rebar box as starter bar

3 Easy Ways of Preparing Starter Bar without Damaging the Formwork

Starter bars are rebars cast into a concrete to give a lapped connection to provide continuity of reinforcement across a cold joint or construction joint. Oriented perpendicular to the existing concrete element in which they are installed, they are also used to extend or rehabilitate existing bridges, roads and building structures.

The easiest and the inexpensive way of designing starter bars is to have them projecting from the concrete surface. However, complications arise when starter bars need to project through the formwork. Timber formwork needs to have pre-drilled holes in the accurate positions which may render the formwork unusable for future projects and cause difficulties when stripping. Not mentioning if it is steel formwork, which creates even greater problems.

Besides, projecting rebars can cause a safety hazard for both trips and falls. The cast in starter bars should have protective caps to minimize these risks. Projecting bars in precast concrete cause additional problems with storage and transport, and as a result are not commonly used.  Rebar will also tend to rust easily when expose to weather.

Organic Resin


Other than having starter bars with cast-in-situ in method, starter bars may be embedded in organic or minerallic mortars from a previously cast surface. Holes are drilled in the concrete at required positions and the bars are fixed with mortar. There are many suitable mortars available, although the higher bond strengths come from organic system, so these tend to be the most popular. The organic resin may be introduced via a gun/dispenser, or in a glass capsule that is broken by the bar, allowing mixing to occur. Care must be taken to treat the drilled hole as recommended to ensure adequate anchorage. The resin method is particularly useful for fixing of items such as posts or barriers where accurate position is needed.
Ankrochim Resin for Anchoring in ConcreteAnkrochim Resin for Anchoring in Concrete2
Injecting Ankrochim resin while withdrawing the nozzle as the hole fills. Insert rebar with a slight twisting motion.

Mechanical Splice System


The easiest way to avoid having to have bars projecting through the formwork is to use a mechanical splice system (Rebar coupler). Simply engage a coupler onto the threaded rebar, which is then cast flush with the concrete (a coupler capping can prevent the concrete slurry from flowing into the coupler).  The second bar is then connected to the coupler. To avoid loss of cross section, the end of the bar is ‘enlarged’ by cold forging the end of the bar before threading.  No drilling is required in the formwork.

Steel coupler for starter bar
Starter bar from diaphragm wall using Moment Jointec Coupler

Reinforcement Continuity


An alternative system (to ensure cost effectiveness for smaller bar diameters) has pre-bent and pre-spaced steel reinforcement supplied in a pre-galvanized steel box that is dimpled and flanged for maximum concrete bond. The system is used to enable efficient and reliable reinforcement continuity for sections of concrete structures that are poured in subsequent phases without the need to drill formwork.

This system not only improves on site productivity due to its installation speed, but also provides significantly higher shear capacities compared to traditional methods due to a higher shear friction. This enables us to reduce the amount of steel bars required to carry the same vertical load; reducing costs and embodied CO2 in the construction.

Installation is simply achieved by nailing the casing to the formwork or wiring it to the existing reinforcement bar cage prior to concreting.  After removal of the formwork the lids of the box is removed and the bended bar being straighten and ready for lapping.

curved rebar boxrebar box as starter bar
Plakabox is the only rebar box capable of making an anchoring which can transfer significant force around the structural joints.

 

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IEM Malaysia Halfen Moment Factory Visit

IEM Factory Visit to Halfen Moment

A group of 20 members of the Institute of Engineers Malaysia (IEM) attended a factory visit to Halfen Moment Malaysia. Participants had a meeting room discussion before the tour, where our Technical Manager, KC Loh presented a lecture on ‘The Different Types and Applications of Couplers and Threading Processes’, explaining how rebar couplers and threading services play an alternative yet important role for conventional splicing, saving the overall cost of the project and reducing rebar wastage.

