ECRL Construction

Top 3 Building Products for Railway Construction You Should be Talking About

Rail transport is still today one of the main transportation method in many countries and remains a key driver of development and socio-economic rebalancing in local areas. The need to create new and strategically important routes has made railway construction one of the most relevant sectors on the global scene.

To ensure high levels of transport safety, railway builders and construction partners involved in this sector must adhere to strict safety standards to use quality construction accessories and innovation to optimise construction for a safer and cost effective railway.

You will always find the following products during the construction of any railway project:
• Post Tensioning System to allow longer span of beams for bridges so less pillars are needed.
• Cast in Channel to fix and support railway services especially if overhead electrification is selected.
• Rebar Coupler to simplify the design and construction of reinforced concrete and reduce rebar congestion.

Post Tensioning System


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The use of post tensioning system in the beams in railway construction allows a longer span of bridges which reduces the number of pillar required. With lesser pillars, there will be less foundation which eventually reduce cost and also construction time.  This minimises the interruption to the existing landscape and will give the planner or designers to have more flexibility and options in plotting out the routes. There is a huge impact to the buildability especially in most MRT/LRT railway projects when they are built in Metropolitan cities which are highly congested with existing services and landscape.

Cast-In Channel


Cast In Channel Tunneling
Cast-in channel provides flexibility in fixing points, therefore future proofing the construction to allow for changes in the arrangement of the services.  The use of cast in channel in fixing the services gives a shorter installation time and therefore reduces the duration of the project.  The superb tolerances feature make the installation faster and easier.

Rebar Coupler


Rebar Coupler for Railway
Rebar couplers offer a full strength connection. They are suitable for projects of any size, including those requiring a high volume of couplers, such as road and rail bridges where fatigue performance may also be a factor.  The use of couplers reduces the congestion of reinforcement bars and this will enhance the buildability which also means speeding up the construction progress.

Halfen Moment has always invested in and consolidating know-how, by providing innovative building solutions for our customers to develop railway construction projects. Contact us today to start improve your project productivity cost effectively!

 

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Halfen Moment Wins Most Active Organisation Award

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We are delighted to announce that Halfen Moment Malaysia has won 2018 Most Active Organisation Award during the IEM’s 60th Annual Dinner and Awards Night.

This is a very proud day for everyone associated with Halfen Moment and we thank you for your continued support. Special shout out to The Institution of Engineers Malaysia (IEM) for the honor, truly an award that belongs to our dedicated team as we drive innovative change in the construction industry relentlessly.

Last but not least, thank you to all Malaysian Engineers and our amazing clients whom made this happen!

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Precast IBS Wall Panel

Latest Developments in Precast Concrete Connections

State of The Art Technologies

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.

There are a number of ways of doing this such as via:
• Grouted Coupler to connect walls and columns to foundations
• Wire Loop Box to connect walls together
• Precast Coupler to connect precast elements
• Dowel Systems for connecting slabs to walls

Moment® Grout Coupler

Grout coupler are traditionally used in the bottom of a column or wall as a means to connect on to starter bars protruding from the foundation. Although they might often be designed as a pin connection, the reality is that this will transfer moment from the foundation in to the wall or column and should therefore always be made of a ductile material that does not compromise the ductility of the steel reinforcement that it is coupling together. To that end, the coupler should always be of a “bar break” type where there is a considerable factor of safety between the bar failure and the coupler failure capacities.

Grout Coupler on Site

Moment® Wire Loop Box

Wire loop boxes are prefabricated components with a constant rebate geometry and 1 or 2 high strength (c. 1600-1800MPa) wire loops. Loops from adjacent elements then overlap during installation of the panels and are secured using a reinforcing bar and a high early strength grout to complete the connection.

They are usually used to connect 2 adjacent precast panels together, where the interlocking rebar and wire loops provides robustness in the event of an Earthquake to ensure that grout degradation would not result in complete collapse.

81Loop Box Used on Site

Moment® Connection Loop

Connection Loop is a single-wire loop used to connect 2 precast boxes for the prefabricated prefinished volumetric construction (PPVC).

In order to connect 2 precast elements, both precast elements has to be cast with the Moment® Connection Loop at the wall. A rebar will then be inserted through the intersection of 2 loops. After placing the rebar, the gap between the precast elements will need to be grouted using a 40Mpa or 70MPa non shrink grout depending on the application. Material strength of the Moment® Connection Loop is 1770N/mm  and complies to EN12385-4:2002+A1.

