Welcome to the Forsa formula, the most advanced construction system for concrete housing that integrates solutions and assessment for proven mechanized construction. It is based on different types of panels or forms that are easy to handle and long lasting which permits fast and safe construction adaptable to many different designs.
Forsa is a well – established Colombian Company based on excellence, innovation, technology and economy.
and continual follow-up until the end of the job to satisfy your needs.
Since 1995 we have offered the best quality guarantees with practical and efficient solutions according to the varied and changing needs of the construction industry.
Advance with our successful Forsa formula like more than 150 construction leaders in more than 20 countries in Latin America and Spain with more than 500,000 houses built.
The success of Forsa lays on it´s deep committment based on loyalty and mangerial style that develops close ties with its customers, employees and stockholders. Loyalty, motivation,learning and shared values and interests are the essential elements of Forsa. Each member of our business strives to improve the efficiency of the product we manufacture while always thinking about increasing the productivity of our customers. Forsa offers a complete integrated system made up of different kinds of panels, tools, accessories, technical assessment
THE FORSA FORMULA • Multiply your productivity. • Increase the number of houses built monthly. • Reduce labor costs. • Decrease waste of materials on the job site.
Multiply your productivity We work with you from the project planning stage assessing interior dimensions of the housing with the purpose of adapting them for the highest number of standard rooms to the Forsa system. In this way the efficiency, productivity and profitability of your project is increased. Forsa offers more productivity to your job making it faster, safer and more economic. Forsa panels are designed to be used more than 1,500 times with proper maintainence generating great economy of scale. Increase the number of houses built monthly Using the Forsa system, execution time for housing is considerably reduced (less than half) compared to traditional systems. This is done with daily pouring cycles for obtaining a house a day. Forsa offers more productivity to your job making it faster, safer and more economic. Reduce labor costs The Forsa system is very simple to use and with few accessories. Personnel to move the panels require a minimum of training and without the need for cranes. The light weight of Forsa panels makes set-up and take down easy since only one man can hold a panel.
Decrease waste of material on the job site With the traditional cinderblock system the wall is absorbent and a final finish must be applied. With concrete, a thin film (3mm) is applied directly to the surface saving finishing costs. SOLID FAMILIES, SOLID AND SAFE HOUSING The Forsa construction system allows simultaneous pouring of concrete for walls, roofs and ends of housing units that is safe and anti-seismic which is widely used and proven throughout the world. This is to say that in the event of an earthquake, tremor or hurricane not only is your investment safe but also your most important asset, your family, will have better protection. Besides the seismic and safety advantages, concrete housing is delivered completely finished. The Forsa construction system permits the progressive development of housing expansion according to your possibilities. From the smallest house to the highest building, it is constructed better with the Forsa formula.
STANDARD PANEL Structural Walls Panels
Transversal supports installed every 30 cm ensure panels being used do not warp under pressure.
The bushings are steel elements used on the lateral profiles of the panels. They are installed as a protective barrier of the perforations for assembly. The 3 perforations give versatility for using different tiers as well as far the installation of the aligners. Its design which hugs the lateral frame protects the profile and the functioning of the angle aligner.
All comers of the panels are re-enforced with triangles which act as supports for the panels.
The panels are made of extruded aluminum profiles of alloys 6061 and 6261, templet 6 which are joined by a tongue and groove welded on with aluminum solder 5356.
STANDARD PANEL Laminated Panel
Aluminum-Wood Panel
Re-enforced Vertical For wider walls a reenforced vertical center panel is installed that guarantees stability resulting in straighter walls.
Structure
Structure
The aluminum lamination alignment 5052 – H38 is highly resistant to warping and is assembled in a smooth aluminum frame.
The wood lamination has a density of 0.5 gr/cm3 and spacing of 15 mm and is assembled to a smooth aluminum frame.
The panel is designed to connect with a grooved panel and both use the same accessories. The height of the panels is up to 2.70 meters and its weigtht is the same as the grooved panels.
This panel can connect perfectly to grooved or laminated panels. The useful life of the wood is estimated at 150 uses but asembly method permits easy changing of the wood portion. The standard panel is 60 x 2.40 and weighs only 25 kilos which makes it light and easy to handle.
STANDARD PANEL Walls 10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
90
5.13 5.41 5.68 5.95 6.22 7.56 8.44 9.09 10.05 10.70 11.56 12.53 13.57 14.22 15.18 15.83 16.90
120
6.84 7.20 7.55 7.91 8.27 10.06 11.02 11.88 13.17 14.03 15.11 16.39 17.64 18.51 19.79 20.65 21.94
150
8.55 8.99 9.43 9.87 10.31 12.55 13.60 14.68 16.28 17.36 18.65 20.25 21.72 22.80 24.40 25.48 26.98
180
10.25 10.78 11.31 11.83 12.36 15.05 16.18 17.47 19.40 20.69 22.19 24.12 25.80 27.09 29.02 30.31 32.02
210
11.96 12.57 13.18 13.79 14.40 17.54 18.76 20.26 22.51 24.02 25.73 27.98 29.88 31.38 33.63 35.13 37.06
240
13.67 14.36 15.06 15.75 16.45 20.04 21.34 23.06 25.63 27.34 29.27 31.84 33.95 35.67 38.24 39.96 42.10
Weight (kg)
Height (cm)
Width (cm)
We handle standard panels with widths between 60 and 90 cm with heights between 210 and 240 cm. However, depending on the design required we can handle widths from 10 to 90 cm and heights from 30 to 300 cm in different combinations.
Width of the lateral frame: 54 mm Contact face is 1/8� thickness
100 - 900 mm
Correct installation, handling and maintenance conforming with Forsa’s recommendations ensures more than 1200 uses.