IEM Factory Visit
Group photo before factory tour

Participants had witnessed our ISO 9001-2015 and 6S Safety Standards certified factory which comes with 360° manufacturing capability from cutting, cold upsetting, threading and packing to shipping. They also had their chance to observe the processes of proof load testing, manufacturing of corrugated duct and assembly of Plakabox.

“Our guests enjoyed both the lecture and the visit to our factory,” KC Loh said. “Our well organized production line made a strong impression on them, too. We hope educational and informational visits such as these will help young graduates and engineers in Malaysia to understand Halfen Moment’s commitment to produce localized building accessories supplies that meet and surpass local needs as engineers design innovative new concrete structures for the future.”

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Token of appreciation from IEM

“Halfen Moment factory, products and especially their company culture cannot be matched. From fork-lift operator, supervisor, to directors, we witnessed the professionalism in each department to deliver steel products and building solutions to the construction industry. I was also personally impressed by their support given to consultants by way of regular testing and technical expertise, and the very evident commitment to safety. The seminar given by KC Loh was more than informative”,   mentioned by one of the visiting engineers.

If you would like to find out more about Halfen Moment, we also invite you to visit our factory. In our guided factory tour, we will show you how couplers, rebar threading and our other products are manufactured.  Please contact us via the contact form. We will contact you soon to arrange a time.

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Building Envelope Seminar Fenestra 2018

Halfen Moment Participated the Building Envelope Design Seminar 2018

Together with our sister company HALFEN, Halfen Moment Group participated the seminar organized by Fenestra Malaysia, in partnership with PAM (Malaysian Institute of Architects) titled, ‘Building Envelope Design 2018’. More than 150 people attended the event including architects, structural and civil engineers, developers, as this seminar covers façade engineering fundamentals, UBBL imperatives for the building envelope, sustainability issues relating to the building skins and the importance of wind tunnel testing for tall buildings.


Halfen Moment team and booth presenting HALFEN cast-in channel fixing systems

Fenestra Building Envelope Seminar 2018 (2)
Over 150 industry professionals attended the seminar

HALFEN cast-In channels were presented during the seminar. More than any structure tall buildings need a significant number of heavy-duty fixings, for example, for the fixing of elevator guide rails or curtain wall facades. HALFEN cast-in channels have been used for the curtain wall façade of Burj Khalifa in Dubai, UAE, with 828 meter, still the tallest building in the world, fixing more than 25,000 prefabricated panels of double-layer glass set within extruded aluminum frames. The use of the cast-in channel fixing system allowed an increase in site productivity of almost 30 % compared to traditional methods such as welding or drilling. It also results in a cleaner and safer worksite, with fewer workers required onsite.

Burj
Burj Khalifa during the installation period of more than 25,000 curtain wall façade panels.

In summary, the HALFEN cast in channel fixing system offers the following benefits:

  • Adjustable and safe connection
  • Highest degree of safety – not depending on workmanship compared to traditional systems
  • No drilling or welding
  • Fast installation – reduction of construction time
  • Allows for simple future replacements / extensions
  • Hot-rolled channels for fatigue relevant loads
  • Serrated DYNAGRIP channels for seismic load application – 3D load introduction
  • Increase in site productivity of up to 30% with reduced labour

For more information on HALFEN cast-in channels, please visit our product page or alternatively discuss your project needs with a Halfen Moment Representative.

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Crack on Slab Forta

What is Concrete Fiber Mesh?

Types of Concrete Cracks

Concrete is broadly known as an extremely versatile, cost-effective construction material. Yet it is also affected with some disadvantages that are inherent to its composition.  By generally accepted engineering standards, concrete is relatively brittle and lacks ductility.  Intertwined with these problems is concrete’s propensity to crack in both its plastic (early-age) and hardened (long-term) state.  Early-age cracks are microscopic fissures caused by the intrinsic stresses created when the concrete settles and shrinks over the first 24 hours after being placed.  Long-term cracking is in part caused by the drying shrinkage that transpires over time.  In either case, these cracks can risk the overall integrity of the concrete and not allow it to uphold or possibly ever achieve its maximum performance capability.