Moment Connection Loop PPVC

HEK Precast Coupler

The HEK Precast coupler is an innovative and versatile solution for fast and easy connection of precast concrete elements.

Cast-in DEMU Fixing anchors i.e. T-FIXX®, bolt or bar anchors transfer the tension and shear force into the precast element.

The main advantage of the system is the fast and efficient positioning of precast elements. The connection can be subjected to load immediately after installation. This results in a substantial improvement in construction time.

 HALFEN HEK Precast couplerHEK Precast Coupler Application with DEMU Fixing Anchor

Invisible Connections

Shear dowel systems are always a challenge as they generally require very tight tolerances to ensure effective load transfer, so systems without grout and oversized holes are almost impossible. Traditionally, precast slabs such as stair landings used to be supported by a steel angle bolted to the wall. Installation was slow, required high degrees of accuracy, tied up the crane with costly hook- time and could only be used on straight walls.

But by keeping the grouting to a minimum, one such technology – Invisible Connections – has revolutionized the use of precast all throughout Northern Europe; it is a patented system, with its origins in Norway, to connect precast concrete without use of corbels or steel angles, and is used extensively throughout Europe due to the independently tested and certified European Technical Approval (ETA [4]) that provides engineers with peace of mind about the capacities.

The product range of Invisible Connections consists mainly of TSS Telescopic Stair Connectors & BSF Telescopic Beam Connectors.

85         BSF Telescopic Beam Connectors

Another topic relating to Invisible Connections will be covered as a future topic in our Academy site.

 

There are many good technologies available, but a dependence on local testing and local reference projects will hinder and slow down their introduction. An increased readiness to accept the certification schemes for prequalification that exist overseas such as ETA[4] and ICC certification where appropriate, will mean that the technologies can help keep pace with the requirements of the precast industry.

For further enquires related to precast connections, feel free to contact us, our engineering team will be happy to assist you further.

 

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Use Personal Protective Equipment (PPE)

10 Tips To Stay Safe At Site In 2019

Safety is our core value in Halfen Moment and it is the responsibility of all of us to work towards our goal: ZER0 fatalities and ZERO accidents. There are plenty of guidelines and regulations that we should follow on construction sites or workplace, and almost all of them pertain to the safety of the people who work there. Here are 10 common construction site safety tips:

Use Caution When Climbing On and Off Equipment


Falls when climbing on and off equipment is common, as is someone getting injured because they got stuck in the process. No one should stretch more than they should to grab onto the handles, nor should anyone carry anything as they are getting up or down. It is also important to never jump down from a machine, as they are when the most accidents happen.
Use Caution When Climbing On and Off Equipment

Stay Away from Operating Machinery


It is common for workers who are waiting for the next step of their job to simply congregate in one area and patiently watch as someone else is doing their job.  This is normally not an issue except when those people are standing too close to operating machinery.  Most of the time nothing will happen, but accidents usually do not announce themselves first, so workers should stay away out of extreme caution.
Stay Away from Operating Machinery

Use Caution Around Fall Hazards


Every construction site has fall hazards and it is the worker’s job to be aware of what they all are.  Safety systems should be in place in those areas to prevent falls from occurring for example, guardrails, safety nets, safety cords, and personal fall arrest systems.
Use Caution Around Fall Hazards

Use the Proper Ladder Height


Some construction workers will try to get away with using a shorter ladder than they should, simply because a taller one is not available. This should be avoided if possible, because every time a construction worker stretches past the point that they should on the ladder they are using, they take the chance that they will fall off the ladder or the ladder will tip over and take them with it.
Use the Proper Ladder Height

Keep an Updated First Aid Kit


That first aid kit from five years ago is going to contain medication that is outdated and band aids that are most likely past their sticky stage.  Everyone should be prepared with an updated first aid kit.  This kit should include disinfectant, ointment, painkillers, and bandages and gauze of all sizes.
Keep an Updated First Aid Kit

Never Use Damaged Equipment


When there is work that needs to be done, some construction workers will simply use what they have available even if that item is damaged.  That is never a good idea, as that damaged piece of equipment can cause an injury rather quickly.  Some damaged parts can include a worn-out cable, worn-out cords, and a worn-out harness.
Never Use Damaged Equipment

Never Unplug a Tool by the Cord


At the end of a long day or after a long tedious project, many construction workers may be tempted to unplug the cord of the tool they are using by simply giving it a good yank.  This motion can damage the tool over time and it can also cause injury to a person.  It is better to take the two extra seconds to go over and pull the plug out of the outlet, because those two seconds can mean the difference between life and death on occasion.
Never Unplug a Tool by the Cord