3.0 mts
300 mm 2.7 mts
2.4 mts 2.1 mts 1.8 mts 1.5 mts
150 mm
300 mm 300 mm 300 mm 300 mm 300 mm 300 mm 300 mm
1.2 mts 0.9 mts 0.6 mts
300 mm 150 mm
WALL SYSTEM Exterior Angle Aluminum profile used to make exterior up to 90 degrees with wall panels corner for internal wall.
Corners for Internal Wall Aluminum element used to make interior corners up to 90 degrees with wall panels. Offered in widths of 10 x10 cm and 15 X 15 cm according to the project layout.
To facilitate the unpacking of the wall panels and the juncture of the panels the total height of the corner form is divided into two sections: the panel for the lower part can be unpacked once the wall panels are removed to be used next. The higher part is taken out after removing the wall panel joint.
WALL SYSTEM Cross Corner
Wall Corner
The cross ensemble is a made up of four wall corners. It is connected with clips and stays like all the other panels.
“L” Corner The ensemble or “L” corner is made up of four pieces:
Exterior Angle
Wall Corner
• A wall corner. • An exterior angle. • Two panels of equal width to the thickness of the wall plus the wall corner. These pieces are connected by clips and stays.
“T” Corner The “T” ensemble is always made up of three pieces: • Two wall corners. • A wall panel of equal width to the thickness of the wall plus 2 EQM. These pieces are connected with clips and stays. • The fronts and exterior sections of housing can be made up in two options: with CAP panels plus standard wall panels or with high panels.
Wall Corner
WALL SYSTEM The fronts and exterior sections of housing can be made up in two options: with CAP panels plus standard wall panels or with high panels.
CAP Panels
High Panels
Serves to compliment the standard panels to finish the total height of the exterior wall holding the thickness of the total panel. The advantage of using this type of configuration lays in the utilization of the standard panel which can be easily adapted to future projects.
The high panel covers the total height of the exterior wall plus the determined thickness of the total panel. Its advantage lays in that fewer number of pieces are handled compared to the CAP resulting in better performance.
Slab Panel
Tie
Wall Panels
Floor
Wall-slab Union height
Wall – Slab Union
Wall thickness
Tie Wall Panels
Free Height= Wall panel height + Wall – Slab Union
Wall thickness
Wall thickness
High wall juncture
High Wall Panel
Standard Wall Panel of 2.10 to 2.40 meters
Wall – Slab Union
Wall thickness
Free Height= Wall panel height + Wall – Slab Union
CAP
Slab Panel
Floor
WALL SYSTEM Panels for Back End (Culatas) These determine the shape, height and angle of inclination of the wall. The panels for back ends are connected to wall panels with a staple pin in the lower edges and clips and stays on the lateral edges.
Wall Top Aluminum profile of 3/8� thickness that is used to close the wall.
> 12
It is assembled the same way as the panels (with clips and stays) or at times, if the configuration is not standard, pin staples can be used. For walls with a thickness greater than 12 cm, the wall top is re-enforced with angle profiles or a tubular profile.
When the design requires wall recesses or doorways, it is necessary to use the wall top with a mold. These are made with aluminum profiles 6061 and should be re-enforced and connected to the wall panels with clips and stays or when necessary pin staples.
10
< 12
WALL SYSTEM Construction in series has to be clearly defined on how to make the transition from one housing unit to another. FORSA delivers key panels and the necessary accessories to do continuous set-ups in whichever of two cases: flat foundations or in tiers.
Double Wall
Angle Stays Slab Panel Wall thickness
Wall Thickness
Angle Stay
Expansion juncture (polystyrene) Double wall tie Wall Panels
Wall panel height
Wall â&#x20AC;&#x201C; Slab Union
Free Height= Wall panel height + wall slab juncture
Wall â&#x20AC;&#x201C; Slab union height
When there are enlarged double walls, special ties are used that are fastened to the wall constructed the previous day, with angle stays.
Floor
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WALL SYSTEM Enlarged Double Walls and Tiers Roof panel
The FORSA wall system permits the wall panels to be used for constructing housing units in tiers which can be between one house and another or within the same housing unit.
Wall thickness Connector height wall
Polystyrene or other material Wall panel height
Wall Thickness
Angle Stay Tie
Wall Panels Floor
Retaining Stay
Free Height= Wall panel height + wall slab juncture
Wall border
Floor
The panels have slots in three perforations of the bushing to permit their use in tiers in multiples of 5 cm, except those tiers between one housing unit and another of 15, 45, 75 and 105 cm.
Retaining Stay Accessory used for connecting the panel to the lower part, when there are tiers up to 50 cm. For higher tiers they are to be used with a construction jack.
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WALL SYSTEM Adjustment Filler
Adjustment Profile
It is used as an adjustment element or for general usage when the spaces are not multiples of 5 cm. In the event that the same work team is building different housing units, they can be included in changes of wall thickness.
In the event that it is necessary to make quick adjustments on the job, the adjustment profile can be used. This is an aluminum profile with an edge for placing a wood board of 1/2â&#x20AC;? thickness with which panels of various widths can be made up to a maximum of 30 cm. Variable
1 cm 2 cm
Max. 30 cm
15 cm 30 cm
30 cm
30 cm
5 cm 30 cm
30 cm
30 cm 15 cm
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STANDARD PANEL Slabs (panels) The panels are made of extruded aluminum profiles of alloys 6061 and 6261 templet 6 which are joined by a tongue and groove between themselves with aluminum weld 5356. Reenforced transversals guarantee better performance against warping of panel in service. The lateral profile uses grovees and is perforated for the assembly of one panel to another. This grooved profile permits the use of these panels in different positions fastened with pin staples. Standard panels used are 90 x 120 cm. However depending on the required design lengths and widths from 10 to 90 can be used in different combinations. Width of lateral frame: 54mm. Contact face of 1/8â&#x20AC;? thickness.
