cpccca3018a construct erect & dismantle formwork for

Type Title Standard Issue Version Ref Release

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LR CCPCCCA3018A NVR Standard 15.5 1 06 Construct, erect and dismantle formwork for stairs and ramps 09/08/2017 19/082013

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CPCCCA3018A

Construct, erect and dismantle formwork for stairs and ramps

STUDENT LEARNING PACK

Student Name ______________________________________________


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Student Information Purpose: The purpose of this learning package is to help you understand the technical and theoretical knowledge and associated skills of your selected trade area. This package contains a number of learning and associated documents for this unit of competency. Please read all parts of this package to ensure that you complete and manage the process correctly. These assessment tools address the mandatory requirements of the unit of competency including, evidence requirements, range statements and the required skills and knowledge to achieve the learning outcomes indicated in the document. Performance criteria are described below. The contents of this unit will contain some or all of the following as required: Unit outlines / Performance Criteria Self-Checks are self-tests for the student. These have in general been extracted from this learning resource.

ELEMENT PERFORMANCE CRITERIA

1. Plan and prepare

1.1.Work instructions and operational details are obtained using relevant information, confirmed and applied for planning and preparation purposes.

1.2.Safety (WOHS) requirements are followed in accordance with safety plans and policies.

1.3.Signage and barricade requirements are identified and implemented. 1.4.Plant, tools and equipment selected to carry out tasks are consistent with job

requirements, checked for serviceability, and any faults are rectified or reported prior to commencement

1.5.Material quantity requirements are calculated in accordance with plans and specifications and quality requirements.

1.6.Materials appropriate to the work application including required fire resistance rating are identified, obtained, prepared, safely handled and located ready for use.

1.7.Environmental requirements are identified for the project in accordance with environmental plans and regulatory obligations and applied.

1.8.Passive and active fire control elements for roof construction are identified and applied.

2. Set out formwork

2.1.Design of stairs and/or ramps and method of joining formwork are identified from job drawings and specifications, and are checked to be in accordance with legislation, regulations and codes of practice.

2.2.Exit and ground finish levels are determined from plans, specifications and site inspection.

2.3.Rise, going and pitch of stairs and ramp are determined from plans, specifications, site inspection, rise measurements and requirements of Building Code of Australia (BCA).

2.4.Full size set out of stairs and ramp is calculated and made to determine rise, going and pitch of stairs to provide location of landings, stringers, treads and posts where specified.

2.5.Location of stair, ramp and newels are determined from plans, specifications and pitch of stairs or full size set out.

2.6.Location of footings are set out to layout of designed stairs and ramp from plans, specifications or full size set out, where specified.

2.7.Materials for formwork, including stringers, are selected and set out to pitch of stairs with rises not exceeding specified space between treads.

3. Assemble and erect formwork

3.1.Landing bearers and joists are placed, fixed and braced according to plans and specifications, where specified.

3.2.Footings are checked for accuracy to requirements of plans and specifications. 3.3.Stairs and/or ramp formwork soffit is erected and braced in accordance with plans and

specifications. 3.4.Formwork stringers are cut square to length and shape in accordance with set out and

junction with newel posts, and are installed and braced. 3.5.Metal angle brackets are screwed/bolted to formwork strings to set out locations of

tread support.


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3.6.Formwork strings for stairs and ramps are located and fixed according to plans and specifications.

3.7.Material for face of treads is set out, cut square to length and fixed to metal angle bracket according to plans and specifications.

3.8.Risers are braced at mid-span to prevent deflection under the load of wet concrete. 3.9.Newels are erected and temporarily braced to plumb position, where specified. 3.10.Formwork tie bolts are located and secured to plans and specifications to maintain

stair width where specified.

4. Strip formwork

4.1.Formwork and bracing are removed sequentially and safely. 4.2.Timber components are de-nailed, cleaned and stored or stacked safely for reuse or removal from site. 4.3.Steel components are cleaned, oiled and stored or stacked to manufacturer’s

maintenance recommendations. 4.4. Damaged formwork components are safely discarded after stripping.

5. Clean up. 5.1. Work area is cleared and materials disposed of, reused or recycled in accordance with legislation, regulations, codes of practice and job specification.

5.2. Plant, tools and equipment are cleaned, checked, maintained and stored in accordance with manufacturer recommendations and standard work practices.

UNIT DESCRIPTOR

CPCCCA3018A Construct, erect and dismantle formwork for stairs and ramps This unit of competency specifies the outcomes required to construct, erect and dismantle formwork for stairs and ramps to form up the concrete that may involve one or more flights in order to provide access between floors and/or landings. It includes timber, metal or prefabricated formwork. ASSESSMENT Overall Assessment Requirements The instructional outcomes required at the completion of this training are satisfactory for each form of evidence resulting in competent. If you do not achieve the required outcomes of competent, for this assessment you will be required to re sit a supplementary examination within a reasonable time of the original examination date. To achieve successful completion of this unit you should achieve a minimum of 3 forms of assessment. Below are some of the forms of evidence that can be used. 1. Written Assessment 2. Third party reports (usually by your employer or supervisor) 3. Workshop/ On Site Activity (generally referred to as “Practical Assessment”) 4. Logbook Evidence (a record of the tasks you carry out for each unit) Theory Examination During the period of this learning you will be required to complete a written theory examination to establish the level of understanding of technical content.


