Comfortable state-of-the-art homes are in increasing demand by Iran’s aspiring and growing middle class – and are being built throughout the country. Currently, an ambitious large-scale housing project is under way in the city of Kermanshah, Western Iran. Here, 57 residential buildings, each with 15 floors, are being built in the city’s Pardis neighbourhood – which, translated, means paradise. They will provide new homes for over 5,000 citizens. Work flow and schedules are tight since the families are anxious to move into their new light-flooded homes by 2014.
All residential buildings have the same layout: four large-size flats are grouped around a central lobby with its staircases and lift shafts. If required, each flat can later be divided into 2 separate flats. The walls, beams, slabs, staircases and lift shafts all have similar dimensions. Thus, all formwork is going to be used hundreds of times throughout the construction process. It needs to be robust and suited for tough on site conditions because the tight schedule won´t tolerate delays through repairs or time-consuming job-built solutions. Contractor Payahoor, an Iranian top-rank contractor specialized on residential construction, decided to invest in MEVA formwork as the ideal solution. The company has been using MEVA systems successfully since March 2010 and has spearheaded the introduction of completely new building methods in Iran, where heavy steel formwork with plywood is typically used. To Payahoor, plywood is no a longer viable option: The 100% wood-free, all-plastic facing used by MEVA in all its formwork systems proved the ideal opportunity to improve quality, safety and speed on all the company’s building sites.
The alkus all-plastic facing, wood-free and durable
The polypropylene alkus facing which is reinforced on the inside by thin aluminium foil, lasts as long as the frame and makes re-facing redundant. No wood needs to be purchased and none is wasted. There are no interruptions to work-flow, which is a major benefit for this project. Minor damages such as nail holes are repaired on site using the identical material. No wood is required. It can be cut, welded and bent for custom-made solutions. Thus, special angle-shaped forms were made from alkus to avoid time-consuming job-built solutions. The alkus angles are used to pour the change in ceiling height that occurs along the inside walls between the lobby and the flats. MEVA’s hand-set formwork system AluFix, made of light-weight aluminium, is used to pour the walls, beams and slab edges. Designed for flexible use, the AluFix contributes to speeding up work in more than one way:
With its panels sizes matched to typical layouts in housing construction, the AluFix drastically reduces the need for job-built compensations or fillers. The 300 cm panels are used to pour the 275 cm high walls while the 35 cm high slab edges and beams are poured using slender 40 cm panels. They also handle the 20 cm (or 25 cm) underside of the beams. All panels can be used and combined both horizontally and vertically. This enhances flexibility on site.
AluFix is fully combinable with its twin system, the steel frame hand-set system EcoAs. The 240 cm high wall end below the beam is poured with the 240 cm EcoAs panel. It is attached to the adjacent AluFix panels with the same assembly lock.
Because they are light, the few panels required for the beams are moved into pouring position by hand, while the large panel gangs needed to pour the walls are lifted by crane from one pouring cycle to the next. This saves assembly and stripping time.
Wall formwork with matching standard panel sizes
MEVA’s hand-set formwork system AluFix, made of light-weight aluminium, is used to pour the walls, beams and slab edges. Designed for flexible use, the AluFix contributes to speeding up work in more than one way:
MevaDec: Early stripping substantially reduces material inventory
The slabs are poured using the MevaDec slab formwork and applying the drop-head-beam-panel method. The drop head allows for early stripping, i.e. the props remain under the poured slabs while the panels and beams can be removed early for the next slab. Thus the site needs 2 sets of props but only 1 set of panels and beams to do the entire slab jobs. With a total of 855 slabs of 700 m² to be poured, MevaDec’s early stripping advantage save the site substantial time and material. MevaDec is also easy to use and avoids assembly errors. The Kermanshah teams, previously not familiar with MevaDec, have been using it corrrectly from the beginning and after only a short training session.
Working scaffolds, shaft platforms, Meva FormSet
All other building parts are also poured using standard systems without the need for job-built formwork solutions – the stair case walls with AluFix panels on shaft platforms and the lift shafts with AluFix panels on KAB working scaffolds. The KAB is also used as a fall-down protection and supports the slab formwork props. The AluFix panels for the slab edges are attached to the walls using the stop-end rails and stop-end spindles of MEVA FormSet programme MFS.
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