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OM 01 EN

COFFOR Revision 0
OPERATING MANUAL Date 03.08.2016
Page 1 of 61

COFFOR OPERATING MANUAL


OM 01 EN
COFFOR Revision 0
OPERATING MANUAL Date 03.08.2016
Page 2 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

1.2 It is necessary to prepare:


- Work schedule: work schedule must contain start date and finish date
of work, time for each operation (formwork, reinforcement,
electrical, concrete pouring, scaffold work, and so on).
- Concrete pouring schedule: concrete pouring schedule must contain
pouring dates, concrete quantity, type of concrete.
- Scaffolding drawings: scaffolding drawings must contain the height,
wide, length, also the type and the quantity of scaffolding needed for
the project.
- Slab formwork plan: slab formwork plan must contain the props
position and the quantity of materials needed for the slab (props,
tripods, beams, and so on).
- Walls push-pull props position: walls push-pull props position must
set the position for the push-pull props that support the walls and
correlate it with the slab formwork plan.
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2. Working tools, small materials and equipment required:

For COFFOR panels:


- Screwdriver cordless
- Circular saw electric
- Drill machine electric
- Angle grinder 9” electric
- Angle grinder 4.5” electric
- Nail gun (gas)
- Extension cable (drum) 50m
- Carpenter hammer
- Hammer 1-2-5kg
- Measuring tape 5-10-50m
- Chalk string- chalk line with red powder
- String
- Cutter
- Pliers – blacksmith tongs
- Steel scissor – for cutting steel bars ø6,8,10mm
- Crowbar small
- Crowbar big
- Work belt-bag – for workers to hold hammer, screws, measuring tape
- Buckets
- Steel bending plate
- Steel bending key
- Bubble level- straightedge aluminum 2m, 1.5m, 1m, 0.6m
- Laser or water hose for level
- Scissor for metal
- Plummet
- Wheelbarrow
- Broom
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- Elbow for corners


- Water barrow
- Aluminum A type ladder
- Lights for night work
- Handsaw

For foundation:
- Spade
- Pickaxes

For concrete pouring:


- Concrete vibrator
- Shovels
- Water hose and mesh fabric for keeping the concrete wet (for slab,
foundation)
- Rubber boots
- Trowel
- Finishing trowel
- Flexible hose for the concrete pump

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. Preparing the working place and marking the walls


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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 rough foundation (Height concrete 45cm) formwork height 55cm

Note that the formwork is higher than the foundation by approximately


10cm. This fact will help at COFFOR panels fixing for the next floor. So
after pouring concrete into the foundation, the formwork must not be
removed and kept until the walls on the next floor will be poured.
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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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Example of foundation ready for concrete pouring


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Checking before pouring:


- Starter steel bars position, for columns and walls
- Electrical and plumbing position
- Approvals

Example of concrete poured into the foundation


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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.

Example of marking the walls with plywood


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4. Columns – steel fixing


Steel reinforcement must be fixed according to the drawings. Steel
bars will be cut at the length needed, stirrups will be made and tied with the
long bars and this will be the columns. Lift the columns reinforcement and
fix it into position according to the drawings, by tying it with the starter steel
bars from the foundation.

Example of columns steel fixing


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5. Fixing COFFOR double panels


For the start, hooks from steel bars will be made and will help the
technicians lift and hold the panels into the air. The panels are very light and
2 technicians can lift it easily.
Method:
- COFFOR double panels have a top and a bottom
- Lift the panel vertically until the panel will be open
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FIRST COFFOR DOUBLE PANEL:


- Grab the panel with the hooks and lift it above the starter steel bars
(which connect the foundation with the walls) and swipe it down
such that the starter steel bars will be inside the panel (between
the 2 faces of the panel)
- Attach the panels on the foundation formwork with screws
- Cut and fix a C profile or a piece of wood on the panels and on the
ground so it will not fall down (this is temporarily - it will be
removed after fixing push-pull props)
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Example of fixing the COFFOR double panels

THE NEXT PANELS:


- The next panels will be fixed like the first panel but they will overlap
the one beside by 1-2cm.
- Screws will be fixed on panels ribs (see photo) every 20cm up to
height 1-1.2m and above every 30cm.
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Example of panels overlapping with screws on each rib

The last panel or supplements (pieces):

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:

a. The gap is less than 20cm


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- 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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b. The gap is more than 20cm

- A double panel can be cut at the required dimension: width needed


plus 2-4cm extra for overlapping with the panels beside it.

- This piece will be overlapped and connected with the panels beside
it with screws on every rib.
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6. Parapets under the windows and closing lintels


Small holes inside walls, like a hole for air conditioning type window
or ventilation holes, can be made by measuring and cutting the panel, with
the angle grinder, after the panels are fixed into place.