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Self Checks Self-checks are to be completed on pages provided when requested by your trainer. These exercises are used mainly as a learning tool; they may form part of your overall assessment if deemed necessary by your Trainer. Verbal Questions Verbal questions may be used and recorded to establish your level of knowledge of the competencies of this learning package. Practical Observation / Assessment Practical may be assessed in either of the following formats: -

1. Practical observations will be undertaken in the workplace. Where the assessor observes the student completing a task in the workplace the observation will be recorded in the observation checklist.

2. Where a student is not able to undertake an activity in the workplace a simulated practical activity will be setup by the assessor. (Refer to the practical exercises outlined in this Student Learning Resource.) The observation checklist will be used to record the student’s performances.

Where a student undertakes an activity in the workplace and the trainer is not able to be present the employer / supervisor will confirm the activity on the Third Party Report. The student and employer / supervisor will provide photographic evidence of the activity with an explanation of the task undertaken. The assessor will contact the student by phone or face to face to question the student about the activity to confirm the students understanding and skills. The outcome of this contact will be recorded in the Practical Assessment.

Log Book or Training Record Book It is the responsibility and requirement for the learner to complete the training record based on the on-the-job and structured training tasks received by the employer or Supervising Registered Training Organisation (SRTO) or as indicated in the training plan, which may be produced to the employer and SRTO at reasonable intervals of not more than 3 months. Log Book evidence from your employer and other forms of evidence relating to this unit of competency will contribute to the outcome of this learning package. If the required activity is not part of your employer’s scope of activity you will be required to complete the skill learning process within a simulated environment. Logbook evidence must reflect the “Elements” shown for this unit. Results A statement of Attainment may be printed for this unit if required, but in general your achievement of this unit will be recorded and presented to you on completion of the entire qualification. Your certificate will record all the units you have completed.


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RPL and Acceleration Recognition of prior learning is available to all students. This provides an opportunity for being credited for previous learning. Acceleration provides an opportunity to reduce the allocated learning hours for this unit of competency. There is a separate RPL kit for this process. Methodology This unit may be provided as a separate learning instruction or provided with other units of competency in a practical or theoretical learning experience. Due care Every care has been taken to ensure that the information in this learning guide is correct, but trainers are advised to check the currency and the relevance of the content to their own training package. Copyright protects this publication. Except for purpose permitted by the Copyright Act 1968, reproduction, adaptation, electronic storage and communication to the public is prohibited without prior written permission. Pre-requisites Pre-requisite units: CPCCOHS2001A Apply OHS requirements, policies and procedures in the construction industry. CPCCOHS1001A Work safely in the construction industry (White Card).

As this is built on the information presented in these two units above the learner must have already been deemed competent in these two units.

Feedback to the learner The trainer will provide feedback to the learner on the progress of assessment.

This learning package is intended for use by those completing the Competency Unit – CPCCCA3018A Construct, erect and dismantle formwork for stairs and ramps as part of the Basic Stream Skills within the Building Construction Skills Stream of the National Competency Framework


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Plan and prepare Regulatory and Legislative Requirements Regulatory and legislation requirements applicable to this unit of competency are found in: ! Work Health and Safety Act 2011 ! Work Health and Safety Regulation 2011 ! Environmental Protection Act (1994) You should make yourself familiar with and apply any regulatory and legislative requirements to your relevant work area.

Australian Standards Standards are published documents setting out specifications and procedures designed to ensure products, services and systems are safe, reliable and consistently perform the way they were intended to. They establish a common language, which defines quality and safety criteria. Standards can be guidance documents including: • Australian Standards®; • International Standards and Joint Standards; • Codes; • Specifications; • Handbooks; and • Guidelines. These documents are practical and don’t set impossible goals. They are based on sound industrial, scientific and consumer experience and are constantly reviewed to ensure they keep pace with new technologies. They cover everything from consumer products and services, construction, engineering, business, information technology, human services to energy and water utilities, the environment and much more. The Building Code of Australia The Building Code of Australia (BCA) is Volumes One (all other classes) and Two (classes 1 and 10) of the National Construction Code (NCC). The BCA is produced and maintained by the Australian Building Codes Board (ABCB) on behalf of the Australian Government and State and Territory Governments. The BCA has been given the status of building regulation by all States and Territories. The goal of the BCA is to enable the achievement of nationally consistent, minimum necessary standards of relevant safety (including structural safety and safety from fire), health, amenity and sustainability objectives efficiently.


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This goal is applied so:

• There is a rigorously tested rationale for the regulation; • The regulation generates benefits to society greater than the costs (that is, net

benefits); • The competitive effects of the regulation have been considered and the regulation is

no more restrictive than necessary in the public interest; and • There is no regulatory or non-regulatory alternative that would generate higher net

benefits. Policy Policies are clear, simple statements of how your organisation intends to conduct its services, actions or business. They provide a set of guiding principles to help with decision-making. Policies don't need to be long or complicated – a couple of sentences may be all you need for each policy area.