Height (cm)
Width (cm)
14
10 20 30 40 50 60 70 80 90
30
40
50
60
70
80
90
100
110
120
130
1.43 1.63 1.84 2.65 3.08 3.54 4.94 5.77 5.69
1.85 2.05 2.26 3.28 3.80 4.35 6.18 7.24 7.05
2.36 2.69 3.02 4.33 5.05 5.82 8.15 9.56 9.39
2.78 3.11 3.44 4.97 5.77 6.63 9.39 11.03 10.76
3.29 3.75 4.21 5.70 6.70 7.79 10.73 12.72 12.47
3.71 4.17 4.63 6.34 7.42 8.60 11.98 14.19 13.84
4.13 4.59 5.05 6.98 8.14 9.42 13.22 15.66 15.20
4.55 5.01 5.47 7.61 8.86 10.23 14.47 17.14 16.57
5.07 5.65 6.23 8.35 9.80 11.38 15.81 18.83 18.28
5.49 6.07 6.65 8.98 10.52 12.20 17.05 20.30 19.65
5.91 6.49 7.07 9.62 11.24 13.01 18.30 21.77 21.02
Weight (kg)
The correct installation, handling and maintenance in accordance with the recommendations of FORSA assure the panels can be used more than 1200 times.
SLABS (PANELS) SYSTEM Union Slab Wall Smooth - Border
Its design in the form of a straight angle or border results in very well defined corners. They can be made in heights of: 5 cm - 10 cm - 15 cm - 20 cm - 30 cm
Wall-Slab Union height
Wall-Slab Union Wall-Slab Union
Wall thickness
Tie
Wall Panels
Free Height= Wall panel height + Wall-Slab Union height
These pieces re-enforce all the corners making them very resistant to severe work conditions that are undergone. They should be periodically checked every 250 uses.
Espesor Losa
Standard Wall Panel of 2.10 to 2.40 meters
An aluminum piece made of a 6061 profile that serves as a connector between the wall panel and slab to make a FORSA solid front.
Slab Panel
Floor
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SLABS (PANELS) SYSTEM Flat Wall Slab Union The connector between walls and slab is done using the Connector Plane which is a piece of aluminum 10 or 15 cm. It supports the upper section of the wall panel. It allows a free height between the floor and slab equal to height of the panel plus the thickness of a 7 mm Flat Wall Slab Union.
The support of the Connector Plane to the wall panel is with a clip and stay.
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Slanted Connector This piece functions as a connector between wall panels and slanted roofs. Every slanted connector is made at the required angle to form slanted surfaces.
SLAB SUPPORT SYSTEM The wall systems needs for support and propping up two elements that work together for good performances of the panels during the curing time of the concrete. These elements are: an aluminum profile and a point leveler of which FORSA has two points.
‘I’ Beam
‘U’ 10 Beam
This first option combines the use of an ‘I’ beam made of aluminum and which is 13.5 cm high. It works together with the point leveler exposing a face to the panel of 20 X 10 cm. This form permits the adjustments of the ‘I’ beam to ensure the wall panel is level.
The use of the 10 cm ‘U’ beam that is 5.4 cm high together with the point leveler 2005 is the second FORSA option as a system for propping up the wall panels. The advantages of this combination against the ‘I’ beam is that it is easier to dismantle the panels and allows for a closer adjustment for a level wall in general.
Point Leveler 2004
Point Leveler 2005
Made of high resistant steel, it serves as the connecting element for the jacks on the right side of the wall. This is to ensure that the wall panel stays propped up correctly from the first day to the dismantling two days later. FORSA delivers three sets.
This is an accessory made of carbon steel and serves the same function as the point leveler 2004.
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SLAB SUPPORT SYSTEM Point Panel This element closes the wall panel which varies between 10 and 30 cm in width and in lengths according to the design. The placement of the jacks is done directly on the point panel positioned on points soldered to the piece. To ensure the reach to the panel, FORSA supplies three sets of the point panel. The use of point levelers is not required.
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Base for the Jack This accessory serves as a support at the juncture of four panels.
Panels for Holding the Wall Slabs
Panels for Domes
This is a combination of panels and supports to firmly hold the walls. They are made in different heights and lengths in agreement with layout and design required. They are fastened directly to the ground with construction bars 5/8â&#x20AC;&#x153; diameter.
The architectural designs placed over the panel are done with a combination of aluminum panels and angle corners which are strengthened with a steel angular structure.
They can be made in heights of 10 cm or more. They are held by a clip and stay.
The dome panels are designed together with an inclined angle to facilitate their dismantling.
When the domes stay inserted on the panel, angle molds for dismantling are included. These are fastened with screws directly to the wall panels.
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FASTENING ACCESSORIES The Accessories for fastening the panels for a wall system are made highly resistant steel thermically treated for heavy-duty work loads. The wall panels are supplied with arrow pins or staple locks. These are accessories that are fixed and installed on panels from 45 cm to 90 cm of width.
Arrow Pin Together with a stay ensures the fastening of the panels. This galvanized protective barrier is long-lasting.
Staple-lock This accessory in the shape of a staple permits the fastening between panels without the need of additional accessories. This diminishes on the job losses. This galvanized protective barrier is long-lasting.
Pins This accessory together with a stay serves to fasten the panels between themselves along with angles, wall corners and wall tops as well as the basic fastening of wall panels. They also work as a complementary accessory for fastening where there are fillers and adjustment profiles.
Plane Pin
Medium Pin 20
Short Pin
Long Pin
FASTENING ACCESSORIES Pin Staple Accessory used for the fastening of grooved rails with perforated rails such as: • Trim panels connected to the wall. • Wall panels connected to the trim panels. • Wall tops connected to wall panels. • Wall panels between themselves.
