Tru-lift: summary Self lifting, core forming system

Formwork: Tru beams

• Faced with 19mm high quality plywood

• Backed by twin steel channel walers

Proven, robust and efficient

Designed for:

• Speed: forming up to 5m in a single lift

• Minimising construction cycle times

• Maximising safety

System characteristics

• 4.1 m Stroke on long cylinder.

• 0.9m Stroke on small extension cylinder.

• Power supply 230v single phase 60 Hz.

• Maximum allowable working load on form support brackets = 155kN.

• Maximum allowable working load on cylinder brackets = 289kN.

• Taper Ties = 150kN (with FOS 2:1).

• Platform loading = 1.2kN/m2.

Features & Benefits (1) • Complete system raised during the

lifting cycle MAXIMISING SYSTEM EFFECTIVENESS

• All sizes of core walls can be accommodated MAXIMISING SYSTEM VERSATILITY

• Controlled lifting of equipment using hydraulics ELIMINATING CRANAGE & MAXIMISING SAFETY

• Fully boarded working platform ENSURES SAFE WORKING AREA

• Trailing platforms allow access to previous pours MAXIMISING EFFICIENCY, ELIMINATING THE NEED FOR INDEPENDENT ACCESS SYSTEMS

Features & Benefits (2)

• Minimal number of components ensures quick and easy erection MAXIMISING CONSTRUCTION CYCLE TIMES

• Unique striking corners QUICK AND EASY RELEASE OF FORMWORK

• Concrete placement from top platform MAXIMISING SAFE WORKING PRACTICES

• Reusable tapered tie system MINIMISING HARDWARE COSTS

• External panels supported from overhead beams SAFE ACCESS FOR PANEL CLEANING AND REBAR FIXING

Raised position

• Forms fully extended to

subsequent pour position.

• Wall support brackets bolted to inserts cast in previous pour.

• Weight of system transferred to wall support brackets.

Setting position

• Bolts securing cylinder brackets to wall

removed.

• Cylinder and bracket retracted and bolted to inserts cast in previous pour.

• Internal forms cleaned and reset into position.

• External forms cleaned whilst retracted.

Pouring position

• External forms rolled back into

pouring position.

• Ties and external yokes installed.

• Concrete placed through hinged hatches on top platform.

Safety features

Safety: handrails

Full perimeter handrails for areas, including:

• Upper platforms.

• Lower platforms.

• Internal hanging platforms.

Safety: Perimeter Screen

• Fully enclosed system.

• Welded loops for securing screen to perimeter framework.

• Screen:

• Reinforced PVC sheeting.

• Strong and puncture resistant.

• UV stabilised.

• Fully printable.

• Ideal for advertising.

• Optional.

Safety: enclosed ladders

Full ladder access between platforms.

• Easy and safe accessibility at all times.

Safety: inbuilt stair access

• Modular stair access tower system.

• Supported off internal platforms.

• Length of tower determined by

floor level egress/ingress required.

• Optional.

Safety: Working Platforms

Safe, level working environment created using timber beams and plywood.

• Minimises trip hazards.

• Fully covered work areas.

• Ply hatches for concrete placement.

Outer Corner Assembly

• External corners easily tied between

yoke blocks, using fast thread ties.

• Yoke blocks bolted to horizontal channel walers.

Inner Corner Assembly

Corner pin used to strike internal forms:

• Drives through offset holes and reversed for ‘reset’.

Trolley

• Designed to roll along lower flange of

overhead beam.

•

Supports the external form using threaded rod

for vertical adjustment.

•

Attached to brackets bolted to Tru Beams.

Internal form hanging bracket

• Adjustable form support bracket head

and clamp plates bolted into wall

support frame.

• Facilitates the connection to the

overhead primary beam.

Internal Corners

• Rigid, flexible and strippable corners

(depending on core profile).

• Where possible, flexible corners used in

conjunction with corner pins.

• Eliminates need to dismantle forms.

Wall Bracket Assembly

• Brackets bolted into inserts cast in

previous pour.

• Connected to wall support frame,

supporting formwork once in lifted

position.

• Finite adjustment for levelling using

Threaded Bar (if required).

