kumk @ fumkans METHOD STATEMENT OF KUMKANG ALUMINUM FORMWORK SYSTEM THE FORMWORKS SPECIALIST We KUMKANG KIND CO.,LTD 1445.2, Kumkang Ind. Bldg, Seocho-Dong, Seocho-Ku, Seoul, Korea. ‘Tel: 482-2-3415-4104, Fax: +82-2-3415-4165 Webpage: ww. Kumkangkind.comKumkang Ind. Bldg,, 1445-2, Seocho-Dong, Seocho-Ku, oie kumkang eer INTRODUCTION The Kumkang Aluminum Formwork System has been designed to be capable of forming ALL the concrete in a building: all walls (external and internal), floor slabs, columns, beams, stairs, window hoods, curved sections and intricate decorative features; whilst at the same time bringing to field construction all the benefits of a factory "assembly line” construction process which is the hallmark of precast concrete systems, but without the deficiencies and disadvantages or precast. The Kumkang Alumii 1um Formwork System produces low cost and quality work at maximum rates of production utilizing unskilled workers. ‘The main limitation of the Kumkang Aluminum Formwork System as with other systems is that there must be sufficient repetition of work to ensure that the forming cost is below that of sawn timber and plywood. Itis, therefore, ideally suited for mass housing and high-rise buildifigyprtj CS CS s SSKalan In. li, 1445-2, eoctn-Dog, Seon Ki, k ‘Seoul, Korea Kucpkans Phone: +822:5413410 pharreetiete BUSINESS PERSPECTIVE ‘THE PRODUCT Kumkang Aluminum Formwork System is a home-grown building technology which has been designed to suit Korean and Malaysian as well as Asian building industry. It consists of aluminum panels which are pre-designed according to the architectural plans to form all the concrete found in the building superstructure, i.e. the walls (external and internal), floor slabs, columns, beams, stairs, window hoods, curved sections and other intricate decorative features. Unlike other existing systems, the Kumkang Aluminum Formwork System is flexible, lightweight and suits all building types without the need to rely on heavy cranes and other heavy construction plant and equipment. Normally one “set” of Kumkang Aluminum Formwork System equipment for a typical project/building would consist of several thousand individual pieces of aluminum sections which will be connected together and produce a “mould” for concrete pouring to cast the various structural components of the building. ‘The equipment will then be dismantled and used repetitively for about 300 times. With its lightweight and a highly efficient work schedule, Kumkang Aluminum Formwork System can build a building at the rate of 4 to 5 days per floor as compared to 7 to 10 days per conventional method. ‘THE MARKET = found to be very suitable for the construction of high-rise apartments and low-tise houses where there are many repeats to a lay-out. This is particularly attractive to the developer of the project as the savings in time means substantial cost savings. Since its introduction to the market about ten (10) years ago, the Kumkang Aluminum Formwork System has won the confidence of many developers, not only throughout the country, but also overseas such as in Malaysia, Singapore, Vietnam and the India. This is evidenced by the various sales and contracts that have been successfully completed to-date,Kamlang lB, 1445-2, Sech-Don, Se Ku, Sel Kot cian! Phones 1822311 Tana aust MODUS OPERANDI ‘The Design Besides marketing the Kumkang Aluminum Formwork System themselves, Kumkang has several specialist contractors to execute the jobs/contracts secured using the system. Most of the building jobs secured is through negotiation rather than through the usual process of tender. The superstructure of any building development is the most important and all other works such as electrical wiring, plumbing, etc. will have to be coordinated together. As such, Kumkang together with the contractors, will work with the architects and the structural engineers at the early stage of planning for the construction. Once a contract has been secured, confirmed drawings of the project will be sent to Kumkang for the design and creation of the formwork set which usually consists of thousands of individual pieces of metal panels. ‘As the design stage which involved computer-aided designing (CAD) is a very intricate process, ‘The manufacturing of the formwork equipment is basically sheet metal working and aluminum welding. Raw materials used include extruded aluminum. ‘The manufactured products are known as components which are of different shapes and sizes. Each set of Kumkang Aluminum Formwork System equipment has a combination of various components in various quantities. Generally about 80% fo 85% of these components are “standards” that can be used for more then one project and the remaining 15% to 20% are “specials” which are designed veryKumlang Ind, Bld, 145-2, Seocho-Dong, Seocho-Kuy, @® kumkang