Job Safety Analysis or Safe Work Method Statement All safety requirements for the tasks you have been asked to do should be written down in the Job Safety Analysis (JSA) or Safe Work Method Statement (SWMS) for the job. Read this carefully and ask questions of your supervisor if these requirements are not clear to you, so that you will correctly follow all safety requirements for the task. Furthermore detail regarding any site safety requirements should be detailed in your organisation’s Site Safety Management Plans. Example of a Safe Work Method Statement is at Appendix A.

Safe Working Procedures/Safe Operating Procedures

Many organisations standardise the way in which they carry out a task, or operate machinery to ensure it is done to achieve a quality product and maintain safety. Previously discussed in this manual is a safe work method statement, this is a form of Safe Working Procedure. Another form is a Safe Operating Procedure (SOP), which is often a standardised way of operating an item of plant or equipment. An example SOP for the operation of a compound mitre saw is shown following.

Work Instructions Before commencing any job, you will need to receive specific work instructions. These are often presented to employees in the form of a Works Order. The instructions may vary according to the size of the task or project and there may even be some circumstances where no work instructions are given e.g. emergencies.


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Obtain, confirm and apply work instructions for the allotted task. Work instructions may include: - Verbal or written and graphical instructions, signage, work

schedules/plans/specifications, work bulletins, charts and hand drawings, memos, safety data sheets (SDS) and diagrams or sketches.

- Plans and specifications. - Quality requirements, including dimensions, tolerances, standards of work and

material standards. - Safe work procedures related to the operation of small plant and equipment on

construction sites. - Manufacturers Specifications are written instructions, which outline the installation,

maintenance and safe use of the manufacturer’s product.

Example of a house plan


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Products and services

Products and services to be provided are developed, checked and for availability and suitability for the job to be carried out. This to be established through the client / project manager and those tasked with performing the task(s). This may include but not limed to:

• Supervisors • Tradespeople • Specialists • Delivery people transported materials

Communication The purpose of communication is to get your message across to others clearly and unambiguously. Doing this involves effort from both the sender of the message and the receiver. And it's a process that can be fraught with error, with messages often misinterpreted by the recipient. When this isn't detected, it can cause tremendous confusion, wasted effort and missed opportunity. In fact, communication is only successful when both the sender and the receiver understand the same information as a result of the communication. By successfully getting your message across, you convey your thoughts and ideas effectively. When not successful, the thoughts and ideas that you convey do not necessarily reflect your own, causing a communications breakdown and creating roadblocks that stand in the way of your goals – both personally and professionally.


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Methods of communication Common forms of communication are verbal, non verbal, body language, signage such as hand signals, hand held radios and mobile phones.

On a building site verbal face-to-face communication is the most common and effective. However, if colleagues are a distance away from you or noise is an issue, hand held radios or mobile phones can assist greatly. Further, if other workers such as crane drivers are required to work on site hand signals are efficient forms of communication.

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In relation to hand signals and mobile phones the following tasks can be conducted safety

and efficiently.

• To guide crane operators when moving timber on site.

• Moving truck / vehicles on and off site

Mobile phones can be used on site for a range of work related tasks such as:

• To make calculations for materials or equipment

• To take photographic evidence of work for a range of purposes

• To communicate over long distances by talk or text.


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Teamwork What is teamwork? Teams are groups of people with complementary skills who are committed to a common purpose and hold themselves mutually accountable for its achievement. Ideally, they develop a distinct identity and work together in a coordinated and mutually supportive way to fulfill their goal or purpose. Task effectiveness is the extent to which the team is successful in achieving its task-related objectives. Shared goals are most likely to be achieved through working together and pooling experience and expertise. Successful teams are characterised by a team spirit based around trust, mutual respect, helpfulness and friendliness.

Benefits of successful teams • Improvements in participants' confidence, attitudes, motivation and personal

satisfaction • Greater clarity in expressing ideas through group discussion

• Better understanding by individuals of the nature of their contribution and of the needs of other team members

• more efficient use of resources – especially time

• Greater optimism – by focusing on positive outcomes and putting less weight on problems

• a wider range of ideas rather than individuals working in isolation

• more effective responses to changes – improved trust and communication help a team to adapt to new circumstances.

Potential drawbacks of teamwork So-called 'group think' can occur when a team is lulled into a false sense of satisfaction and loses its critical edge. Team members can waste time and energy in disputes and some members may opt out of the process – 'social loafing' – leaving others to do all the work. This can occur particularly when people feel they are dispensable.


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Reporting and Record Keeping Make sure you record any action you have taken and talk to your supervisor and WHS officer about the control strategies in place. Reports and records include: • Risk assessment reports • Incident reports • Job safety analysis (JSA) • Safe work methods (SMWS) • Workplace procedures

Keeping records is important as they can help ensure that any risk management activities are traceable. Records also provide a basis for improving methods and tools in the risk management process as well as improving the overall process. Sufficient Lighting To ensure work is carried out in a safe manner and access and egress to the work area is safe, operators must ensure that sufficient lighting is available and positioned appropriately. This includes entry / exit points. Ensure that if work is to continue during hours of darkness sufficient lighting is set up prior to conditions declining. If sufficient lighting is not available all work must cease immediately.

