Method Statement -Bondek Installation

1.0    OBJECTIVE

     

Outline the Method statement for bondek installation for (your project name).

2.0    SCOPE OF WORK

This method statement shall be used for installation of bondek.

3.0    RESPONSIBILITY

Site Supervisor, Project Engineer

4.0    WORK METHODOLOGY

4.1      INSTALLATION

Bondek II is delivered in strapped bundles. If not required for immediate use stacks sheets or bundles neatly and clears of the ground, on a slight slope to allow drainage of water. If left in the open, protect with waterproof covers.

4.2      PROPPING

It is common practice to specify unpropped Bondek II formwork, however, depending on the span of a Bondek II slab, temporary propping may needed between the slab supports to prevent excessive deflections or collapse of the formwork.

Bondek II formwork is normally placed directly on prepared propping. Props must stay in place during the laying of Bondek II formwork, the placement of the concrete, and until the concrete has reached the strength of 20 MPa. Propping generally consists of substantial timber or steel bearers supported by vertical props. The bearers must be continuous across the full width of Bondek II formwork.

Where the underside of Bondek II formwork is featured as a finished ceiling, wide form-ply strips attached to the bearers will minimize marking. The width of the form-ply strips depends upon the slab depth, Bondek II metal thickness and span. Form-ply strips of 300mm width have been used successfully. Propping must be adequate to support construction loads and the mass of wet concrete.

4.3      LAYING

Bondek II must be laid with the sheeting ribs aligned in the direction of the designed spans. Other details include the following:

-            The slab supports must be prepared for bearing and slip joints as required.

-            Lay Bondek II sheets continuously over each slab span without any intermediate splicing or jointing.

-            Lay Bondek II sheets end to end. Centralise the joint at the slab supports. Where jointing material is required the sheets may be butted against the jointing material.

-            Support Bondek II sheets across their full width at the slab support lines and at the propping support lines.

-            For the supports to carry the wet concrete and construction loads, the minimum bearing is 50mm for ends of Bondek II sheets, and 100mm for intermediate supports over which the sheeting is continuous.

4.4      INTERLOCKING THE SHEETS

Overlapping ribs of Bondek II sheeting are interlocked. Either of two methods can be used in most situations, though variations may also work.

In the first method, lay adjacent sheets loosely in place. Place the female lap rib overlapping the male lap rib of the previous sheet and apply foot pressure, or a light kick, to the female lap rib.

                                                                                                                                                                            

In the second method, offer a new sheet at an angle to one previously laid, and then simply lower it down, through an arc.

If sheets don’t interlock neatly (perhaps due to some damage or distortion from site handling or construction practices) use screws to pull the laps together tightly.

4.5       SECURING THE PLATFORM

Once laid, Bondek II provides a stable working platform. Bondek II shall be fixed to supporting structure at end supports with screws or nails or equivalent. Where additional security is needed you can use :

-            weights

-            screws or nails into the propping bearers.

Take care if you use penetrating fasteners (such as screws and nails) because they can make removal of the props difficult, and perhaps result in damage to the Bondek II.

4.6         INSTALLING BONDEK II ON STEEL FRAMES

Bondek II may be installed directly on erected structural steelwork.

Fastening composite beams

Stud welding through the sheet has been considered a suitable securing method for the sheeting in a composite beam; however some preliminary fixing by one of the methods mentioned above is necessary to secure the sheeting prior to the stud welding. Some relevant welding requirements are :-

-            Mating surfaces of steel beam and sheeting to be cleaned of scale, rust, moisture, paint, overspray, primer, sand mud or other contamination that would prevent direct contact between the parent material and the Bondek II.

-            Welding must be done in dry conditions by a certified welder.

-            For pre-painted Bondek II sheets, special welding procedures may be necessary, and

-            For sheets transverse to beams, stud welding must be between pan flutes to ensure there is no gap between mating surfaces.

