Gamuda IBS’ Way of Precast Wall To Wall Connection

Gamuda IBS is a well-known precast manufacturer in Malaysia. Being one of the key clients of Halfen Moment, Gamuda IBS has been collaborated with us, using our innovative building solutions in many of their prestigious projects. Moment Multi Wire Loop Box is one of the latest product being implemented for precast wall to wall connection.

 

Gamuda 1 Gamuda 2

With the ongoing close partnership with Gamuda IBS, Halfen Moment had the opportunity to conduct demonstrations at their precast yard to showcase the application of Multi Wire Loop Box for precast wall to wall connection. After rounds of testing based on different possible applications, Gamuda IBS engineers were satisfied and confident with Multi Wire Loop Box advantages as follows:

  1. The long multi wire loop box version creates a perfect alignment to wall panels, acts as a shear key and simplify the design of the formwork.
  2. The magnet option provides easy installation onto the formwork.
  3. Able to customize the number of wire loops and length of steel box to match the height of the wall.

In the own words of the Head of Technical of Gamuda, Thoo Hoi Hian, and Engineer Steven Goh Nai Jun, “I would highly recommend this wire loop box to other engineers. Not just because of the quality of the product but the easy installation which makes wall to wall connection 50% faster when compared to traditional method, helping us to save our labour and time cost.”

With the positive response received from Gamuda IBS, more drawings with Multi Wire Loop Box have already been incorporated into the precast design of their future projects.

Easy Installation Saving More Time & Cost

1. Multi Wire Loop Box is attached to the formwork using magnets before the panel is casted.

Gamuda 4.1 The Secret to Precast Wall Connection

2. After removing the formwork, the protective tape is removed, and the loop can be then be bent to the operating position.

Gamuda 5.1 Gamuda 5.2

3. The wire loops are bent out and straightened with a hammer claw.

Gamuda 6.1 Gamuda 6.2

4. Lastly, insert the reinforcement bar and concrete grout is poured into the joint shown below.

Gamuda 7.1The Secret to Precast Wall Connection

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Innovative Shortcut For Precast Connections

1

Developer: Micron Technology
Client: JEKS Group
Product Supplied: Moment Grout Coupler

Project Description

Micron Technology’s new center of excellence for SSD Assembly and Test is located in Batu Kawan Industrial Park, Penang, Malaysia. This new facility development is located on a 52.6-acre site which represents an investment of US$356.6 million (RM1.5 billion) over five years.

The Problem: The conventional method of lapping long rebars according to Eurocode standards has caused inconveniences on site. Handling long lapped length of rebars protruding from precast beams and columns is very tedious. Not to mention that the long starter bars are very dangerous to be installed which has alarmed safety concern from the site management.

IMG-20191114-WA0010
Long rebar lap length caused long installation time on site along with safety concern

The Solution

After understanding the pain points of our client, instead of using the conventional method which involves corrugated duct and long lapping of rebars, Halfen Moment proposed the solution of using Moment Grout Coupler to connect precast beams & columns.

With the application of Moment Grout Coupler, our client were able to reduce 60 to 70% of the rebar lapping length with this rebar coupler system, saving more rebars and also reduce the installation time. Moreover, when the long rebars length were reduced significantly, site safety factor has been improved as well.

Besides, the advantage of Moment Grout Coupler as a transitional coupler gave more flexibility to our client as the rebar sizes varies from level to level on site. Lastly, the rough surface of the coupler’s body managed to provide a strong bonding between the coupler and the concrete.

IMG-20191115-WA0019
Moment Grout Coupler with precast elements before casting

The Result

Our client was very happy with the quality of the supplied Moment Grout Coupler, especially when barbreak system was achieved when testing was conducted. Overall, the usage of Moment Grout Coupler has make our client’s life much easier, not only to the precasters but also the contractors from Micron’s project. Nonetheless, the time saving from connecting precast beams and columns, has improved our client’s productivity, with less workers needed.

