see paragraph 2.3 PANELS TO SHORT

SOLUTION 2: CUTTING COFFOR PANELS (solution when labour cost is expensive compared to material cost)

1- Placing all panels 2- Fixing them with channels or boards 3- Cutting the opening with a circular saw

5- COFFOR lintel fixed with channel or board

5- Traditional formwork for lintel

OR

!

!

!


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6. INSERTING REBAR

SEE THE ANIMATED POWERPOINT PRESENTATION

(With COFFOR, rebar is placed after panels are positioned)

6.1) REBAR IN CURRENT PORTION OF THE WALL

(NORMALLY NON NECESSARY UP TO 5-STORY BUILDINGS)

Anti crack welded wire is not necessary with COFFOR

6.1.1 HORIZONTAL REBAR

Slide horizontal rebar over the connectors. Attach from the outside horizontal rebar to the COFFOR panel

!


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Slide rebar grouped by pair into COFFOR

6.1.2 VERTICAL REBAR REBAR GROUPED BY PAIR TO BE ORDERED OR FASTENED ON SITE

Top connection

Rebar by pair

Bottom connection

View from top

Bar !5


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6.2) REBAR FOR ANGLE WALL AND CROSSING WALL

SEE CONSTRUCTIVE INSTRUCTIONS FILE

6.3) REBAR FOR LINTEL AND BEAM SEE EXHIBIT 2

6.4) REBAR FOR COFFOR ROOF SEE EXHIBIT 3

6.5) CONNECTING WALL AND FLOOR SEE EXHIBIT 4


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7.USING SINGLE COFFOR PANELS FOR HIGHLY RENFORCED WALLS

In situations when walls are very renforced, the rebar are placed FIRST and then the single Coffor panels around.

1. PLACE THE SINGLE PANELS TO THE RIGHT POSITION AGAINST THE REBAR ALREADY IN PLACE 2. TIE TUBES (OR L PROFILES OR TIMBER) HORIZONTALLY TO THE C PROFILE OF THE PANELS EVERY 50 CM 3. THE HORIZONTAL TUBES ARE TIED ON BOTH SIDES 4. TIE THE HORIZONTAL TUBES FACING EACH OTHER WITH Ø 4 MM WIRE MAKING SURE THAT C PROFILE JUST TOUCHES THE REBAR

WHEN CONSTRUCTION IS DONE WITH SINGLE SIDE COFFOR PANEL, THE DISTANCE BEWTEEN HORIZONTAL TUBES AND VERTICAL SUPPORTS OR TUBES IS REDUCED : - 0.80-1.20 M TO 0.50 M FOR HORIZONTAL ALIGNMENT

- 3 M TO 1 M FOR VERTICAL ALIGNMENT

Rebar already in place Single COFFOR panel

!


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5. PLACE VERTICAL SUPPORTS ON ONE SIDE EVERY 1 M. 6. TIE EVERY TUBES TO THE VERTICAL SUPPORTS 7. ADJUST THE SUPPORTS TO MAKE SURE THE PANELS ARE STRICTLY VERTICAL 8. ANCHOR SECURELY THE VERTICAL SUPPORTS TO THE FLOOR WITH SCREWS OR WITH RESERVE WIRE (Ø 4 MM DIAMETER) FROM THE FLOOR. 9. CLOSE THE EDGES


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8. FRAMING OF COLUMNS AND BEAMS

Coffor can be used to build columns and beams. The technique is identical as the one for building very armed walls. Coffor single panels are used and placed after the rebar. Single panels are folded using a wood plank that is placed in parallel to the profiles according to the dimension of the column or beam to build. It is recommended to use two single Coffor panels.


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9. EDGE CLOSING

9.1) OPENINGS See SECTION 5.

9.2) WALL EDGE Using plank Using rib lath

Plank screwed To C profile

Rib lath screwed to C profile

(horizontal ribs)


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10. CONDUITS

1- Cutting the rib lath with Shear or circular saw 2- Fixing reserves to tubes coming from the floor 3- A complete floor can be done in one day

Conduit coming from the floor

Reserve placed by the electrician


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11. CHECKING BEFORE CONCRETING BEFORE CONCRETING, IT IS NECESSARY TO CHECK: • WALL ALIGNMENT • CLOSING OF CORNER, EDGES OF DOORS AND WINDOWS • REBAR POSITIONING • THE SECOND WORK RESERVES RE COMPLETED • THE GROUND AREA AROUND THE COFFOR PANELS IS CLEAN THESE STEPS ARE IMPORTANT FOR A GOOD AND CONSISTANT QUALITY WORK


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12. CONCRETING

12.1) FROM THE FLOOR BEING CONSTRUCTED

(SLOWER METHOD BECAUSE A PLATFORM IS NEEDED)

Type of concrete • Normal concrete • Slump around 12-18 cm • Aggregates 0/20

Pouring

• With a bucket • With a pump with a two-throw bend to reduce the speed of the concrete flow • Diameter of the nozzle should be less than 10 cm.

Two-throw bend

Place starter bar


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12.2) FROM THE UPPER FLOOR

USING TRADITIONAL FORMWORK OR PREFABRICATED FLOOR OR HOLLOW-CORE FLOOR

Formwork crossbracing

!

