Comfortable state-of-the-art homes are in increasing demand in many emerging countries in Asia, the Pacific Rim, India, and the Middle East. A good example of state-of-the-art technology helping to make large-scale construction projects successful is in the city of Kermanshah in Western Iran. Here, 57 residential buildings, each with 15 floors, are being built in the city’s Pardis neighborhood, which translates to paradise. They will provide new homes for more than 5000 people. Work flow and schedules are tight since the families are anxious to move into their new light-flooded homes by 2014.

All residential buildings have the same layout: Four large-size flats are grouped around a central flat. The walls, beams, slabs, staircases, and elevator shafts all have similar dimensions. Thus, all formwork is going to be used hundreds of times. It needs to be robust because the tight schedule won´t tolerate delays due to rework or time-consuming job-built solutions. Contractor Payahoor decided to invest in MEVA formwork because plywood is no longer a viable option: The 100% wood-free, all-plastic facing used in all its formwork systems proved the ideal solution.

Alkus all-plastic facing, wood-free and durable

The polypropylene alkus facing, which is reinforced on the inside by thin aluminium foil, lasts as long as the frame and makes re-facing redundant. No wood needs to be purchased and none is wasted. There are no interruptions to workflow, which is a major benefit. Minor damage such as nail holes are repaired on site using the identical material. It can be cut, welded, and bent for custom-made solutions. Thus, special angle-shaped forms were made from alkus to avoid time-consuming job-built solutions. The alkus angles are used to pour the change in ceiling height that occurs along the inside walls between the lobby and the flats.

Early stripping substantially reduces material inventory

The slabs are poured using the MevaDec slab formwork and applying the drop-head-beam-panel method. The drop head allows for early stripping, the props remain under the poured slabs while the panels and beams can be removed early for the next slab. Thus the site needs two sets of props but only one set of panels and beams to do the entire slab jobs. With a total of 855 slabs of 7800 square feet to be poured, MevaDec’s early stripping advantage saved the site substantial time and material. MevaDec is also easy to use and avoids assembly errors. The Kermanshah teams, previously not familiar with MevaDec, have been using it corrrectly from the beginning and after only a short training session.

Wall formwork with matching standard panel sizes

The same hand-set logic that makes the MevaDec system work applies to the hand-set formwork system AluFix, made of light-weight aluminium and used to pour the walls, beams, and slab edges. Designed for flexible use, the AluFix contributes to speeding up work in more than one way. With its panels sizes matched to typical layouts in housing construction, the AluFix drastically reduces the need for job-built compensations or fillers. As with the MevaDec panels, the few panels required for the beams are moved into pouring position by hand by just one or two workers. This saves assembly and stripping time.