TQM Finds Do It Yourself Works With LYSAGHT BONDEK®

Location:	Rockdale, New South Wales
Country:	Australia
Builder:	Stephen Fabrizio TQM Design and Construct Pty Ltd Ph: 02 9764 6653
Products Used:	LYSAGHT BONDEK®

A successful Sydney design and construction company is completing a new apartment block at Rockdale using materials and methods it has combined to maximise speed and efficiency. TQM Design and Construct Pty Ltd has only operated since 2000, but its record of success is already the envy of many competitors.

The Soho Apartments block includes six large retail spaces on one level and 103 apartments over seven levels above five levels of underground parking.

"This is one of the largest buildings we have taken on, but we have successfully completed several 60 unit apartment blocks in the Alexandria area," said Construction Manager, Stephen Fabrizio.

He also pointed out that that TQM Design and Construct has a healthy order book which will keep its multi skilled workforce busy through much of 2007.

Composite slabs created with LYSAGHT BONDEK® structural steel formwork are integral elements in the Soho Apartments project and have been used on previous TQM constructions.

"We took on this project from development application stage and carried out the complete design and construction task," Stephen Fabrizio said.

TQM's speed and efficiency isn't just achieved at the construction phase. The company sets the basis of its success by using a design process with the focus on making the structure easy to build.

"I get involved with the structural engineers from the outset," Stephen said. "I've had experience with other structural steel formwork systems before, but my preference is to use BONDEK®," he said.

"One of the things we like about BONDEK® is that it is so easy to install. As part of our efforts to increase our efficiency we have ensured that our workforce is multi skilled. It takes the average worker only an hour to learn how to install BONDEK®, so it was very easy to take that trade in house. By using the 0.6mm BONDEK® to form composite slabs we have been able to specify concrete thickness of 150mm for each floor instead of having to use 200mm."

"We are achieving 1.5 metre spacing for the propping during concrete pours and there are no visible deflections. There aren't even any indentations left along the propping lines. When you calculate the reduced requirement for concrete and reinforcing steel over the eight above ground levels of the building, that design has achieved significant time, labour and cost savings."

"The composite slab design allowed us to use smaller foundations, smaller transfer beams and smaller transfer columns. Upper levels have a perimeter concrete beam and because of the weight reduction over a conventional slab we have been able to incorporate cantilevered areas of up to four metres. That's not just good for the builder, it also provides column free areas which can improve the look of the building."

TQM also designed the Soho Apartments building with a system of AFS composite walls, installed at the same time as each BONDEK® based slab.

Penetrations cut in the pans of the BONDEK® sheet above each panel allowed a single concrete pour for each slab and for the composite walls on the level below.

Stephen Fabrizio believes thick post tensioned concrete slabs have their place in construction, but that there are often better methods which are just as effective and not as expensive.

"We've been successful by designing buildings which are easy and economical to build, using our own workforce for much of the work," he said.

"Using our own workers to install the BONDEK® is another important thing we can do to give us greater control of the construction schedule. On this building we've only needed ten to 12 workers for the formwork and the stripping out is really simple. When you compare this approach to using conventional formwork we've halved the manpower requirement while doubling the speed and follow on trades are just as happy working with BONDEK® as they are with a conventional slab."

"Plumbers create penetrations by boxing up an area before the slab is poured and then cut the BONDEK® with an angle grinder when the concrete has cured. Plasterboard just goes on with needle fasteners."

Stephen Fabrizio said BlueScope Lysaght deliveries had also been reliable. "This is a very congested area, with no room to store material, so you have to establish delivery schedules and stick to them and that has happened," he said.

With its busy construction schedule, TQM Design and Construct is keen to apply the lessons learned from each project to the way it goes about designing and building its next.

"We are happy with what we have achieved here, but there are a few things which we could tweak for our next project," Stephen Fabrizio said.

"From what I now know about BONDEK® and how it has helped us with this project, I'll be looking to make the most of its spanning ability on our next residential project. By specifying a greater thickness we will be able to absolutely minimise propping requirements for the spans which we typically use."

BONDEK® has excellent spanning capacities for greater strength and less deflection. Ribs at wide 200mm centres, with slip resistant embossments ensure a safe and easily trafficable deck for formworkers.

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