Severe Road Cracking Forta
Severe cracking from years of heavy truck traffic            

Crack on Slab Forta
Slab-on-ground crack          

Why Use Reinforcement in Concrete?

This is the basic reason why reinforcement in concrete is essential.  Irregular cracks are unattractive and hard to maintain although generally do not affect the concrete’s integrity.  Joints in concrete slabs are simply pre-planned cracks that are created by forming, sawing, or tooling. Concrete slabs that are designed for serviceability typically use reinforcement such as deformed reinforcing steel bars (rebar) or welded wire fabric (WWF) to hold cracks tight.  The primary function for the reinforcement is to maintain aggregate interlock for load transfer and improve joint strength.  Rebar and WWF do not inhibit the formation of cracks, but if properly positioned provide reinforcement once a crack has developed.

Fiber reinforcement provides the similar function, is mixed throughout the concrete and distributes the stresses attributed to shrinkage throughout the concrete panel making the joints much more stable. This distribution of fibers offers a complete reinforced cross-section of concrete and changes the way the concrete works.

Synthetic and steel fibers have been applied in concrete for over 30 years to improve concrete’s plastic (early-age) and hardened properties.  Micro-synthetic fibers have been used to control random plastic-shrinkage cracking.  Steel fiber and Macro-synthetic fibers have been used to provide crack width control in concrete after it reaches a hardened state.  Combining both products gives advantages in both plastic and hardened state.  The concrete applications that fiber reinforcement is used in includes, but not limited to, slabs-on-ground, composite metal deck slabs, topping slabs over precast panels, precast, and shotcrete.

Fiber reinforcement makes good concrete better because fiber reduces cracking and adds long-term durability to a wide variety of concrete applications.  Fiber reinforcement offers an alternative construction method to traditional welded wire fabric and rebar reinforcement and provides additional benefits, including guaranteed 3-dimensional reinforcement, safer installation and more cost-effective.

Warehouse floor forta ferroBike path
Utilize of FORTA fibers to reinforce multiple slab applications of warehouse and bike path, increasing the load capacity of the slab and the fatigue performance.

 

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Top 10 Essential Building Products for 2018

Committed to delivering excellence in the construction industry, Halfen Moment Group has selected 10 essential building products which have significantly improve the construction site safety, efficiency, cost and speed. These selected top 10 products have been vastly used by our clients and proven to
i) reduce construction time,
ii) improving construction quality,
iii) increase of lifetime of concrete structures,
iv) reducing of total construction costs.

Mechanical Splices

 1) Having rebar congestion problem during lap splicing? Do you know you can easily eliminate the consequences of 40D rebar of wastage, by saving substantial amount of time and cost? Click to learn more about our Moment® JoinTec Coupler

2) Do you know that you can connect precast concrete elements by using coupler? Used together with Moment’s proprietary 100MPa grout, this coupler is tested to meet seismic requirements and can achieve bar break technology. Click to learn more about our Moment® Half Grout Coupler

3) Ever encounter a site situation where rebar threading is not possible for further rebar connection? A simple step by step execution of cold forged gripping the coupler sleeve against the rebar makes it possible!
Click to learn more about our Moment® Bargrip Coupler

4) Looking for a specific coupler for repair works, especially where one bar is already fixed in concrete with insufficient space? No threading is required and easy to install! Click to learn more about MBC Coupler

Precast Technologies

5) Is the connection between the construction junctions of your precast elements strong enough? Would you like to have a stronger connection with more flexibility? Click to learn more about Moment® Wire Loop Box

6) Looking for a quick, less labor and economical way of solution for connection to foundation or linking columns together? Immediately loadable, hence bracing is not required! Click to learn more about Halfen Column Shoe