Hazardous substances Workplace hazardous chemicals are substances, mixtures and articles used in the workplace that can be classified according to their health and physicochemical hazards. Health hazards are hazards like skin irritants, carcinogens or respiratory sensitizers that have an adverse effect on a worker’s health as a result of direct contact with or exposure to the chemical, usually through inhalation, skin contact or ingestion. Physicochemical hazards generally result from the physical or chemical properties, like flammable, corrosive, oxidising or explosive substances


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The manufacturer or importer of a substance is responsible for determining whether or not it is hazardous. We can identify if a substance is hazardous by referring to the hazard statement on the first page of the safety data sheet. Hazardous substances are to be used, handled and stored in conjunction with manufacturer’s instructions.

Safety Data Sheets The hazards of chemicals cannot usually be identified by their name since they often have a trade name, giving no information about how to work with them safely. The information for the safe handling and storage of chemicals comes from the document that generally accompanies the product, known as the Safety Data Sheet (SDS).

The SDS will give information about the make-up of the substance, how to store it, first aid instructions and how to clean up spills or fires. There is a great deal of useful information on a SDS, which will assist in managing the chemical

The other source of information is the label, with very strict legislative requirements for the information that must be included. There are specific risk and safety phrases that form part of the label, and these phrases assist in managing chemicals and training employees.


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Environment The environmental impact of chemicals and other materials is diverse. Traditional painting materials and processes can have harmful effects on the environment, including those from the use of lead and other additives. Measures can be taken to reduce environmental impact, including accurately estimating paint quantities so that wastage is minimized, use of paints, coatings, painting accessories and techniques that are environmentally preferred. All jobs should be facilitated in accordance with the environmental plan with all regulatory obligations adhered to. Paints and other associated materials should always be disposed of appropriately in accordance with EPA guideline. Environmental protection is everyone’s responsibility and environmental protection regulations must be followed at all times.

Signage and barriers Control of access and egress to and from the worksite is imperative for the operational actives and for of all safety concerned. Signage and barriers are available in numerous, types, sizes and colour. To select the most appropriate signage and barriers for the task consultation should be carried out with the supervisor. In addition, there will be various acts, regulations, and code of practice that will need to be adhered to. Furthermore, there may be various permits and or licences required to perform at the site. Highlighted below are some of Signage and barriers types available:


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Plant Under the WHS Act 2011 a PCBU has a primary duty of care to provide information, training, instruction or supervision that is necessary to protect all persons from risks to their health and safety arising from work carried out as part of the conduct of the business or undertaking. In relation to information, training and instruction for plant; the WHS Qld Plant Code of Practice (2005) states that: Workers who are likely to be exposed to plant risks and anyone supervising these workers should be trained and provided with information and instruction on: • The nature of the hazards and risks associated with the plant and systems of work. • The need for, and correct use and maintenance of control measures. • Operation of plant and the procedures for safe use of the plant.

• Emergency procedures in case of a plant malfunction or other incident. Generators and air compressors are typical plant utilised by trades people.


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CPCCCA3018A Construct, erect and dismantle formwork for stairs and ramps Introduction Any building which is something more than a simple slab on the ground structure, requires some form of stairway The materials chosen for stair construction are determined by such considerations as • The availability of the various materials

• The position the flight will occupy in the building

• The degree of exposure to weather conditions

• Whether a fire rating if required

• What aesthetic qualities the stairway should have

Stairways may be constructed of timber, brick, stone, steel or concrete. Concrete stairways are versatile in application, and the construction of the formwork for concrete stairs form the content of these class notes. For the construction of concrete stairs, knowledge of concrete formwork and general stairway calculation methods are essential. Topics • Terminology

• Regulations

• Stair Plans

• Formwork Details

• Calculations

• Construction of Formwork

Your objectives At the completion of this unit you will be able to: • Correctly use terms and name the components relevant to the formwork required

for concrete stairs • Interpret regulations with respect to formwork for concrete stairs • Draw a vertical section through the formwork and falsework for a concrete stair • Perform the necessary calculations required for setting out concrete stair formwork • Calculate the quantity of concrete required for concrete stairs • Set out and construct the formwork and falsework required for a flight of concrete stairs or ramp Terminology Much of the terminology used for general stair construction is applicable to concrete stair work, e.g. rise, going, rise of flight, going of flight, quarter and half spaced landings and headroom.


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In addition to these we have:

Sole plate A Sole Plate is a horizontal piece of timber or other rigid material, beneath a short pop or jack to distribute the load from the member above.

Stiffening piece Raking members frequently 100x75, placed on top of the riser boards, used in conjunction with cleats to prevent the rise boards, used in conjunction with cleats to prevent the riser board bending or bulging along their lengths.

Carriage piece A Carriage piece is similar to a joist in concrete stair formwork situations; these can be seen sitting on the bearers supporting the decking of the stair soffit.


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Brace A horizontal or raking member resisting a compressive or tensile stress in a bracing system. In the image above on the right, the cleats and the braces can be easily seen.

Folding wedges Wedges used in pairs to tighten, loosen raise or lower props or other members. Example seen in the image above. They are used to aid in the release of forms after concrete has set.

