GRP Permadeck Formwork
Transcription
GRP Permadeck Formwork
Max Frank Australia Pty. Ltd, 1/42 Balaclava Street, Woolloongabba QLD 4102, Australia Tel: 1300 853 235 Email: [email protected] www.emjplastics.com GRP Permadeck Formwork GRP Permadeck Formwork www.emjplastics.com / www.maxfrank.com.au 385BR01/01-AU/GB-05/15 www.maxfrank.com.au GRP Permadeck Formwork Introduction GRP Permadeck Formwork GRP Permadeck Formwork www.emjplastics.com / www.maxfrank.com.au 2 385BR01/01-AU/GB-05/15 GRP Permadeck Formwork Contents GRP Permadeck Formwork GRP Permadeck Formwork GRP Permadeck Formwork Section 1 Introduction Section 2 GRP Permadeck Formwork Section 3 GRP Permadeck Formwork - Sample Projects Section 4 Specialist Products - Sample Projects Section 5 GRP Permadeck Technical Information Section 5 GRP Permadeck Installation Information www.emjplastics.com / www.maxfrank.com.au 3 385BR01/01-AU/GB-05/15 Introduction GRP Permadeck Formwork GRP Permadeck Formwork EMJ Plastics has been manufacturing GRP products for the construction industry for nearly 50 years. Located in North Yorkshire, United Kingdom, EMJ is the UK’s leading manufacturer of GRP Bridge Deck Formwork (Permadeck) and has worked with all major UK construction companies and engineering consultants. Internationally, EMJ has supplied projects in central Europe, the Caribbean and the Middle East and is continuing to develop its services for growing demand from international markets. The ease of transport of EMJ Permadeck Panels has contributed significantly to its recent export growth. EMJ’s large production facility facilitates an increase in capacity when necessary. EMJ’s products include, but are not limited to the following: • GRP Permadeck Formwork • Cladding for Bridges & Buildings • Specialist Moulds for Water Utilities • Pier and Column Moulds • Coffer Moulds • Tunnel Liners • Patterned Wall Shutters • Custom Built Mouldings EMJ has appointed Max Frank Australia Pty. Ltd. as its agent for the growing Australia and New Zealand markets. www.emjplastics.com / www.maxfrank.com.au 4 385BR01/01-AU/GB-05/15 GRP Permadeck Formwork GRP Permadeck Formwork GRP Permadeck Formwork GRP Permadeck Formwork GRP Permadeck Formwork Permadeck Standard Range EMJ’s standard range includes 13 no. panel sizes, each of which are specifically designed for different spans and deck thicknesses. Advantages of GRP Permadeck Panels EMJ GRP Permadeck Panels offer both time and cost savings. Panels are capable of spanning up to 5.7 m with loads in excess of a 700mm concrete deck and comply with all relevant design standards. EMJ’s GRP Permadeck Formwork Panels are primarily designed as permanent bridge beam infill shuttering. The many advantages of the strong, lightweight, steel reinforced glass fibre panels extend it’s range of uses to include the construction of floors, sewage treatment plants, tanks, large area one-piece covers and many other applications. Economy of Use The ease of installation and lightweight nature of the product enable the client to make vast savings in on-site labour due to reductions in handling costs. Also, as panels are custom-built and delivered ready for use no on-site cutting is required. Access to the underside of the panel is unnecessary, eliminating the need for expensive scaffolding or staging. Also, as the panels are a permanent fixture, the requirement for stripping after casting is eliminated. The panels are extremely light and can be supplied as standard panels or to bespoke design widths or lengths. They can be tailor made to suit individual bridges. Panels can be supplied with a variety of permanent finishes to the soffit and standard units are coloured grey to British Standard 4800 10--A-03. Time Saving Advantages: • Panels are manufactured to suit standard, skewed or tapered decks - minimising cutting, reducing site labour time. • The Manufacture and curing period is relatively short - allowing extra panels to be ordered at short notice. • The laying time of the panels is extremely rapid up to 6 times faster than concrete panel systems. • The lightweight formwork allows panels to be fixed to braced pairs of beams prior to lifting into place - cutting down on possession time and providing a safer working environment. www.emjplastics.com / www.maxfrank.com.au 5 385BR01/01-AU/GB-05/15 GRP Permadeck Formwork GRP Permadeck Formwork Cost Saving Advantages: • Minimum craning required - 2 men can handle standard panels up to 2m long. • No intermediate support or underbridge access is required. • No silane or other treatments necessary. • No further requirements after casting of deck. • Shorter possession periods. GRP Permadeck Formwork Further Benefits: • Fatigue tested for a 120 year lifespan. • Panels do not debond from insitu concrete. • Panels do not creep during concrete setting. • Butyl Sealant System prevents grout loss. • Safe handling - steel is fully encapsulated. • Resistant to chemicals. • Resistant to salt attack. www.emjplastics.com / www.maxfrank.com.au 6 385BR01/01-AU/GB-05/15 GRP Permadeck Formwork • • • • • • Zero water absorption . High resistance to abrasion and impact. Unaffected by climate variation. Extremely high strength:weight ratio. Versatility - numerous variations/applications. Rib depths and centres can be varied to suit requirements. GRP Permadeck Formwork - Sample Projects GRP Permadeck Formwork GRP Permadeck Formwork GRP Permadeck Formwork Rio Grande Bridge, Portland, Jamaica This project comprised a 230m two-lane road bridge over a large river to replace the previous bridge destroyed by Hurricane Dennis. The steel beams provided support for the GRP Permadeck Formwork. The GRP Permadeck system provided a safe and efficient solution, whilst providing a safe workign platform at height over the river. The make up of the Permadeck panels allows for efficient packaging and shipments delivered across the world. www.emjplastics.com / www.maxfrank.com.au 7 385BR01/01-AU/GB-05/15 GRP Permadeck Formwork - Sample Projects GRP Permadeck Formwork GRP Permadeck Formwork A228 Stoke Bridge, Isle of Grain, Kent, UK This project involved the construction of a 5-span, single carriageway steel beam road bridge with a 275mm concrete deck over a Network Rail Line. EMJ manufactured and supplied 858 EMJ Standard Type Panels to suit a 2.8m clear span at various lengths and widths. www.emjplastics.com / www.maxfrank.com.au 8 385BR01/01-AU/GB-05/15 GRP Permadeck Formwork GRP Permadeck Formwork - Sample Projects GRP Permadeck Formwork GRP Permadeck Formwork GRP Permadeck Formwork Toddington Interchange Overbridges, Luton, UK EMJ undertook this project for Costain Carrillion on behalf of the Highways Agency. EMJ manufactured and supplied 1,120m2 of Special Skewed GRP Permadeck Formwork Panels to suit a span of 2.36m with a 300mm concrete deck on a steel beam bridge. www.emjplastics.com / www.maxfrank.com.au 9 385BR01/01-AU/GB-05/15 GRP Permadeck Formwork - Sample Projects GRP Permadeck Formwork GRP Permadeck Formwork Twin Sails Bridge, Poole, Dorset, UK EMJ’s client, Hochtief (UK) Construction Ltd requested that we manufacture and supply 922m2 of GRP Permadeck Panels in assorted sizes. EMJ provided panel lengths of 1,850mm clear span to facilitate a 225mm concrete deck. www.emjplastics.com / www.maxfrank.com.au 10 385BR01/01-AU/GB-05/15 GRP Permadeck Formwork Specialist Products - Column Moulds/Special Bridge Deck Panels GRP Permadeck Formwork GRP Permadeck Formwork GRP Permadeck Formwork Transport Interchange, Hull, UK Tabor Rail Bridge, Bechyne, Czech Republic EMJ manufactured and supplied GRP Eliptical Column Moulds to be split to form 2 no. half sections with external vertical flanges. The 6 no. column moulds had funnels built into the top to facilitate pouring concrete and an access hatch incorporated into each. EMJ also provided 6 no. GRP kicker moulds. EMJ manufactured and supplied special trough shaped permanent formwork panels to this rail bridge in a busy city centre. The panels contained aesthetically pleasing high gloss finish to the soffit. The panels were trough shaped to provide maximum ground clearance from the road beneath. www.emjplastics.com / www.maxfrank.com.au 11 385BR01/01-AU/GB-05/15 Specialist Products - GRP Composite Panels Specialist Products Specialist Products Specialist Products Specialist Products - GRP composite Panels Bespoke Panels EMJ Plastics manufacture and supply an economic GRP coated composite permanent formwork panel. This GRP composite panel has been designed for use as