Stays These work together with the clips and arrow, pins. Its curved shape permits easy insertion and lessens the risk of damage to the panel. Because they are subjected to high stress loads, we recommend they be checked every 500 uses to verify their conditions. If they are excessively worm, they should be changed.
Ties This accessory of carbon steel to fasten and separate panels to determine the thickness of the mass. They are installed at wall junctures of panels of any height every 30 cm.
2.4 mts 2.1 mts
Because of their demanding function, it is recommended that they be checked and changed every 250 uses.
1.8 mts 1.5 mts 1.2 mts
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BASICS ACCESSORIES Maintaining the horizontal alignment of the wall panels achieved with the use of these accessories especially the angle aligners ¼ “ x 2” x 2” (FORSA does not supply these). They are installed horizontally every 90 cm and depending on the height of the wall 2 or 3 lines of point aligners should be used.
Horizontal Point Aligner This design is used between wall panels with an arrow pin or clip and stay.
Point Aligner Staple Lock This design is used with panels connected with staple lock.
Vertical Point Aligner The vertical point aligner is used align vertically the front between wall panels and the end and is required because of the height. They are fastened to the panels with a clip and stay.
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ALIGNMENT ACCESSORIES Tensor for Doorways and Windows
Aligners for Caps- Losa Alineador Muro
The perfect size and placement of doorways and windows is guaranteed with the use of these tensors. In the case of doorway where there is no frame then two height tensors should be used. Its screw-and-bolt design permits the opening and closing between walls for variations up to 2 cm.
Its function is to guarantee that the Cap is vertical the safety of a worker using a lifeline. It can be used to complement wall supports that are in tiers or not.
Wall Tensors This assures the panelâ&#x20AC;&#x2122;s angle when it is not solid front. Its design for extreme pivoting assures the walls position to the floor.
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SUPPORT ACCESSORIES Exterior Scaffold Scaffolds are in general support accessories that besides serving as an exterior wall platform for the ladders also position and support upper floors.
Wall Panel Cured concrete Wall Phase 2
Wall thickness
Wall or end juncture
Angle 2” X ¼” of thickness
FORSA supplies 2 sets of perimeter scaffolds used for setting up the first and second day. Tie
Wall Panel
angle stay
Exterior scaffold
Cured concrete wall Phase 1
Floor
The supervisor must assure the correct use of these platforms which are correctly installed over two ties with respective clips and stays. At the same time the installation of life-lines should be checked to guarantee the safety of the workers on them.
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SUPPORT ACCESSORIES Upper Scaffold
End Scaffolds
It is used to make an access platform on upper floor. It is fastened to the wall of the lower section with an adjustable screw.
It is installed over wall panels to serve as platforms for installing upper sides, ends and borders.
Adjustable screw
Doorway Scaffold
Upper Support
Its design permits to be installed over doorways or beams greater than 15 cm to make an exterior access platform. It is recommended that it be used for only two story constructions.
Serves as a support element up to 60 cm.
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OTHER SYSTEM Collar System Panels with runners Ceiling spacer
Juncture smooth wall and ceiling
Standard 2.10 panel
Wall spacer
Tie
Wall panel
Sipport 25 cm high Floor
This system guarantees good leveling and alignment of the panels and besides a quick take-down. This consists of panels that are called COLLARS and are 20 cm. high and with porforations for installing 2 ties and an angle in the lower part for easy dis-assembly.
Step 3 Install each of the wall panels above the collars and complete all the walls.
Step 4 Later, install the ceiling junctures as required. SETTING-UP PROCESS Step 1 Install the collar around the perimeter of the walls of the house tying them together with a double tie to ensure they will not move.
Step 2 Once the collars are aligned and levelled install the wall corners.
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Step 5 For the second floor, move the collar 5 cm from the first floor so that the connection is more precise.
THE GANG SYSTEM Panel Clamp Industrial Contractors are always asking for ways to improve their time on the job. For these contractors long walls are very important. FORSA has come up with a system to join several panels in series to form a great panel. Once the concrete has been poured the panel can be removed quickly with a crane for re-use. This system permits the removal of joined panels of lengths up to 4.80 meters using panels of 2.10, 2.40, 2.70 and 3.00 meters of height.
The fastening of two panels with adaptors can be done using pins, conventional clips or bolts. For the wall separators quick release screws held in place with lock nut can be used. Two aligners both upper and lower should be used to ensure the walls are level and do not warp. These aligners are held in place with high resistant steel bolts.
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ALUMINUM BEAM SYSTEM
The aluminum beam is designed as a structural member for the concrete pouring of walls and large floors for big areas with an irregular distribution of beams, columns and woodwork. Our beam takes into account three factors that are necessary for construction success: • High productivity • Versatility • Safety
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OTHER SYSTEMS Thermic Isolation in Walls
Floors Over Cinderblock Walls
FORSA uses the following system when thermic isolation is required: STEP 1: verify the position of all re-enforced ironwork and the installation of steel mesh. Then proceed to install wire mesh with bars of 6 mm diameter towards the resistant side of the wall. This mesh will serve to support the column to be placed.
FORSA has designed a system for pouring concrete floors over cinderblock walls. The objective is to facilitate the whole process of construction where time is important.
6 mm mesh This system is based on floor panels supported with transition panels where the base is supported at points around the whole perimeter. STEP 2: After placing the column, install ‘U’ sheetmetal of galvanized steel forming a frame for doors and windows to guarantee measurements. The thickness of the column depends on the thermic grade. ‘U’ sheetmetal of galvanized steel STEP 3: Install the separators of the mesh, the column and the ‘U’ of structural steel to guarantee the separation between the 2 structural wire mesh elements. Finally proceed with the installation of the panels.
