design manual...vulcraft offers two standard stair and landing types: metal pan stairs and metal...

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Design Manual

TABLE OF CONTENTS

CORTEK REPRESENTATIVE CONTACT INFORMATION..............................................................................................CORTEK SYSTEM OVERVIEW............................................................................................................................................................ DESIGN TEAM QUICK REFERENCE...............................................................................................................................SIZING AND MODULARIZATION...................................................................................................................................................... FORM WALL THICKNESS......................................................................................................................................................... MODULE CONFIGURATION................................................................................................................................................ MODULE JOINT ELEVATIONS........................................................................................................................................... COMPOSITE MODULE CONFIGURATIONS.........................................................................................................FINISHES.................................................................................................................................................................................................................STAIRS......................................................................................................................................................................................................................OPENINGS.................................................................................................................................................................................................ALTERNATE FRAMING...............................................................................................................................................................................STRUCTURAL..................................................................................................................................................................................................... REINFORCEMENT................................................................................................................................................................................. CORTEK SPECIFIC REBAR PLACEMENT PATTERNS................................................................................... CORNER REINFORCEMENT................................................................................................................................................. OPENING REINFORCEMENT................................................................................................................................................ SPECIAL STRUCTURAL WALLS (SEISMIC APPLICATIONS).................................................................... FOUNDATION CONNECTION.......................................................................................................................................... FLOOR AND ROOF CONNECTIONS....................................................................................................................... STANDARD EMBED CONNECTION TABLES.................................................................................................... STANDARD CONNECTIONS FOR SLABS............................................................................................................. STANDARD CONNECTIONS FOR STEEL BEAMS.......................................................................................... STEEL BEAMS TRANSFERRING AXIAL LOADS................................................................................................. OPEN WEB STEEL JOISTS AND JOIST GIRDERS...........................................................................................CONSTRUCTION............................................................................................................................................................................................FORM SYSTEM INSTALLATION.......................................................................................................................................................... REBAR AND CONCRETE PLACEMENT.................................................................................................................... CONCRETE PLACEMENT RATE.......................................................................................................................................... CONCRETE MIX RECOMMENDATIONS................................................................................................................ TEMPORARY CONSTRUCTION LOADS...................................................................................................................PRODUCT SPECIFICATION GUIDE................................................................................................................................................CODE OF STANDARD PRACTICE................................................................................................................................................

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Vulcraft reserves the right to change the design or details of its products without notice. The information in this catalog is presented for general information only and is not to be used or relied upon for any application without complete review of the proposed application and without a complete review by a licensed professional architect, engineer, designer or other qualified professional.

Vulcraft assumes no liability whatsoever for the accuracy or completeness of the information contained herein.

Vulcraft makes no representation or warranty of any kind, either express or implied, respecting any information contained in this catalog including, but not limited to, the accuracy, completeness or suitability of such information for any particular purpose or use.

In addition, Vulcraft expressly disclaims any liability for incidental, special, consequential or punitive damages including, but not limited to, loss of profits or loss of use arising out of this catalog or its use.

Vulcraft’s liability, warranties and other obligations with respect to its products are set forth in the Terms and Conditions of Sale provided to Buyer in connection with the provision of such products.As used herein, references to Vulcraft include its parents, affiliates and subsidiaries.

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ABOUT US

Nucor’s MissionNUCOR IS MADE UP OF MORE THAN 20,000 TEAMMATES WHOSE GOAL IS TO TAKE CARE OF OUR CUSTOMERS. WE ARE ACCOMPLISHING THIS BY BEING, THE SAFEST, HIGHEST QUALITY, LOWEST COST, MOST PRODUCTIVE and MOST PROFITABLE, STEEL AND STEEL PRODUCTS COMPANY IN THE WORLD. WE ARE COMMITTED TO DOING THIS WHILE BEING CULTURAL AND ENVIRONMENTAL STEWARDS IN OUR COMMUNITIES WHERE WE LIVE AND WORK. WE ARE SUCCEEDING BY WORKING TOGETHER.

Taking care of our customers means all of our customers: Our Employees, Our Shareholders, and the people who purchase and use our products.


CorTek SALES REPRESENTATIVES

Glenn ElrodSales ManagerP: 402.644.8520E: [email protected]

Ryan AndersonProject ManagerP: 402.644.8525E: [email protected]

Jim FreibergSales RepresentativeP: 303.921.7289E: [email protected]

Paul JohnsonDesign Build SupervisorP: 402.844.2581E: [email protected]

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CorTek SYSTEM OVERVIEW

GENERAL SYSTEM DESCRIPTION

The CorTek Form System is a stay-in-place modular steel form system engineered to simplify and accelerate on-site construction of cast-in-place reinforced concrete or reinforced masonry cores in buildings. The form system is designed to support light construction loads, which allows floor and roof framing members to be erected prior to concrete placement.

FEATURES OF THE FORM SYSTEM

• Factory built, high tolerance, steel construction • Rapid, simplified erection procedure • Erection of form system can be concurrent with erection of building framing • Horizontal reinforcement steel installed at the factory* • Rapid field installation of vertical reinforcement facilitated by guide fixtures* • Stairs pre-installed at the factory, providing safe early trade access to building floors • Form system is designed by Vulcraft to support limited construction loads prior to placement of concrete; typically self-weight of the framing member plus a 20 psf construction live load. • CorTek modules do not require stripping • Corrugated steel surface can be left exposed or clad with almost any architectural material • Available for forming cast-in-place reinforced concrete cores ranging in thickness from 8” to 20” • Contact Vulcraft for LEED information. *All reinforcement shall be designed and specified by the specifying professional

DESIGN TEAM QUICK REFERENCE

The following is a quick reference for the building design team when specifying the CorTek Form System. The specifying professional(s) is responsible for producing drawings and specifications which define the requirements for the core walls and stairs in the final constructed form.

The structural drawings or specifications should include:

•Elevations for all core walls, dimensioned for all geometry and annotated with reinforcement requirements (vertical and horizontal rebar sizing and spacing). Due to form construction, vertical bars must be spaced at 8” increments. Horizontal bars must be spaced at 4” increments.

•Details of all special reinforcing elements including headers and boundary elements (the


design of these elements will require detailing coordination with Vulcraft, but is by the specifying professional).

•Nominal thickness of core walls. This is the design thickness required by the specifying professional for the shear wall design. Typical thicknesses would be 8”, 10”, 12”, 14,” 16”, 18”and 20” nominally. Due to the 1” steel deck skins of the form system, walls will have an out-to-out dimension of 10”, 12”, 14”, 16”, 18”, 20”, and 22” respectively.

•Core elevations must clearly define rough opening sizes and locations. If no rough opening is provided, 1” will be added to each side of the opening.

•Definition of the top of foundation walls supporting the core walls. Typically, a minimum of 6” below the top of the floor level slab so that the connection between the core wall and foundation wall is hidden below the top of slab.

•The preferred connection between core walls and foundation walls. Vulcraft can supply embed plates or, if welding is not available on site, contact Vulcraft for a weldless alternative. Final embed design will be performed by Vulcraft.

•All loads at the connection between the core walls and foundation walls. These loads are used to design the connection at the foundation. Loads must be broken down per load type and indicated as service level or ultimate.

