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Building & Construction - Shuttering

Building & Construction - Shuttering
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  For lightweight waffle floors spanning in two directions Waffle type floors can provide considerable economies in construction by a reduction in concrete and steel as reduction in weight and therefore a reduction in the support and foundation work. The main reinforcement in the rib runs in two directions in order to resist the transverse and longitudinal bending moments in the panel.

FRP Moulds have been specially designed for the construction of waffle floors and may be carried on the minimum of support work.

Although the ribs produced by these moulds are at equal centers in both directions, the moulds themselves are square in plan. They are designed to be used with a quick-strip support system, enabling the moulds and 50% of the support work to be removed 2 or 3 days after casting concrete.

This unique feature gives a faster turnaround of equipment, reducing hire charges and site storage space.

FRP Moulds are contact moulded F.R.P., light in weight, easy to handle and form a waffle floor with a module of 900 to 1500mm C to C.

They are produced in four sizes ranging from 900 to 1500mm and depths from 300 to 600mm. Adjusting the depths of the concrete over the top of the mould can vary the total depth of the floor cast upon them.

KAE Engineers offers FRP Moulds for sale and on turnkey basis can arrange for their erection and support on contract basis.

Architectural considerations
FRP Moulds are smooth and impart a good finish where they are in contact with the concrete. Where the architect wishes to leave the underside of the floor exposed he should be aware that the normal as-struck finish may not be considered "fair faced". The soffit of the floor formed by the FRP Moulds is smooth but the joints between adjacent moulds and between moulds and their bearers are visible.

For industrial structures such as warehouses, car parks,commercial building,Institusional building, multistorey residential flats etc., the "as-struck" soffit of an FRP Mould floor should be quite acceptable but where emphasis is laid upon the appearance of the underside, special care must be taken in staging & casting and finishing treatment will probably be necessary.

The architect should consider whether any particular detail should be used at the head or foot of the partition and walls to allow for the movement of the floor under load. During construction the floor may be erected with an upward chamber, but the chamber cannot prevent deflection taking place under load. This aspect of the design needs particular attention with floors of long span.

Advantages
The floors are designed to span in two directions and having ribs on each direction. They offer the most economical form of long span floor construction.

The deeper the floor the greater the saving in materials and weight.

Since the floor is an in situ construction it offers the engineer the best opportunity to use the floors as an integral part of the structure.

FRP Moulds have the following advantages over other moulds:

1. The deformation of the surface under pressure of the concrete is greatly reduced by the inclusion, on the inner face, of stiffening ribs and by the uniform thickness of the walls of the mould obtained by the contact moulding process.

2. The shape has been designed to allow a "quick-strip" method of construction, so that fewer moulds need be stored on site and more rapid re-use can be obtained.

3. The floors can remain propped while the moulds are removed and erected elsewhere in the structure.

4. The moulds are very accurately made (plus or minus 1% at 25C) and are intended to fit into metric modular dimensions.

5. Of the light material, two men can carry mould easily and they are easy to place in position. During stripping the mould can be supported by one man.

6. KAE Engineers maintain the stock of many mother moulds in all sizes from which large quantity of FRP Moulds can be produced in short periods. We also hold large quantity of new and used FRP Moulds available for immediate despatch.

Mould Characteristics
The mould are available in thee plan sizes and varying depths as shown in the table below. A uniform rib size can be obtained by staging the mould on equal distances in two directions. The total depth of the floor is dependent upon the thickness of the topping over the crown of the mould, which is designed to support up to 150mm of wet concrete.

The moulds are intended to be striped from concrete by air within three days of casting and the best results would be obtained under these conditions. The boss is provided in the center of the lower surface of the crown of the mould receives a standard Schraeder nozzle for an air line. A short blast of air is sufficient to break the bond between the mould and the concrete allowing the mould to be drawn freely from the floor. Air release is often unnecessary with the smaller depths of FRP Moulds.
 
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