Micron Moment Grout Coupler 
Once filled with grout, bracing around the element can be removed after 3 days

 

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The Bolted Coupler Which Does Not Require Rebar Preparation

  MBC Coupler
Developer: Oberoi Realty
Main Contractor: Samsung C&T Corporation
Product Supplied: Moment® Bolt Coupler (MBC)

Project Description

Oberoi 360 project is a mixed development located in the Worli, district of Mumbai, Commercial & High end Residential Hub of Mumbai, north of the central business district. The site, lying just 600 meters east of the Arabian Sea, is contextualized around the nearby water. As most of the surrounding buildings are low-rise, the tower’s western facing sightlines are maximized to offer views of the sea.

The Requirement : Rebars protruding from the foundation piles were too short to allow traditional lapped splice.

MBC Application
A nut runner is always recommended to tighten the bolts for higher precision and faster installation.

The Solution

The best solution for the continuity of bars protruding from the foundation piles is using the Moment Bolt Coupler (MBC). As the bar end does not need to be prepared in advance, MBC coupler is a flexible solution for contractors. It only requires a wrench or a nut runner  to tighten the bolts along its serrated hollow body. Hence, it is easy to operate even in a confined area at site.  The installation is very straight forward with simple demonstration and guidance.

The Result

Halfen Moment India supplies a significant amount of MBC coupler to this mixed development project , which proves that MBC coupler is the ideal and cost effective coupler for remedial and repair works, particularly when one bar is already fixed in the concrete. The team of Samsung & Oberoi appreciate the convenience of this coupler as it managed to save more time and were able to execute the work well in advance.

MBC Application
Using MBC coupler is a cost effective method of joining reinforcing bars, particularly when the fixed bar is already in place.

 

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Precast Connection Using Moment® Grout Coupler

PanaHome Malaysia Sdn BhdHalf Grout Coupler
Main Contractor: PanaHome Malaysia
Product Supplied: Moment® Half Grout Coupler

Project Description

PanaHome Malaysia uses the Wall-Panel Concrete (W-PC) construction method (a pre fabrication construction method involving large concrete panels moulded at a temporary factory at the development site and later assembled using a crane) to build double-storeys semi-detached innovative eco-homes. This project utilizes the reinforced concrete panel technology to be more environmental friendly, energy-efficient and to ensure consistent high quality building structure.

The Requirement: A mechanical connector to connect the reinforcing bars end to end, suitable for assembling precast elements.

The Solution

The best solution for precast elements connection is the Moment® Half Grout Coupler. With the feature of a threaded end (used for the connection to reinforcement at the precast yard) and a wide cavity to perform a grout connection at site, Half Grout Coupler is designed to provide structural integrity between load bearing precast concrete elements such as columns, beams, shear walls, and panels.

Moment Half Grout Coupler Cast Half Grout Coupler

Moment® Half Grout coupler was mounted on T16 rebar which has been threaded with JoinTec threading which makes the installation easier as the first rebar has been tightly screwed to the couplers before casting. The couplers were installed at the bottom of each precast element, are then cast as part of the precast wall panel element.

Grouting

After bracing the precast panel in its final position, non-shrink grout was injected into the cavity of the coupler to create the rebar connection. Moment® Half Grout coupler requires less usage of grout and is not dependent on any specific type of grout. Different brands of grout can be used, easing local scouring and to keep the costing low. The bracing around the panel was then removed after the grout has attain the prescribed strength.

The Result

Halfen Moment Malaysia proudly supplied more than 50,000 pieces of Moment® Half Grout coupler to this project, which also proves that the use of Half Grout coupler for precast panel is a time-saving and economical way to quickly take advantage of the precast technology.

 

 

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Does The Tightness Between Rebars Determine The Strength Of The Connection? (TRX)

TRX
Developer: TRX City Sdn Bhd
Contractor: Bachy Soletanche
Product Supplied: Moment® JoinTec Coupler, Moment® Bargrip Coupler

Project Description

The Tun Razak Exchange, TRX, is an iconic 70-acre development in the heart of Kuala Lumpur that is set to become a leading centre for international finance and business. The master plan includes a total of 26 buildings and over 21 million ft2 of total building Gross Floor Area (GFA) spread across office, residential, hotel, retail, F&B and cultural offerings. TRX has a development period of 15 years to be completed in phases with the initial Phase 1 slated for completion in 2017/2018.