•End reactions for all beams and other floor or roof members framing into the concrete core. These loads must represent the end reactions on the core during the occupied life of the building and must be broken down into their load types (i.e. dead load, live load, construction load, eCT).

•All loads and deflection limits required for structural design of stairs and handrails

The architectural drawings must include:

•Any geometry of the stair cores not defined by the structural drawings

•Stair layouts including stair type, rise, run, and plan dimensions

•Handrail requirement including type of rail, finish, and standoff from wall

CorTek SYSTEM OVERVIEW


SIZING AND MODULARIZATION

FORM WALL THICKNESS

The CorTek Form System has a width of 1” on each face of wall including the form corrugations. The form itself and the concrete in the corrugations should not be considered as part of the structural capacity of the core. Therefore, shear walls formed using the CorTek Form System must have a plan dimension 2” thicker than the wall thickness required by the structural design of the core.

FIGURE 1: CORTEK FORM WIDTH

TABLE 1: AVAILABLE CORTEK WALL THICKNESSES

Representative CorTek Wall ThicknessesNominal Thickness Overall Thickness

8” 10”10” 12”12” 14”14” 16”

Note: Contact a CorTek representative to discuss the availability of wall thicknesses which are not represented within this table

Vertical Rebar

Lattice Column

Horizontal Rebar

Truss

Vulcraft 1.0C Galv. Steel Deck

10”

8”

1”



MODULE CONFIGURATION

A typical CorTek module is a four-sided box. The height of the module is determined by Vulcraft, and is approximately one half story height. Please confirm the suitability of something other than a four sided box with your Vulcraft representative prior to preparing contract documents.

Module plan dimensions are determined by the specifying professional.

The maximum size of a single module is controlled by shipping regulations and fabrication capabilities. The standard maximum module size is 8’ x 15’x 32’. Note that local shipping regulations may superseded these maximum dimensions. For cores exceeding these plan dimensions, compound modules spliced together on site may be an option. Please contact a Vulcraft representative for more information.

FIGURE 2: STANDARD MAXIMUM MODULE DIMENSIONS


MODULE JOINT ELEVATIONS

Vulcraft determines module joint locations. Joint elevations typically occur several inches below the top of concrete elevation.

When both stair and elevator cores occur in a building, the typical practice is to splice the elevator core modules at the same levels as the stair core modules.


COMPOSITE MODULE CONFIGURATIONS

Composite plan shapes and plan dimensions exceeding single module shipping limitations can be achieved by combining module shapes on site. Contact a Vulcraft representative for availability and recommendations.

FIGURE 3: POTENTIAL COMPOSITE MODULE SHAPES, CONTACT A VULCRAFT REPRESENTATIVE FOR MORE INFORMATION


FINISHES ATTACHMENT METHODS

Furring Strips

Wood or steel furring strips can be used with the CorTek Form System. Typical attachment methods (masonry screws, shot pins, eCT.) can be used. If screwed fasteners are to be used to install materials prior to concrete placement, avoid placing fasteners in the same vicinity of rivets. This prevents screws from impacting the form structure. Though furring strips may be attached prior to concrete placement, the finishes themselves (such as gypsum board) must not be installed until after concrete placement. This will prevent unnecessary loads on the unfilled form system and damages to interior finishes during concrete placement.

Masonry Ties

Masonry ties can be attached to the CorTek Form System in the same manner as if it where a typical CIP wall. Because the form system includes a stay-in-place internal steel structure, installing drilled fasteners may be difficult. There-fore, powder-actuated fasteners are recommended.

Direct Attachment

Certain finishes can be attached directly to the CorTek Form System. These include gypsum wall board, wood or metal paneling, or any other finish that does not require furring strips on other anchors. After concrete placement, masonry screws may be used. Adhesives can also be used. Ensure any adhesives used are compatible with galvanized metal.

Unfinished (Galvanized Steel Deck)

The CorTek Form System can be left bare in both interior and exterior conditions if no finish is required or if the metal deck finish is desired.

As stated in the features of the form system, virtually any cladding material may be applied to the interior or exterior surface of the form. When cladding is to be applied to the interior of the core, the cladding thickness must be taken into account when determining all stair dimensions.


STAIRS

Metal Grating

Both stair treads and landings can be produced from Nucor Grating and pre-installed in the CorTek Form System at the factory. Any of Nucor’s grating profiles can be used to fabricate the stair system.

Metal Pan with Concrete Fill

Metal pan stairs can also be installed at the factory, this includes the stair pans and metal deck for the landings. Once in place, the concrete can be placed in the stair system along with the rest of the concrete on the project. The stair pans allow workers to access the upper floors as soon as the cores are placed, reducing the need for lifts or ladders.

Vulcraft offers two standard stair and landing types: metal pan stairs and metal grating stairs. Structural design of the stairs, landings, and their connection to the core is by Vulcraft. All dimensions, loads, and serviceability requirements needed for the structural design of the stairs and landings must be supplied to Vulcraft by the specifying professional. If other types of stairs are desired or required for your project, please contact a Vulcraft representative.

Handrails and Guards

Vulcraft offers pipe or tube balustrades and handrail. Structural design of the handrail system is provided by Vulcraft. All dimensions, loads, and serviceability requirements needed for design of the handrail system must be supplied to Vulcraft by the specifying professional.

Stairs and handrails fabricated by others may also be installed in the CorTek Form System. However, any connections that require modifications of the standard CorTek form must be provided as soon as possible in the design process to be considered in the design and fabrication of the form system.

NOTE: ALL LIFE SAFETY AND DIMENSIONAL REQUIREMENTS OF STAIR DESIGN IS THE RESPONSIBILITY OF THE ARCHITECT OF RECORD.


OPENINGS

Doors & Windows

Door and window openings will be formed with stay-in-place light gauge galvanized metal that is attached to the form system. Door and window frames can be welded or attached with fasteners to the form system. The CorTek Form System is not designed to carry any loads from doors or windows. All doors and windows should be installed after concrete is placed and cured. If modifications to the typical openings are required, Vulcraft must be made aware as soon as possible in the design process so that changes can be made prior to form construction.

Openings During Construction

At large wall openings, Vulcraft provides temporary bracing for dimensional stability during shipping and erection. These temporary braces are removed after concrete placement and may be returned to Vulcraft for recycling or disposed of in an appropriate manner.

Dimensions Required for Fabrication

Openings in the CorTek Form System can be specified in the same manner as if they were in a typical concrete wall. A rough opening size must be provided to Vulcraft, If no rough opening is provided 1” will be added to each side of the opening.Opening Locations

All rough openings must be a minimum of the overall wall thickness from the outside corner of the core. Placing openings closer causes issues with fabrication of the form system. For example, an 8” nominal (10” out to out) CorTek form would require openings to be placed a minimum of 10” from the outside corner of the form system.

Openings Required for Other Trades

Any openings in the core walls required for other trades (i.e. fire sprinklers, electrical, plumbing, HVAC, eCT) must be addressed in the same manor as for a standard-formed CIP wall. The specifying professional is responsible for ensuring the design of the concrete core will not be compromised by the openings. Any sleeves, conduits, or additional fire-proofing is not provided by Vulcraft.

