How it Works

EasySet™ Construction Procedure

General Construction Procedure

In order to ensure that the EasySet™ system can be used to achieve a one day cycle, it is important to follow the standard construction sequence provided. Aluma suggests the follow working procedure:

  • Step 1 Preparation of foundation – not critical to achieving the cycling time. This step can be completed before using of forms for typical floors and slab.
  • Step 2 Fixing of Wall Rebar
  • Step 3 Installation of Electric and Plumbing Fittings inside wall
  • Step 4 Set-up EasySet™ Wall Panels
  • Step 5 Installations of EasySet™ Slab Panels
  • Step 6 Fixing of Slab Rebar
  • Step 7 Installation of Electric and Plumbing Fittings inside slab
  • Step 8 Pouring Concrete
  • Step 9 Stripping of EasySet™ Form and move to new position
  • Step 10 Panel Cleaning

Preparation of Base Slab

Preparation of the base is the first thing to do. It is important to have a firm and level base for the structure to be built on. There are different kinds of foundation, the contractor should follow the engineers instruction to contract the foundation accordingly.

However, the following is the most important for the work to carry out afterwards.

  • The completed slab must be firm and with required strength.
  • The finished slab must be level.
  • The starter rebar must be at their correct position and alignment.

Setting Out Method

For each line of wall, mark 4 lines on top of the completed slab; two lines showing both sides of the wall and the other two lines 60mm off, showing outside edge of EasySet™ Form.

Mark all turning points at the wall with a triangular solid mark. These are the control points, the erection of EasySet™ wall panels should be started from these points.

On the inside of the two lines showing the location of wall, install guides at all corners and at every 1.2m following the wall run. The guide can be used as a guide for EasySet™ form to maintain correct thickness and alignment of the completed wall.

These guides can be in the form of concrete nail, steel pins installed in predrilled holes, plastic spacers fixed to the slab, or any other alternative method serves the purpose.

Fixing of Wall Rebar

Rebar

Next step is installation of wall reinforcement, usually in form of wire mesh. When installing the rebar, make sure they are vertically plumb and securely fixed to the starter bars.

EasySet™ Flat Ties are 40mm deep and place at 150mm from the bottom, thereafter spacing at 300mm. Make sure the wire mesh is arranged so that it will not interfere with the flat ties.

Spacers

After the wall rebar is completed, install concrete spacers to prevent the steel wire mesh from touching the EasySet™ panel face during concreting. The same spacer can be used to control the thickness of wall as well. The spacer can be in plastic rings or concrete block.

Fixing of Service Fittings

After the rebar work is completed, electrical, sanitary and gas fittings can be installed.

All electrical, sanitary and gas conduits should be carefully fixed to the rebar securely to avoid dislocation during concreting.

All electrical boxes should be firmly anchored to the steel mesh, using additional steel bars when necessary.

All electrical boxes should be filled with moist paper and conduits end covered with plastic wrap to prevent concrete from entering during concreting. Do not rely on the Easy Panel face to cover these openings.

Erection of Wall Form

Before the erection of wall panels, check to make sure all the rebar, conduits and electrical boxes are properly installed and secured.
Check to make sure all the panel faces are clean and treated with fore releasing agent and all the tie bars are covered with plastic wrap

Always start erection of wall forms from one of the corners.

Set Up Inside Wall Form

Actual erection processes starts with Inside Wall Form Panel at the corners.

With the help of panel identification numbers printed on the Form Panels, Form Panels can be erected in sequence accordingly.

Once the inside corners are erected, continue to erect the inside walls as per the design drawing.

 

 

Use of Pins & Wedges

Pins & Wedges are used to lock the Form Panels together and to connect accessories.

First align the panels, then put the Pin through both holes of the adjacent panels and then drop in the Wedge to lock the two panels together.

Do not tighten the Wedge by hitting the Wedge hard during this stage.

Wedges should be tightened with a hammer only when the complete wall is erected, the tie bars are installed, and all the Pins are in position.

Erection of Stair Form

Stair Form Installation – 1

Staircase mid-wall panels and lower wall form should be first installed.  Before installation of the panels can begin, the opposing wallform panels must be in place with tie bars installed.

Mid-wall and lower-wall panels can then be installed as per typical procedure.

 

 

 

Stair Form Installation – 2

Then the Runner and Raiser Side Form should be installed by attaching it to the mid-wall panel and lower wall form panels.

Stair Form Installation – 3

Install Stair Raiser Form. The form is fixed to the Runner and Raiser side form by Pins and Wedges.  Depending on the formwork set, the stair form may also include a runner to form the top of the stair. If runners are included the recommended procedure is to install the riser first then the adjacent runner as you progress up the stairway.

Erection of Slab Form

Slab form Installation – 1

Slab form installation will begin with the Stripping Inside Corners form located on top of the inside wall form panels. As with the wall form panels, it is advisable to begin installation at the inside corners and progress to the center of the wall.  Workers are not to climb up the form using the side rails of the wall panels while installing the slab form panels.

 

 

 

Slab form Installation – 2

Then install the Ledger Panels with Post Head between the Stripping Inside Corner forms as per the design drawing.

In most cases it is advisable to assemble the Ledger Panels on the ground and lift the whole assembly into position as one unit.

Slab form Installation – 3

Slab deck forms will begin at one end of the Ledger Panel installing panels progressively until the other end is reached. In areas where there is one Ledger Panel, simply start at one end of the room and continue to the other side. Ensure ALL pins and wedges are installed at every hole location. Continue until slab deck form is complete.  No workers are allowed on top of the deck panels until all deck panels are secured and guardrail posts are in place.

