Rented the form panels last Friday and started setting them up this weekend.
Semi-slow process as a one-man operation. The panels are 1 1/8" MDO plywood which, a full 4x8 sheet weight over 100 lb. So the half panels are still 50+ lb. Not horrible but I need to carefully stack the panels on top of eachother and manouver them over the sharp edges of the rebar and tie wire. . . all the while dealing with a panel that was recently coated in slippery form release agent.
Fun.
Oh, and the various panel sizes tend to be more nominal than actual. Panels sizes have been varying by 1/2 - 3/4" +/- in many cases with the edge not cut square. Lots of futzing and re-cutting about 1/3 of the panels. Next time I won't design in such tight tolerances. The panels are also pretty beat up from the rental use over time. So the concrete will look a bit more "rustic".
I have about 75-80% of the panels installed but still need to plumb and square them up plus install the door buck outs and chamfer strips. Still much to do.
1200+ lb. worth of rented formwork panels.
Panoramic view of my back yard with the new patio off to the left and the
shed work zone straight ahead. Picture is looking straight down the access
path from the fence gate. Off to the right is material storage (on the other
side of the trailer) for the lumber and plywood that is out of the vehicular
access path.
The wall formwork is 3 ft tall and employs a 1 ft wide panel (on the bottom)
and a 2 ft wide panel (top). This shows the 1 ft wide panels set into the
clips that were nailed to the top of the footing concrete. You can see the
form ties spanning between the two panel lines that will help to hold the wall
together when the concrete is poured.
The 2 ft panels are being installed here. They are set on top of the lower
panels and sandwich the form ties. Metal "shoes" are then slipped over the
ties and hammered tight to help lock in the panels. Top spreader clips are
still needed to keep the tops of the panels from flopping out. It's tricky
because the two stacked panels aren't really stable until you get the ties and
spreader clips at the top attached to both inner and outer from panels. Lots
of precarious balancing until then.
Setting up the big shed building now. Note the 2x8 blocks set across the
lower wall panels to help support the horizontal rebar until it was tied off.
For the top band of rebar some clamps did a good job as temporary ledges
to support the rebar until it was tied off.
Working to set up the form panels on the shed building. Each panel was
coated in diesel fuel as a release agent before installation. It made handling
the panels a bit more tricky with them being slicked up. The back panel can
be seen leaning against the rebar until the panel on the saw horses is fully
coated and installed.
Working methodically around the perimeter of the foundation. The walls are
somewhat self supporting at this point but they are still wobbly. Eventually
they will be double checked for alignment and braced off.
Shot of the form cavity with the rebar running right down the middle.
This is where things are at now. The end walls were left un-finished as I cut
some wood for the door buck outs.
Some 2x8's ripped down to an exact 6" wide and then cut to length for the
door buckouts. The holes are drilled in the bottom pieces to let air escape
and (hopefully) prevent air pockets and voids under the buckouts.
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