The Requirement: To connect bended rebars to micropile, which connects to the slab.

The Solution

In order to connect the bended rebars to the micropile, Moment® JoinTec Coupler with Type B thread has been used. The Type B thread has a double thread on one of the bars to be coupled. This facilitates the installation of the system by allowing a coupler to be screwed fully on to one of the bars. When the second bar is ready for coupling, the coupler can now be rotated off one bar and on to the other. In this case study, the full thread has been threaded for the bottom bar which has already cast in concrete.

During the coupler installation of bended rebar to the casted bar of micropile, the contractor realized that the bar cannot be tighten as this bended bar needs to face a specific direction. Fortunately, our specialized engineer visited the site and assured that the tightening is not the main factor which affect the strength of the rebar connection. In fact, the engagement of the thread is the key factor which determine the strength of the connection.

R&D has been made by Halfen Moment on the percentage of thread engagement needed, hence, even if it is slightly looser, the connection will still achieve the BarBreak system. Therefore, 80% of thread engagement has always been suggested to our clients during installation to achieve the full thread engagement.

Micropile at TRXJT Coupler with Bended Bar
Installation of bended rebar to the casted bar of micropile with Moment® JoinTec Coupler

The Result

Halfen Moment Malaysia has currently supplied Moment® JoinTec Coupler & Bargrip Coupler, we believe with our quality assurance and professionalism, there will be more continuous support from Halfen Moment to this prestigious project.

 

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New headquarter office for YTL Corporation Bhd

Seamless Connection For BB Tower

ytl-bb-tower
Developer: YTL Corporation Bhd
Main Contractor: Syarikat Pembenaan Yeoh Tiong Lay Sdn Bhd
Product Supplied: Invisible Connections TSS41 along with Halfen Cast-In Channel, Moment® Coupler and Plakabox

Project Description

The BB Tower is the new headquarter office for YTL Corporation Bhd located along Jalan Bukit Bintang, in the heart of Kuala Lumpur. This 0.75 acre project development consists of a 32-storeys office tower over four basement level car parks, with a total built-up area of 25,800 m2.

The Requirement: To connect precast concrete staircases and walls without denting the appearance of architecture.

The Solution

Partnering with Invisible Connections, Halfen Moment Malaysia offered an innovative solution by providing TSS41 to connect all precast concrete staircases with hidden connections in the walls for the entire building, offering clean streamlined aesthetics architecture, without using integral corbels.

The TSS units were developed as a connection detail between precast landings or stairs and walls in stairways, and all that is required in the wall is a recess. The inner tube is retracted into the unit during erection, to be pulled out into the recess when the precast element is in the correct position. A safety stop will prevent the inner tube from excess protrusion. A rubber pad at the support in the wall is available in order to reduce the impact sound transfer from the stairs to the walls. It provides hidden connection, quick erection, and no site work is necessary with bolts, welding or mortar.

Other than TSS41, Halfen Cast-In Channels with ETA-16/0453 approval & CE Marking approvals were supplied for façade fixings, while Moment® Coupler and Plakabox were also used in the development for connection reinforcement.

The Result

The TSS connectors were supplied to YTL for precast and installation work. It was chosen in compliance with the high quality finishes, as Invisible Connections products are being used to satisfy robust, quick, clean and efficient connection.

Invisible Connections TSS41 Staircase Landing Precast (3) Invisible Connections TSS41 Staircase Landing Precast (4)Invisible Connections TSS41 Staircase Landing Precast (5)

TSS41 being cast in precast staircase landing

 

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KAHRAMAA – Water Security Mega Reservoirs Project

Kahramaa Water Security Mega ReservoirsDeveloper: Qatar General Electricity and Water Corporation
Main Contractor: Consolidated Contracting Group (CCC) & Teyseer Contracting Co. JV
Product Supplied: Epoxy Moment® JoinTec Coupler

Project Description

Due to the continuous growth and development in Qatar, and consequently the huge increase in water demand, Qatar General Electricity & Water Corporation (KAHRAMAA) has decided to launch an ambitious water project to provide 7 days strategic water storage within its network system.