Be Aware of Surroundings at All Times


Construction job sites are busy places, which is why workers will want to be aware of their surroundings at all times.  No one thinks that something bad is going to happen to them as they are simply sitting there taking a break, but one second of unawareness can lead to a person getting hit on the head by a falling object or getting run over by a piece of machinery.
Be Aware of Surroundings at All Times

Use Personal Protective Equipment (PPE)


Employers have duties concerning the provision and use of personal protective equipment (PPE) at work. PPE is equipment that will protect the user against health or safety risks at work. It can include items such as safety helmets, gloves, eye protection, high-visibility clothing, safety footwear and safety harnesses. It also includes respiratory protective equipment.
Use Personal Protective Equipment (PPE)

Manual Handling Tips for Safe Lifting


Over 40% of site injuries come from handling goods. Costs from handling errors leading to injury may include compensation and lost productivity. Putting in place control measures to help employees understand how to lift, push and pull correctly can solve the majority of these accidents.
Manual Handling Tips for Safe Lifting

These safety tips are designed to keep everyone safe on the construction site, and while many of them are basic common-sense things, they are still overlooked numerous times a day around the world.  The one thing that every construction worker needs to remember is that accidents happen and everything that they do when they are on the job can be potentially hazardous in one way or another.  Therefore, they need to be cautious every minute of the day, so that they can leave and go home the way that they came.

 

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Concrete Spacer

The Guide to Select the Right Concrete & Plastic Spacer

Selection of the Right Spacer


Concrete or Plastic spacers are little accessories used to maintain the position of rebars in the concrete structures before pouring the concrete. This is necessary to maintain a clear distance (cover) between the surface of the concrete and the rebar, as if there is insufficient cover, the rebar will start to corrode and result in spalling concrete. These spacers then become the permanent part of the structure after pouring. Although different types of spacers have similar features but the selecting the right one will ease the construction efficiently and safely. Hence, the selection of spacer will be based on the following factors:

Height of Spacer


The minimal height of spacer is equivalent to the dimension of the spacer to form the exact concrete cover for the rebar in concrete. Hence, this is the key specification needed while ordering. With the multi-dimension spacer, the heights for supporting the rebars will vary in depend on the position of installation. In a project, where the reinforced concrete structures have various concrete cover thicknesses, it is practical to select the multi dimension spacers with the appropriate dimensions.
Concrete Spacer
Different heights of concrete spacer

Firmness of Subgrade


The spacers placed under the rebar mesh will be impacted by the forces from above such as the weight of rebars, workers and machines. If the contact area of the spacers with the soil/stone subgrade are not suitable, they can settle during construction. This condition will reduce the concrete cover thickness as required. Hence, if the subgrade is not firm, the spacers will need sufficient contact areas or some additional plates to spread the load from the spacer.
Importance Of Concrete Spacer
Suitable and sufficient of concrete spacers are essential to avoid reduction of concrete cover thickness

Material


The material of the spacer being selected needs careful consideration as each material type has its pros and cons. Plastic spacers provide no compromise in terms of serviceability, but are generally weaker than steel and concrete versions. Therefore, if the cage being supported is very heavy or if the rebar has a high risk of being walked on, then plastic spacers should only be selected with extreme care. Steel spacers are more robust, but come with the added problem that there will be some non-structural steel within the cover zone. This can often lead to small rust spots being visible on the concrete surface, so if the surface is exposed and visible, steel spacers should also be avoided. In general, the simple concrete spacers can be used for all structures, providing the concrete spacer grade is similar to that of the surrounding concrete. Too much variation in properties can lead to localised cracking and compromise the integrity of the concrete locally around the spacer. There are many kind of spacers with various shape and use for selection. The users should firstly analyse the conditions and then select the right product in order to obtain the best efficiency.

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Moment plastic fast spacer- Designed for low loads

Connection of Spacer and Rebar


There are a few examples of common options of connection between spacer and rebar:
a) Spacers are placed on horizontal surface and support the steel rebar above. By the weight and fixation of steel mesh then the spacers can be fixed without the binding connection. In this case, the spacer works as the blocks to form the right cover thickness. The long plastic spacer (continuous spacer) is the most cost effective alternative, placing under low loads area. It can be used in non-critical locations.

b) The spacer with tie wire or plastic/steel hooks for connection with rebar. By hook or tied-wire, the spacers are fixed at right positions and not falling out. This kind of secure connection is critical when spacers are vertically placed (when rebar cage is lifted or vibration of concrete).

c) The spacer with holes at their centers for inserting the rebar. Consequently the spacer can connect with the rebar and will not be taken apart even if the rebar moved.