Jack Bracket

• Supports and houses hydraulic cylinder.

• Bolted into inserts cast in previous pour.

• Supports the formwork system during

lifting sequence.

• Remain fixed to hydraulic cylinder

during retraction and relocation.

Walkway Bracket

• Bolted to overhead beam system.

• Hanging below the bottom of the

formwork system.

• Facilitates retracting of forms, steel

reinforcement fixing and cleaning of

forms.

• Designed to be used in conjunction with

timber beams and plywood.

• Creating a level and hazard free working

platform.

Internal Trailing Platform

• Supported from overhead steel beams.

• Provide safe access for operatives.

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Ducab VCV tower, Dubai - UAE

Project: Ducab-HV (400kV) Cable Factory - 1st Facility of it’s kind - Fast Track (12 month program) Sector: Industrial Details: RC Tower - 24 x 22m footprint - 44 storey – 153m high - Unique – large core structure, large openings, changing wall thickness Contractor: Khansaheb Civil Engineering

Ducab VCV tower

Ducab VCV tower

Shutter assembly

Pre-assembly of many components greatly reduces the set up time onsite and can be started well in advance of the site being ready to install the formwork.

Shutter assembly Pre-assembly of the formwork is carried out using fabrication jigs and can also be done well in advance of the actual site set up (on or off site).

Shutter assembly

In some cases, by prior arrangement, the fabrication of the formwork panels can be assembled off site, then transported to site fully assembled and ready to install. This can save space on congested work sites.

Shutter assembly

Larger panels that are too big to be transported by road can be assembled on site.

Set Up

The formwork panels are then prepared and oiled prior to lifting into position.

Set Up

The Internal Rigid Boxes are installed first and fixes the internal shape/dimensions of the core – this is a unique feature of the Tru-lift Self Climbing Formwork System.

Set Up The Steel Walers are easily spliced to any length enabling very large panels such as this 4.2m high x 20m long panel to be fabricated and lifted into position in one piece.

Set Up

Set Up

Set Up On completion of the rebar and formwork installation the steel grid beams are positioned.

Set Up

Set Up

Bolts and Grid Plates are used for the connections between the grid beams, the Formwork and Hydraulics.

Set Up Top Decking and Edge Protection are added upon completion of the Grid Beam placement.

Operation The Tru-lift Self Climbing System is operated from a central control room. Each of the Hydraulic Rams can be controlled individually or collectively with the flick of one switch.

Operation The Tru-lift Self Climbing System is generally mounted to the walls of the first pour. However if the customer would prefer, it can be designed to form the first pour and push off the base slab as was done on this particular project.

Operation The Tru-lift Self Climbing System is truly unique in that the whole system is jacked in one Jack stroke, eliminating the need for resetting the hydraulics throughout the lift saving a great deal of time. On this particular project the 3.8m typical floor height was easily accommodated by jack stoke and capacity.

Operation The Tru-lift Self Climbing System is to be used to form the first pour. The Hydraulic Rams should be prevented from movement by setting brackets around the bottom of it into the base slab.

Operation

External Hanging access brackets are added on the initial lifts until the desired length is achieved.

Operation

Suspended access scaffolds can also be accommodated as seen here from below.

Operation

Operation

Rebar cages can be prefabricated and craned into position to speed up the cycle times if desired.

Operation When the setup is complete the Tru-lift self climbing system is operated completely independently, without the need for a crane to handle the Formwork and easily out performs traditional Jump form systems.

Operation The contractor using the Tru-lift System on this particular project was able to achieve a pour cycle of just 48 hours with 1,100m2 of formwork being jacked in 20-30 minutes.

Dismantle

Upon completion of the structure the system is dismantled in the reverse order to that of the erection. The Hanging access platforms are removed first.

Dismantle Followed by the external formwork.

Dismantle Next the top decking is systematically removed.

Dismantle

Dismantle

The final step is the removal of the internal formwork and wall brackets.

Methods

Detailed method statements are provided for assembly, erection, running and dismantle of the system. Site supervision is provided at all stages of the contract.

RMD Australia - Tru-lift Self lifting, core forming system