COFFOR exterior side higher to eliminate edge formwork

Traditional formwork, prefabricated or hollow core slab


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POURING

12.3) VIBRATING

• External vibrating with a wooden hammer (preferably) • Inside vibrating possible - diameter of the needle < 25 mm The needle should stay 40 mm away from the rib lath Stop vibrating as soon as chalking starts to come out

12.4) SMOOTHEN THE SURFACE

The panel surface should be roughly smoothed and the excess chalking going through the rib lath be recuperated.

!

!

Concrete is poured on the floor

Concrete is pushed with a shovel, or use of a ramp


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12.5) CONCRETING THE WALLS AND THE UPPER SLAB IN ONE PASS To optimize concreting time and quality of construction, it is recommended to pour in the same pass the walls and the upper slab. This will provide a concrete monolithic structure of the best quality. This implies of course that rebar reinforcement of the upper slab must be set before concreting the walls

13. WALL FINISHING • Traditional or projected finishing, plaster • Any cladding is possible: wood, stone, plasterboard, etc.


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EXHIBITS


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EXHIBIT 1: CONSTRUCTIVE INSTRUCTIONS

SEE THE CONSTRUCTIVE INSTRUCTIONS MANUAL


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EXHIBIT 2: LINTEL AND BEAM

1. PLACE THE COFFOR LINTEL

2. TIE THE COFFOR LINTEL TO THE TWO ADJOINING COFFOR WALLS AT

THE 4 CORNERS OF THE LINTEL WITH WIRE

3. PLACE THE HORIZONTAL REBAR

4. PUT THE U BAR FROM BOTTOM AND TIE THE U BAR WITH THE HORIZONTAL REBAR

5. FIX THE COFFOR LINTEL WITH HORIZONTAL TUBES AS NORMAL WALL

PANELS

6. CLOSE THE BOTTOM WITH TIMBER


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EXHIBIT 3: COFFOR TO BUILD ROOFS

To build a slab or a roof with COFFOR a single side panel must be used. 1. Timber is placed horizontally every 150 cm. 2. Supports are placed under the timber approximately every 200 cm.. 3. The horizontality is checked. 4. Timber is placed perpendicularly to the timber that is attached to the wood supports approximately every 50 cm. 5. The single face Coffor panels are placed on the timber. The C profiles of the panel should be perpendicular to the direction of the timber underneath it. The C profile will be used as a support for the rebar. 6. One should not walk on the Coffor mesh where there is no timber directly underneath it.

7. The rebar are added according to the civil engineer calculations. 8. The concrete is poured with a pump or with a shovel. The slump should not exceed 10-15 cm (max). The COFFOR panels that will support the slab will preferable have the exterior face higher tht the interior face of the thickness of the slab. The exterior face of the COFFOR panel will therefore replace the edge formwork. For a roof having a slope greater than 30 degree, normal double sided COFFOR panel must be used.

!

SUPPORT

TIMBER

TIMBER

!


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EXHIBIT 4: WALL/FLOOR CONNECTION

4.1) SLAB/CONTINUOUS FACADE WALL

1) THE COFFOR PANEL ACTS AS EDGE SLAB FORMWORK THE EXTERIOR SIDE IS HIGHER TO ELIMINATE THE EDGE FORMWORK

THE SLAB FORMWORK IS IN TRADIONAL PLYWOOD, COFFOR SINGLE SIDE

OR PREFABRICATED

2) REINFORCING THE SLAB

Based on the engineer’s calculalations

Slab Coffrage contre plaqué

Starter bar

Plywood

Standard reinforcement

Standard reinforcement


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COFFOR panel

3) PLACE THE COFFOR PANEL ON THE STARTER BARS OF THE UPPER FLOOR

4.2) SLAB/FACADE WALL

1) THE COFFOR PANEL ACTS AS EDGE SLAB FORMWORK THE EXTERIOR SIDE IS HIGHER TO ELIMINATE THE EDGE FORMWORK

THE SLAB FORMWORK IS IN TRADIONAL PLYWOOD, COFFOR SINGLE

SIDE OR PREFABRICATED


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2) REINFORCING THE SLAB

4.3) SLAB/INTERNAL WALL

THE SLAB FORMWORK IS IN TRADIONAL PLYWOOD, COFFOR SINGLE SIDE OR PREFABRICATED

Plywood Prefabricated

Prefabricated slab

Prefabricated

Plywood Prefabricated slab


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3) REINFORCING AND CONCRETING THE SLAB

Nappe d'acier supérieure

Nappe d'acier inférieure

Traditional reinforceme

Upper reinforcement layer

Lower reinforcement layer

Traditional reinforcement


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4.4) SLAB - CONTINUOUS INTERIOR WALL

1) THE FORMWORK OF THE SLAB IS IN TRADITIONAL PLYWOOD, COFFOR SINGLE SIDE OR PREFABRICATED

2) SLAB REINFORCEMENT AND CONCRETING

Traditional plywood Prefabricated


Lower reinforcement layer

Traditional anchoring


Lower reinforcement layer Traditional reinforcement


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3) PLACEMENT OF THE COFFOR PANEL ON THE STARTER BARS OF THE UPPER FLOOR

COFFOR panel

Operating Manual - August 2009

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