The structure of the CorTek Form System must not be damaged or removed prior to placement of concrete. However, drilling through or removing portions of the steel deck skin and internal form components is acceptable after concrete has cured. If requested, Vulcraft can indicate locations on the core that can be field cut for other trades.

NOTE: Braces to be removed after concrete placement


ALTERNATE FRAMING

Floor and Roof Framing Within Core

Typically, shear cores within buildings are located at stairways and elevators. However, the construction of a shear core lends itself to many other uses as well, such as:

•Storage Rooms

•Storm Shelters

•Panic Rooms

At the option of the buyer, Vulcraft can supply steel framing and steel deck (composite or form deck) for floors on the interior of the cores. Framing types available include open web steel joists and structural steel beams. All roof and floor framing must be designed and specified by the specifying professional. End reactions of this framing must be provided to Vulcraft by the specifying professional to allow embedded connections to the core wall to be designed by Vulcraft.

SLOPING ROOF CONDITIONS

The CorTek Form System may be modified to accommodate sloped roof conditions as shown in the below detail. All parts supplied by Vulcraft are designed by Vulcraft. The specifying professional must provide all loads required for design.

FIGURE 4: SLOPING ROOF AT TOP OF CORE


STRUCTURAL INFORMATION

The CorTek Form System is intended to act as a form for cast-in-place reinforced concrete cores. These cores are designed by the specifying professional and play an important role in both gravity and lateral force resisting system of a building. The CorTek Form System is best suited for low to mid-rise building construction, especially for buildings such as hotels, apartments, and offices.

Reinforced Concrete Shear Core Design Principals

ForcesReinforced concrete shear cores play an important role in transferring in-plane, lateral forces to the building foundation. Such forces are typically caused by wind or seismic activity. Reinforced concrete shear cores also add stiffness to the building system and resist vertical loads from floor and roof framing.

Design Standards and Building CodesThis document cites various ACI standards and the IBC for reference purposes only. The specifying professional must use the same standard of care when designing and specifying a CorTek formed shear core as he or she would with any other reinforced concrete shear core. All applicable building codes and standards must be followed.

Material SpecificationsIt is recommended that the maximum aggregate size of concrete mixes used within the CorTek Form System not exceed ¾”. The design of the concrete mix and specification of concrete compressive strength should be completed by a qualified design professional and is not by Vulcraft. At this time, self-consolidating concrete is not recommended for use with the CorTek Form System.

ReinforcementThe CorTek Form System provides a simplified rebar installation process. Reinforcement for the concrete shear core is designed and specified by the specifying professional and factory built to maCTh those specifications. Horizontal bars are installed in the factory, and vertical bars are shipped cut-to-length and installed by hanging at the top of each module in the field.


The specifying professional must be aware of a few limitations for rebar mat placement: • The CorTek Form System can accommodate either a single or double mat of rebar at the exterior faces of the walls. A single, centered mat is not currently an option. • Vertical bars must be spaced at 8” or 16” increments. • Horizontal bars must be spaced at 4” increments. • The images below depict the reinforcing zones for an 8” and 12” CorTek formed shear wall. • From the images below, it is apparent that the ¾” cover for #11 and smaller bars required by ACI 318 will be maintained. • Note, reinforcement zones below are not adequate for below grade applications. The CorTek Form System is not currently recommended for below grade construction.

FIGURE 5: REINFORCING ZONES FOR 8” AND 12” WALLS

STRUCTURAL INFORMATIONREINFORCEMENT


The rebar placement patterns below are recommended for use with the CorTek Forming System. Vulcraft does not provide shear core design or reinforcement design. All rebar and shear wall design is the responsibility of the specifying professional.

Note: Due to form system limitations, vertical rebar must be spaced at increments of 8” o.c.

TABLE 2 - TYPICAL VERTICAL REINFORCEMENT BAR PATTERNS

Note: Due to form system limitations, horizontal rebar must be spaced at increments of 4” o.c.

TABLE 3 - TYPICAL HORIZONTAL REINFORCEMENT BAR PATTERNS

Typical Vertical Reinforcement Bar Patterns

Bar Size SpacingBar Area

(in2)

Area of Steel PerHorizontal Linear Foot of Wall

Single Mat Double Mat#4 1'-4" 0.20 0.15 0.30

#5 1'-4" 0.31 0.23 0.46

#6 1'-4" 0.44 0.33 0.66

#7 1'-4" 0.60 0.45 0.90

#8 1'-4" 0.79 0.59 1.19

#4 8" 0.20 0.30 0.60

#5 8" 0.31 0.46 0.92

#6 8" 0.44 0.66 1.32

#7 8" 0.60 0.90 1.80

#8 8" 0.79 1.19 2.37

Typical Horizontal Reinforcement Bar Patterns

Bar Size SpacingBar Area

(in2)

Area of Steel PerVertical Linear Foot of Wall

Single Mat Double Mat#4 1'-4" 0.20 0.15 0.30

#5 1'-4" 0.31 0.23 0.46

#6 1'-4" 0.44 0.33 0.66

#7 1'-4" 0.60 0.45 0.90

#8 1'-4" 0.79 0.59 1.19

#4 8" 0.20 0.30 0.60

#5 8" 0.31 0.46 0.92

#6 8" 0.44 0.66 1.32

#7 8" 0.60 0.90 1.80

#8 8" 0.79 1.19 2.37

STRUCTURAL INFORMATIONREBAR PLACEMENT PATTERNS



CORNER REINFORCEMENT

In lieu of the traditional 90-degree hooked reinforcement bar, Vulcraft provides a 180-degree hooked reinforcement detail as shown below:

FIGURE 6: STANDARD 180° HOOK REINFORCEMENT DETAIL FOR CORNERS

SEE TABLE ON PAGE 20 FOR MAXIMUM REINFORCING BAR SIZE PER WALL THICKNESS



Maximum Rebar Size (standard mat) Based on Wall Thickness and Cover Requirements

Wall ThicknessMinimum Cover

Requirements Maximum Rebar Size

8”

3/4” 6

1” 6

1 1/2” 5

10”

3/4” 8

1” 8

1 1/2” 7

12”

3/4” 8

1” 8

1 1/2” 8

Notes:

1. Considers transverse reinforcement with standard 180-degree hooks per ACI 318-14 Table 25.3.1

TABLE 4 - MAXIMUM HORIZONTAL REINFORCING BAR SIZE PER WALL THICKNESS


OPENING REINFORCEMENTReinforcement around openings, such as windows and doors, must be indicated on the contract drawings by the specifying professional. CorTek form components are installed for the purpose of concrete forming only and shall not be considered to provide reinforcement around openings during the life of the structure. In some cases, steel angle walers will be required to accommodate the reinforcement and ensure the strength of the formwork. These walers must be removed after concrete is placed.