It is very important those cinderblock walls are measured off with a lead deadweight. A perfect leveling of the upper cinderblocks is not required because they are already aligned by the poured concrete.
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OTHER SYSTEMS Columns, Beams and Floors
Kinds of Columns
The FORSA system permits the construction of columns, beams and floors combined with the wall panels. All panels are made of aluminum profiles. Assembly accessories are made of high resistant steel that is thermically treated. Columns are formed using panels and angles.
FORSA delivers aluminum transition panels which can handle all the beam pieces. Later the floor system is installed with all its pointwork.
With aluminum panels, FORSA can fabricate all kinds of columns that are square, round or oval shaped. Vertical and horizontal re-enforcement are placed according to the structural design.
And the same system proceeds floor by floor.
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TOOLS Tie Remover This is used to remove ties that are still in the wall after the panels have been already removed. Good performance depends on correct placement in the eye of the tie.
Panel Remover Used to facilitate the removal of wall panels.
Level Bar Used to lift and align one panel with another.
Staple Remover Tool used to remove pin staples and staple locks.
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OTHER PRODUCTS
32
Step Ladder
Ladder
For higher installations, FORSA supplies a step ladder that is stable and workers can trust. Also, its compartments are convenient for soring pins, clips and other accessories.
Reaching the right panel from the floor requires the use of a ladder designed for that height. This ladder is adjustable.
Glove for Ties
Wall and Panel Separators
Made of polyethylene, they are used as a glove cover for different kinds of ties. Its main function is to protect and facilitate the removal of ties ensuring that they can be re-used. This product comes spools containing 250 meters. The spool is 79 cm high.
The Wall and panel separators are used to maintain a constant distance between the wire mesh and the panels. This ensures that the concrete covers the mesh uniformally on both sides. The ‘U’ serves to keep the panels aligned during set-up.
Grease Gun
Emulsion
This tool is for greasing staple locks. Its flexible hose permits the lubrication of all staple locks on the wall panel without taking them out.
‘DESENFOR’ is an emulsion that is applied directly onto the mold to keep concrete from adhering to the aluminum during use. It is delivered in containers holding 208 liters.
Cleaner
Steel Wood Pads
This product is applied on the surface area of the aluminum to remove any encrusted concrete. This can be applied by immersion or by manual spray.
These steel pads are used to clean the panels daily. They remove any concrete residues encrusted from the day before.
STEP BY STEP MORE PRODUCTIVE 1. Cementing
5. Setting up Ceiling
2. Placement of Wire Mesh
6. Placement of Re-enforced Steel Slabs
3. Electrical and Plumbing Installation
7. Pouring of Concrete
4. Setting-up Walls
8. Dis-assembly
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INDISPENSABLE TOOLS Make sure that the following elements and materials are available at the job site for the best performance, handling and cleanliness of the forms. Tools per assembly worker • • • • • • • • •
Claw hammer. Trowel. Wire cutter and pliers. Tape measure. Plastic bucket for transporting pins and wedges. Plastic bucket for transporting staple pins. Plastic bucket to contain release agent liquid. Leather gloves. Safety goggles.
Tools for general use • 3 wheel barrows. • 4 rounded shovels for clean up. • 2 square shovels for clean up. • A heavy duty drill (percussion type). • 2 aluminum bar levels for the roof. • 2 needle vibrators (minimum). • 1 steel pike. • Hacksaws. • 1 saw. • 1 hand 36” shears. • Machete. • Ladders. • Electric drill with bits of 3/16” - 1”. • 4 mixed wrenches of 15/16”. • Plastic material to wrap up the ties (polypropylene 3 mm in thickness).
Cleaning Materials • A permanent supply of sufficient water. • 2 hoses with respective couplings. • Manual fumigating sprayer for applying releasing agent. • Rubber mallets. • Electrical energy supply. • Electrical extensions. • Electrical/gasoline vibrators for concrete. • Mops. • Wire brush. • ACPM (Diesel). • Solvent. • Standard releasing agent (Can be a mixture of motor oil with ACPM). Slab foundation readiness • Contract labor. • Foundations for slabs completely finished. • Steel wire mesh installed. • Electrician and hydraulic personnel contracted. • Guaranteed concrete supply. • Concrete pump and cement mixers. • Angle irons 2 ½ - 2 ½ - ¼ to be used for alignment. • Jacks and pole supports for walls and roofs. • Wooden planks to be used as walkways.
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FORSA RECOMMENDS Before Set-up Apply non-stick oil to all contact faces of the panels with a roller or oily rag to form a complete film.
Always cover the ties with polyethylene foam to facilitate extraction and avoid damage to them.
During Set-up and Disassembly
The panels should be lifted on your shoulders when being moved to be put into place. The panels must not be laid on concrete and never tossed.
Never use the panels as supports, bridges, stairs or any other use different than molding walls or floors. Never stand or walk on the panels.
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FORSA RECOMMENDS After Set-Up Clean the contact face of the panel and the sides to avoid the accumulation of concrete.
Avoid unloading the panels over hard surfaces.
Never use an iron hammer or bar to strike the panels violently. If a panel cannot be easily removed then look for the impediment.
If arrow pins are used as a ladder, this will permanently ruin the life of the panel.
Apply the emulsion to the panels before re-use or storing them.
Store accessories in closed receptacles if not to be used immediately. Carefully stack panels by size and shape.
ยกNever permit concrete to stick to any side of the panel! FORSA RECOMMENDS
Note: All accessories should be properly stored including: hammer, spatula, levelers and buckets for pins and clips.
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PREPARING THE LAND Foundations Mark off the contours of the house. Place the foundation slab forms according to blueprint.