Riser board The board that forms the vertical face of a step, seen above between the wall and side stringer.


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Cleat • A timber member nailed across a

number of boards to hold them together.

• A block fixed to a minimum member to

provide a bearing or resist a thrust

Seen in this photo the cleat supports the side formwork where two timbers are joined for the building of a ramp.

Wall string A raking member fixed to the wall above the ends of the riser boards, where the stairs are constructed against an existing wall and to which cleats are fixed which then hold in position the ends of the rise boards.


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Outer string A raking member of formally or boards cleated together, placed on edge and set at right angles to the raking decking to resist the lateral thrust of the wet concrete, and to take cleats which position the riser boards.

Decking The sheeting to a soffit form. This deck is one of the parts of the preformed staircase. It is the form ply sheeting that is on the angle shown in the image on the left.

Tie wire A term of many meaning, but generally any wire, that holds two members in their relative positions whether to form members or secure reinforcement.

Bearer A Bearer is a horizontal member supported on shores or hangers and carrying joists. In this image three bearers on props, can be seen holding up the underside of stairs till concrete has set.


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Spacer A short piece of timber or other material to hold form faces at the correct spacing’ These members when combined come into the category of formwork or falsework. Formwork refers to the sheeting that actually contains the plastic concrete, forming it to the required shape and size, while falsework refers to the structure, which supports those forms.

Regulations and requirements Although formwork and false work are temporary structures, a high standard of accuracy and workmanship must go into their construction. The same rules apply to formwork for concrete stairs, as applied to other types of formwork. The forms are constructed the reverse shape of the intended structure, and must be capable of supporting their own load, the load of the plastic concrete, and the loads of any equipment and workmen placed upon them. The basic requirements of good formwork are always: • Quality • Safety • Economy Quality is achieved if we acquire: • Accuracy in size, shape, position and alignment • Sufficient rigidity to prevent movement, bulging or sagging during the placing

of the wet concrete • Tight joints, which do not leak mortar • Forms which give a good finish


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Safety is achieve when we: • Erect a strong structure designed to carry the full load and side pressures

from wet concrete • Use durable materials of correct size and quality for the job Economy has been achieved when the forms are: • Simple to erect and dismantle • Easily handled due to their lightweight • Standardised • Re-usable Dead load The dead load (static load) refers to the load applied to the formwork from the reinforcement and concrete.

Live load The live load (superimposed load) refers to the load applied to the formwork from the weight of workmen and construction equipment used for the correct placement of the concrete. Because there is a tendency for inexperienced form-setters to underestimate the stresses imposed on false work, legislation has been passed to ensure that formwork be designed by qualified persons.

Formwork code of practice 2006 Regulations in the Building Code of Australia relating to the design of stairways, apply equally to concrete stairs, as well as to stairs constructed of other materials.

Stairway dimensions The widths of the stairways must not be less than 750, which distance must be clear of all obstructions and projecting parts. The vertical clearance must extend to a height of 2000 for the full length of the stairway, measured vertically above the nosing line.


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Landings The maximum number or rises a stairway may have is 18. Where more than 18 rises are necessary, a landing must be included. The landing must be not less than 750 wide clear of all projecting parts, and not less that 750 in length.

Proportioning of stairs

Regulations require that the going and rise to be constant through out all flights in that stairway. A well-proportioned stairway must satisfy the equitation. 2R+ G = 550 – 700 R = rise G = going

Regardless of the above equation the rise must not exceed 190 or be less than 115, and the going must not exceed 395 or less than 240


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Handrails and balustrades Where a stairway is more than 1000 high, any side which is not bounded by a wall, must be provided with a balustrade. The handrail is to be fixed to a height of not less than 865 above the nosing’s of the stair treads. It must be continuous between landing and have no gap in the rail wider than 125. No obstruction is permitted either on or above them which will tend to break a hand hold.

Stair plans - Refer to BCA - Building Code of Australia

Stair plans used for the majority of concrete stairways are basic and include the following; • Enclosed straight flight • Straight flight with balustrade • Enclosed straight stair with landing • Straight stair with landing, newels and balustrade • Stairway with quarter spaced landing • Stairway with half spaced landing On some public buildings such as libraries, geometrical stairs of various styles are added, where a need is felt for a certain aesthetic appeal.

Stairway with quarter spaced landing Polished concrete with split direction stairs


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Enclosed straight flight Straight flight with balustrade

Enclosed straight stair with landing Open straight stair with landing and

balustrade

Stairway with half spaced landing

Stairway with winders (only three winders should be used)


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Formwork details The following details are typical of construction methods for formwork and should be studied in relation to the appropriate paragraphs in this class note.

Formwork for concrete stairs


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Prefabricated concrete stair form Helical concrete stairs

As concrete work has progressed so much in the last ten years many concrete forms are premade in factories or yards and then transported to site. Preformed flat panels and staircase construction has become more cost effective and work efficient to be prefabbed. Unfortunately many small formwork jobs are built on site so the knowledge to both how to build and calculate formwork is definitely needed.