FIGURE 6: REMOVABLE FORM WALERS REQUIRED FOR SOME HEADER REINFORCEMENT CONDITIONS


FIGURE 7: EXAMPLE OF HEADER REINFORCEMENT DETAILS THAT CAN BE ACCOMMODATED BY THE CORTEK FORM SYSTEM


SEE TABLE ON PAGE 23 FOR MAXIMUM REINFORCING BAR SIZE PER WALL THICKNESS

HEADER REINFORCEMENTFor headers over openings, The CorTek Form System can accommodate reinforcement that consists of a single or double layer of horizontal bars confined by stirrups. Vulcraft requests header stirrups to be specified with a 135-deg bend at one end and a 90-deg bend at the other end for fabrication purposes. Bend diameters and extension lengths shall comply with minimums given by ACI 318. Header reinforcement will arrive on-site installed as required by the specifying professional.



Maximum Rebar Size (Headers) Based on Wall Thickness and Cover Requirements

Wall Thickness

Minimum Cover Requirements

Vertical Stirrup Size#3 #4 #5 #6

8”

3/4”

Max

imum

Hor

izon

tal

Reba

r Siz

e

#6 #6 #5 -

1” #5 #5 - -

1 1/2” - - - -

10”

3/4” #8 #8 #7 -

1” #7 #7 #7 -

1 1/2” #6 #6 #6 -

12”

3/4” #8 #8 #8 -

1” #8 #8 #8 -

1 1/2” #8 #8 #8 -

Notes:

1. Considers transverse reinforcement with standard 180-degree hooks per ACI 318-14 Table 25.3.12. All headers with less than 1 1/2” cover require removable angle walers on outside of form3. Where “-” is indicated, rebar will not fit due to internal form work structure and/or thickness of wall

TABLE 5 - MAXIMUM HEADER REINFORCING BAR SIZE PER WALL THICKNESS


FIGURE 8: TYPICAL WELDED PLATE FOUNDATION CONNECTION

STRUCTURAL INFORMATIONCONNECTIONS

SPECIAL STRUCTURAL WALLS (SEISMIC APPLICATIONS)The CorTek Form System is currently under development for use with boundary elements as required for special detailing requirements. At this time, the CorTek Form System cannot accommodate the special reinforced boundary zones at the corners and openings of reinforced concrete shear cores qualifying as special reinforced concrete shear walls by ACI 318.

FOUNDATION CONNECTIONThe vertical reinforcement at the bottom CorTek module of each core is connected to the building foundation using a welded plate connection, contact Vulcraft for a weldless alternative if necessary. In either case, Vulcraft furnishes the design and embedded materials required to make the connections. Embed plates or alternates are installed by the foundation contractor. All loads at this connection must be provided to Vulcraft by the specifying professional for design of this connection.

The bottom of the CorTek base module is supported nominally 6” above the top of the foundation level by adjustable leveling pedestals built into the module. The 6” space between the module and the foundation allows access for physically making the attachment between the embedded portion of the connection set in the foundation and the vertical reinforcement in the CorTek wall. After this attachment is complete, the concrete contractor provides temporary form material (typically plywood or dimensional lumber) to enclose the 6” space prior to placement of the first lift of concrete.


STRUCTURAL INFORMATIONEMBED CONNECTIONS

FLOOR AND ROOF CONNECTIONSThe design of floor and roof framing connections is provided by Vulcraft as part of the CorTek package. The specifying professional must provide loads at all beams, joists, shelf angles, eCT. framing into the core. Loads must be unfactored and broken down by load type (i.e. dead load, live load, eCT.) Calculations can be provided upon request.

The CorTek Form System is designed to support limited construction loads prior to concrete placement. Recommended maximum construction loads and a description of how Vulcraft calculates these loads are as follows. For loads exceeding these, please consult a Vulcraft representative to assess your individual need. • Shelf angles: self-weight of angle and any metal decking attaching to the angle plus a 20psf vertical construction live load (400plf maximum vertical construction load) • Beam or joist connections: Self-weight of the beam or joist and any metal decking attached to it plus a 20psf vertical construction live load (2000 lb maximum single vertical construction end reaction spaced a minimum of 5’ o.c.) • Note: in no case should floor slabs be placed nor should heavy materials unrelated to CorTek installation be stored on the floors prior to concrete placement in the form system

The specifying professional may choose to indicate a preferred type of connection (i.e. shear tab, double clip angle, eCT). Coordination with Vulcraft may be necessary for specific details. Some detailing limitations exist when specifying the CorTek form system. These limitations include the following: • Due to the fact that the CorTek form system is load bearing for limited construction loads prior to concrete placement, embed plates for steel framing must be sized to span between internal CorTek form trusses.



STANDARD EMBED CONNECTION TABLESThe images and tables that follow describe CorTek’s typical standard embedded connections for use with the CorTek Form System. Vulcraft reserves the right to provide alternate materials and connections that meet the specified load requirements for the project

TABLE 6 - CORTEK TYPICAL EMBED CAPACITIES

CorTek Typical Embed Capacities

Edge Conditions Embed TypeWall

Thickness

Factored LRFD Shear

(K)

Corner(Reference Details for

Edge Dimensions)

A

8”

53.0

B 57.0

C 60.5

D 64.0

Center(Reference Details for

Edge Dimensions)

A

8”

53.0

B 57.0

C 60.5

D 64.0

A

10”

59.5

B 63.0

C 67.5

D 71.0

A

12”

64.5

B 69.0

C 74.0

D 78.5

Notes:

1. A108 3/4” dia. welded headed studs, 5 5/8” effective depth2. f’c = 4000 psi 3. Not applicable to Seismic C, D, E, F4. NW Concrete (145pcf)5. 1/2” A36 Plate6. Load assumed concentric with bolt group7. Review Figures 9 & 10 for assumed concrete edge distances, reduced edge distances will reduce the capacity of the embedded connection



FIGURE 9 - TYPICAL EMBED PLATES AND H.A.S. LOCATIONS FOR CONNECTION OF FLOOR AND ROOF FRAMING TO CORE , “CORNER

CONDITION” CONCRETE EDGE LIMITATIONS FOR TABLE 6. NOTE THAT THE 19” MIN ALLOWS FOR A 4’ 0” O.C. BEAM SPACING.



FIGURE 10 - CENTER CONDITION CONCRETE EDGE LIMITATIONS FOR TABLE 6

FIGURE 11 - TYPICAL HEADED ANCHOR STUD FOR EMBEDDED CONNECTIONS FRAMING INTO CORE



STANDARD CONNECTIONS FOR SLABS (AND SLABS SUPPORTED BY METAL DECK)

Vulcraft provides the connection design of the angle supporting the slab/deck to the core. The specifying professional must provide all loads that must be transferred into the concrete core for connection design. Loads provided must represent the end reactions on the core during the occupied life of the building and must be broken down into their load types (i.e. dead load, live load, construction load, eCT) The specifying professional is responsible for the connection design of the slab to the angle or slab to core wall. This includes the design of connecting items such as headed anchor studs and deformed bar anchors (DBA) into the floor slab.