Pour the Foundation Floor Make one final check to ensure accuracy before pouring the concrete.
Remove the surface layer of soil, filling with new material until it is compact and leveled. Use an aluminum level extruded bar and vibrators during the pouring process to obtain the best finished floor surface.
Exactly place the reinforced steel concrete, the starting steel bars and the hydraulic, sanitary and electrical installations. Install the steel wire mesh on top of the foundations.
You should be especially careful in leveling and finishing of the floor to facilitate mounting the FORSA forms. FORSA RECOMMENDS 37
PREPARING THE LAND Placement of the Wire Steel Mesh The first step in erecting the wall forms is to mark off with chalk on top of the slabs the exact position and thickness of the walls. You must assure that the forms will fall in uniform distance from the steel bars coming out of the slabs.
Thickness of the walls: you must mark off 4 lines, 2 internal lines establishing the thickness of the wall and 2 external lines corresponding to the thickness of the forms which is 55 mm. Next, place the steel wire mesh vertically on top of the slab, aligned with the steel bar coming out of the floor. The mesh should be securely fixed to the steel bars with wire. If necessary additional steel reinforcing bars can be added.
When placing the steel wire mesh, make sure that the corners are at the correct angle and not curved. Check the steel wire mesh with a lead drop weight. The ties of the Forsa system start at 15 cm and after go each 30 cm but not along with the ends of the wire mesh.
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Pinning Stakes Along the two internal mark lines, drill a hole every 60 cms to introduce a steel pin along the steel wire mesh; the purpose of these pins is to maintain the correct thickness of the wall and serve as a guide for the FORSA forms, so they are well - aligned. (page 3).
The function of the rivet and plastic separators is at the top of the panel to keep the right width and to serve as a guide that the Forsa panels are well aligned.
PREPARING THE LAND Sanitary and Electrical Installations Install separators to avoid that the steel wire mesh sticks to the wall forms. FORSA offers the plastic dividers for wall that they save time and improve the assembly(montage) (pag. 32). Also they can be made of the work with concretly.
Fill the electrical boxes with moist paper to avoid concrete getting in.
Carefully attach all the electrical boxes, sanitary and gas conduits to avoid that they are moved or twisted during the concrete pouring.
Firmly anchor the electrical boxes, using a steel bar at the base and two vertical forming a â&#x20AC;&#x153;Uâ&#x20AC;? as shown.
After the installation of the steel wire mesh and conduits, make a general check and clean up before starting the erection of the FORSA forms. FORSA RECOMMENDS 39
FORSA WALLS SYSTEM Wall Mounting The FORSA form system for walls is so practical and modular, that its erection can be done in two ways: • Mount the interior forms of the wall first and later the exterior. • Simultaneously mount the exterior and the interior forms. This mounting sequence is recommended by FORSA as more agile, faster and safer.
2
Insert the arrow pin through the holes in the forms. One of FORSA’s innovations is the ARROW PIN, which comes integrated to the form to facilitate joining panels making it faster and more efficient. One of FORSA’s innovations is the ARROW PIN, which comes integrated to the form to facilitate joining panels making it faster and more efficient.
Before starting the erection of the forms verify that they have the releasing agent film coating on the side facing the concrete and that the ties are properly wrapped. FORSA RECOMMENDS
Installation Sequence
1
Begin the installation in the corners of the building aligned with the chalk strip. Fasten the wall corner forms on both sides for stability.
As a final step insert the steel wedges into the arrow pin and other pins slots.
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FORSA WALLS SYSTEM Installation Sequence
3
Place the ties at the extremes of the forms inserting the pins in the tie holes.
The tie acts as a separator permiting the wall to obtain homogeneous thickness and support the pressure of the concrete poured. The FORSA R & D team came up with a practical plastic covering die casted, to replace the wrapping of each tie, saving time and money.
4
After securing the corner mold forms, continue simultaneously assembling the exterior and interior wall forms, repeating steps 1, 2 and 3, until you complete the house.
In joining the forms make sure they are aligned with the chalk lines. If you have to push them, use the special tool provided for that purpose. Closing the wall: at the wall ends, use the extruded aluminum wall seal piece EQM to close them.
Never leave out installing a tie or a pin since this can damage the form due to stress. FORSA RECOMMENDS 41
FORSA WALLS SYSTEM Installation of Caps Fix the â&#x20AC;&#x153;capsâ&#x20AC;? or borders of the slab to the exterior wall panel with a pin staple. The caps are completely above the wall in exteriors.
Window and Door Frames With the FORSA form system, window and door frames stay well defined and completely sealed with the extruded aluminum seal piece, joined to the wall forms with the pins and wedges.
Be sure to install accessories like ties, pins and stays as well as the pin staples that secure the caps to the wall panels.
Once the caps are installed along the contour of the entire wall than install the cap aligners.
To guarantee that windows and doors keep the required measurements place a tensor as indicated in the picture. This fixture must be placed 1/3 of the way from the top in windows, and in the lower 1/3 in doors.
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FORSA WALLS SYSTEM Horizontal Alignment To improve the alignment of the walls, place portable aligners and Steel angle aligners to the internal and external forms.
Insert each portable aligner in the holes of the forms (as shown), creating two horizontal levels, one at the top of the form and the other in the bottom part.
Installation of Slanted Roofs When the project has slanted roofs proceed to install the panels after mounting the wall panels. First set up the alignment scaffolds to facilitate setting up the slanted roofs.
According to the plan, choose each slanted panel and install it above the corresponding wall panel using pin staples. Between the slanted panels, install ties and hold them in place with pins and stays until the entire wall and the slanted roof are perfectly aligned.
Place the steel aligner over the portable aligners attached to the forms. This aligner is an angle steel bar 2 ½” x 2 ½” x ¼”.