Pattstiog Kind 1-3415-4165 specifically for a particular structure. The latter generally cannot be re-used and have to be sold as scraps or in some instances sent back to Kumkang to be re-fabricated. The lead time between the receipt of the drawings and arrival of equipment to the site is normally about 6 to 8 weeks for Malaysia and Singapore, other region will be 8 to 10 weeks. ‘The Field Application With the equipment at site, a site manager/engineer will coordinate with 3 to 5 supervisors/foremen and a crew, varyi in number, depending on the size of the project which can range from 20 to more than 100 workmen to construct the building complete with all internal and external walls, stairs, lift shafts, balconies, sun hoods, etc. at the rate about 4 days per storey. Detailed field working drawings are supplied by the design office to facilitate easy use equipment at job sites. In the case of exports to overseas, Kumkang will undertake to send trained technicians to help the buyers to fix and used the equipment.Kalan Ind Blip, 1452 Sech-Dong,Sosh-Ke, ton one kumkang Phone: 829 415410 fae Tea ulsates COMPETITION AND INDUSTRY OUTLOOK Traditionally, timber and plywood are used for formwork fabrication for the construction of concrete structures. It is still the most widely used medium as it is the most versatile since they can form the most intricate shapes and forms of the structures. However, needs many skilled and unskilled workers besides being very time consuming. In today’s competitive market, speed and efficiency is of primary importance. In view of this, many various construction systems have been introduced over the years such as the “Tunnel” formwork system, the “Peri” formworks system and the “Table” formwork used by various parties. However, all these systems are not “complete” systems in that they are able to form only parts of the building structures such as the wall or lift core, etc. The Kumkang Aluminum Formwork System was introduced into the market about ten (10) years ago and has been successful in gaining market acceptance from the local and overseas construction industry. Among the key success factors of this system are: Speed: the system allows 100% of the building superstructure to be constructed or formed at the rate of 4 days per floor as against the traditional approach which will take at least 7 to 15 days a floor. Even then, the latter can only do for columns, beams and slabs only and the infill walls have to be built and plastered later. Quality: substantial cost-saving. In addition, all the structures are accurately works to correct inaccuracies are eliminated.Kunkang In Bl, 1445-2, Seoch-Don, Seocho-K, ‘Sent Koch @® kumkang Phone: 48223414108 Vo 18223418-4165 to release the slab forms. Overlooking of re-propping in one of the commonest causes of fatal accidents on building sites. Apart from the above, the system also provides other advantages such as non-dependence on skilled workmen such as carpenters, bricklayers and plasterers, which because of the unavailability, may seriously delay the project; the elimination of scaffolding: the minimal usage of cranes and the ability of system to build “load bearing wall” which is structurally more efficient and stronger than the traditional RC frame. The overall advantage is the cost and time savings to the developer. In view of the above, Kumkang has a very competitive state-of-the-art technology which has gained market acceptance over a relatively short period of time as evidenced from the major projects completed and new projects secured to-date, Some of the Kumkang’s clients are established and reputable developers and contractors which lend much credence to the Kumkang Aluminum Formwork System. The fact that the Kumkang Aluminum Formwork System has made inroads in the highly competitive and advanced countries such as Taiwan and Hong Kong is sufficient of Kumkang Aluminum Formwork System superior formwork technology. in the revival in the local construction industry, in particular that of low and low-medium cost houses, as well as massive demand for speedy social housing development in the countries in the Asian region and other parts of the world, Kumkang foresees a tremendous growth potential in its business possible major downturn in the local construction industry.Kumkang Ind. Bldg., 1445-2, Seocho-Dong, Seocho-Ku, @ kumkang hone: agnor ul 482-2-3415-4104 Kind Fax +822-3415-4165 METHOD OF STATEMENT Like most engineering systems, the Kumkang Aluminum Formwork System comprises two distinct parts; the hardware and the software. THE HARDWARE consists of over one hundred standard pieces of equipment, manufactured to fine tolerances, The majority of the equipment comprises panel sections while the rest includes vertical and horizontal comer sections, bulkheads and special floor slab