FIGURE 12 - TYPICAL SHELF ANGLE DETAIL FOR FLOOR OR ROOF DECK SUPPORT



TABLE 7 - LOAD CAPACITIES FOR TYPICAL CORTEK SHELF ANGLES

CorTek Shelf Angle Capacities (f’c = 4000psi, NW concrete)

Anchor Material

Bolt Diam, in

Bolt Spacing, in

Bolt hef, in

Vertical Uniform Load on Outstanding Angle Leg (Factored for LRFD), klf

ASTM F1554 Gr 36

5/8 24 4 2.5

5/8 18 4 3.4

5/8 12 4 3.9

ASTM F1554 Gr 55

5/8 24 4 2.9

5/8 18 4 3.5

5/8 12 4 3.9

Notes:

1. L4x4x3/8, 50ksi angle assumed for all conditions2. 8” thick walls assumed for all conditions3. Edge anchor assumed at 4.5” min from edge of wall



FIGURE 13 - TYPICAL SHELF ANGLE DETAIL FOR SHEAR TRANSFER FROM SLAB TO ANGLE USING DEFORMED ANCHOR BAR INTO SLAB

STANDARD CONNECTIONS FOR STEEL BEAMS

Vulcraft provides the connection design of the steel beam to the core. The specifying professional must provide all loads required for connection design. Loads must be provided as unfactored and broken down by load type.

The following tables and figures are examples of the typical beam to core connections that will be provided by Vulcraft. The specifying professional may request a preferred connection type.

SLAB TO CORE CONNECTIONS FOR SHEAR TRANSFER

When project shear values require additional attachment of slab to the core, the following details are recommended for use with the CorTek Form System. All materials supplied and pre-installed by Vulcraft, including the shelf angle and anchors embedded into the core wall, are designed by Vulcraft. The specifying professional must supply all loads required for design. Loads must be supplied as unfactored and broken down by load type. Any materials not supplied by Vulcraft (headed anchor studs and deformed bar anchors into the floor slab) must be designed by the specifying professional.



TABLE 8 - CAPACITIES FOR SHEAR TAB CONNECTIONS FOR W-SHAPED BEAMS

Shear Tab Connections for W-Shaped Beams

Member Depth Rows of Bolts Length of Tab (in)

Max Factored Permanent End

Reaction (Factored for LRFD), k

W8 2 6 29k

W10 2 6 29k

W12 3 9 48k

W14 3 9 48k

W16 4 12 67k

W18 4 12 67k

W21 5 15 85k

W24 6 18 97k

W27 7 21 115k

W30 8 24 130k

Notes:1. All capacities calculated with no beam cope2. Capacities do not include strength of embed plate and HAS

FIGURE 14 - SHEAR TAB FOR W-SHAPED BEAMS


FIGURE 15 - DOUBLE CLIP ANGLE CONNECTION FOR W-SHAPED BEAM,


TABLE 9 - CAPACITIES OF TYPICAL DOUBLE CLIP ANGLE CONNECTIONS FOR W-SHAPED BEAMS

Double Clip Angle Connections for W-Shaped Beams

Member Depth Rows of BoltsLength of Clip

Angles (in)



W8 2 6 26k

W10 2 6 27k

W12 3 9 47k

W14 3 9 54k

W16 4 12 74k

W18 4 12 82k

W21 5 15 121k

W24 6 18 152k

Notes:1. All capacities calculated with single bottom flange cope to accommodate field installation.2. Capacities described in table are for steel portion of connection only, HAS into concrete wall not considered.



FIGURE 16 - SINGLE CLIP ANGLE CONNECTION FOR W-SHAPED BEAM

TABLE 10 - CAPACITIES FOR TYPICAL SINGLE CLIP ANGLE CONNECTION FOR W-SHAPED BEAM

Single Clip Angle Connections for W-Shaped Beams

Member Depth Rows of BoltsLength of Clip

Angles (in)



W8 2 6 21K

W10 2 6 21K

W12 3 9 39K

W14 3 9 39K

W16 4 12 59K

W18 4 12 59K

W21 5 15 78K

W24 6 18 97K

W27 7 21 115K

Notes:1. All capacities calculated with single bottom flange cope to accommodate field installation.2. Capacities described in table are for steel portion of connection only, HAS into concrete wall not considered.



STEEL BEAMS TRANSFERRING AXIAL LOADS

Steel beams designed to transfer axial tension or compression loads, commonly referred to as drag struts, should be connected to core walls only at the centerline of the opposing core wall. Vulcraft provides the connection design, including design of any studs or rebar required within the core walls to drag the axial forces into the core. The specifying professional must supply all loads required for connection design. Loads should be provided as unfactored and separated by load type.

Connection of two drag struts at 90 degrees to each other at a common corner may be impractical due to extreme rebar congestion. Contact a Vulcraft representative to discuss feasibility when required.

OPEN WEB STEEL JOISTS AND JOIST GIRDERS

Vulcraft provides connection design of the steel joist to the core. The specifying professional must provide all loads required for connection design. Loads must be provided as unfactored and separated by load type.

The images and tables below describe typical seated connections provided by Vulcraft. Note that capacities for each connection vary depending on the joist series type. This is due to the eccentricity of the end reaction which is affected by the maximum bearing length available based on the typical joist seat depth for each joist series (max bearing length is typically 4” for a k-series joist and 6” for a long span joist). Joists were assumed to have a ½” hold-back from the face of the embed plate, and to bear as far on to the angle seat as possible (minimum top chord extension length assumed).



FIGURE 17 - UNSTIFFENED SEATED CONNECTION FOR JOIST

Unstiffened Angle Seat Connection for Joists

Angle Support Size Max Factored Permanent End Reaction (Factored for LRFD), k

K-series joist LH-series joist or Joist Girder3 1/2 x 3 1/2 x 3/8 5.3K INADEQUATE BEARING LENGTH

4 x 4 x 1/2 10.2k INADEQUATE BEARING LENGTH

5 x 5 x 5/8 13.0k 17.4k

6 x 6 x 3/4 13.0k 27.3k

6 x 6 x 1 25.3k 41.3k

Notes:

1. Assumes 1/4” fillet weld on both vertical legs of angle seat to embed plate2. Calculations per AISC Construction Manual 15th Ed.3. Values in table are for connection capacity only, loads may exceed maximum end reactions for listed joist series

TABLE 11 - CAPACITIES FOR UNSTIFFENED ANGLE SEAT CONNECTION FOR JOIST OR JOIST GIRDER



FIGURE 18 - TYPICAL STIFFENED SEATED ANGLE CONNECTION FOR OPEN WEB STEEL JOISTS

TABLE 12 - STIFFENED SEATED ANGLE CONNECTION CAPACITIES FOR OPEN WEB STEEL JOISTS

Stiffened Angle Seat Connection for Joists

Angle Support Size Stiffener Thickness

Max Factored Permanent End Reaction (Factored for LRFD), k

K-series joist (or short bearing LH) LH-series joist

3 1/2 x 3 1/2 x 3/8 3/8" 8.7k INADEQUATE BEARING LENGTH

4 x 4 x 1/2 1/2" 16.7k INADEQUATE BEARING LENGTH

5 x 5 x 5/8 1/2" 24.0k 32.3k

6 x 6 x 3/4 3/4" 25.3k 41.3k

Notes:

1. FY Stiffener = 50ksi2 Assumes 1/4" fillet weld on both vertical legs of angle seat to embed plate3. Assumes 1/4” fillet weld stiffener to angle seat4. Calculations per AISC Construction Manual 15th Ed. 5. Values in table are for connection capacity only, loads may exceed maximum end reactions for listed joist series


COORDINATION WITH BUILDING FRAMING3D Building Information Models (BIMs) are available for coordination during the detailing process. Please consult a Vulcraft representative for more information on file types and approximate schedules for receiving BIMs.