Anchoring in Concrete

7) Still using the expensive site drilling method to install a support bracket? Or would you prefer to install a channel via casting, with unlimited adjustment along the line of the channel, and yet safer and more reliable? Better safe than sorry, Click to learn more about HALFEN Cast-In Channel

Reinforcement Products

8) Is your reinforced concrete structure vulnerable to corrosion or early deterioration? Would you like to maintain the proper distance between rebar and form face, yet with a 75% reduction of time? Click to learn more about our Moment® Fast Spacer

9) Facing any cracks issue in concrete due to shrinkage or expansion? Would you like to use macrofiber which is as strong as steel, with increased shatter and impact resistance? Click to learn more about our Forta Ferro® Macrofiber

Sacrificial Formwork

10) Experiencing tedious and slow foundation works? Ever thought of gaining 60% time during foundation works using less labour? Click to learn more about our Speedform™ technology

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Halfen-Moment Malaysia Supporting University of Malaya on Innovative Precast System Research

Half Grout Coupler Moment Half Grout Coupler
The connection of precast components on construction sites has always been a difficult challenge due to manufacturing tolerances and the need to transfer loads through the structure; even more so when you factor in a required resilience to a seismic events. Precast components are inherently stiff, so it is essential that the connection components are robust enough to allow the structure to absorb the energy of the earthquake, whilst providing enough robustness to avoid collapse.

As innovation is one of our key drivers, Halfen Moment Malaysia will be supporting a research project by Faculty of Engineering, University of Malaysia to examine the mechanical and technical properties of Half Grout and Full Grout couplers, which has been widely used for precast connection.

This research will focus mainly on
1) The compressive strength of the grout material which fills the coupler duct in different ages of the grout mix.
2) The effect of the embedded length of the steel bar inside the coupler duct for half grout and full grout couplers.
3) The effect of the steel bar eccentricity and grout volume surrounding bar during the installation process inside the coupler duct.

The findings of this research will be important in guiding designers, fabricators and contractors in the field of civil engineering in order to select the best solutions of couplers for splicing of RC bars in the precast industry. Halfen Moment will provide our products and advice in this research to ensure this research to run smoothly and achieves the intended output successfully.

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centerjpg

Halfen Moment Unveils New Brand Identity And Logo

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Halfen Moment Group is proud to announce that we are releasing an updated brand identity, including our new Why, logo and tagline. It marks the occasion of celebrating our incredible growth journey across 27 years from a start up to a market leader in building construction accessories with more than 500 clients across 30 countries.

 

New Company Logo


HalfenMoment_Logo 2018

New Why


Our group’s new Why is to be an innovative solution provider for the building structure, offering localized products, which ultimately improve progress efficiencies and reduce overall costs for our valued clients. “Along with our new Why, our new logo better communicates what Halfen Moment stands for today, I’m delighted that we’ve delivered something that takes into account other people’s views from within the company and one that showcases who we are externally too.” said Andi Lapon, Managing Director of Halfen Moment Group. ”

We emphasized our forward-thinking mindset and objective to achieve strong growth, driving innovation while focus on localization. The new visual identity presents the company as modern and evolving, reflects the strength and direction of its brand portfolio, and underscores its commitment to local solutions for local problems with the most suitable technologies.

New Tagline: Driving Change


Since we began our journey as a company in 1991, we have carried the same logo and it has taken us through initial phase of our growth but going forward we need to be the game changer, driving the change in the construction industry. Halfen Moment has been part of CRH, a leading global building materials group, since 2012. By integrating ‘A CRH Company’ endorsement in our new company logo, we are taking the opportunity to establish our credentials as part of this highly successful group with global recognition.

New Brand Identity


You will see our new brand at construction sites, at exhibitions, on social media, on our products and so on. We believe that the new look represents our incredible growth journey from a start up to a market leader and of a company that is modernizing and growing at a rapid pace riding on its advanced technical advice, innovative design and most simplified interactions.