For the excellent connection of the walls and slanted panels, we recommend using wall tensors especially designed to connect the panels. FORSA RECOMMENDS 43
FORSA SLAB SYSTEM
Once the assembly of the wall panels is finished put in place the Forsa slab system. For that there is a wall-slab joiner that consists of a profile in two forms: straight angle or curved profile.
Installation Sequence
1
Place the roof corner connector on top of the wall form and attach them using the staple pin.
2
Accocding to the blueprints attach the roof forms and other crowns securing all together with the staple pins.
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3
Continue joining the roof forms using short pins and wedges.
FORSA SLAB SYSTEM 4
5
Place the bases for the jacks according to the blueprints and / or advice of your technician.
The Forsa system counts on several options for placing the slabs. - The I beam or the U beam with its respective point leveler. Place the I beams where the blueprihts indicate and connet them to the roof forms using staple pins. Place a pole support leveler where blueprihts indicate.
The function of the Forsa pole support leveler is to facilitate the roof form dismantling and guarantees roof stability after removal of the forms which permits their re-use the next day. FORSA RECOMMENDS
After finishing the installation of the roof slabs proceed to the installation of the steel wire mesh roof reinforcement and all conduits, hydraulic and sanitary accessories corresponding to the roof. Later install the upper mesh to ensure the plumbing stays between the two and avoids ruptures.
- Supporting the slab Continue the same way, installing the poles where the blueprints indicate and securing the slab panels with pin staples. Later install parrallel bars and jacks.
Check the position of the steel wire mesh separators, like the overlapping between other mesh, while at the same time assuring they are properly attached with steel wire.
5
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FORSA SYSTEM Final Check
Concrete Specifications
Before each concrete pouring a supervisor must check each assembly, verifying that the walls are verticals with lead drop weights and assuring the correct and complete installation of accessories.
Thanks to the versatility of FORSA forms system, you can pour simultaneously walls, roofs and ledges, resulting in a one piece earthquake resistant structure. Concrete Specifications for Walls Use concrete from 1.200 psi to 3.000 psi and gravel from 3/8” to 3/4”depending on the thickness of the wall. Concrete Specifications for Roofs Use concrete with 3.000 psi and gravel from 3/8”, with an additive to accelerate the drying in order to facilitate the dismantling.
Remember to apply ACPM to the contact mold face using a sprayer roller, or mop, to avoid the concrete sticking to the forms. FORSA RECOMMENDS
Concrete Type
Walls
Roofs
Specification Resistance
105, 140, 175, 210, 245, 280 Kg/cm2 after 28 days 24% de f´c after 12 hours Equal Code F, or smaller inches
105, 140, 175, 210, 245, 280 Kg/cm2 after 28 days 24% de f´ c a 60 hours Equal Code C, or ¾ in Code M inches
Cold weather 1.5 hours Warm weather 1 hour 7 inches Cold weather: initial 6 to 8, final 8 to 10 hours Warm weather: initial 4 to 6, final 6 to 8 hours 2.200 a 2.400 Kg/m3 Maximun 3 %
Cold weather 1.5 hours Warm weather 1 hour 4 inches Cold weather: initial 6 to 8, final 8 to 10 hours Warm weather: initial 4 to 6, final 6 to 8 hours 2.200 a 2.400 Kg/m3 Maximun 3 %
Specification aging Maximun gravel size Handling time Settling design Setting time Density Air content
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POURING THE CONCRETE
Stant pouring in a corner of the wall letting the concrete to run.
The pouring of premixed concrete can be done with a cement mixer or buckets, taking into account the advantages or disadvantages of each project such as: time, cost, productivity, quality, etc.
Start the vibration once the concrete begins to stabilize. Use a 35 mm needle vibrator to extract the air from the concrete.
With the pouring of the concrete, hit the exterior forms with a rubber mallet forcing the concrete to move towards the center to obtain a well planed finished surface.
Immediately after pouring the concrete wash the formsâ&#x20AC;&#x2122; fins with water pressure using a hose to avoid concrete build up. If you do not have water on the job site assure you have enough diesel fuel on the fins to avoid concrete build up. FORSA RECOMMENDS 47
DISMANTLING FORSA EQUIPMENT Wall Panels The next day after verifying that the concrete has set sufficiently (minimum 10 hours) begin dismantling the wall panels in the middle of one interior wall and a corner of the exterior walls.
1 2
Take out the aligners and the portable aligners.
Take out the wedges and pins toward the left of the arrow pins which are fixed to the forms.
4
Pull out the ties using the tie extractor, a tool especially designed for this function.
3
Remove the forms one at a time on both sides of the walls using the correct tool. Assure that the panels are uniformly pulled backwards to ensure the quality of the concrete wall srface.
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DISMANTLING FORSA EQUIPMENT Roof Forms The Forsa support system facilitates dismantling of the roof, speeding the process permiting their use the next day.
If using the slab point system, first remove the stays, pin staples and pins dismantling one form at a time leaving one point in place with its respective jack.
Begin the dismantling of the roof forms on one side of the house.
1
Take out the wedges and the staple pins and remove one roof form.
2
To dismantle the I or U beam profile lower the screw of the point leveler without removing the jack.
Before re-using the panels make sure to remove all residual concrete using a trowel or wire brush.
The Forsa form system permits leaving the concrete roof in place with the pole levelers guaranteeing the roof level and stablility. The roof forms can be Re-used 100% inmediately.
The pins, stays, ties and portable aligners should be kept in their respective buckets to avoid being left on the floor. The ties should be cleaned before their next use. FORSA RECOMMENDS 49
ADDITION OF MORE FLOORS Installation of Scaffolds As you are finding out, the Forsa system is simple, versatile and quick. Follow the same process for more floors and see that each time is easier.
