15105BearGuideFIN-2012-04-27sfa - QUARK 8 …

1 Construction GuideThe Pre-Finished, Stay-in-PlaceConcrete Wall FormworkVersion Building Technologies Inc. is an inno-vative quality-driven building technologies compa-ny. Since the introductionof CONFORM (formerlyRoyal Building SystemsTM) in 1992, the producthas received global recognitionfor its approachin providing an innovative solution to the con-struction a patented polymer-based stay-in-place formwork for concrete walls. The extrudedcomponentsslide and interconnect together to cre-ate a concrete formwork. The result is perma-nent, attractive, andpre-finished concrete wallsthat can be easily constructed in any climate. CONFORM is composed of numerous modularcomponents for 100mm, 150mm and 200mm (4 , 6 and 8 ) concrete walls that can be assem-bled to suit any wall layout, whether you are build-ing a vehicle wash, an agricultural facility or alarge industrial no painting, and resistsultra-violet radiation.

2 The polymer components will notdecay or deteriorate over a lifespan that can bemeasured in decades. Furthermore, CONFORMis highly durable, virtually maintenance free,impervious to weather, and energy manufactured using R3 extrusiontechnology as an environmentally friendly prod-uct. The polymer components contain over 55%recycled content and are recyclable, energy effi-cient,mold and mildew resistant and complete design flexibility andan innovative building product that is easy tomaintain, friendly to the environment, and builtto last. Whether you area developer, contractor,architect, engineer, or designeryou can find attrac-tive and cost effective solutions for your next proj-ect with CONFORM. Copyright 2012 Nuform Building Technologies rights reserved. No part of this publication may be reproduced in any form or by any means without written permission from Nuform Building Technologies other products, names and services are trademarks or registered trademarks of their respective Solutions for a Better Introduction.

3 12. Project Organization .. General .. Planning .. Individual Components .. Pre- assembled Wall Sections ..43. Wall Materials .. CONFORM Components .. Concrete Mix .. Steel Reinforcing Bars .. Fasteners, Bracing, Others ..94. Equipment .. Hand Tools .. Power Tools .. Erection Equipment .. Construction Equipment ..105. Safety .. Workmen .. Weather Conditions ..116. Site Preparations .. Site Grading and Access .. Storage of Material .. Foundations .. Wall Dowels .. Underground Services .. Electrical Power .. Water Supply ..147. Wall Erection - General .. Orientation .. Layout .. Erection Procedure .. Wall Length .. Starters .. Doors, Windows, Openings .. Electrical ..208. Wall Erection- Individual Components .. Erection Procedure .. Erection Sequence ..219. Wall Erection- Pre- assembled Wall Sections .. Erection Procedure .. Individual Components .. Erection Sequence.

4 Doors, Windows, Openings ..2710. Placement of Steel Reinforcing Bars .. Reinforcing Bars .. Sequence ..3011. Bracing .. of Wall .. of Wall .. of Wall .. , Corners, Intersections .. Openings ..3612. Concrete Placement .. Pour .. Measures ..4013. Finishing .. Band ..4214. CONFORM Repair .. and Tools Required .. Surface Damage - Patching Holes .. Surface Damage - Patching Cracks or Butt Joints ..4615. Alternate Wall Finishes .. Stucco .. - Direct Apply Method .. - EIFS System Method .. Graphics .. and Siding .. Board ..53 Appendix A - Construction Bulletins ..53 Appendix B - Bracing for CONFORM .. General .. Bracing Design Guidelines .. Single Bracing .. Double Bracing .. Vertical Bracing at Corners, I-Intersections and Ends .. Bracing at Openings .. Bracing at Piers, Columns and Double Walls . Bracing Example ..68 This Construction Guide has been prepared by NuformBuilding Technologies Inc.

5 (NUFORM ) to assist contractors,engineers and architects in the understanding of the con-struction procedures for bearing walls using CONFORM . Itis a part of our continuing effort to provide current and prac-tical information to the users of Construction Guideprovides information on the fol-lowing aspects of construction using CONFORM: Project Organization Wall Materials Equipment Safety Site Preparation Wall Erection - General Wall Erection - Individual components Wall Erection - Pre- assembled Wall Sections Placement of Steel Reinforcing Bars Bracing Concrete Placement Finishing Repair Alternate FinishesIn addition to this Construction Guide, the following guidesare also available to assist in designing and building yourprojects using CONFORM: Technical Guide Engineering GuideAlthough every effort has been made to ensure that all theinformation provided in the Construction Guide is factualand consistent with good construction practice, NUFORM does not assume any liability for errors or oversights result-ing from the use of information contained in this making use of the information provided in theseguides assumes all liabilityarising from such use.