FORM SYSTEM INSTALLATIONThe following section covers typical handling and erection procedures for the CorTek Form System. These instructions will also be included on the detailed drawings provided for each CorTek project. Always review all notes included on the CorTek detail drawings for each specific project as requirements and instructions may vary on a case-by-case basis.

HOISTINGThe installer is responsible for providing rigging necessary for hoisting. Rigging must be attached only to the designated lifting lugs on the modules. Lifting cables and/or slings shall always be arranged such that the angle of the cable is no less than 45 degrees from horizontal.

FIGURE 19: TYPICAL LIFT LUG DETAIL

STORAGEWhen modules are stored on site, support each module above ground surface on wood dunnage. Place dunnage at a minimum of 4 locations either directly beneath outside corner struts or directly beneath lattice column bases.

CONSTRUCTION


ERECTION PROCEDURES1. Before erecting the base module of each core, accurately establish and mark the location of the core wall lines on the foundation below the core. The base module will include threaded rod connectors at each of its corners which allow the base module to be leveled and provide attachment to the foundation during construction. Establish the plan locations of these connectors using the dimensions from the Vulcraft provided detail drawings. The dimensional tolerance for core wall locations is plus or minus 1/16” in any horizontal direction.

2. Hoist the base module and place it on the foundation, carefully aligning the foundation connectors with the layout marks. Check the top elevation of the bearing dowels at each corner of the module. Adjust the double nuts at the threaded rod connectors, if needed, to bring the top of the module to the exact elevation as shown on the Vulcraft provided detail drawings. Weld the threaded rods to the embed plates as indicated in the Vulcraft provided detail drawings.

3. Install and weld the lattice column base connections as indicated in the Vulcraft provided detail drawings.

4. Tighten double nuts at threaded rod foundation connectors.

5. Install vertical reinforcement bars as indicated in the Vulcraft provided detail drawings. At the base module, these vertical reinforcement bars must be attached to the foundation before concrete is placed in the base module.

6. Before installing each subsequent module, check all module bearing surfaces and interior cavity for cleanliness. Clean if necessary. Verify that vertical reinforcement bars have been placed in the supporting module. Hoist each module and lower it onto the previous module, using the alignment guides at each corner of the module to bring the module into alignment. Install Vulcraft provided high strength bolts and nuts at the corner struts. Install vertical reinforcement steel before erecting the next module.

CONSTRUCTION


FIGURE 20 - TYPICAL THREADED ROD FOUNDATION CONNECTOR

CONSTRUCTION


7. At each floor level, check horizontal and vertical alignment of module prior to placement of concrete and connection of any floor framing.

8. Before using any CorTek stairs for construction access, install permanent panel railing or temporary railing or temporary barriers necessary for compliance with applicable safety regulations. Vulcraft does not supply temporary railings or barriers.

9. Remove temporary braces at openings in core walls only after concrete has been placed within the form wall and has reached 75% of its specified 28-day strength.

CONSTRUCTION


REBAR AND CONCRETE PLACEMENT

INSTALLATION OF HORIZONTAL REBARVulcraft provides horizontal rebar to meet the requirements set forth by the specifying professional in the structural drawings and specifications. Horizontal rebar is installed by Vulcraft in the factory. All modules arriving on site will have horizontal rebar pre-installed.

INSTALLATION OF VERTICAL REBARVulcraft provides vertical rebar to meet the requirements set forth by the specifying professional in the structural drawings and specifications. Vertical rebar is supplied in pre-cut segments that must be installed at the top of each Vulcraft form module prior to concrete placement. Each vertical rebar segment is supplied with a small hook on one end for simple installation into guides at the top of each module.

CONSTRUCTION

A vertical rebar segment’s length will exceed the height of its module in order to form a non-contact lap splice with the vertical rebar segment in the module below. It is important to plan concrete lifts to allow for installation of vertical rebar segments above. Vulcraft detail drawings include an elevation guide to aid in this planning process.

INSTALLATION INSTRUCTIONS1. Install vertical reinforcement steel before erecting the next modual.

2. When installing vertical rebar, ensure the bottom of the rebar passes through the same rebar pocket as the top of the rebar.


FIGURE 21 - EXAMPLE CONCRETE PLACEMENT ELEVATION GUIDE

INSPECTION OF REBARCorTek modules arrive on site with steel deck skins and horizontal rebar pre-installed. When special inspections of rebar are required by code, an inspector may visit the factory during manufacture of the modules and prior to skin installation, or the inspector may view the rebar from the opening at the top of each module on site.

CONSTRUCTION


PLACEMENT RATEPlace concrete using recommendations of ACI “Manual of Concrete Practice”, latest edition, sections ACI 304R and 304.2R, as applicable. The CorTek Form System is designed for a maximum form pressure of 900psf.

Place concrete in 6-foot maximum lifts, allowing sufficient time between lifts for concrete to solidify to the extent that fluid pressure is relieved from form walls. Alternatively, place concrete in 4-foot maximum lifts at a maximum placement rate calculated according to formulas set forth in ACI 347 to produce a form pressure of no more than 900 pounds per square foot. Vulcraft does not calculate or provide placement rates.

CONCRETE MIX RECOMMENDATIONSConcrete and concrete mix design is not provided by Vulcraft. However, due to the specialized construction of the form system, it is recommended that the maximum aggregate size not exceed ¾”.

TEMPORARY CONSTRUCTION LOADSCorTek Forms are designed and manufactured to support vertical construction loads of limited magnitude prior to placement and cure of concrete. After a lift of concrete has been placed and has achieved 75% of its specified 28-day strength, all loads on that portion of the wall and below should be considered to be resisted by the reinforced concrete wall alone with no contribution from the form system.

Prior to concrete achieving 75% of its specified 28-day strength, the maximum safe construction loads which can be applied to any beam connection point or shelf angle will be shown on the elevation views of the detailed drawings supplied by Vulcraft.

WARNINGS1. Do not erect core modules on foundations until foundation concrete has achieved 75% of its specified 28-day strength.

2. The maximum height to which core modules may be stacked without concrete having been placed within the form and achieved 75% of its specified 28-day strength is typically 3 module heights high (this height will vary per project, please consult project- specific, detail drawings provided by Vulcraft).

3. Do not place any concrete on floor or roof slabs supported by the core until concrete within the form walls has been placed to at least the top elevation of the slab and has achieved 75% of its 28-day strength.

4. Do not use the CorTek Form System as a brace for plumbing or stabilizing the building framework. Steel framing and concrete formwork shall be independently braced for stability.

CONSTRUCTION


5. Do not stack heavy construction materials or equipment unrelated to CorTek on floor or roof areas supported by CorTek form modules prior to placement of concrete within the form wall to at least the top elevation of the floor or roof and having reached 75% of its specified 28-day strength.

6. Do not modify any aspect of the CorTek Form System or Vulcraft supplied stairs without the written direction of Vulcraft. Unauthorized modification will nullify the Vulcraft product warranty.

