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Operating Manual 61pp
Operating Manual 61pp
Operating Manual 61pp
COFFOR Revision 0
OPERATING MANUAL Date 03.08.2016
Page 1 of 61
TABLE OF CONTENT
1. Planning..................................................................................................................................................... 2
2. Working tools, small materials and equipment required: ........................................................................ 3
For COFFOR panels: .................................................................................................................................. 4
For foundation: ......................................................................................................................................... 5
For concrete pouring: ............................................................................................................................... 5
Consumables: ............................................................................................................................................ 5
Small materials:......................................................................................................................................... 6
Equipment:................................................................................................................................................ 6
Safety equipment:..................................................................................................................................... 7
3. Preparing the working place and marking the walls ................................................................................. 7
4. Columns – steel fixing ............................................................................................................................. 15
5. Fixing COFFOR double panels ................................................................................................................. 16
6. Parapets under the windows and closing lintels .................................................................................... 24
7. Reinforcing the lintels ............................................................................................................................. 25
8. Fixing horizontal C profiles for alignment ............................................................................................... 26
9. Aligning the wall on vertical , plumbing .................................................................................................. 27
10. Extra reinforcement into the columns .................................................................................................. 28
11. Closing the exterior corners .................................................................................................................. 31
12. Slab formwork execution and fixing single COFFOR panels.................................................................. 34
13. Reinforcing the slab and connecting it with the next level................................................................... 37
14. Pouring concrete into COFFOR panels, for walls and slab .................................................................... 38
15. Removing the formwork ....................................................................................................................... 42
16. Possible errors when fixing COFFOR panels ......................................................................................... 42
17. Controls before and after pouring concrete in COFFOR panels ........................................................... 43
18. Annex tools...........................................................................................................................................43
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1. Planning
1.1 Before starting a construction work with COFFOR, it is necessary to study
all drawings:
- Formwork drawings
- Reinforcement drawings
- Electrical drawings
- Plumbing drawings
- Architectural drawings
For foundation:
- Spade
- Pickaxes
Consumables:
- Cutting disk (for wood) for electrical circular saw
- Cutting disk (for metal) 4” and 9” for angle grinder
- Drill bits for concrete ø 8,10,12mm
- Powder for chalk string
- Carpenter pencil or markers
- Bit PH2 for screw machines
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- White chalk
- Nails and gas for the nail gun
- Light bulb for night work
Small materials:
- Tie wire 2.5-3mm thickness for formwork
- Tie wire 1.25mm thickness for steel bars
- Concrete spacers – for keeping steel distant from formwork (concrete
cover)
- Screw (black for drywall) 3.5x25(35,55)mm
- Self-drill screw (black for drywall) 3.5x25(55)mm
- Plywood, wood 1’’x4’’, 2’’x4’’
- Nails for wood 6,8,10mm
- Combustible : for generators, or vibrators
- PEE foil
- Masking tape (ex: for electrical boxes)
Equipment:
- Truck mounted telescopic forklift (Manitou type)
- Extension forks (3 m) for ruck mounted telescopic forklift for
unloading COFFOR panels from the container
- Props for the slab
- Tripods for props
- Forks for props (on head)
- Wood beams or Doka beams – different length
- Push-pull props – with plate at both heads
- Light scaffolding
- Power generator
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Safety equipment:
- Coveralls
- Safety boots
- Helmet
- Safety goggles
- Gloves
- Reflecting vest
- Face shield mask for cutting
- Safety harness
3.1 Marking the foundation and mounting the starter steel bars for the
COFFOR panels (walls).
The foundation formwork and reinforcement will be made according to
the drawings.
In this operating manual, we will focus on the starter steel bars fixing
from foundation to the walls above.
Example of steel reinforcement for foundation, only the inferior layer, in this case wire mesh fixed
on 75mm plastic spacers
After fixing the inferior reinforcement we can mount the starter steel
bars which will connect the walls with the foundation, and then the
superior reinforcement can be finished.
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Example: starting with the column reinforcement with stirrups, and continue with the steel
bars for the walls (steel green color painted with epoxy paint)
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Example of electrical or plumbing into the foundation which will continue into the walls
(COFFOR double panels)
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3.2 Marking the walls and site preparation for fixing COFFOR panels
Marking the walls will be done as per the formwork drawings. It is very
important to mark also the axes (A, B, C... 1, 2, 3 ...) on the foundation
formwork and keep it until it will be transmitted onto the upper level.
Marking the walls can be made with chalk string-chalk line (with powder)
on the floor. Then some plywood or wood (1’’x4’’ or 2’’x4’’) must be fixed
along the chalk line, with concrete nails or drill and fix it with steel bars. This
will help the panels not to move during the concrete pouring.
