Olympic Stadium

Construct 19 no holding down bolt boxes for test erection of the new flexible seating conversion to
a football stadium for West Ham Utd. Seating is also removable and re-configures for athletics. Stadium will be used for 2015 Rugby World Cup.

The contract was awarded on Thursday 13th March 2014, on Friday 14th work on site with 2 men. 12 boxes were ready and poured on Monday 17th and the last of the boxes was poured at 1pm on Tuesday 18th March. All shutters stripped and removed from site by 9.30am Wednesday 19th March. Huge savings in cost due to lower hire and reduced labour.

Brief

Fast-Form Systems Ltd were approached by Brett Noble MD of BDN Construction Ltd to supply a formwork system to construct 19 no bolt bases ranging in sizes from 1.3m x 1.3m x .9m deep to 3.9m x.1.9m x .9m deep, including hire of all ply (Wysaform MDO used) and materials required delivered to site in Newark in 2 days time.

The other systems considered were traditional timber shutters and well known panel system so we are able to show cost & time comparisons which are shown below.

Fast-Form provided the lowest quotation for the works and was also asked to install the system, this was then passed to one of our nominated who undertook the contract on a supply and fix basis. The boxes had to be finished by Wednesday 19th March at the latest for the steel contractor to start erecting the seating. All boxes had to be shuttered at once so no re-use of materials!

The contract was awarded on Thursday 13th March 2014, on Friday 14th work on site with 2 men. 12 boxes were ready and poured on Monday 17th and the last of the boxes was poured at 1pm on Tuesday 18th March.

All shutters stripped and removed from site by 9.30am Wednesday 19th March. Huge savings in cost due to lower hire and reduced labour.

You will see from the photo’s that we have used timber rails to extend the centres of the brackets to reduce the number of brackets per base this was in part due to the short notice of the order which meant we were low on stock and also to show how less brackets can be used if you use a rail.

We also we tested smaller brackets strength by extending their height with 4 x 2 so a 600mm high bracket poured a 900mm high base proving the bracket can take much more than its own height in pressure. Normally ply would be applied directly to the brackets with no timber rails but at closer centres.

Alkus ply was used to demonstrate the strength of the new German ply with no rails at 600mm centres. Alkus will shortly be offered on a hire and sale basis.

Comparisons costFast-FormPanel SystemTraditional shuttering
Hire / Cost
£1,725
1 weeks
hire included all ply and timber, fixings.
No other props or material required.
Drill bits / plant hire etc: £400
£2,400
Min 2 week hire
Prop hire: 200 no £600
Drill bits / plant hire etc: £400
Ply 50 sheets: £1,500
4×2 600m: £900
Nails etc: £100
Prop hire: 200 no £600
Drill bits / plant hire etc: £400
Delivery / collection
£70 each way
No forklift required
Non articulated transport
£200 each way
Forklift req’d
Articulated transport
£1,000
Labour included to strip/ de-nail or load. Materials require storage or disposal afterward and are not included in costs.
Make up shutters
Not required
Not required
2 men 5 days

£1,500

Installation time
including hanging 96
holding down bolts
3 men 3 days

£1,350

2 men 10 days

£3,000

2 men 5 days

£1,500

TOTAL COST
£3,615£6,800£7,500
Duration3 days2 weeks2 weeks
Comparisons usedFast-FormRMDTraditional Shuttering
Speed of system
Lightweight and fast to erect, no make-up required
Metal panels and rigid sizes mean oversizing some bases resulting in higher concrete costs or ply inserts resulting in more time to fit
Make up of shutters double duration of the contract, also timber needs stripping and de-nailing and needs to removed from site
Environmental
Low carbon footprint
High carbon footprint
High carbon footprint
Weight of system
Lightweight all brackets can be lifted easily by hand max weight 12kgHeavy system with panel weights in excess of 100kg, needs mechanical liftingShutters when made are heavy and can exceed 100kg
Safety
Come with full structural calculations for loadings
Come with full structural calculations for loadings
No calculations
available

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