link beams that can be dismantled without removing the props supporting the floor slabs. A "set" of equipment for a particular project can consist of thousands of pieces, which, when connected together provide a mould for the monolithic pour of the concrete for the walls, columns, beams, slabs and other structural components of the section of the building to be cast in that pour. The equipment is of aluminum construction and sections are extruded or manufactured to be sufficiently large to be effective and yet sufficiently light to enable ease of handling by a single worker. Consequently, the Kumkang Aluminum Formwork System does not rely on heavy cranes and other heavy construction plant and equipment. Each of the components of the hardware is connected by simple pins and wedges or U-Clip, and a light hammer is the only tool required in assembling and dismantling the equipment - skilled labor being practically dispensed with. five days.Kumkang Ind. Bldg., 1445-2, Seocho-Dong, Seocho-Ku, Seoul, Korea @ kumkang Phone: +82-2-3415-4104 Kind Fax: _+82.2-3415-4165 THE SOFTWARE can be sub-divided into two phases ‘The first phase comprises computer modulation and selection of equipment. The Kumkang Aluminum Formwork System s extremely adaptable and flexible, and it is very seldom necessary to amend building designs to accommodate the system. Based on the architectural and structural drawings of the building, a process of computer modulation is carried out. During modulation, iteration and optimization techniques are utilized in the selection of the most economical and practical fitting of the individual components from a large database containing all the standard pieces of equipment. Layout and shop drawings from the results of the computer run are subsequently generated for the execution of the works. This is the most important stage in the system design process; and the proficiency of the CAD Design Department, in this regard, is one of the major strengths of the Kumkang Aluminum Formwork System. The second phase is to establish the daily construction cycle of work, and the co-ordination and ‘management of the other trades such as the fixing of steel reinforcement, ducting works for electrical and mechanical installations and the placing of concrete. The Kumkang Aluminum Formwork System disciplined and highly efficient working schedule ensures that the other related trades follow in 12012 AANS standards expected in the construction industry, in terms of quality and accuracy. This enables plumbing and electrical fittings to be prefabricated with certainty. The construction accuracy of the conerete works - with the barest of surface imperfections or blemishes, will also benefit other finishingKumkang Ind, Bldg,, 1445-2, Seocho-Dong, Seocho-Ku, @ kumkang ‘Seoul, Korea Kind Phone: +82-2-3415-4104 Fax: _+82-2-6415-4165 CAPABILITY STATEMENT ‘The Kumkang Aluminum Formwork System for forming concrete will perform as follows: i) Form ALL the concrete for columns, beams and floor slabs for rigid frame construction; ii) Form ALL the concrete for walls, floor slabs and stairs for monolithic load bearing wall construction; iii) _ Form concrete structures to any architectural dimensions. As the system is modulated in multiples of 25 mm, any architectural feature or form can be obtained within a tolerance of 12.5 mm, which is well within the tolerance expected in the construction industry. The Architect is, therefore, not required to modify his designs to s iv) Form stairs, lift shafts and window hoods with any combinatior or floor slabs. When it is confirmed that Kumkang Aluminum Formwork System has been chosen for use on a particular project, the first step taken by Kumkang is the production of a Shell drawing by the CAD Design Department, based on the Architectural drawings with cross reference to the Structural Engineering drawings. Occasionally, some dimensional discrepancies between these two supplied sets of drawings are found. In the course of preparing the Shell drawings, Kumkang Aluminum Formwork System CAD designers will attempt to resolve these discrepancies with the agreement of both the Architect and ‘Structural Engineer, prior to submitting the Shell drawing to the Client for confirmation, The Shell drawing is the final, dimensioned layout from which the design of the set of KumkangKumkang Ind. Bldg., 1445-2, Seocho-Dong, Seocho-Ku, @ kumkang ‘Seoul, Korea Kind Phone: +82-2-3415.4104 Fax: 482.2-3415.4165 Aluminum Formwork System is produced. ‘The design of a set of system formwork is an extremely intricate process, where separate consideration must be given to each and every single detail of creating the required building shape. In addition, the shape and size of each individual piece of system formwork relates to the shape and size of every other adjacent and