New EasySet™ onstruction Procedure · 2013. 2. 28. · Panel leaning 26. Page 3. onstruction...

EasySet™ Construction Procedure

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


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


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


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.


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.


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.


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.


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.


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


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


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)


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.


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)


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.


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.


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.


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.


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.


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.


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.


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.


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.


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).


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.


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

THIS PAGE LEFT INTENTIONALLY BLANK

Aluma Systems International, Inc.

55 Costa Road, Concord, Ontario

L4K 1M8

Canada

Tel.: +1 (905) 669-5282 Fax.: +1 (416) 736-2924

New EasySet™ onstruction Procedure · 2013. 2. 28. · Panel leaning 26. Page 3. onstruction...

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