Calculations: The diagram above is a sectional elevation through a flight of concrete stairs and landing. The rise is 170mm and the going is 250mm. The riser is splayed back 25mm. The width of the landing and stairs is 1.250m. Length of parallelogram 2.420m To calculate the volume of concrete required to construct the stairway and landing complete, the following method may be used. Divide the sections into calculable parts A, B, C, D (Z length = 700mm) Note Z length is not to scale. In practice the formwork is constructed before the concrete is ordered, therefore sloping lengths can be measured directly from the existing formwork.


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Calculations for above diagram • Divide the section into the calculable parts ‘A’, ‘B’, ‘C’, ‘D’ • Calculate the areas of each part and total same 8 times the area of triangle ‘A’ = 8 × Base × Height

2 = 8 × 0.275 × 0.170m2

2 =0.187m2

2 times the area of triangle ‘B’ = 2 × Base × Height 2 = 2 × 0.250 × 0.170m2

2 = 0.0425m2

Area of parallelogram ‘C’ = Side × perpendicular distance between sides = 2.420 × 0.150m2 = 0.363m2

Area of Rectangle ‘D’ = Length of z × depth = 0.700 m × 0.150 = 0.105m2

Calculate total area = 0.187 + 0.0425 + 0.363 + 0.105 = 0.6975m2

Find the volume by multiplying sectional area by width of stairs Round up to the next 0.2 of a metre = 0.6975 x 1.250

=0.872 to next .2 of m3 =1m3

Calculations for rises and goings When calculating the rise, going, number of treads in each flight, headroom etc., the same procedure is followed as for timber stairs. The calculations for rise and going and other items are below. Example: A straight concrete stairway in two flights, with a middle landing is to be constructed between two concrete floors. The total rise is 2275 and the rise must not exceed 180. Calculate the rise and a suitable going, the number of rises in each flight, and the going of the stairway. The middle landing is 900mm long.


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We proceed as follows: Trail number of Risers = total rise

trail rise = 2275 ÷ 180 = 12.638

As the rise must not exceed 180 we will use 13 rises. Rise = total rise

number of rise 2275 ÷ 13 = 175

Suitable going (2R +G) = 600 = 600 – 2R = 600 – 350 = 250

Total number of rises is 13

The 7 rises are in the lower flight

And 6 rises are in the upper flight

No. of goings in lower flight =7 – 1 = 6

No of going in upper flight = 6 – 1 = 5

Total number of goings = 11 + 1 middle landing

Total going = (11 x 250) + 900 = 3.65m

Construction of formwork The set out when adjacent to a wall. When the stairs are to be constructed adjacent to a wall, the position of the various members are easily located by marking the height of the landing on the wall, and drawing the zigzag line which represents the top of each step, and the face of the riser. The thickness of the concrete for the landings and the throat thickness are marked on the wall and the soffit lines drawn in. The necessary falsework is then drawn in place. By using this full size in situ set out, the position of the members is fixed, and the lengths of the carriage pieces, joists and props can be determined. The props may be timber, or adjustable steel or a combination of both. Procedure 1. Set out accurately the going rod and the height rod.

2. Check the total height and total going and number the rods correctly.

3. Mark the line for height of landing or floor on adjacent brick or concrete wall.

4. Draw zigzag line to give front and top of each step by working from height rod and going rod. (Use a level and straight edge for this purpose).


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Procedure for setting out concrete stairs

5. Measure required thickness of concrete below top of landing and under the stairs

and draw soffit lines. (see Figure 4)

6. Draw U beam in position allowing for regulation covering of concrete

7. Measure for thickness of decking and draw lines parallel to soffit lines.

8. Draw formwork round beam. Draw supports for formwork.

9. Draw carriage piece, landing joist and formwork.

10. Draw timbers above the stairs to show sectioned riser boards, stiffening piece with

cleats and wall string.

11. Cut and erect formwork adjacent to the setout.

Procedure for setting out concrete stairs


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Stiffening piece The purpose of the stiffening piece is to prevent the riser board from bulging along its length as a result of the pressure from the wet concrete. They are commonly of 100x75 in section, and in a wide flight of stairs, more than one may be needed. They are placed on the rake, resting on the top of corner of the riser boards. Cleats with one end cut to fit against the riser, are nailed alternately to opposite side of the stiffener. A strut cut between the lower end of the stiffener, and if possible an opposing wall, helps to prevent movement. Tie wires taken over the stiffening piece down through the decking, and around the carriage piece or bearer help to prevent the stiffener from being force upwards as the wet concrete is placed. See diagram and image below.


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Intermediate support An intermediate support consisting of a cross member known as a bearer supported on props, and located half way along the length of the carriage pieced is required for all but very short flights.

Tolerances

Absolute accuracy should be aimed for in the finished stairway, however certain tolerances are accepted. As per AS3610 formwork for concrete

A part of a sectional elevation of concrete stairs. Use of metal props


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Method of supporting wall strings and stair on brick wall

Large set of concrete stairs laid on top of cut stone Hickson Rd Sydney


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Formwork for concrete stair (wall strings)

Beams Refer to diagram above and below with regards to beams. Where large well – holes are required in floors to receive stairs and allow for sufficient headroom a concrete beam. Reinforce with either mild steel rods or a U beam is placed at the edge of the well hole to support the floor.

Well in floor for cellar in kitchen Concrete surround metal stairs.