7. Construct temporary rails and barriers as needed to comply with applicable safety regulations. Employ fall protection systems where rail and barrier systems are not feasible. Vulcraft does not supply temporary rails, barriers, or fall protection devices.

CONSTRUCTION


PRODUCT SPECIFICATION

Specifier Notes: This guide specification is written in Construction Specifications Institute (CSI) 3-Part Format in accordance with the SI Construction Specifications Practice Guide, including Master Format, Section Format, and Page Format.

This section must be carefully reviewed and edited by the Architect or Engineer to meet the requirements of the project and governing building code. Coordinate this section with Division 01, other specification sections, and the drawings. Delete all Specifier Notes after editing this section.

Section numbers and titles are based on Master Format 2014 Update.

SECTION 03 11 13MODULAR STAY-IN-PLACE METAL FORM SYSTEMS

PART 1 GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of contract, including General and Supplementary Conditions and Division 01 specification sections apply to the work of this section.

B. The Work under this section shall be subject to all applicable provisions of the state and local building and safety codes and other codes and standards referenced in this specification.

C. In case of conflict among documents, including architectural and structural drawings and specifications, notify the Architect prior to submitting proposal. In case of conflict between the structural drawings and specifications, the strictest interpretation shall govern. All references shall be latest edition.

1.2 WORK INCLUDED

A. Extent of work is shown on the drawings, including schedules, notes and details which show size and location of formed concrete walls.

B. Furnish CorTek modular stay-in-place metal form systems for cast-in-place concrete construction. Modular permanent systems include, but are not limited to, the following:

1. Metal wall forms, factory assembled into modules for shipment to the project site.

2. Designs, shop drawings and assembly instructions as required for proper performance and field assembly of the form systems in accordance with performance requirements established by this specification and the project drawings.



3. Concrete reinforcing complete with required supports, spacers and related accessories.

4. Anchors, plates, and inserts required for attachment and/or support of structural and/or architectural precast concrete, structural steel or other materials and furnished under other specifications.

5. Anchors, plates, and inserts required for attachment of the metal form systems to the foundation.

6. Connection materials and fasteners for joining of adjacent form modules during construction.

7. When modular permanent metal form systems include pre-fabricated metal stairs, furnish stairs, landings and railings of style selected by Architect from among manufacturer’s standard styles. To the maximum extent practical, stair and landings shall be factory-installed within the modules prior to shipment. Stair railings shall be shipped loose for field installation.

1.3 RELATED WORK SPECIFIED ELSEWHERE

A. Division 03 – Concrete

B. Division 05 - Structural Steel 1.4 REFERENCE STANDARDS

A. ACI 347R - Guide to Formwork for Concrete

1.5 QUALITY CONTROL

A. Design formwork under direct supervision of a Professional Structural Engineer experienced in design of concrete formwork and licensed in the State in which the Project is located.

1. The manufacturer is responsible for in-house quality control, including workmanship and materials. 2. The manufacturer shall maintain records of in-house inspections and documentation. of materials incorporated into the form systems.



1.6 SUBMITTALS

A. Submit shop drawings and special instructions in accordance with the following:

1. Submit (3) copies of each shop drawing. Reproducible copies of contract documents shall not be used as shop drawings. Shop drawings shall be reviewed by Contractor prior to submission. Drawings shall bear Contractor’s approval stamp accepting responsibility for coordination of dimensions shown in the contract documents, quantities and coordination with other trades. Drawings not bearing contractor’s stamp may be rejected at the discretion of the Architect or Structural Engineer. One copy will be returned with Architect/Engineer comments. Allow 14 calendar days in the Structural Engineers office for review of shop drawings.

B. Shop drawings shall include the following:

1. Overall dimensions of each form module.

2. Dimensional locations of all module splice locations.

3. Dimensional location and sizes of all openings.

4. Detail drawings of all concrete reinforcement bars and their placement.

5. When stairs are provided, detail drawings of all stairs and railings.

6. Detail drawings of all foundation embeds, and placement drawings for same.

7. Identification marks as required for field assembly.

8. Limitations on the height of concrete pours

PART 2 PERFORMANCE REQUIREMENTS

2.1 DIMENSIONS

A. Form modules shall be manufactured to the overall dimensions shown on the drawings. Openings for doors, windows, and other penetrations shall be provided according to the sizes and locations shown on the drawings. The manufacturer shall designate module joint locations to facilitate manufacture, shipping and installation operations.

B. When stairs are provided, stair layout dimensions, including rise, run, and landing sizes, shall conform to the dimensions shown on the project drawings.



2.2 DESIGN CRITERIA

A. Forms shall be designed to safely withstand a maximum form pressure of 900 psf equivalent fluid pressure caused by the placement of concrete.

B. Individual form modules shall be designed to be self-supporting during loading, shipping and erection. Form Modules shall be designed to be self-supporting when stacked vertically 3 modules high prior to and during placement of concrete. Additionally, forms shall be capable of safely supporting the following minimum construction forces, acting alone or in combination, prior to and during placement of concrete:

1. A wind load of 15 psf applied normal to any exterior face.

2. A uniform load of 100 pounds per linear foot applied vertically downward at the top surface of the module.

3. A uniform load applied vertically downward at the top surface of any shelf angle equal to the weight of the floor deck being supported plus a 20psf construction live load.

4. A point load acting vertically downward at each framing connection point equal to the weight of the framing member and floor deck being supported plus a 20psf construction live load.

5. When stairs are provided, each stair and landing shall be capable of safely supporting a load of 500 lbs.

C. Reinforcing steel shall be proportioned and assembled to satisfy the steel reinforcement ratio for each structural element as required by the structural drawings.

D. Anchors, plates, and inserts required for attachment and/or support of structural framing members shall be designed to support the reactions shown on the structural drawings.

E. When required to satisfy these requirements for temporary strength and stability, temporary bracing, installed at the factory to the maximum extent practical, shall be provided by the manufacturer.

F. When stairs are provided, the load bearing elements of all stairs and railings shall be designed to support loads required by the applicable Building Code.



2.3 MATERIALS

A. Reinforcing Steel Bars:

1. ASTM A615, Grade 60, except as noted otherwise on drawings. Welding reinforcing bars not permitted except where specifically indicated.

2. All reinforcing required to be welded shall conform to ASTM A-706, Grade 60.

B. Metal form systems:

1. Commercial quality steel sheet, plate and shapes.

PART 3 EXECUTION

3.1 GENERAL

A. Delivery, Storage and Handling

1. Deliver, store, handle and erect form systems in exact accordance with manufacturer’s latest published requirements, specifications, and shop drawings.

B. Contractor coordinate sequencing, schedule, shop drawings, fabrication, delivery, and installation.

3.2 CONCRETE PLACEMENT

A. Place concrete in strict accordance with “Standard Specifications for Structural Concrete,”ACI 301, and manufacturer’s written instructions.