The first phase of the project will provide the 7 days of storage for the expected water demand at horizon 2026, with 5 mega reservoir sites. The second phase will provide the 7 days of water storage for expected demand in 2036 by adding additional reservoirs within the 5 mega reservoirs sites.

The Requirement: In order to prevent corrosion at this salt water structure, this project requires epoxy coated couplers to connect with the epoxy coated steel bars.

The Solution

To match the requirement of this project, Halfen Moment Malaysia designed the first ever epoxy coated Moment® JoinTec Coupler. Stringent testing procedures had been carried out, even when it comes to the smallest details on the thickness and adhesiveness of the epoxy coating, these aspects were all tested and inspected carefully by the production and quality control department.

A total of 2.5million Epoxy JoinTec Coupler were commissioned (300,000 couplers to be delivered each month), hence the production line and operators were expanded to meet the production capacity and for better quality control. These Epoxy JoinTec Couplers had went through a few rounds of quality measures before delivered, below were the main areas focused:
1) Threads to be free from epoxy coating
2) Visibility of the marking on the couplers after coating
3) Dimension and threading check
4) Tensile test for each batch of couplers
Standards operating procedures and strict quality control protocols were the keys to maintain the quality of the couplers and also to keep to the promised delivery timeline.

On top of that, 26 threading machines were also supplied and mobilized on site to produce the threading of 5 million threads. It was a challenge for the threading machines to work under a high temperature between 40-50 degrees in Qatar, therefore these machines were all maintained regularly to avoid any unexpected breakdown during production.

The Result

Halfen Moment Malaysia is proud to be associated with this prestigious project. This mega reservoir project was a great experience for the entire Halfen Moment Group as huge coordination and hard work had been contributed from all departments to make this a success.

IMG-20160808-WA0024_1471965950106IMG-20160808-WA0027_1471965949668
Picture above showing Epoxy Moment® JoinTec Coupler and rebar threading performed at site.

 

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The Malaysian Mass Rapid Transit System, SBK Line

MRT Line 1

Developer: MRT Corporation Sdn Bhd
Main Contractor: MMC Gamuda
Products Supplied: Moment® JoinTec Coupler and Moment® Spearline Coupler

Project Description

The first line of the Klang Valley MRT Project is the MRT Sungai Buloh-Kajang (SBK) Line. The line begins from Sungai Buloh, located to the north-west of Kuala Lumpur and runs through the city centre of Malaysia’s capital city before ending in Kajang, a fast developing town to the south-east of the city. The 51km long-line required couplers and quality rebar threading to connect the reinforcement bars within the railway structure. Proof load for each coupler is also required to suffice the specified quality assurance requirement.

The Solution

Halfen Moment Malaysia has supplied 200,000 of Moment® JoinTec couplers and more than 100,000 Moment® Spearline couplers, together with our quality rebar threading services at our production plant. To fulfil the requirement of quality assurance, we have also managed to provide proof loading for each coupler with a strong local team. The purpose of proof loading to be performed on a rebar with coupler especially for bigger rebar size (>40mm dia) is to check the embrittlement of the threads and also helps to control the slip. It is our part of the quality control procedure developed to reassure good quality of threads before we supply it to MRT sites. After all, a good quality connection between rebars is not only determined by the quality of the coupler but equally by the quality of the threads.

The JoinTec coupler which is seismic and impact resistant, has a straight parallel thread to provide an absolute bar break system where the rebar remains the weakest point. It has the most comprehensive system which eased the various applications needed in MRT projects.

Whereas the Spearline coupler which is the slimmest profile of our coupler, provided a full strength system capable of exceeding the nominal ultimate characteristic strength of the connecting reinforcing bars.

The Result

Halfen Moment Malaysia has supplied to most of the MRT stations. The feedback has been extremely positive and we will be continuing to supply couplers to the Malaysia railway industry.

MRT Line 1 Railway Construction
Picture above showing Moment® JoinTec Coupler supplied for reinforcement bar within the railway in MRT SBK Line 1.

 

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