INFORMATION ON TUNNEL MOLD APPLICATIONS;

1-INSTALLATION OF TUNNEL MOLD:

Axle concrete is poured on the foundation before the mold, whose assembly is completed, is placed on the foundation. Because in order to correct the wrong measurements, you will have to break it and pour it again later.

Level lines should be drawn for each room on the poured axle concrete. This is 67 mm from the floor top. After this process, the assembled tunnels start to be moved to their places on the foundation. Before resting the half-tunnel on the axle concrete, the materials related to the curtain reservation and installations on the half-tunnel, if any, are placed on the vertical panel and pushed until the panel is taken to the axles. It is brought up to the code line with the panel jacks.

The plumb line of the tunnel is adjusted with the sewing wheel, bolts and cones are placed on the vertical panels. It is checked whether the curtain front elements are in place. Curtain iron rust margins are placed.

The second half tunnel was in the same shape, placed on the other axle, the same works were done.

Both tunnels are connected to each other with fastening hooks.

Since the strut wheels will no longer be used, they are screwed upwards and disconnected from the ground.

After the assembly of the half tunnels is completed, the formwork scaffolds are moved to their new places.

In the first assembly, make the regulation of the mold. For this, extend a smooth gauge over the horizontal boards and bring the horizontal boards to the gauge with the help of the counters. Adjust the non-adjustable counters and fix them with the cetusure bolt. In the meantime, reverse deflection the horizontal panels in the tunnels. (The tunnel opening is calculated as 1 mm for 1 m, ie 1%)

Bring the tunnels (at 4 different points of each opening) which are roughly adjusted by being brought to the code line, to the code with the level.

Adjust the slab front elements to their size and tighten the bolts.

Tighten the bolt nuts and check again whether all of the panel jacks are loaded.

Position the reservations and installations on the floor

Place the axle concrete and its elements.

Place the tunnel heaters inside the tunnel and close the curtain tarps.

Pour the concrete; Concrete pouring sequence should start from the middle curtain and pour evenly to the sides. During concrete casting, a double vibrator should be used and a large diameter bottle (vibrator tip) should be used first, followed by a small diameter bottle. Turn on the tunnel heaters approximately 1 hour after the concrete is poured, because when the existing heat of the concrete and the curing heat of the concrete are combined during the concrete pouring, too much heat will be generated and the concrete may burn.

2-TUNNEL MOLD DISASSEMBLY INSTRUCTIONS:

a ) Heat insulation tents are opened and heaters are collected.

b) The bolts are removed and mounted on the back U's. Nuts are preserved until the next operation.

c) Slab front element bolts are loosened.

d) Axle concrete brackets and distance adjustment elements are removed and left on the floor.

e) The bolts of the floor-mounted reservations are removed and removed. Reservations on floors and curtains, and screws and bolts related to electricity and installations are removed and checked.

f) Remove the fastening hooks connecting the two horizontal panels.

g) Lower the panel jacks of the first half-tunnel so that the half-tunnel falls onto the wheels.

h) Push out the first half tunnel by hand and continue until the center of gravity hole is out of the slab. Attach the lifting triangle to the half tunnel that goes on the formwork scaffolding, and make sure that the nut is tightened well.

i) Lift the half-tunnel with a crane and move it to the place where you will use it next, clean the mold and lubricate it with mold oil. Support the floor where you took the half tunnel with telescopic poles and lower the panel jacks of the second half tunnel and remove the second half tunnel in the same way.

j) Remove all independently assembled reservations, clean, lubricate and move them to their new places.

k) Remove the cones with a conical removal punch, clean and lubricate them, keep them in a basket to prevent loss, and transport them to their new location.

l) Repair the defects that will occur on the concrete surfaces after the mold is taken, fill the conical holes, so you will prepare the structure for other works.

 3-ELEMENT DISTRIBUTION FOR ONE SET TUNNEL MOLD:

• Tunnel form engineer 1 person
• Tunnel foreman 1 person
• Tunnel formwork master 10 people
• Tunnel formwork blacksmith 10 people
• Tunnel formwork electrician 4 people
• Tunnel formwork plasterer 1 person
• tunnel formwork tower crane operator 1 person
• Tunnel external vibrator + concrete worker 5 people

TOTAL 33 Persons

With this number of elements, each casting must be made with each mold. Mold operation system; The mold is given to the concrete at about 15 o'clock on average. Part of the tunnel assembly team quits work and takes a break. Concrete strength is obtained after about 8 hours. Concrete pouring starts at around 5 o'clock the next day, and the formwork is completed and the mold is placed in the concrete at the normal time.

4-PERIODIC MAINTENANCE OF TUNNEL MOLD:

a) After all the formwork and reservations are removed from the concrete, they are cleaned with a mold spartula and a bristle brush. Formwork oil should be applied immediately to the vertical boards. Horizontal boards should be lubricated just before laying the mesh steel.

b) Lubricate the moving parts of the panel jacks, counters, upright wheels and panel wheels with grease.

c) Lubricate the conical bolts, blocks and nuts on the horizontal and rear panels and all the moving parts in the reservations with a high viscosity oil.

d) If any part is damaged, broken, crushed or lost as a result of impact, they must be replaced with the original one immediately. Otherwise, working with damaged equipment both endangers work safety and directly affects the concrete quality.

e) Panel jacks, wheels, counters, strut wheels and other moving parts should be inspected weekly.

f) Formwork removal scaffolds and outer panel scaffolds, exterior scaffolds should be kept under constant control. Loose damaged areas should be repaired.

g) The lifting triangle of the panel should be checked daily and the presence of loose bolts and the strength of the welding and ropes should be checked continuously and carefully, and the gear shaft and nut of the lifting apparatus should be replaced with a spare every 6 months.

A-INSTALLATION SITE:

It should be prepared in accordance with the diagram and explanations given in the appendix.

B- LOCATION OF MOLDS AND EQUIPMENT:

The area where the preparations will be made should be chosen close to the foundation where the first application will be made.

C-CRANE TO BE AVAILABLE (TO BE USED):

After the start of the assembly work, it is ready to work all day for the assembly work and the lifting capacity should be considered as 1 ton per 30 m.

D- REQUIRED MAN POWER:

4-5 person assembly team

For nailing wood to 2-3 person scaffolding and pouring the first axle concrete

As the assembly team, our technical staff should consist of masters with military welding knowledge, as the people you will put under your command will be the ones who will carry out the tunnel mold work later on.

E-HAND TOOLS AND TOOLS TO HAVE:

FOR ONE SET

F- PREPARATION OF FIRST AXLE CONCRETE:

Tunnel formworks are manufactured in millimeters according to the project dimensions. Therefore, all the faults in the foundation dimensions and level are eliminated in the axle concrete. Namely: The axle concrete must be a projection of the axle concretes at the roof level.

G-DRAWINGS OF INSTALLATION RESERVATIONS TO BE PREPARED:

It shows the places on the mold for all the spaces and installations you want to come out of the concrete. You must clearly draw the reservation plans, electrical and plumbing connection holes. The technical staff we will send for these drawings can provide you with guidance.