Construction Process and Steps

View the photos (below) of the sequence of construction, manufacturing and erecting a Tilt Lift Structure, take a look at our interactive demonstrations page.

You will find a step by step guide to how a tilt lift building is made, from start to finish.

 

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    1. Casting Beds - The first step in panel process. They are laid on levelled earth ready to form the first panel. The layout of these beds is crucial as they influence the lift sequence and the finish to the panel
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    2. Pouring the Casting Beds - Site Preparation - This step is the preparation step for steel and chairs to be placed in the panels.
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    3. Marking the Boxes - Site Preparation: Form Work - Form work is built to rigid design specifications
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    4. Boxing Up - Formwork - This step is forming up the individual design of each panel to pour, the process is layered on stacks with sometimes each panel being a different design requiring additional formwork.
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    5. Chairing Up - reinforcing - steeling up, fixing of chairs (which hold the mesh), laying the mesh and bar, sometimes in multiple layers and then tying off of these elements by the steel fixers. The process is also inspected by engineers and has the comply with the design and engineering of each panel.
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    6. Steel Re-Bar - is the laying of bar which is part of the reinforcing process.
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    7. The Pour - This stage of the pour is where the concretor vibrate and moves the concrete into position by hand.
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    8. The Pour, Vibrating - This stage of the pour is where the concretor vibrate and moves the concrete into position by hand.
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    9. The Pour, Trowell Machines - This stage of the pour is then completed by trwell machines on the surface.
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    10. The Pour, Hand Trowelling - Hand Trowelling and edging is done to give the panel a complete finish.
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    11. Applying the Bond Breaker - between each panel layer an element called bond breaker is applied, this enables the panels to come apart during the lifting stage
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    12. New Layer form and Pour - This stage of the tilt lift is the preparation for more formwork to be put on top of the existing panel, to create another panel.
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    13. The Panel Drying - The finished panels, drying.
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    14. Full Box, The final stage before curing - the finihed pours await the removal of the form work. this process is known as De-Pinning.
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    15. Form work removed, and the panels are curing - The panels stacks with their formwork removed are left to strengthen, while they await the lift process.
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    16. Find the Locator Pins - All locator pin placements are designed in the engineering process and are placed before the panels are poured.
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    17. Find the Locator Pins - All locator pin placements are designed in the engineering process and are placed before the panels are poured.
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    18. The Crane attaches to the panel - The final adjustments are made as all the props are attached to the panel before the lift begins.
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    19. Tensioning - The dogmen instruct the crane operator in this delicate process to tension the lifting gear.
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    20. The Lift in Progress - Massive amounts of suction from while the panels are curing as all air is expelled from inside the concrete. In this process, the crane driver carefully breaks that suction between the panels
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    21. The Lift in Progress - Lifting cranes are chosen by the weight of the panels. Small franas are used for dado panels and pillars, then the size of the crane is picked by the lifting capacity in relation to the tonnage of the panel
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    22. The Lift in Progress - Lifting is done in sequence, with each panel propped and secured before the next sequence.
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    23. The Lift in Progress - The buildings go together like a giant jigsaw puzzle. This is why key planning at the beginning of the job is such a high priority.
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    24. The Lift in Progress - Once the panel is upright, it is ready to be moved into place.
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    25. The Lift in Progress - The crane slowly rotates the panel in order to begin to align it into position
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    26. The Lift in Progress - During the rotation and walking of the panel, Dogmen maintain control of the bottom of the panel to stop it from swaying
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    27. Aligning the panel - While the weight of the panel is still held by the crane, manual force is used with the help of berk bars to align the panel to the location pins at ground level. Lifting is done in sequence with each panel placed like a giant jigsaw.
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    28. Propping - Props are secured to deadmen in the ground (Concrete structures underneath the earth designed specifically to hold the props in place)
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    29. Setting up the panel and props - Props are also used to align the panel into the correct position and plumb up.
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    30. Aligning the panel to within 5mm - Now the panel is ready to released from the crane.
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    31. The panels are now up, tie to put the roof on - Different sized props are used according to the size of the individual panel. This is engineered. Props are placed as required for both safety and stability
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    32. Jointing and Patching - This is the final stage of tilt panel construction, a specialised patcher comes in and covers any marks left during the lifting process. Jointing this is done by a licenced contractor who fills in the gaps between each panel, this is fire rated, with a certificate provided.
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    33. The Finished Building