GRP Permadeck Formwork

Transcription

Max Frank Australia Pty. Ltd,
1/42 Balaclava Street,
Woolloongabba QLD 4102,
Australia
Tel: 1300 853 235
Email: info@maxfrank.com.au
www.emjplastics.com
www.emjplastics.com / www.maxfrank.com.au
385BR01/01-AU/GB-05/15
www.maxfrank.com.au
Introduction
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385BR01/01-AU/GB-05/15
Contents
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
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Introduction
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.
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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.
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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.
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.
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•
•
•
•
•
•
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
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.
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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.
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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.
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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.
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Specialist Products - Column Moulds/Special Bridge Deck Panels
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.
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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.
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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.
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GRP Permadeck - Technical Information
Permadeck Panel
EMJ Grey Butyl tape with Polyester
backing 50mm wide x 35 mtr Butyl tape
applied to the top of adjoining panels.
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Cantilever Panels
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385BR01/01-AU/GB-05/15
en
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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.
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ne
Pa
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GRP Permadeck - Installation Advice
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.
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Max Frank Australia Pty. Ltd,
1/42 Balaclava Street,
Woolloongabba QLD 4102,
Australia
Tel: 1300 853 235
Email: info@maxfrank.com.au
www.emjplastics.com
385BR01/01-AU/GB-05/15
www.maxfrank.com.au

GRP Permadeck Formwork

Transcription

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