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
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