permanent deck infill shuttering and hence avoids the need for inconvenient temporary formwork. The Glass Reinforced Polyester Coating is to both the soffit side of the finished deck and to the top surface. Panels are factory manufactured to a specific size for each bridge which avoids the majority of site cutting. Substantial labour savings can be achieved as the pre-cut panels are placed onto an EMJ Butyl Bead system which, in turn, is laid onto the beam rebate and the butt joints sealed with EMJ Butyl Tape. The deck is then ready for reinforcement. GRP Composite Panels can be supplied in 20mm and 24mm overall thickness to suit customer requirements. www.emjplastics.com / www.maxfrank.com.au 12 385BR01/01-AU/GB-05/15 Specialist Products - Cladding/Moulds Specialist Products Specialist Products Specialist Products Teesdale Bridge, UK EMJ manufactured and supplied glass fibre panels for cladding of the bridge over the waterway which holds the UK Slalom Canoe Races. The panels were flat and curved in sections with hidden fixings and a high quality finish to the soffit bridge deck (with walkway underneath). EMJ devised a very simple and rapid method of fixing the composite steel beam bridges. This new hidden method of fixing for steel beam bridges cut normal installation time by up to 75%. Harrogate Conference Centre, UK In order to form the decorative ceiling, EMJ manufactured and supplied the moulds to cast the fixed concrete ceiling (coffer moulds). The moulds are available in various shapes, sizes, depths etc to form decorative effects and for other purposes. The moulds provided at Harrogate Conferene Centre related to the spiral ramp ceiling which spanned 3 floors of the building. www.emjplastics.com / www.maxfrank.com.au 13 385BR01/01-AU/GB-05/15 GRP Permadeck - Technical Information GRP Permadeck Formwork GRP Permadeck Formwork GRP Permadeck Formwork Permadeck Panel EMJ Grey Butyl tape with Polyester backing 50mm wide x 35 mtr Butyl tape applied to the top of adjoining panels. gt b Ri Cantilever Panels s tre h 385BR01/01-AU/GB-05/15 en 14 www.emjplastics.com / www.maxfrank.com.au lL Standard Panels Bearing Onto Concrete Beams ne Haunched Panels Panel Height Pa Standard Panels Bearing Onto Steel Beams EMJ Butyl 2 x 6mm Ø Twin-track adhesive bead x 8mtr length. Applied to steel beam flange and concrete rebate once formwork has been made available locally. EMJ recommends 10 to 20 linear metres to be laid in any one go, dependent on conditions at time of laying. Sealants tested for adhesion. n Ce ne Pa th id lW GRP Permadeck - Installation Advice GRP Permadeck Formwork GRP Permadeck Formwork GRP Permadeck Formwork EMJ provide Permadeck Panels labelled, palletised and shrink wrapped ready for transportation. EMJ can provide panels stacked in a specific order for convenience and ease of installation on site. This is particularly useful where panel dimensions vary on skewed bridge beams. EMJ recommends the use of hard hats, safety boots, quality rigger gloves and safety vests for general work with formwork. The responsibility for the implementation of health and safety regulations and safe installation lies soley with the contractor once the formwork has been delivered. Lifting equipment can be used for ease of installation on larger scaled projects Permadeck formwork is generally placed in a convenient area for laying; this will reduce the amount of physical lifting required. Once the panel is correctly positioned it is capable of supporting the live load weight of the operative and can be walked upon ideally on spreader boards. Caution should be observed when working near the edges of panels at height. Permadeck panels are lightweight. This allows panels to be installed onto braced pairs of beams prior to lifting into place, thus cutting down on possession time, also adding an increase in safety whilst placing intermediate panels. www.emjplastics.com / www.maxfrank.com.au 15 385BR01/01-AU/GB-05/15 Max Frank Australia Pty. Ltd, 1/42 Balaclava Street, Woolloongabba QLD 4102, Australia Tel: 1300 853 235 Email: [email protected] www.emjplastics.com GRP Permadeck Formwork GRP Permadeck Formwork www.emjplastics.com / www.maxfrank.com.au 385BR01/01-AU/GB-05/15 www.maxfrank.com.au GRP Permadeck Formwork