After studying and surveying various industrial production construction systems, tunnel molding method was noticed of being resistant enough against the earthquake, properly fast, and cost-effective, and some projects in KARAJ, MASHAD, and RASHT branches were designed and constructed with this method.
Excavation Implement of MEGER Concrete
First the land is excavated to the planned dept and after setting up the foundation axels by topography team, the MEGER concrete is implemented under the foundations.
Foundation Pad Stall
The armature team finishes arming the foundation and pad stalls according to the plans, then molding the foundation and finally concreting is done.
After that, guided by the topography team, molding of pad stalls is done more carefully. Before concreting the cross junctions of water and sewage pipes is isolated by plastic-foam and finally concreting is done.
Armed Concrete Skeleton
The concrete skeleton in this system begins with implement of RAMKA with height of 10Cm. RAMKA is used in order to fix the molds in place. On the other hand since the molds are lower than the height of the floors, RAMKA closes the gap under the wall molds and prevent the concrete running. Arming the walls, housing the pipes, fixing the electricity pipes and switch and plug cases are done carefully after implementing RAMKA.
After constructing the walls, molds are transferred from the lower floors to the upper floors by tower-crane. In this phase the architectural detaches are put in place between the wall molds. After outlining "L" shaped molds, the molds can be balanced by the jacks set under the molds to the desired height. After the topographer do the final check and the molds, the bullets, and the related jacks are fixed, strutting the system comes to the end. Now, arming, housing the pipes, and completing the electricity pipes in the ceiling go on fast. In this phase the installment ducts and toilet casings are molded before concreting. After the technicians control the checklists, the walls and ceiling of one floor are concreted solid, Hose vibrators and vibrators attached to the molds bodies compress the concrete at the same time, and after that the final surface of the concrete is furnished by hand or electrical trowel. The concrete lab, examines the concrete while concreting and the results are documented.
Immediately after concreting the required maneuvers for protecting and processing the concrete begin.
In cold seasons using gas stoves and closing the intake of the tunnels by tarpaulin. the molds are heated from the lower side. The surface of the concrete on the ceiling is protected by a layer of glass-wool. In hot seasons we use spray-water in order to caver the concrete.
After the concrete comes to the desired resistance, the molds are opened and transferred to the upper floor again. Use of safety jacks after taking off the molds is a must.
Stairs
After the concrete skeleton is set up the pre-made stairs are installed. Having foreseen the metal junctions in pre-made pieces and surrounding concrete wa Is, installment of stair pieces of one block is easily done within one day.
Thermal Isolation of the Building Facade
In this project, all the blocks are thermally isolated. The ceiling is isolated by a layer of compressed poly-astern with a thickness of 5Cm. A product called 3D-wall is used to isolate the external walls. Among the advantages of these walls we can point to the fast Installment, resistance against the earthquake, thinness, thermal is01ation and omitting the lintel above the windows.
Flooring the Units
In order to fix the carpets, a thin cement layer is implemented on the floor. Since there is no pipe in the layer the thickness of the cement can be reduced to at least 4Cm.
Indoor Ribs Door Frames
The indoor ribs are made of plaster panels with thickness of 8Cm that is used according to the related details. Lightness, price-effectiveness, and fast handling are the
major advantages of these ribs. In order to prevent the plaster rib cracking around the doors, we first attach the door frames to the floor and ceiling, and then we put up the rib.
Tiling Pseudo-ceiling of the Bathrooms
The tiles can be fixed by glue or cement. In this project we choose one of these two methods depending on the case. In order to cover !he pipes under the ceiling of the bathrooms, we use plaster ceiling panels or PVC sheets, which are nice and moreover allow us to access the pipes at any time.
Air Conditioning
The units are cooled by the water coolers located at the roof and connected to the units through specific channels. As per heating, the central heating system of the block is connected to the radiators through uncovered raisers.
Cold and hot water and sewage raisers are foreseen in installment ducts and are divided in bathrooms and the kitchen uncovered. The major advantage of this method is the easy access to the pipes during the future repairs.
Paving the Stairs
The totally flat surface of pre-made concrete stairs enables us to pave the stairs by stones with thickness of2Cm using special glues. Obviously in addition to cost-effectiveness, this method is faster.
Indoor Paining
The major advantage of tunnel system is omitting the mud plaster and whitewashing operations. The walls and ceiling are concrete and painting is easily possible on the concrete that is cost-effective, and speeds up the construction.
Landscape
Finally, designing and constructing a nice landscape, with proper green area, present a pleasant complex offering peace of mind to the valued clients