opposite (in the case of vertical system formwork) component. Further levels of design complexity can be understood when it is remembered that the holing pattern of each edge of each component must be designed with assembly in mind - sometimes in the same plane, sometimes at right angles and sometimes at some other angle - o that at least two holes on each edge will match with two on each edge of each adjacent panel, for fixing purposes. Put all these in the context of one set of system formwork consisting of many thousands of individual pieces and it i easy to see why the design and checking process will take 2 to 4 weeks on average! Because an apparently small change in the layout will have dramatic "knock-on" effect on the whole system formwork design, Kumkang are clearly unwilling to proceed with any design until the Shell drawing is confirmed by the Client as "Approved for Construction”. Confirmation of the Shell drawing is to be regarded by all parties involved as the end of the building design process. If changes will to be i sted upon by the Client after his confirmation of the Shell drawing, there will certainly be serious and unavoidable consequences: additional costs will be incurred and time will be SPECIAL CONDITIONS ‘The following special conditions must be adhered to for the Kumkang Aluminum Formwork System to operate as intended:Kumkang Ind, Bldg., 1445-2, Seocho-Dong, Seocho-Ku, @ kumkang es ii) iii) Kind $82.2-3415-4108 Fax: +822-3415-4165 ‘The Kumkang Aluminum Formwork System is manufactured in metric sizes. Any imperial dimensions on the final drawings will be converted to metric, and rounded to the nearest 25 millimeters. All dimensions of structural members will be adjusted to multiples of 25 millimeters, Alll construction cold joints for slabs and corresponding beams will be along the centerline of beams unless hampered by congestion of reinforcing steel. In that event, the construction cold joint will be placed at the one-third point of the slabs. ‘The minimum striking time of the Kumkang Aluminum Formwork System will be as follows :~ Columns, beam sides, walls .. 10 hours Deck soffits . 36 hours Props to beams .. 9 days (max. prop spacing = 1.35 m) Props to deck soffits . (max. prop spacing = 1.35 m)Kumkang Ind. Bldg., 1445-2, Seocho-Dong, Seocho-Ku, Seoul, Korea @ kumkang Phone: 482-2-3415-4104 Kind Fax: +82-2-3415-4165 SUMMARY OF ADVANTAGE! ‘THE IBS BUILDING SYSTEM Speed ‘The Kumkang Aluminum Formwork System allows 100% of the building (i.e. all internal walls, all external walls, stairs, lift shafts, balconies, sun hoods, etc.) to be constructed at a rate of 4 days per floor against the traditional approach which will take at least 12 days a floor (for columns, beams and slabs only — then the infill walls have to be built and plastered). ‘This means that the total structure is completed in a third to a quarter of the time required to build conventionally. Thus, the Developer saves on project financing costs and site overheads are also significantly reduced. In terms of a pre-sold project, the cash value of the building becomes available to the Developer much earlier — often more than a year earlier ~ than might otherwise occur. At worst, this money can yield substantial interest if left on deposit in the bank — but Developers can usually find better returns than this! ual ity ‘The flat, off-the-form finish produced by the Kumkang Aluminum Formwork System simply requires a 2-3mm skim coat before decoration, thus eliminating the need for plastering. (Often, clean plastering sand is scarce and if poor sand is used, 1 leads to unraveling of plastered surfaces in a short period of time). In addition, all the elements of the building are ac vertical, horizontal and square in plan and section as intended, so inaccuracies are eliminated. As service collars can be accurately located and cast-in as the slab cor PET A AEEKumkang Ind. Bldg., 1445-2, Seocho-Dong, Seacho-Ku, @ kumkang ‘Seoul, Korea Kind eliminated. This is a major hidden saving, as builders are very reluctant to admit (even to themselves!) the true costs of locating and remedying leaks ~ these costs get swept into the “contingency” figure. In addition, the bad publicity that a “leaky building” attracts has a very damaging effect on a Developer's reputation. Safety ‘The props of the Kumkang Aluminum Formwork System an integral part of the formwork, so that they do not have to be removed to release the slab forms — and therefore the reproping of the slab cannot be forgotten about. Overlooking reproping is one of the commonest causes of fatal accidents 0 building sites, and the elimination of reproping means the Kumkang Aluminum Formwork System is inherently safer to use on site than traditional forming with timber and plywood and any other systems that require reproping after the removal