6 The suggested suppliers for various products described inthis guide are for information purposes, only. NUFORM does not warrant or guarantee the performance the per-formance of any of the products. Please consult each sup-plier for specific information regarding their products, andrecommended application and warranty, if any. 1. Bearing Wall Project11. CONFORM consists of extruded rigid polymer compo-nents that serve as a stay-in-place formwork for concretewalls including bearing walls, non-bearing walls, shearwalls, retaining walls and foundation walls. The extrudedcomponents slide and interconnect together to create aconcrete formwork that remains in place after the concreteis poured and cured. Four different CONFORM types areavailable, as identified in the following Table : Table : CONFORM2. The time to erect and brace CONFORM depends on thespecific project. General guidelines are provided in and 3.

7 The time to place the concrete in CONFORM dependson the placement method. With a concrete pump, an averageof 225 m3or (300 yd3) can be placed in a 10 hour day ( m3(30 yd3) per hour). However, this can vary significantlydepending on the project. 1. The planning and preparation of the site, materials, equip-mentandrelated trades varies with each project and cangreatly affect the erection and economy of It cannot be overstated how important it is to haveall activities prepared and coordinated prior to startingerection of CONFORM. CONFORMis based on a conceptof sliding componentstogether, which is so simple andeasy that any difficulties with any other aspect of thework can greatly hamper and delay the CONFORM erec-tion. Only if all activities are pre-planned and well organ-ized can CONFORM be erected in an efficient and eco-nomical One of the major construction decisions regarding theplanning and organization is whether to erect the CON-FORM components individually or in pre- assembled wallsections.

8 This affects all aspects of the project: the CON-FORM drawings, shipping, off-loading, storage, bracing,erection methods, construction schedule and project The decision to ship and erect CONFORM using indi-vidual components or pre- assembled wall sections is basedon the project size, the wall height and the availability ofconstruction equipment. The following is a general guide inselecting the appropriate erection method: Table : CONFORM Erection General2. Project OrganizationCONFORMCF4CF6CF8CF8iConcrete Core95 mm( ")145 mm( ")195 mm( ")139 mm( ") "(54 mm)Overall(Nominal)100 mm(4")150 mm(6")200 mm(8")200 mm(8")Wall ThicknessCF4 CF4 walls are erected individually and not pre- assembled , except for headers and sills and forwalls of selected custom projectsCF6 &CF8 CF6 and CF8 walls less than 4300 mm (14')high are erected individually except for walls ofunique projects and for headers and sills.

9 Pre- assembled walls sections are used for wallsover 4300 mm (14') highCF8i CF8i walls less than 3000 mm (10') high are erected individually and are not pre-assembledexcept for walls of unique projects and for head-ers and sills. Pre- assembled wall sections are used for wallsover 3000 mm (10') high(1)The CF8i components are pre-insulated with 54 mm ( ") of polyurethane insulation cavity is on the exterior side of the wall and protected from the interior with the non-combustible concrete Also, the decision to ship and erect CONFORM usingindividual components or pre- assembled wall sections isbased on the site storage, the amount of double handling,the erectionsequence and the erection costs. For individualcomponents, the labor costs for off-loading, sorting, han-dling and erection are increased. For pre- assembled wallsections, the cost for shipping and equipment rentals Once the erection method is finalized, the erectionsequence must be determined.

10 The erection sequenceaffects the shipping, off-loading, material handling, constructionmethods and construction schedule. The erectionsequence is selected, for each project, to minimize the con-struction time and material handling based on the site con-ditions, bracing requirements,reinforcing bar spacing andthe available Typically, individual components are used for small proj-ectsthat are not more than 900 m2(10,000 sq. ft.), wherewall heights are less than m (14') or where the use of aboom truck, scissors lift and telescopic boom lift is not Components that are shipped individually require lesstrucking space since the components can be stacked tight-ly to completely fill a closed trailer or container. The individ-ual CONFORM components are manually loaded andunloaded from the closed trailer. Generally, it takes approxi-mately 4 hoursfor 6 men to unload a 48' trailer or a 40' con-tainer.