Erection of Guardrail Post

Installation of Guardrail Post

Guardrail Posts are installed on the Outside Edge Form Panel. Prior to any working activities taking place on the completed slab deck, all Guardrail posts, as well as guardrails, should be installed and secured (by contractor). When working close to the edge of the building, workers should have proper fall arrest protection.

Installation of Catwalk Bracket

For multi-storey buildings, catwalk brackets need to be installed and all guardrails need to be installed and secured (by contractor) prior to working on there.

Fixing Slab Rebar & Installation of Services Equipment

Installation of Slab Rebar

Once the slab form is completed, fixing of slab rebar can be started immediately.

Installation of Services Equipment

After the rebar work is completed, electrical, sanitary and gas fittings can be installed.

All electrical, sanitary and gas conduits should be carefully fixed to the rebar securely to avoid dislocation during concreting.

All electrical boxes should be firmly anchored to the steel mesh, using additional steel bars when necessary.

All electrical boxes should be filled with moist paper and conduits ends covered with plastic wrap to prevent concrete from entering it during concreting.  Do not rely on the Easy Panel face to cover these openings.

Pouring Concrete

Before pouring concrete, make sure all the rebar and services conduits and junction boxes etc. are installed and secured in their correction position.
Also, make sure all EasySet® accessories such as Flat Tie, Aligner, plumbing Brace and Guardrail are properly installed.

Pouring Wall

Start pouring the wall at one of the outside corners and let the concrete run. Use vibrators whenever necessary but remember do not over vibrate and never let the vibrator contact the wall panel.

Pouring Staircase

Usually staircases are located at center of building. It is recommended to pour the walls from one end to the center, then pour half of the staircase, then start pouring the walls from another side towards the center, then complete the rest of the staircase.

Pouring of Slab

Once finished concreting of all vertical members, start pouring the slab concrete, again from the outside to the inside.

It is important to make sure the completed slab is level for the next pour.

After Concreting

Immediately after concreting:
Use water jets to clean the back of all EasySet® Panels to ensure there is no concrete accumulated on the horizontal faces and around the Pin & Wedge.
Also, clean the bottom of all wall panels to avoid concrete build-up, which will make the panels difficult to strip and cause damage to the panel.

Stripping EasySet™ Panels

Before starting the stripping process, make sure the finished concrete attained the strength as approved by the Engineer.

Removal of Aligner and Plumbing Brace

Start the stripping process by removing all the Box Aligners, Aligner Support Bracket and Plumbing Braces.

Stripping of Opening Forms

All the Panels forming the openings are completed with the stripping slope. The panels can be easily taken out after removing all the Pins and Wedges connecting it.

Put the opening forms aside in their correct order so that they can be easily identified when required to use them again.

 

Stripping Wall Panels

Locate the Stripping panel and always start stripping from there. 

Remove the Pin and Wedge connected to the Stripping Panel using the correct hand tool and following the correct method.

Once all the connecting Pins and Wedges are removed, for the sloping edges at the stripping panel, it should be taken out easily. If found necessary, use correct hand tools to facilitate the operation.

Once the first panel in the run is removed, following the panels should be easy, coming out following the same procedure.

Stripping EasySet® Panels

Install Tie Filler (Bench) at all Tie Bars that support the Starter Panels immediately after removal of inside form.

Tie Bar Supporting Starter Panel

For Tie Bars supporting Starter Panels, they should be fixed in position by installing Packers with Pin & Wedge immediately after stripping of the inside form. 

Removal of Flat Tie

Removal of Flat Tie

Once the panels are removed, the Flat Ties can be easily removed by proper tools using the proper method.

If the Flat Tie is required for other uses, such as fixing the Catwalk Bracket or Starter Panel, Flat Tie Filler (Bench) should be installed immediately to keep the tie in position.

Preparation of Flat Tie

After the Flat Tie is removed from the poured concrete, carry out a visual inspection and make sure the tie is suitable for the next use.

Clean the tie with a scraper if any concrete is stuck on it, apply a releasing agent to it if necessary. 

Wrap the tie with a polyethylene glove cover or any alternative product.

The tie is now ready for its next use.

Removal of Slab Form

EasySet™ Post Head system allows the stripping of slab panels without disturbing the Support Post. This permits early stripping, thus speeding up the process and saves equipment .

Stripping Slab Form

EasySet™ slab form comes with Stripping Panels which make stripping an easy job.

Always start stripping at the Stripping Panels. Locate the Stripping Panels from the drawing before starting any stripping work. 

Once the first panel is removed, following the same procedure, the rest of the panels can be stripped easily.

After the slab soffit panels are removed, the corner pieces and ledger panels can come down.

Panel Cleaning

EasySet™ Post Head system allows the stripping of slab panels without disturbing the Support Post. This permit early stripping, thus speeding up the process and saves equipment.

Clean Panels

Clean all dirt stuck to panel surfaces or edges with a scraper or fine steel wool pad. Do not apply excessive force, for it will damage the aluminum surface. If there are stains that cannot come out, use generic products provided by concrete chemical specialists and follow their instruction.

Clean panels by spraying fresh water and carry out visual check for any damage of panel. Report immediately if any structural damage occurred; the panel should be put aside for further investigation.

Let panel dry completely before applying a thin layer of form releasing agent to their surface.

The panel’s now is ready for it’s next use.