The Rail Track was removed and the Slab demolished after the crane passed through. There is 6 Ball Mills so this process was done several times.

South Road Superway Video

The South Road Superway is a cool elevated road structure, the first of it’s kind for Adelaide.

The South Road Superway is starting to take shape. More will be revealed

Click the images for a larger more detailed picture.

Bolt Template

The bolt template is made from steel in order to support the weight of the bolts. The template must have the Center Lines scribed into it in order to place it into the correct position.

The template is clamped onto aluminium formwork beams. The beams are secured onto the formwork shutter with a timber and Z-Bar holding-down assembly.

The center of the bolts was marked onto each side of the forms and a string line was stretched across.

Then we used either a plumb bob, or spirit level to align the string line with the scribed centers on the template.

Doing this positions the bolts pretty close, but not close enough for a mining job. Later surveyors will come and check the bolt centers and each bolt position.

The total weight of the bolts is 480 kg. It is essential to get the assembly positioned as close as possible so that it makes it easier to lever into a spot-on position with the surveyer.

The Bolts

For safety reasons, we found it necessary to lift these bolts in one at a time with a crane.

Tolerance Tubes

After the bolts are in, polystyrene Tolerance Tubes must be added to the bottom of the bolts at the correct height. The height was established and scribed onto the formwork shutter, then transferred onto the bolts with a spirit level.

Adding the Shear Key and Bottom Template

The Shear Key was added next. After that the bottom template made from form ply was added.

A hanging assembly made with timber and z-Bars was used. The Z-Bars were used to wind the Shear Key up until it buts up tightly into the Spreader Bar timber holding it firmly in position.

The Z-Bars are also used to “Crack’ the Shear Key after the concrete is poured. Crack the Shear Key while the concrete is soft (Don’t wait till the next day).

Concrete Finished

One down, 7582 to go Personally, I’d rather be fishing.

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Obviously you would not cut these down to size from a brand new length, but because cutting Z-Bars to size is common, there will always be lots of Off-Cuts which can be used for this.

Z-Bar Pin And Wedge

To use the pin and wedge system, you must first have location pins on the inside of the formwork. This will prevent the formwork going over the line when the wedge is hammered in. These location pins are usually some thin steel around 10mm, but some projects do not allow steel so fiberglass pins are used.

Next, drill a hole larger than the Z-Bar to allow for a pretty loose fit. You’ll know the hole is too small if you have to use a hammer to drive them in.

Ensure there is a nice gap for the wedge to fit in. I often use a piece of plywood as a packer between the forwmwork and the drill bit. This leaves a gap of around 20mm which is heaps for a wedge.

After the hole is drilled, tap the wedge in until the formwork hits the location pin on the other side. Then secure the wedge with a nail wrapped around the pin to ensure the wedge stays in while the concrete is being vibrated.

Z-Bar Pin And Wedge

Using Z-Bar pins and wedges ensures that the formwork stays in the correct position while the concrete is being poured, plus, it’s fast and is easy to strip.

Similar Articles

• The Correct way to Secure Timber Formwork with Pins and Wedges
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