We hope you like this new look and feel for the new Halfen Moment. Our marketing materials and signage will be updated gradually, you may see the previous logo in use for a short while as we undertake this process. To request for artwork, please email to info@halfen-moment.com.

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20180604_144647 (1)

Supporting University of Malaya on Innovative Precast System Research

20180604_144647 (1)

The connection of precast components on construction sites has always been a difficult challenge due to manufacturing tolerances and the need to transfer loads through the structure; even more so when you factor in a required resilience to a seismic events. Precast components are inherently stiff, so it is essential that the connection components are robust enough to allow the structure to absorb the energy of the earthquake, whilst providing enough robustness to avoid collapse.

As innovation is one of our key drivers, Halfen Moment Malaysia will be supporting a research project by Faculty of Engineering, University of Malaysia to examine the mechanical and technical properties of Half Grout and Full Grout couplers, which has been widely used for precast connection.

This research will focus mainly on
1) The compressive strength of the grout material which fills the coupler duct in different ages of the grout mix.
2) The effect of the embedded length of the steel bar inside the coupler duct for half grout and full grout couplers.
3) The effect of the steel bar eccentricity and grout volume surrounding bar during the installation process inside the coupler duct.

The findings of this research will be important in guiding designers, fabricators and contractors in the field of civil engineering in order to select the best solutions of couplers for splicing of RC bars in the precast industry. Halfen Moment will provide our products and advice in this research to ensure this research to run smoothly and achieves the intended output successfully.

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concrete framing

Industrialized Building System: The Malaysian Approach

What is the Industrialized Building System(IBS)?

An Industrialized Building System (IBS) refers to a technique of construction whereby components are manufactured in a controlled environment – either onsite or offsite – placed and assembled into construction works. The term IBS is often tossed around in the world of construction in Malaysia, overseas it goes by other terms such as Pre-fabricated construction, Modern Method of Construction (MMC) or even Off-site Construction.

IBS is also defined as an integrated manufacturing and construction process, carefully planned organization, and efficient management, preparation and control of resources, activities and results from the highly developed components. The manufacturing of the components are done with machines, templates, and other forms of machinery and equipment. Components manufactured off-site, once completed, will be delivered to the General Assembly and erection of the construction site.

The five main IBS groups present in Malaysia:

• Precast Concrete Framing, Panel and Box Systems – pre-cast columns, beams, slabs, 3-D components (balconies, staircases, toilets)

concrete framing

• Formwork Systems – tunnel forms, EPS-based forms, beams and columns moulding forms, permanent steel formwork

formwork systems

• Steel Framing Systems – steel beams and columns, portal frames, roof trusses

steel framework

• Prefabricated Timber Framing Systems – timber frames, roof trusses

prefab wood

• Block Work Systems – interlocking concrete masonry units (CMU), lightweight concrete blocks

block work system

The Benefits of the IBS

• Higher quality products and minimum waste, due to a factory work environment that is easier to control.
• Elimination of conventional timber props and an obvious decrease of supporting materials, through the use of complete assembly elements or prop system for the onsite casting process.
• Stronger and safer work platform, produced through a complete assembly element.
• Faster completion, due to the introduction of prefabricated components to replace onsite fabrication.
• Safer, cleaner and more organized site, due to the reduction of construction waste, site workers and prefabricated construction materials.
• Cheaper total construction cost, resulting from the above factors.

The general idea the IBS is to realign effort and resources away from the less controlled environment of the construction site to the more controlled environment of the workshop. The implementation of IBS aims to create higher quality levels of construction at its core through control and consistency. As it stands right now, the implementation of IBS is met with many challenges but IBS is the future of construction and will play a key role in the future of the industry.

Overview of Halfen Moment Portfolio for the Precast & IBS Industry

The building below shows some of the possible applications for Halfen Moment products in the precast/IBS industry, from mechanical splices to specifically designed precast technologies for lifting and connections. Whether for civil engineering or in residential and commercial projects, Halfen Moment products play a crucial role behind the concrete.

