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Jinse Jiayuan concrete formwork materials Project
● Project Overview
The standard floor height of buildings 6#~7#~8# and 9#~10# in Phase II of Jinse Jiayuan, Vanke City, Dongfeng, Zhongshan, is 2800mm. For the construction of beams, slabs, columns, and walls in the standard floors of the tower, aluminium concrete formwork materials will be utilized. Aluminium concrete formwork materials offer convenient installation and dismantling, ensuring good flatness, verticality, and concrete molding. These materials can be reused for over 300 cycles and have significant recycling value, making them an energy-efficient and environmentally friendly product.
● Construction Challenges:
1. Uses new aluminium concrete formwork materials to replace traditional construction methods. The key to successful construction is ensuring the strength, rigidity, and stability of the formwork systems for concrete.
2. It is crucial to choose a suitable support system that ensures the safety of the structural construction.
3. It is essential to ensure that concrete force on formwork remains under control by verifying concrete formwork loads and pressure calculations.
4. It is essential to strictly control the concrete formwork removal time to ensure the quality of the concrete molding.
5. Due to the connection between buildings 6#, 7#, and 8#, as well as the connection between buildings 9# and 10#, there is a deformation joint in-between. The construction sequence involves first constructing one side of the wall structure, filling the gap in the lower-level structure with foam boards. These foam boards will be removed after pouring concrete. The specific procedure will follow the construction nodes illustrated in the diagram below.
● Aluminium concrete formwork materials preparation
The supply of aluminium concrete formwork materials is the most critical factor in ensuring both the construction schedule and quality. To ensure proper material supply, the following aspects should be given priority:
Timely procurement: After obtaining approval from the project manager, the purchasing officer should proceed with the procurement in a timely manner. Following the requirements of the construction schedule, materials should be procured and delivered to the site promptly, avoiding any work disruptions or delays caused by material shortages.
2. Strict quality control: The procurement personnel should be the first line of defense. The aluminium concrete formwork materials must come with proper certification and utilize advanced concrete materials. Upon arrival at the construction site, the site quality department must conduct thorough random inspections and rechecks. Quality inspectors and on-site construction workers must carefully inspect the materials at each stage to achieve a 100% qualification rate. Additionally, concrete formwork certification should be conducted for the aluminium formwork.
3. Formwork system matching: A set of aluminium concrete formwork materials (includes concrete column formwork materials，formwork materials for concrete slab, wall concrete formwork materials, beam concrete formwork materials). Three sets of concrete formwork braces for slabs, four sets of concrete formwork braces for beams, and five sets of concrete formwork braces for cantilevered structures.
| Aluminium concrete formwork materials plan table | |||
|---|---|---|---|
| Num | Material name | Unit | Quantity |
| 1 | Aluminiumconcrete formwork materials | M2 | 3800 |
| 2 | Concrete formwork braces | Unit | 4000 |
| 3 | pins | Unit | 50000 |
| 4 | Concrete formwork tie bars | Unit | 4000 |
| 5 | Pvc casing | M | 10000 |
| 6 | Plastic cup | Unit | 10000 |
| 7 | Other tools | Batch | 1 batch |
● Construction Schedule
The project plans to start construction of the first floor wall columns on June 10, and the construction period is 162 days. The specific plan is as follows:
| Construction Schedule | |||
|---|---|---|---|
| Parts | Planned construction period(days) | Cumulative construction period(days) | Remark |
| First floor wall columns and 2nd floor beams | 15 | 15 | timber formwork for concrete walls and timber concrete column formwork |
| 2-floor wall columns and 3-floor beam slabs | 11 | 26 | concrete formwork timber and aluminium concrete formwork materials |
| 3-floor wall columns and 4-floor beam slabs | 4 | 30 | Aluminium concrete formwork materials |
| 4-floor wall columns and 5-floor beam slabs | 4 | 34 | Aluminium concrete formwork materials |
| 5-floor wall columns and 6-floor beam slabs | 4 | 38 | Aluminium concrete formwork materials |
| 6-floor wall columns and 7-floor beam slabs | 4 | 42 | Aluminium concrete formwork materials |
| 7-floor wall columns and 8-floor beam slabs | 4 | 46 | Aluminium concrete formwork materials |
| …… | 4*4 | 62 | Aluminium concrete formwork materials |
| 12-floor wall columns and 13-floor slabs | 4 | 66 | Aluminium concrete formwork materials |
| 13-floor wall columns and 14-floor slabs | 4 | 70 | Aluminium concrete formwork materials |
| …… | 4*9 | 106 | Aluminium concrete formwork materials |
| 23-floor wall columns and 24-floor slabs | 4 | 110 | Aluminium concrete formwork materials |
| 24-floor wall columns and 25-floor slabs | 4 | 114 | Aluminium concrete formwork materials |
| …… | 4*9 | 150 | Aluminium concrete formwork materials |
| 34-floor wall columns and 34-floor beam slabs | 4 | 154 | Aluminium concrete formwork materials |
| 34th floor roof | 4 | 158 | Aluminium concrete formwork materials |
● Construction Preparation
1. Based on the structural form of the project and contractual timeline requirements, design and document the concrete formwork process and necessary precautions for the construction site of the tower.
2. Prepare the aluminium concrete formwork materials in accordance with the concrete formwork design.
3. Construction personnel should undergo training on concrete formwork manual.
4. Mark the positioning lines for the walls and columns, 300 control lines, and elevation control lines.
Before the concrete formwork installation, it is essential to double-check the floor elevations and major control axes.