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Concrete with mild steel rods The diagram below shows the formwork for a enforced concrete beam consisting of a soffit and two beam sides. Supported by cross heads and props. On the right is the formwork supporting the floor concrete and reinforcement (all reinforcement is omitted for clarity). Note provision in the decking for expansion and the space at the end of the joist for wedges. This ensures that the joists do not bind tightly on the beam sides, making stripping difficult. On the left the formwork for the upper portion of the concrete stair is shown in position against the beam. The carriage piece is birds mouthier over the crosshead or bearer; (sometimes over a runner resting along these cross heads, as is the case where the suspended method is used) a pair of folding wedges is fitted between the vertical cut of the birds mouth and the end of the cross head, to simplify the stripping of the formwork. The outer string shown rests on edge on the decking at the pitch of the stair. The upper end of the string is cut off vertically to butt against the beam side- the portion shown dotted. After the two strings are butted and fixed to the beam side, a portion of the latter is cut away between the tow-strings down to the level of the decking. This is to form an opening through the beam side at the top of the stair, to allow the concrete of the stair to merge with that of the beam.

Top of flight showing reinforced beam and propped shuttering


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Reinforcement The size and position of the reinforcement is calculated by a designing engineer, and is not the responsibility of the builder. However the builder is responsible for the placement of that reinforcement according to the plans and specifications. It should be placed in position before the riser boards are in place. It may be in the form of fabric, or rods with hooked ends running from top to bottom of the flight. Where the flight is to join a concrete floor already poured and set, the hooked ends of the reinforcing rods should be left projecting from the floor, to be tied to the reinforcement of the stair.

Concrete with u beam

Diagram above shows the formwork for concrete beam reinforced by a U beam from which the shuttering is suspended. The carriage piece is birds mouthed over a runner, which rests on the crosshead. There are no wedges used at the birdsmouth but they may be used in the space left between the carriage piece and the beam side. This space also allows the carriage to be easily stripped from the decking when the crosshead and runner are released from the U bolt.

Straight stair sectional elevation


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Ramps Within this topic there has been much discussion on the formwork and set out methods of stairs. As the topic also includes ramps we will also examine:

• Places where we build and use ramps • Formwork for ramps • Rules for construction of ramps

The function of a ramp is to form an uninterrupted path of travel. A ramp may be installed inside or outside the home. The reasons are numerous as to why ramps are use in certain places, these may including

• Mobility purposes for the elderly or disabled. • Fun • Sport • Aesthetics - Pleasing to the eye (looks good) • Ease of access when providing deliveries • Providing ease in travel

Places we use ramps Ramps give the user clear direction from one level to another. In sporting situations ramps are used in swimming pools, skate parks and cycle ways as a means to cross main roads and train tracks. When ramps are used in skate parks the Australian standards for ramps are not followed as trick areas are involved. As both swimming pools and cycle ways are in public areas Australian standards are involved and used.

Aesthetically Pleasing


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Mobility purposes

Access to sporting facilities


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Fun and sporting purposes

Ease of travel up hill Wheel chair access to National parks


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Concrete boatramp Circular carpark ramp

Formwork for ramps Formwork for ramps is simple and should follow the basic rules of good formwork as already discussed with regards to concrete stairs being made with Quality, Safety and Economy always in mind. The forms are constructed the reverse shape of the intended structure, and must be capable of supporting their own load, the load of the plastic concrete, and the loads of any equipment and workmen placed upon them. Below are images of different formwork for ramps.

Formwork for skate park ramps and tricks Concrete being sprayed onto forms

Concrete at threshold Spiral car park formwork


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Formwork for ramps Formwork combined stairs and ramp

Formwork for ramps includes similar items to those used in other formwork situations. For example bracing cleats to hold the sides of the formwork in place. Steel Rio mesh is put in place and end stops are placed to finish at a certain location. Timber and steel panels are used to create forms required. Rules for construction of ramps The rules for construction of ramps are listed below. AS 1428.1 outline the minimum gradient requirements for ramps in public buildings.


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When building accessible ramps to building or paths inside a building to all services and facilities for people with physical disabilities with regards to movement the items below should be investigated and contemplated. Is there a clear accessible path of travel with no steps or other barriers (such as steep inclines, bollards, uneven or loose surfaces) from each accessible entrance to all areas and facilities used by the public including reception areas, interview rooms, toilets and other facilities?

Are passageways wide enough for a person using a wheelchair or walking frame to pass by someone else or are there regular passing spaces?

Are floor coverings slip-resistant, firm and smooth?

If the path of travel includes a ramp does it have a gradual slope/incline? Does it have handrails, safety kerbs or kerb rails at the floor level to stop wheels going over the edges? Does it have level landings at regular intervals to allow someone to rest?

Clean up On completion of any concreting work the area should be completely cleared and waste material disposed of safely. Any excess materials should be stacked and stored to allow for use at a later date. All tools and equipment should be cleaned, maintained and stored away in a safe manner.


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Care and Maintenance of Plant, Equipment and Tools You should follow any organisational protocols when managing tools and equipment. However the following general principles will apply to all tools on site. • Tools and equipment must be cleaned, maintained and stored correctly.