When the project is more than one floor, be sure that the roof is well leveled and verticle floor to floor. FORSA RECOMMENDS
Scaffolds serve to align the exterior surface of the panel and allow movement of personnel. The upper two ties should be left in place on the first floor holding the scaffold pins so they do not come out.
Continue in the same way as the walls of the first floor using the panels from the first floor on the second floor. For the construction of two or more floors, install scaffolds around the perimeter.
Life lines and platforms for walking should be well secured to the scaffolds. FORSA RECOMMENDS 50
QUALITY FINISHES
The Forsa form system produces an excellent concrete finish due to the exact precision of the mechanically manufactured parts and the completely smooth contact surface. A minimum of finishing is needed for a concrete wall for the best appearance.
To refill holes left by the ties prepare a mix of cement and water and an adherent. Fill the hole using a putty knife spreading the filler until it is smooth.
The final result is a beautiful and complete house wilth all the basic elements and details constructrd in a day. Now the only thing remaining to do is apply a coat of stucco or paint the color of your choice.
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SPECIAL DESIGNS
FORSA designs and fabricates all kinds of decorative and architectural details according to the specifications of the building plans. We are capable of fabricating circular or square window with borders of different dimensions with or without decorative lintels.
With FORSA panels it is possible to construct streetside fronts that are curved, straight or in different configurations. Circular and straight steel molds are fastened to the front wall panels where prefabricated details can later be installed such as gargoyles. Decorative lintels can be fabricated curved or straight according to the needs of our customers. 52
ONE FLOOR HOUSING Panama
Venezuela
Mexico
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TWO STORY HOUSING Guatemala
Peru
Guatemala
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FOUR TO SIX FLOOR HOUSING Peru
Trinidad and Tobago
Venezuela
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BUILDINGS Spain
WAREHOUSES Dominican Republic
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Stairs
Penitentiaries
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HIGH-RISE BUILDINGS Colombia
Panama
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HOTELS Dominican Republic
Mexico
El Salvador
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MAINTENANCE GUIDE Emergency Repair Panel Straightening Place the bent panel on twp wood planks approximately 3â&#x20AC;? X 3â&#x20AC;? as shown in the illustration. Place another wood board in the center of the panel and use a jack to apply pressure until is straight. Soldering of cracks, face of supports Do a general clean-up to remove any residue (concrete, grease, dirt, etc.) so that solder can be applied. Proceed to weld using a torch for aluminum electrodes.
Mainrainence Activities
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Activity
Number of uses
Activity
Number of uses
Panels in aluminum, ends. Angles and accessories Clean contact face Clean the sides Clean upper and lower borders Apply emulsion to contact face Apply emulsion to sides Apply emulsion to upper and lower borders Apply oil to the exterior face before placement Clean off excess concrete Check condition of accessories Check the flatness of the panel Check the straightness of the side and horizontal borders Check all welds Wall Corner Clean contact face Clean the sides Apply emulsion to contact face Apply emulsion to sides Clean off excess concrete Check angles up to 90 degrees Straight and inclined wall juncture Clean contact face Clean the sides
Daily 50 250
Straight and inclined wall juncture Apply emulsion to contact face Apply emulsion to sides Clean off excess concrete Check angles up to 90 degrees Check panel re-enforcement Check lengths Standard wall top eith mold Clean the external contact face Apply emulsion to contact face Clean off excess of concrete Check wall top flatness Check the condition of the molds welds Pins and Clips Make an inventory Ties Cover well with the polyethylene glove Check straightness Check that the pin holes are round Change ties Pin Staple Make an inventory Make adjustments Arrow pin an staple lock Lubricate with oil Clean off excess of concrete
Daily 50 250 X X X X X X
X X X X X
X X X X X X X X X X
X X X X
X
X X X X X X X X X
X X
X X
X
MAINTENANCE GUIDE Mainrainence Activities
FORSA Guarantee
Activity
Number of uses
Scaffolding in general Make an inventory Clean off excess of concrete Check condition of the welds Check inadequate use Aligners in general Make an inventory Clean off excess of concrete Check for inadequate use Check the condition of the welds Front clips and stays for the scaffold Make an inventory Clean off excess of concrete Aligners, pint base and clips stays Make an inventory Clean off excess concrete Check the conditions of the welds Check for inadequate use Tensor walls, doors and windows and point leveler Make an inventory Clean off excess of concrete Check and lubricate when needed Chute for empty concrete Clean off excess of concrete Check the conditions of the welds Check for inadequate use
Daily 50 250 X X X X X X
X X
X
X X
X X
X
FORSA guarantees that all products that carry its trademark and made by them free of defects at the time of packing and delivery to the costumer (except for those products made by others). The guarantee is limited to replacement of the product when fabrication and/material defect has been proven. The guarantee will not apply in the following cases: a) When inadequate use of the parts has been shown. b) For negligence of the operator which causes ruptures of accidents
X X
c) When the elements or parts of them have been repaired, replaced or altered by personnel other than from FORSA. d) When the parts have been subjected to conditions, forces or excess weights different from the recommendations of the FORSA factory.
X
X
The durability of FORSA panels has been evaluated on a technical and practical level. For this reason, if maintenance norms as recommended and explained in this manual are completed the FORSA panel set can last more than 1500 uses.
X X
Formaletas S.A. counts on personnel made up of professionals and trained technicians that are always available to you and your staff to instruct on the use and maintenance of the panels as well as handling concrete and techniques for construction.
The inappropriate use of the panels or accessories can cause accidents, severe damage or death. Completion of all safety norms and permanent supervision of the work site is recommended. Equipment or accessories in poor condition must be replaced immediately. FORSA RECOMMENDS
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