IMPORTANT: Must be marked: the walls, the doors, technological openings
for plumbing or electrical, window area, or other openings.
If for completing the wall we have one of standard dimension for COFFOR
panels, (width: 30cm, 50cm, 70cm, 90cm, 110cm) it will be used.
If for completing the wall there’s not a standard dimension, then there are 2
options:
- From one COFFOR simple panel with the same height we will cut
the piece we need but wider by 2-4cm so it can overlap the ones
beside it.
- The piece should be cut such that the C profile will be in the middle.
- The piece will overlap and be connected with screws by the panels
beside it on every rib.
- For more safety the C profiles, one in front of each other, can be
caught between them, with tie wire 2.5mm thickness every 40 cm.
- The same method should be used for closing the gaps between the
panels at columns in the middle of the wall
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- This piece will be overlapped and connected with the panels beside
it with screws on every rib.
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After assembling the COFFOR panels in place, steel bars can be fixed
to connect the panels with the columns complying with the drawings.
Example of steel bars fixing for connecting the panels with the columns in the middle
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Example of steel bars fixing for connecting the panels with the columns in the corners
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For closing the corners, single panels can be used, cut and bent with
the right dimension.
Example: corner 16x16cm
- Cut from one single panel, at the right height, a piece with the
width 34cm-36cm (the middle between C profiles should be the
middle of the corner).
- On the edge of the corner hit all the panel ribs with the hammer
and the chipping chisel, then bent the panel at 90°.
- Fix the corner panel into position and connect it with the panels
beside it with screws.
-
Closing the upper jamb, sides jamb and sills at windows and doors
for COFFOR panels
For closing the COFFOR double panels at doors and windows, U-shape
metal strips (0.6-0.7mm thickness) can be used.
Very important: when the measurements are made, increase them by 1-2cm,
so the gap will be larger than needed because concrete deviation is
measured in centimeters not millimeters.
The slab formwork is usually made from metal props with tripods and
forks, wood or metal beams, or combined metal and wood beams, placed
into 2 directions.
With COFFOR there’s no need for plywood for the slab. Single COFFOR
panels replace the plywood.
Fix the COFFOR single panels on top of the wooden beams. Overlap the
panels 1-2 cm on each other, same as the walls. No need to connect the
panels with screws. For smaller pieces, cut from a big panel.
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Example of slab formwork made with metal beams on one direction and
wooden beams on the other direction
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13. Reinforcing the slab and connecting it with the next level
After placing the single COFFOR panel on the slab support, reinforcing
the slab can start. It can be done with independent steel bars or wire mesh
(welded steel bars). At the same time, beams can be fixed and also the steel
bars which connects the slab with the next level walls if there is one.
Very important: do not step on COFFOR panel’s mesh. Walk on the “C”
profiles or put a temporally plywood or wood to step on.
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14. Pouring concrete into COFFOR panels, for walls and slab
The pouring can be start only after checking the quality of fixing
COFFOR panels. The visual check will detect any possible defect that must be
repaired.
One of the major feature and advantage of COFFOR system is noticed
in the concrete pouring. The pouring can be made into the walls and on the
upper slab in the same time. This will produce a full monolithic structure.
For pouring, at the end of pump hose, it is recommended to fix an
extensible hose, which will not allow the concrete to have a big pressure
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when it reaches the panels. The concrete can be poured on the edge of the
slab and then push inside the walls.
For pouring concrete inside the walls it is recommended to do it in
layers, 1m height, until the walls are full of concrete.
The concrete should have 180mm slump for the walls so it will not need
vibrator inside the panels, and 140mm for the slab.
When the concrete is poured, if there’s a gap inside the wall, a
carpenter’s hammer and a piece of wood can be used, to fill it. Place the
wood on the panel and slowly hit the wood with the hammer, as you pour
the concrete inside the panels.
Example of concrete pouring into the walls and the slab in the same time
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Example of concrete pouring into COFFOR panels (for a fence H=2.80m). Do not pour the concrete full
height inside the panels. Layers must not exceed 1-1.5m height
Example of pouring concrete into the slab. The green steel bars are for the next level or in this case, for
roof parapet
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SLAB: Slab formwork can be removed after a few days, when the
concrete reach 80% of his final strength. This depends also on the weather.
Measuring tape 5m
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Plummet Broom
For foundation:
Spade
Pickaxes
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Rubber boots
Trowel
Concrete vibrator
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Consumables:
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Cutting disk
White chalk
Concrete spacers
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Plywood
Masking tape
Nails
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Equipment:
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Light scaffolding
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Safety equipment:
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Helmet
Coveralls
Safety goggles
Safety boots
Gloves
Face shield mask for cutting
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