• Hire equipment items must be counted, accessories noted, and all must be located where the hire company can pick them up with any faulty parts noted.

• Company – owned tools and equipment must be checked and maintained.

• Timber handles on tools can be wiped with raw linseed oil.

• Metal blades on tools can be wiped with mineral oil.

• Equipment with their own storage cases must be returned to their cases together with blades, attachments and accessories.

• Any damaged or faulty equipment must be tagged and reported so that it can be repaired.

• Safety signs and barricades must be removed and stored for later use.

• Rubbish and recyclable materials to be disposed in accordance with environmental policy.

• Any plant hired is to be returned in accordance with hire company protocols and organizational safe work practices.

NOTE: Any machines used must be greased and, if necessary, have them serviced before returning them to storage so that when they are next required they are ready for operation. Work Area ! Work area is cleared and materials disposed of or recycled in accordance with

project environmental management plan. ! Machinery, tools and equipment are cleaned, checked, maintained and stored in

accordance with manufacturers’ recommendations and standard work practices. ! Any defects or damage to the equipment must be noted and reported in accordance

with the site procedure to allow any repairs or servicing to be carried out.


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Materials It is important that all waste material is removed from the site. This may include: ! Particleboard, MDF, timber plywood offcuts etc.

! Oils and fuel

! Garbage materials, general waste.

Restoring the Worksite ! The final operation at the worksite is the restoration of the site.

! The extent of the work required will depend on the size of the work undertaken and the location of the worksite.

Clean up is not only for the benefit of the customer but also for yourself. It helps in a number of ways for example, shows you what materials you have left and can save you on the next job. It helps make sure you have all your tools after the job is finished, as they are costly to replace. It gives you an excellent name in your business and can be a way of getting more work, as people will talk about great workers and how clean you left the worksite. It also creates a better job completed.


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Q1. Name the five items indicated by the arrows.

Q2. After stripping steel formwork list three (3) jobs that should be undertaken to ensure it is ready for reuse?

1. _______________________________________________________________

2. _______________________________________________________________

3. _______________________________________________________________

Q3. Explain the construction method used to prevent the centre of the riser boards form bulging upwards.

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

Q4. What is the purpose of splaying the riser?

__________________________________________

Self Checks


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Q5. Sketch a section of concrete stairs to illustrate the throat.

Q6. What is the maximum allowable splay for risers?

__________________________________________

Q7. Select two (2) power tools that you would use constructing formwork and state two (2) items that you would check prior to using the tool.

Power tool Check List

1. 1.

2.

2. 1.

2.

Q8. List two (2) environmental protection requirements that you would consider prior to constructing formwork.

1. __________________________________________________

2. __________________________________________________


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Q9. List two (2) appropriate signs that should be displayed on a building site where concrete formwork is being undertaken.

1. __________________________________________________

2. __________________________________________________

Q10. State the minimum and maximum rise for treads in a concrete stair.

Minimum rise __________________________________________

Maximum rise __________________________________________

Calculate the required amount of concrete required to build a set of stairs between a split level with overall size of 1.150m wide. The total rise is 1.220m high and the rise of each step is between 165 and 180mm. Length of parallelogram 1.990m. Throat depth 0.150m The going of each step if the Quantity of 2R + G = 610 The number of risers Rise of step *Going of each step * The total going of the flight Parallelogram length 1. Steps area

2. Base heel and top heel area

3. Parallelogram area

Calculate the total area Find the volume of the concrete required for pour.

Practical Exercise 1


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Don’t forget to complete the Job Safety Analysis on the last page for Construct, erect and dismantle formwork for stairs and ramps project. Please hand this in to your trainer to be compiled with your written Assessment. The work location is on-site. Write in some of the hazards below before attempting JSA as a team. _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Conclusion This learning package has combined the theoretical and practical components required for the competency unit CPCCCA3018A Construct, erect and dismantle formwork for stairs and ramps Having successfully completed the requirements of this competency unit you now understand the correct methods for building stairs and ramps from formwork and falsework in your carpentry trade field and different situations in which they may be used. In addition, you have applied the knowledge and skills in a number of real life situations.

You can expect to apply your knowledge and skills again and again on a range of construction sites both for new homes and in existing building renovations.

Practical Exercise 2


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Student Name : Student Signature:

Project: Trainers Name:

Location: Date: Accepted: Yes " No "

Procedure - List of steps in doing a Job on a site.

Possible Hazards – What things can happen or go wrong, also what hidden dangers are there on this Job Site?

Risk

Safety Control – How can I stop or minimize these things happening or going wrong or injuries occurring?

Risk

Signature Trainer / Site Leader_____________________________________ Signature Building Supervisor___________________________________

Job Safety Analysis – 1 Copy to be handed in for each unit


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Consequence

Likelihood1 2 3 4 5

Insignificant Minor Moderate Major Catastrophic

A (AlmostCertain)

11 16 20 23 25

B(Likely) 7 12 17 21 24

C(Possible) 4 8 13 18 22

D(Unlikely)

2 5 9 14 19

E(Rare) 1 3 6 10 15

Low Medium High Extreme

JobSafetyAnalysis–RiskMatrix

cpccca3018a construct erect & dismantle formwork for

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