Consequences of without proper concrete spacer Consequences of without proper concrete spacer1

Consequences of without proper concrete spacer- Vulnerable to corrosion and the concrete to early deterioration

 

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Exhibiting At BuildTech Asia 2018

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Inspiring meetings and interest from participants 

Halfen Moment Singapore participated in BuildTech Asia 2018 exhibition from 22-24 October 2018. BuildTech Asia is the region’s leading trade show for the building and construction industry that addresses the challenges of building and construction across different verticals. Around 10,000 people in related industries from Singapore and the neighbouring countries attended this event.

A full range of innovative building materials were presented at our booth, showcasing the various applications of  how Halfen Moment products can be used in a construction, from connection technology to reinforcement technology, providing solution and possibilities for a faster and safer construction. At Halfen Moment, we develop and supply essential building components, providing strength and stability to buildings and structures in Asia and Middle East.

We would like to thank you for spending your time visiting our booth at BuildTech Asia. It was our pleasure and honor as we enjoyed many inspiring conversations.  We consider our participation in this event a success! To learn more about the Halfen Moment products portfolio, please feel free to contact us at hmsg@halfen-moment.com.

We look forward to see you again!

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Halfen Moment Singapore Team

Halfen Moment Booth
Halfen Moment Booth

 

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ASEAN Railway Summit

Halfen Moment Sponsored ASEAN Rail Summit 2018

With all the support given, the ASEAN Rail summit has been successfully held at the Hilton Hotel Kuala Lumpur, Malaysia from September 27th to 28th, 2018. Thanks to the strong support from the government and industry associations and other organizations, including Ministry of Transport of Malaysia, Embassy of the People`s Republic of China in Malaysia, Philippine National Railways, The Light Rail Transit Authority of Philippine, Indian Railways, Light Rail Manila Corporation, Sri Lanka Railways, Ministry of Transport and Civil Aviation Sri Lanka, China Railway Engineering Corporation(M) Sdn Bhd, China Communications Construction Company (M) Sdn. Bhd etc.

The ARS 2018 themed on
• One Belt One Road
• All-dimensional Connectivity
• Smart Innovation
• Welcome to the Future Together

Inherited the successful experience previously, inviting core rail transportation company from Chinese and ASEAN countries and government agencies, well-known suppliers, third party consultant and other decision makers.

The five general sessions discussed during this summit were
1) Urbanization and Globalization Trend
2) ASEAN Rail Transit Industry Policy and Market
3) Multi-dimension Cooperation to realize sustainable development operation
4) Global Technology Innovation Guiding Smart Railway Future
5) Improving International Project Cooperation, Global Opportunity Challenge.

This two-day schedule mainly focused on the ASEAN Rail Market through these five dimensions.

We sincerely thank all the delegates and hope that you have had a nice time during this summit. We believe we could carry out more extensive and friendly cooperation in future connection and wish you all the best!

ASEAN Railway Summit
Attended by more than 100 professionals from the railway industry in ASEAN

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Inspiring meetings and interest from participating engineers in our products

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Halfen Moment Completed IEM Seminars For 2018

Halfen Moment Malaysia and Institution of Engineers Malaysia (IEM) completed full day seminar event in Kuala Lumpur, Johor and Sabah respectively, addressing a wide range of salient topics to engineers in Malaysia including the topic of Mechanical Splices and Precast Lifting & Connecting.

The seminar held in 3 different states were attended by more than 200 engineers from Civil and Structural Engineering Technical division. Focused on a few of our key products, our speaker, Gary Connah, Managing Director of Halfen Moment Singapore discussed the available types, designs and applications of Mechanical Splices in the market. Innovative building accessories for precast lifting and connections were presented during the second half of the seminars.

Commented by one of the participating engineer, “The seminar’s technical, educational and learning features brought industry professionals in close contact with the global construction market and the latest technologies and developments, offering more than 5 CPD-certified educational sessions.

Please feel free to reach us if you would like to have us organizing a similar talk session in your office. Meanwhile, please visit our product page on Mechanical Splices and Precast Technologies or alternatively discuss your project needs with a Halfen Moment Representative. Stay tune for more IEM collaboration events in 2019, and we look forward to meeting you in our next event!

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Jointly held seminar with IEM KL

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Jointly held seminar with IEM Johor Bahru

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Jointly held seminar with IEM Sabah

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Group photo with Halfen Moment team, IEM committee and secretariats

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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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