4.7      CONSTRUCTION AND MOVEMENT JOINTS

Joints used between Bondek II slabs generally follow accepted construction practices. Construction joints are included between slabs for the convenience of construction. Movement joints allow relative movement between adjoining slabs. The joints may be transverse to, or parallel with, the span of the Bondek II slab. Movement joints need a slip joint under the Bondek II sheeting.

The Bondek II sheeting and any slab reinforcement are not continuous through a joint.

Design engineers generally detail the location and spacing of joints because joints effect the design of a slab.

4.8      FASTENING SIDE LAP JOINTS

If Bondek II sheeting has been distorted in transport, storage or erection, side-lap joints may need fastening to maintain a stable platform during construction, to minimize concrete seepage during pouring, and to gain a good visual quality for exposed soffits.

4.9      CUTTING AND FITTING EDGE FORM

EDGE FORM is a simple C-shaped section that simplifies the installation of most Bondek II slabs. It is easily fastened to the Bondek II sheeting neatly retaining the concrete and providing a smooth top edge for quick and accurate screeding. We make it to suit any slab thickness.

EDGE FORM is easily spliced and bent to form internal and external corners of any angle and must be fitted and fully fastened as the sheets are installed. There are various methods of forming corners and splices.

Fasten EDGE FORM to the underside of unsupported Bondek II panels every 300mm. The top flange of EDGE FORM must be tied to the ribs every 600mm with hoop iron 25mm x 1.0mm.

4.10    INSPECTION

We recommend regular qualified inspection during the installation, to be sure that the sheeting is installed in accordance with this publication and good building practice.

4.11    CUTTING

It is easy to cut Bondek II sheets to fit. Use power saw fitted with an abrasive disc or metal cutting blade. Initially lay the sheet with its ribs down, cut through the pans and part-through the ribs, then turn the sheet over and finish by cutting the tops of the ribs.

4.12    SEALING

Seepage of water or fine concrete slurry can be minimised by following common construction practices. Generally gaps are sealed with waterproof/masking tape or by sandwiching contraction joint material between the abutting ends of Bondek II sheet.

5.0 SAFETY & ENVIRONMENTAL PROGRAMME

Bondek II is available in long lengths, so large areas can be quickly and easily covered to form a safe working platform during construction. One level of formwork gives immediate protection from the weather, and safety to people working on the floor below. The minimal propping requirements provide a relatively open area to the floor below.

The bold embossments along the top of the ribs of Bondek II enhance safety by reducing the likelihood of workers slipping. Some Lysaght centers, may supply Bondek II with knurling on the upper face of the flutes, which provides even more safety against slippage.

It is commonsense to work safely, protecting yourself and workmates from accidents on the site. Safety includes the practices you use; as well as personal protection of eyes and skin from sunburn, and hearing from noise. For personal safety, and to protect the surface finish of Bondek II, wear clean dry gloves. Don’t slide sheets over rough surfaces or over each other. Always carry tools, don’t drag them.

Occupational health and safety laws enforce safe working conditions in most locations. Local laws may require you to have fall protection which includes safety mesh, personal harnesses and perimeter guardrails where they are appropriate. We recommend that you adhere strictly to all laws that apply to your state.

Bondek II is capable of withstanding temporary construction loads including the mass of workmen, equipment and materials. However, it is good construction practice to ensure protection from concentrated loads, such as barrows, by use of some means such as planks and/or boards.

·         All HSSE procedure and regulations shall be complied with.

·         To provide proper and safe access for inspection and working.

·         Site personnel must be in proper safety working attire e.g. Safety boots and helmets must be worn at all times.

·         Proper and adequate lighting to be provided when working at night.

·         Water ponding must be constantly pumped out and mosquito infestation checked and controlled.

6.0 QA/QC PROGRAMME

6.1          Inspections and Test Plan

In order to ensure the quality of bondek installation works meet the requirement, inspection and test shall be carried out as per the Project Quality Plan (PQP).

•             Inspection Request Form (IRF) attached with Checklist