IBS Precast Product Map

 

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Moment Coupler

Mechanical Splices vs Lap Splicing

Lapping of rebars has long been considered an effective, economical splicing method, but today’s more demanding concrete designs are forcing builders to consider alternatives.

In almost all reinforced-concrete structures, rebars must be spliced. The required length of a bar may be longer than the stock length of steel, or the bar may be too long to be delivered conveniently. In either case, rebar installers end up with two or more pieces of steel that must be spliced together.

Lap splicing, which requires the overlapping of two parallel bars, has long been accepted as an effective, economical splicing method. However, there has been a shift in recent years. Continuing research, more demanding designs in concrete, new materials and the development of composite materials have forced designers to consider alternatives to lap splicing, which is mechanical splices.

Mechanical splices are mechanical connections between two pieces of rebar that enable the bars to behave in a manner similar to continuous lengths of rebar. Mechanical splices join rebar end-to-end, providing many of the advantages of a continuous piece of rebar. They are more reliable than lap splices because they do not depend on concrete for load transfer. Today, a range of mechanical splices are available to ensure that a precise, reliable connection can be made quicker and easier.

Benefits of Mechanical Splices


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Mechanical splices offer builders the following benefits:

Improved structural integrity
Mechanical splices maintain load path continuity of the reinforcement, independent of the condition or existence of the concrete. To use splices in tensile regions, they must be able to develop the full strength of the rebar and not create a weak point. Therefore the performance of the system is assured throughout the strain-hardening region where plastic deformations occur. In seismic applications, mechanical splices maintain structural integrity when bars are stressed beyond yield, allowing the predictable formation of plastic hinges.

No reliance on concrete for load transfer
In coastal regions, rebar corrosion can produce concrete delamination and spalling. Since lap splices transfer load through the surrounding concrete, when the concrete is gone, the lap splice in effect has failed. Mechanical splices do not rely on the concrete for load transfer and therefore maintain the structural integrity.

Elimination of lap splice calculations
Mechanical splicing does away with the tedious calculations needed to determine proper lap lengths and the potential calculation errors.

Reduced material costs
Because mechanical splices do not overlap, less rebar is used, reducing some of the material costs. This cost savings can be particularly significant for jobs requiring expensive epoxy- coated or galvanized bars, since building codes require up to 50% longer splice laps for these bars than for standard rebars.

Reduced rebar congestion
A common complaint of concrete placing crews is that they can’t get the concrete through the rebar cages. Laps effectively double the steel to concrete ratio, and the resulting congestion can restrict the flow and distribution of larger aggregate particles and limit the effectiveness of vibration. Mechanical splices will significantly reduce this congestion.

Cost Comparison

Although the advantages of mechanical splices are well recognized, a major concern has been their high cost for applications where the codes permit the use of lap splices. But is the perception that mechanical splices cost more than lap splices a reality? By using couplers, contractors can be more cost efficient, able to achieve from 20-50% of cost savings compared to lap splicing. Apart from that there are many other savings which can be anticipated such as;

Reduction no. of joints
6 meters length will be most ideal for joining and this would result in reduction of no. of laps by,

Assuming height of building: 100 metres
Typical floor height: 3.2 metres

No. of laps: 100 / 3.2 = 31 laps
No. of coupler joints: 100 / 6 = 16 joints

Therefore reduction in no. of laps: ((31-16)/31) x 100% = 48%


Minimal wastages of HTDBs
Assuming floor height of 3.2m and lap length of 1.275m
Length of steel bar per floor is : 3.2m + 1.275m = 4.475m
For a 12metres steel bar, two nos of 4.475metres length bar could be prepared.
Balance: 12metres –4.475metres –4.475metres = 3.05metres

By adopting a 6m bar for coupler joint. No wastage is anticipated. Therefore wastage occurred due to lapping is (3.05m/12m)*100% = 25.42%

 

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