END OF SECTION


CODE OF STANDARD PRACTICE

GENERAL

In this document, the seller refers to Vulcraft, the manufacturer and distributer of the CorTek Form System. The buyer refers to the party that receives, orders, and pays for the CorTek Form System. The relationship between the buyer and the seller is defined by the signed purchase contract. Though only one of the following directly pays the seller, all are involved in the buyer’s side of the equation:

The OwnerThe Specifying Professional (Engineer/Architect)The General Contractor/Construction ManagerThe Steel FabricatorThe Steel ErectorThe Foundation ContractorThe Concrete ContractorManufacturers of roof or floor framing materials

Other trades that may be involved include:

The Mechanical ContractorThe Elevator ContractorThe Electrical ContractorThe Fire Sprinkler Contractor

ESTIMATES

The buyer shall provide a set of plans which show the work required in enough detail to produce an accurate estimate. The following information must be included:

1. Elevations for all core walls, dimensioned for all geometry including rough opening sizes and locations 2. Nominal thickness of core walls 3. All reinforcement requirements for core walls a. vertical and horizontal rebar sizing and spacing (note that vertical bars must be spaced at 8” increments, and horizontal bars must be spaced at 4” increments due to form limitations) b. details of all special reinforcing elements including reinforcement around openings and header reinforcement c. required development length for non-contact rebar splices 4. Definition of the tops of foundation walls supporting the core walls


5. Definition of all members framing into the core at floor and roof levels a. Preferred connection types when applicable b. All vertical and horizontal loads for connection design (framing member to core) 6. The preferred connection between core walls and foundation walls (embed plate preferred) 7. All loads that must be transferred at the connection between the core walls and foundation walls 8. Stair layouts including rise, run, and plan dimensions 9. Preferred stair type (i.e. metal pan stairs) when applicable 10. Preferred handrail type when applicable 11. All loads and deflection limits required for stair and handrail design

The typical scope of estimated work includes the following:

1. Stay in place steel formwork modules for all reinforced concrete cores 2. All rebar required by the specifying professional within the reinforced concrete core a. Horizontal rebar will be provided installed within the form modules b. Vertical rebar will be provided loose for field installation 3. Design and material to provide connections between floor and roof framing members and the reinforced concrete core 4. Design and material to provide connection between the CorTek formed core and the foundation walls below 5. Metal stairs and handrail, when applicable a. To the maximum extent possible, metal stairs and landings will be provided attached to the core modules b. Handrails are to be field installed

The following are not included in the typical scope of estimated work, but may be included at the request of the purchaser at the time of the estimate:

1. Pre-installed furring strips for drywall 2. Pre-installed flat steel embed plates for connection of elevator rails (*note: Vulcraft does not provide design, material, or recommendations for elevator rails, brackets, or inserts.) All loads required to be transferred to the core wall by the flat steel embed plates must be supplied to Vulcraft. All locations and dimensions of flat steel embed plates must be supplied to Vulcraft. 3. Pre-installed elevator hoist beams (*note: Vulcraft does not provide design of elevator hoist beams) . Sizes and locations of hoist beams must be supplied to Vulcraft. End reactions of elevator hoist beams must be supplied to Vulcraft for design of embedded connections.

All construction phase activity, including site storage and erection, is by the buyer or his agents.



SHOP DRAWINGS

Prior to fabrication of the CorTek form modules, the seller will submit detailed shop drawings to the buyer for review by the buyer and any other necessary reviewer such as the specifying professional(s) or general contractor. Fabrication does not begin until the drawings are returned with final approval from the buyer.

The building plans and specifications supplied to the seller by the buyer are assumed to be accurate unless written notice is provided to the contrary. When discrepancies between plans and specifications are noted, the Structural Contract Drawings will take precedence over the specifications.

Vulcraft detailed shop drawings for approval will include the following:

1. Elevations of the core including module joint lines and rough opening sizes 2. Plan views of the core showing dimensions and locations relative to the specifying professional’s defined building grid 3. Elevations of the core including rebar placement and necessary splices meeting the specifying professional’s design intent 4. Connections for all roof and floor framing members, including a representation of the construction loads and permanent loads the connections were designed to resist 5. Shelf angles and their connection to the form and core, including a representation of the construction loads and permanent loads they were designed to resist 6. Details of the foundation to core connection 7. Details of the stairs and handrails, when applicable, including locations, dimensions, and members sizes meeting the specifying professional’s design intent

RESPONSIBILITIES OF THE BUYER

The following is a discussion of the division of responsibilities between the numerous parties on the buyer’s side of the buyer/seller relationship.

The Owner: The owner initiates the process and defines requirements for the building including building type, usage, and features. The owner is responsible for hiring the specifying professional and general contractor/construction manager.

Specifying Professional: The specifying professional is the architect/engineer responsible for designing the building to the owner’s requirements as well as to the appropriate codes and regulations. This party prepares plans and specifications with enough detail that other parties can understand the labor and material required for their scope of work (ref. Estimates in the General section above for more information regarding drawing and specification requirements for the CorTek Form System.) The specifying professional is responsible for reviewing and approving shop drawings. This approval is for ensuring



conformity with the design intent, and does not approve deviations from the original specifications nor ensure dimensions or fit-up.

General Contractor: The general contractor carries out the building construction process to completion. This party is responsible for clearly dividing work amongst sub-contractors.

Steel Fabricator: The steel fabricator supplies fabrication and erection drawings of steel frame work for the building. In the context of the CorTek Form System, some coordination between the steel fabricator and the seller will be required for connection locations and details of steel members framing into the core.

Manufacturers: Other manufacturers, such as those manufacturing steel deck and joists, supply fabrication and erection drawings for their products. In the context of the CorTek Form System, some coordination between these manufacturers and the seller may be required when a manufacturer’s product frames into the core.

Foundation Contractor: The foundation contractor is responsible for constructing the foundation according to the plans and specifications. In the context of the CorTek Form System, this party installs all embeds supplied by Vulcraft which are required for the connection of the foundation to the core above.

Steel Erector: In the context of the CorTek Form System, this party receives all shipments of form modules on site and checks for shipping damage and quantities. This party also erects all form modules, installs vertical rebar, installs the foundation to core attachment, and makes framing attachments. The erector is also responsible for temporarily bracing the building and its elements during erection. The CorTek Form System is not to be used as temporary bracing for lateral loads during erection and construction.

Concrete Contractor: In the context of the CorTek Form System, the concrete contractor is responsible for supplying concrete to meet the specifications set forth by the specifying professional and for the placement of concrete within the form system. This party must ensure the maximum form pressures as indicated in the Vulcraft detail drawings are not exceeded during concrete placement. This party also supplies and installs a temporary bulkhead around the base of the form system where the approximately 6” gap exists for facilitation of the foundation to core connection.



Other Trades: Other trades involved in building construction include mechanical contractors, finish contractors, and any other trade installing materials required to complete the building. In the context of the CorTek Form System, other trades must ensure they do not damage the CorTek Form System by:

1. Applying construction loads in excess of the indicated maximum construction loads at each shelf angle or framing member prior to concrete being placed in the core and reaching an appropriate level of strength 2. Cutting or noCThing structural elements of the form system prior to concrete being placed in the core and reaching an appropriate level of strength 3. Using the form system to support, plumb, or otherwise brace any building or construction elements other than the indicated floor and roof framing members



design manual...vulcraft offers two standard stair and landing types: metal pan stairs and metal...

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