IN PLACE : COFFER SYSTEM

Elements And Panel Assembly

The formwork system comprises of two filtering grids made of rib mesh reinforced by vertical stiffeners called ‘C’ channel which is made up of galvanized sheet having zinc coating .The grids are connected by rebar which acts as horizontal stiffeners and connector which act as a shear link

The vertical steel channels and horizontal steel bars act as steel reinforcement for load bearing wall. The connectors help to fold the formwork for easy transportation. Concrete is poured into these gaps between ribmehses The panels are prefabricated which when arrive on the construction site are installed and ready for concreting. The Formwork System is generally used for residential buildings upto G+4 storey, Industrial buildings, Underground Tanks, Water retaining structures, Storm water drains, Compound walls etc. and also as shuttering material for slabs

Types Of Panels

'C’ Channel ReBar

Standard single panel

These panels shall be used for slab shuttering but may also be used as shuttering option for RCC wall having thickness of more than 350mm.

ib Mesh

Standard double panel

Insulated double panel Fibre cement double panel

Insulated Double panel –These panels shall have an integrated insulation on the exterior side The insulated material shall be of polystyrene or polyurethane of required thickness as per design. Used for main walls in structures

These shall have inbuilt steel and not require extra reinforcement. shall be of fixed size and need to be cut on site for openings etc but there are also Customized double panels from the factory that shall have required cutting for openings as per drawing and no need to cut on site. These panels shall be used for load bearing walls, retaining walls and shear walls.

NAME: Muskan Aanand (19110016) Page No:5

Katta Sheetal (19110011)

Amasa Pranay (19110002)

Shreyes Gupta (19110025)

These panels shall have its interior face as fibre cement board which has smooth surface and avoid plastering of walls. These panels may be used for water retaining structures.

ARN - 303- Building Construction - IV

Date: 24-09-2021

C'

STAY IN PLACE : COFFER SYSTEM

MANUFACTURING PROCESS FLOW CHART

Marketing PPC Panel Designer Plant store, Issue of raw material Production of Components

MANUFACTURING/INSTALLING MACHINERY

Production of Single panerls

Assembly Machine

Production of Double panels

Quality check Packing and Dispatch

Construction Accessories

studs and scews

Single coffer panels

Horizontal steel C profile and scaffholding

NAME: Muskan Aanand (19110016) Page No: 6

Katta Sheetal (19110011)

Amasa Pranay (19110002)

Shreyes Gupta (19110025)

ARN - 303- Building Construction - IV

Date: 24-09-2021

Images From BTMPC manuals and videos

LAYOUT AND BLOCKING 1.

2. ERECTION AND POSITIONING OF PANELS

3. CONSOLIDATING THE PANELS

Tracing On Ground

The alignment shall be traced with chalk on the two sides. Boards/battens shall be nailed on the ground to indicate the positioning of of the panels.Then the vertical reinforcing starter bars are projected on this alingnment after checking the verticality.

4. INSTALLING REINFORCEMNET BARS AT THE EXTREMITIES AND NEXT TO OPENINGS

TEMPORARY PLACEMENT

The Structural formwork panels shall be fitted over projecting vertical reinforcing starter bars. On a provisional basis, each panel shall be positioned vertically with the help of c channel of wooden battens or metal bars. Then, the small left over gaps after placing all panels is adjusted by cutting a panel with a vertical saw and is fixed in accordance with the width of that gap

5. CLOSING THE EXTREMITIES/ANGLES

Horizontal Alignment Vertical Alignment Scaffolding

When all the panels are installed, these shall be consolidated with horizontal steel profiles fixed(Screwed) on single side at every 80 cm and which ensures a perfect alingnment of coffer panels that are bound together by these profiles. Also, Scaffolding ensures the vertical alignment of panels and serves as a work platform that are fixed to the panels.

The angle panels shall preferably be fixed as follows:

CLOSING THE EDGES OF OPENINGS

Once the panels are correctly stabilized, reinforcement bars shall be installed Details of the reinforcement elements in the angles and around the openings shall be the same as for traditional walls of reinforced concrete. Vertical bars and horizontal bars in U-shape, shall be placed in the angles and openings- bound together and tied by a steel wire

BENDING THE PANEL ON SITE

The angles shall be closed with Formwork angle panels delivered from the factory. In the absence of angle panels delivered from the factory, panels of expanded metal shall be press-formed on the site.

a. On the inside with a batten of panel placed vertically all the way up the angle. This batten shall be bounded around the stiffening sections of Formwork panels of the angle b. On the outside right angle accessories are used as braces fixed on the angle panels . they are either screwed or tied.

Once done, the The verticality of all the pnels fixed shall be checked using a plumb line or level.

NAME: Muskan Aanand (19110016) Page No:7

Katta Sheetal (19110011)

STAY IN PLACE

ARN - 303- Building Construction - IV

Date: 24-09-2021