of forms. Independence from Scarcity of Skilled Tradesmen ‘The Kumkang Aluminum Formwork System eliminates the need for skilled plasterers as noted above, but it also eliminates the need for skilled carpenters and block layers. Projects have often been seriously delayed because of the unavailability of these skilled trades. Scaffolding ‘The need to carry the cost of scaffolding for the construction of the structure is eliminated, as the Kumkang Aluminum Formwork System provides its own work platform brackets, which ascend the build < uilding, ai Bonce0 < Gi20te Cranage NS APT roKumkang Ind. Bldg., 1445-2, Seocho-Dong, Seocho-Ku, @ kumkang ‘Seoal, Korea Kind Phone: +82-2-3415.4104 Fax: +82-2-3415-4165 ‘The crane is not required for the movement of the forms up the building as the construction proceeds. ‘Thus the crane is available for concrete and steel placing and other materials movement. The crane is only required for moving the forms down from the top of the completed building, Structure ‘The Kumkang Aluminum Formwork System allows consideration of @ “load bearing walls” structural design or “Shear Walls” approach. A LBW/SW design will always be more structurally efficient than a traditional “reinforced concrete frame” approach and will give a very much stronger building, It will therefore be less expensive to construct and to provide foundations for. Because the Kumkang Aluminum Formwork System is modular, it can be fitted to any architectural or structural layout. Thus, the designers can be as creative as they like and yet be confident that advantage can be taken of the system approach to construction. In this regard, the Kumkang Aluminum Formwork System is quite different to Tunnel Forming or systems based on the use of Flying Forms ~ both of which require the designers to modify the design the building to suit their particular system. Not only does the Kumkang Aluminum Formwork System give a remarkable construction speed, it gives the speed reliably. We will contractually undertake to complete 6 floors per month (i.e. 6 floors at 4 days per floor, plus approx 6 days to spare for items outside control e.g, crane breakdown, access handover of apartments or commercial space to Clients. Overall Financial Advantage EAR ET EE TTKankang In Bll, 145-2, Sect Dong, Seoch-Ke, Sous ea Kukang Pons 28228134108 When the above are taken into consideration over the construction period of a suitable project (i. one ‘where there are more than about 50 repeats of a typical layout), the overall profit to the Developer can be increased by a factor of from 10 to 30%. EERIEfone civ tees ee mkan oe kumkang eal REQUIREMENTS CHECK LIST All the following are required on or before contract signing, to enable the Kumkang “shell drawing” to be completed. ‘The “shell drawing” will take approximately 2 weeks to complete. Kumkang shop drawings and equipment production cannot commence until the client confirms the “shell drawing” by signing and returning one copy. ‘The lead time between receipt of the confirmed “shell drawing” and arrival of equipment on site is 10 to 14 weeks. ‘Changes requested prior to confirmation of the “shell drawing” may possibly be accommodated (it depends!), but if so, may extend the above times WAL a Ne an i Changes sisted upon after confirmation will extend the times g CIEEKumkang Ind. Bldg., 1445-2, Seocho-Dong, Seocho-Ku, (@® kumkang pe ooriera Pax: 1822-3415-4165 Item] Description Date Architectural Drawings (“For Construction” Release) Action by Received 1. | Site Layout Plan 2. | Floor Layout Plan - Typical Floor Floor Layout Plan (s) — Typical Floor(s) 4, Roof Plan Building Sections, showing all height dimensions 6. | Building Elevations: North, South, East, West Door and Window Schedule, with finish floor level to window sill * mension 8. | Staircase Details and Section Bathroom/toilet Section, showing heights, floor drop details, kerb * or other special feature dimensions 10. | Details of any balconies, parapet walls or other low walls Details of any special external fagade forming um requirements 12. | Window hood details & dimensions (if applicable) 13. | Weather-throttling/drip stop layout (if applicable) 14. | Void/opening locations and details 15. | Lift shaft and door opening details Date Structural Drawings (“For Construction” Release) Action by Received 16. | Piling/Footing Layout 17. | Structural Layout Plan, showing all required openings —Kumkang Ind, Bldg., 1445-2, Seocho-Dong, Seocho-Ku, @ kui m kang rae ‘Seoul, Korea Typical Floor 18. | Ditto. ~ Non-typical floor(s) Beam Details and Sections through all non-regular 19. a 20. | Columns/shear wall (or load-bearing wall) Schedule Details of column/shear wall shrinkage requirements: * floor(s) on which required and direction of shrinkage 2, | Lift Wall Details including details of all openings