housing construction process

8/7/2019 Housing Construction Process

1/64


2/64

Wall-Ties & Forms, Inc, (WTF) is one of the world's largest

companies in the concrete forming business, as well as the premier

designer and manufacturer of concrete forming systems. Over 33

years ago as a new business, WTF manufactured ties - thousands of

them. Today we produce and ship over 30 million ties a year and

over 200,000 aluminum concrete forms.

It started in 1976 when Orval Engelken and Ross Worley, two menwith extensive knowledge of the construction industry. They left long

and successful careers, one a national sales manager and the other

a product design and manufacturing expert, knowing they could do a

better job.

Three principles guided them:

1. Produce the best quality and most labor friendly product.

2. Offer unsurpassed customer service.

3. Provide it all at a competitive price.

The rest is history!


3/64

WTF Manufacturing Facility

160 Employees

Over a 120,000 Sq. Ft.


4/64

The WTF Formwork System (manufactured byWall Ties & Forms, Inc.) is unique because itforms all of the components in the structureincluding, walls, floor slabs, columns, beams,stairs, window details, balconies, and variousdecorative features in exact accordance with

the architect's design. No other system canmatch WTF Formwork flexibility to handle alldesign conditions.


5/64

The WTF System is erected by unskilled labor andwithout the need of hoisting cranes. The largestcomponent weight is not more than 32 kgs (70 Lbs).This enables a single worker to handle the WTFformwork components. The forms and other sections aresecured and fixed with steel pins and wedges with

formwork ties. The only tool required is a hammer. TheWTF System can save as much as 10 - 20% of the totalcost of construction and increase speed as much as 30 -50% over traditional methods such as block andpost/beam construction.


6/64

The WTF Aluminum Formwork System for concreteconstruction is the most versatile construction system inthe world. Unlike other systems, it is equally suited toconstruct both high and low rise structures.


7/64

The WTF Formwork System is specifically designed to allow the rapid construction of multiple unit projects.The system is cycled daily to achieve optimum productivity.

One and two story duplex project in Mexico consisting of 8,500 units


8/64

The simplicity of the WTF aluminum

formwork is ideal for unskilled labor andenables unskilled labor to achieve thehighest of production rates.

Every component is light enough to behandled by one worker, minimizing theneed for heavy lifting equipment.

The only toolneeded to erectthe formwork is ahammer.


9/64

WTF aluminum formwork enables the developer tocast most if not all elements of the structure.

This includes structural, non-structural, andarchitectural elements


10/64

The formwork for these structures included all elements, structural, non- structural, and architectural. Thearchitectural elements include, radius headers, decorative columns, pitched concrete roof, and rain gutters castdirectly into the decorative moldings.


11/64

Casting all elements achieves a costsavings of 10-20% over traditional methods.This home was constructed by Homex ofMexico. Homex is the largest builder inMexico with 51,000 home starts a year as of2009.


12/64

Casting all elements also speedsconstruction 30 - 50% over traditionalmethods. This is achieved by thespeed of the formwork system, thereduction of follow-on trades, and theease of finishing the surfaces.


13/64

One of the principal technical features whichenables the speed to be attained using asingle set of formwork is the unique deckbeam system. This allows the formworkremoval to take place while leaving the decksupports undisturbed. The deck panels canthen be reused immediately.


14/64

The precision of the WTF Formwork enables doors and window frames to be directly installed on sitewith no re-sizing required.


15/64

Because openings are so precise, the developer can beconfident in the pre-purchase of doors and windows.Often times the developer can purchase these items foran entire project with huge cost savings.

Th t f d d ith th


16/64

The concrete surface produced with theformwork allows the achievement of a highquality wall finish without the need forextensive plastering.


17/64

Formwork set for final inspection at manufacturing facility in Shawnee, Kansas, USA.

Because the WTF Formwork is constructed with the highest quality aluminum and

welded with robotics, developers can expect 2,000 uses or more with proper care.


18/64

Often times the formwork outlives the life of the project and can be cycled to a new project. Because

the formwork is modular 70- 90% of the forms are easily adapted to new construction projects.


19/64

From foundation to multi-story construction, the following pages illustrate the WTF Formwork process.


20/64

The process begins with compaction of the site. Trenches are

then dug, plumbing installed, and WTF slab formwork is set.


21/64

Once structural footings are dug, slab steel isinstalled in accordance with local code.


22/64

Concrete is then placed using local methods.


23/64

Wall steel is then tied in accordance with local building codes.


24/64

Electrical boxes and conduit are attached to the wall steel. Rigid or flexibleconduit may be used depending on local building codes.


25/64

When constructing mass housing projects it is wise toprep slabs well in advance. The WTF FormworkSystem can be cycled daily for very rapid construction.


26/64

The beginning of the WTF formwork process normallystarts in a corner or multiple corners depending on thenumber of workers. This process continues until all

walls are erected.


27/64

Once wall forms are set, decking can begin.Decking like wall formwork is hand-set andbegins in a corner.


28/64

Upon completion of

decking, steel andelectrical is installedin preparation ofconcrete placement.


29/64

When all prep work is complete,concrete is placed monolithically inwalls and deck. Concrete placementis normally completed using a boompump but is dictated by local marketequipment. This can include trailer

pumps, crane buckets, and evenhand bucketing.


30/64

The WTF formwork is removed

the very next day to begin thecycle again.

F lti t t t


31/64

For multi-story structuresscaffolding is then attached.The scaffolding not onlysupports the weight of theworkers but also supports theexterior wall forms.


32/64

Steel is tied, forms set, andconcrete placed repeatingthe daily cycle.


33/64

For markets with extreme climates, the WTFFormwork System easily incorporatesinsulation into the construction process. Theexpanded foam insulation is installed betweenformwork ties prior to setting exteriorformwork.


34/64

After concrete placement and curing, formwork is removed leavingfoam insulation permanently bonded to the concrete.


35/64

The WTF Formwork Systemis in use in over 45 countriesworldwide. The followingpages are just a fewexamples of the WTF globalpresence.


36/64


37/64


38/64


39/64


40/64


41/64


42/64


43/64


44/64


45/64


46/64


47/64


48/64


49/64


50/64


51/64


52/64


53/64


54/64


55/64


56/64


57/64


58/64


59/64


60/64


61/64


62/64


63/64


64/64

housing construction process

Documents