● Aluminium concrete formwork wall installation
1. Before installation, apply concrete formwork form oil properly.
2. Start installing the internal concrete formwork wall from the corners and proceed towards both sides according to the numbering. During installation, temporary supports should be used to secure the formwork in place.
3. Before closing the concrete formwork components, place PVC pipes and ensure that the rubber cups make smooth and seamless contact with the concrete formwork.
4. The pins for vertical concrete formwork should be arranged at intervals of 300mm. The pins should be inserted from top to bottom to prevent grout leakage and detachment during the pouring process.
5. The concrete formwork waler should be installed in the sequence bottom-up, starting with the exterior walls and then the interior walls. Special connectors should be used to reinforce the formwork.
6. Each concrete formwork waler should be installed with concrete formwork spacers and concrete screws, and both sides should be reinforced simultaneously. The protruding screw threads of concrete screws should not be less than 50mm for protection.
7. Push pull props should be installed on both sides of the concrete formwork wall for the interior and secured at the embedded anchor locations. For concrete formwork wall for the exterior, push pull props can only be installed on one side.
● Aluminium concrete formwork for beam and slab installation
1. To install the concrete formwork for beam and slab, it is important to start by completing the installation and support of one formwork, and then gradually expand outward to maintain the stability of the supporting system.
2. After the floor keel is installed, the diagonal lines of the floor should be checked. After the inspection is correct, the installation of concrete formwork for beam and slab begins.
3. If there are any deviations, they should be corrected by adjusting the supports until achieving overall flatness and the corresponding elevation. The support rods should be vertical and secure, with no looseness.
● Aluminium concrete formwork removal
1. For non-load-bearing concrete formwork components in cast-in-place integral structures, they can only be removed when the concrete has reached a strength that ensures their surfaces and edges won't be damaged during dismantling. Load-bearing concrete formwork components, on the other hand, can only be removed after they have reached the strength specified in the construction acceptance specifications and have been approved by the project engineer.
2. The removal of concrete formwork components should follow a top-down sequence, starting with the side concrete formwork components and then removing the load-bearing concrete formwork components. Supporting elements and connectors should be dismantled one by one. If there are aluminium concrete formwork large, where feasible, they can be removed as a whole.
3. The concrete formwork components of walls (columns) can be removed after 12 hours, concrete formwork components of slab can be removed after 24 hours, and concrete formwork components of beam can be removed after 48 hours. All support rods should be removed after 21 days. Please note that the specific timing may vary based on the local climate conditions at that time.
4. While remove concrete formwork components, it is strictly forbidden to use excessive force or hammering. Handle each piece gently, removing support elements and rods individually. Avoid throwing or damaging the components, as it may cause concrete formwork bendigo. It is crucial to preserve the integrity of the concrete formwork components during the removal process.
5. Before removing the aluminium concrete formwork components, ensure that all concrete formwork accessories, such as concrete formwork loop ties, concrete formwork liners, concrete formwork pins, concrete formwork brackets, concrete formwork chamfer strip, and others, have been removed.
6. When removing concrete formwork for beam and slab, it is necessary to dismantle the pins and wedges. Additionally, the aluminium concrete formwork components should be dismantled piece by piece and neatly stacked. It is strictly prohibited to directly remove the entire block.
7. After removing the aluminium concrete formwork, it is important to promptly rinse the concrete surfaces with water. This serves two purposes: firstly, it aids in the curing of the concrete itself, and secondly, it helps to remove the water-soluble concrete formwork oil. This is good for advance concrete forms.
8. The concrete formwork components and concrete formwork accessories that have been taken down should be piled up in the specified area. Arrange them in an orderly manner according to their assigned numbers. Concentrate the accessories and attachments in one location or store them in a designated container.
9. Once the project is finished, keep the aluminium concrete formwork components either outside or in a warehouse. Ensure that the storage area has a level ground, and stack the components no higher than 1.5 meters.
10. The aluminium concrete formwork components can be transported manually, piece by piece, using the Reserve holes in the floor slab. Each hole has dimensions of 700X200. Taking safety into consideration, once the materials for the next level have been transferred, it is important to promptly fill the holes with additional concrete to properly seal them.
● concrete formwork pour
1. During the pouring of the upper layer of concrete, any cement slurry that flows into the lower layer should be promptly cleaned (flushed) to ensure a visually appealing appearance of the walls and columns. The concrete or mortar used for sealing the base of the walls and columns should also be washed off in a timely manner. This helps reduce the difficulty of concrete formwork removal and ensures better protection for achieving good concrete formwork finishes.
2. Be mindful of the evenness and levelness at the base of the walls and columns. This makes it easier to check the formwork systems for concrete and minimizes the chances of grout leakage from the bottom of the walls and columns.
3. It is not advisable for the vibrating rod to directly contact the exposed concrete formwork during the pouring process.
4. Pouring sequence: Start pouring from the middle of the walls and columns to enhance stability.
5. Considering stability, the arrangement of the conveying pipes is as follows:
When using the "pipe-hoisting" method with a tower crane for construction, it is important to take note of the following: during the pouring of the upper layer of concrete, four pre-embedded steel reinforcement hoops should be placed around the openings reserved. This is done to fix the concrete conveying pipes and prevent any horizontal collision with the aluminium concrete formwork.
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