Example of Air Conditioner hole inside the panels (60x40cm)


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Larger openings, like windows openings, can be made with 2 options:


1. After fixing the panels in place, the opening can be made with the angle
grinder
2. A small height panel can be fixed into position, the height should be
until the opening starts, and then a lintel can be fixed above the opening
same way the lintel above the door is fixed. (see photo below)

Example of fixing lintel above a door

7. Reinforcing the lintels


Before closing the COFFOR double panels at doors and windows, place 2
steel bars above the opening inside the lintel for reinforcing the lintel.
This will help the concrete on that area not to crack.
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8. Fixing horizontal C profiles for alignment


For aligning the panels, we can use “C” profiles or “Ω” profiles. The
profiles will be connected on panels with screws 3.5x25mm.
The first profile will be fixed horizontally, at a height between 50cm
and 100cm from the ground. The next profiles will have a distance, between
them, from 100cm to 150cm.
The horizontally profiles are fixed to the “C” profiles inside the panels
with screws.
The horizontal profiles must also overlap each other at least 40cm.
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9. Aligning the wall on vertical, plumbing


For supporting the walls and align them vertically, push-pull props will
be used.
The push-pull props will be fixed only on one side of the wall, at the
height 2/3 from the wall height, with a distance from 1m to 1.5m between
them. The push-pull props will be fixed on the panels with tie wire 2.5mm
thickness. After fixing the push-pull props, temporarily sustain profile or
wood can be removed (see chapter 5).
Using push-pull props instead of normal props have the advantage
that walls can be aligned vertically more easily, by pushing or pulling the wall.

Example fixing push-pull props


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10. Extra reinforcement into the columns

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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11. Closing the exterior corners

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.
-

Example of corner panel


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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.

Alternatively, wooden boards can be used instead of metal strips.


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Example of jamb closing


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12. Slab formwork execution and fixing single COFFOR panels

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.

Example of slab formwork with wood beams placed into 2 directions

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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Example of fixing Single COFFOR panel on the slab


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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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Example of slab steel reinforcement

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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Example of cleaning the walls right after pouring the concrete


VERY IMPORTANT: Immediately after pouring concrete inside the walls,
cleaning excess concrete must be done. Use a trowel or a finishing trowel
and remove the fresh excess concrete.
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15. Removing the formwork

WALLS: After at least 12 hours since the concrete pouring is finished,


formwork can be removed:
- Push-pull props can be removed,
- Horizontal aligning can be removed,
- Plywood or wood from the base of the wall can be removed.

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.

16. Possible errors when fixing COFFOR panels


- Improper marking the walls
- When fixing COFFOR double panel, one or more panel can be
mount upside-down: result the beam above the panel will not be
horizontal.
- Cutting the panels in wrong dimensions.
- Cutting the gaps at the exact dimensions needed without
considering concrete deviation, for plumbing, ventilation or other
gaps for windows and doors, will result smaller gaps after
concrete pouring and it will be needed to brake it.
- CONCRETE POURING: do not hit with the hammer directly on the
COFFOR panels, use a piece of wood or a plywood.
- CONCRETE POURING: do not pour the concrete with pressure
directly into the COFFOR panels. Use a flexible hose to decrease
the pressure and pour the concrete on the slab edge and push-it
inside the panels.
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- After concrete pouring, immediately, check the walls to be


vertically straight.
- After concrete pouring, clean the walls and the surrounding area
(scaffold, level below)

17. Controls before and after pouring concrete in COFFOR panels

- Starter steel bars position from foundation to the ground floor


walls.
- Steel bars fixing into the lintels.
- Positions and dimensions of gaps and holes for plumbing, electrical
and ventilation.
- Visual check of the panels for damages that may occur during
transport and fixing into place.
- When steel fixing for slab, be careful not to walk directly on the
panel’s mesh or on the plumbing and electrical. You can step only
on C profiles
- When cutting the panels, check the mesh not to be detached of C
profiles. If it is, fix it with screws.
- If there is gaps inside the panels larger than 1-2cm, cover it with a
piece of COFFOR mesh or a plywood and fix it with screws.
- Right after concrete pouring, check the walls to be aligned and fix
them by pushing or pulling with the props.
- Note on a paper (or concrete register book) every time concrete is
poured, concrete quantity, concrete type, weather condition o
- at time of pouring.
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18. Annex TOOLS

For COFFOR panels:

Screwdriver cordless Drill machine electric

Circular saw electric Angle grinder 4.5” & 9” electric


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Nail gun (gas) Carpenter hammer

Extension cable (drum) 50m Hammer 5kg

Measuring tape 10-50m


Hammer 2kg

Measuring tape 5m
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Chalk string- chalk line with red


powder
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Pliers – blacksmith tongs-knipex


String

Steel scissor – for cutting steel bars ø6,8,10mm


Cutter

Crowbar small + big


Buckets
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Work belt-bag – for workers to hold hammer,


screws, measuring tape Handsaw

Steel bending plate Laser auto-level

Bubble level- straightedge aluminum 2m, 1.5m, Level water hose


1m, 0.6m
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Scissor for metal Wheelbarrow

Plummet Broom

Elbow Aluminum A type ladder


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Water barrow Lights for night work

For foundation:

Spade
Pickaxes
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For concrete pouring:

Rubber boots

Trowel

Flexible hose for the concrete pump


Finishing trowel

Concrete vibrator
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Consumables:
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Powder for chalk string

Cutting disk

Carpenter pencil or markers

Drill bits for concrete ø 8,10,12mm

Nails and gas for the nail gun

- Bit PH2 for screw machines

Light bulb for night work


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White chalk

Screw (black for drywall)


3.5x25(35,55)mm

Tie wire ø1.25mm & 2.5mm

Concrete spacers
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Plywood

Masking tape

Nails
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Equipment:
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Truck mounted telescopic forklift

Props for the slab

Extension forks (3m)

Tripods for props

Push-pull props with plate at both heads

Generator for power

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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Reflective vest Safety harness

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