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The Technic

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Phase 2 : Formwork and GBE System

 

1. Internal formwork

 

  • Once the formwork panels have been assembled in accordance with manufacturer recommendations, install the first set of formwork panels on the inside, with their stabilizers (as per manufacturer recommendations).

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  • Connect the formwork panels (roller nut system with inverted cones or keys).

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  • Level the first set of formwork panels: this action is completed using a basic levelling jack.
  • Verticality adjustments; place the magnetic plumb line on one of the sides of the vertical beam. Adjustments are made using the strut at the bottom of the formwork.
  • Mark out level, openings, pipe or services sleeves, etc.
  • Install, adjust and attach the jigs and pipe or services sleeve using magnetic clips (metal formwork or any other system if wooden formwork).
  • Install the ends to create wall stops.

 

 

2. Internal reinforcements

 

  • Connecting rebars installed against formwork (supporting wall in contact with the recessed joints and floors).
  • Incorporation of electrical ducts, networks and various pipe or service sleeves to be used by secondary trades.

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3. Installation of insulation

 

  • Measure position of daggers on plates in advance, so that they are correctly aligned with the rebars and not with the jigs.
  • Dagger-bolts are to be distributed with at least four per insulation panel, in proximity to the angles at a distance of between 10 cm to 25 cm from the edge of the panels, making sure there is no more than 1 m between each dagger.
  • Insert the dagger (purple) that fits the characteristics of the constructed wall into the insulation (from between 5 cm and 34 cm), one to two daggers per metre square (minimum) and position the internal connector (green).

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  • Check that the internal and external connectors are effectively installed.
  • NB: the number of connectors depends on:
    1. The thickness of the insulation: for the same type of insulation, thicker insulation plates means fewer connectors are required.
    2. The dimensions of the insulation panels. Use large-dimension panels whenever possible.
  • Rotate the connector one quarter of a turn to ‘block’ the assembly to prevent contact being lost between all internal and external connectors.

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  • Place the insulation and connectors with guaranteed thermal and mechanical performances in the facade wall system, against the internal structural reinforcements, by turning the dagger knob to pass through the rebars. The connectors that are being used as spacers must abut the inner formwork.
  • Turn the connector one quarter turn using the outer knob to avoid the rebars and maintain the insulation in its preliminary phase.

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  • Insert the self-boring spacers (Figure A, green) fitted with sleeves (Figure B, orange) in the insulation above the tightening holes until they abut the inner formwork.

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  • Drill next to the tightening holes using spacers. Holes to be labelled as and when activities progress.
  • “The self-boring spacers are designed to:
    • limit the rising up of the insulation during casting.
    • counter the compression forces during tightening of formwork panels.
    • install work and security platforms (wide end pieces distribute the compression forces and thus protect the outer concrete facing wall).”
  • Juxtapose the insulation panels while checking insulation continuity (horizontal and vertical):
    • Use tape to connect panels to prevent knock-on.
    • Keep the insulation panels together using silicone and staples.

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  • Keep the workstation clean throughout the process.
  • Apply pressure manually to check the insulation panels are correctly assembled against the rebars.

 

 

4. Internal reinforcements

 

  • Install rebars in outer facing wall against the insulation.
  • Install stainless steel u-shaped tie bars on wall head to connect the two wall surfaces.
  • Check that rebars are installed securely.

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  • Fix the ends of the spacers according to the thickness of the wall to be made and its finish (Figure C. orange).

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5. Next stage of formwork

 

  • Check appearance of matrix before closing formwork panels.
  • Position the second set of formwork panels.
  • Thread the tightening rods in the positioned formwork panel set by crossing through the spacers.

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  • Tighten the upper and lower tightening rods (by doubling up nuts if there are multiple heights).
  • Unhook from crane.
  • Fix the end scales at the end of the formwork panel (butt traps held in place).
  • Check verticality of formwork and alignment of formwork panels.

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“Do not forget collective protection equipment (handrails, reinforcement protection, etc.) .”

 

 

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