casting bigger than usual bolts into concrete

8/13/2019 Casting Bigger Than Usual Bolts Into Concrete

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Casting Bigger Than Usual Bolts Into ConcretePosted on April 5, 2011by Ed

Here is a formworkbolt assembly we used to cast some 40 KG bolts into a 5 meter high pedestal. The assembly includes

a pre-fabricated Shear Key (which is always fun)

Click the images for a larger more detailed picture.

BOLT TEMPLATE


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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.


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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.


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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.


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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 (Dont wait till the next day).

CONCRETE FINISHED

One down, 7582 to go Personally, Id rather be fishing.


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HOLDING DOWN BOLTS

We also manufacture special Holding Down Bolt Frame Assemblies to order. Click "CONTACT US" to enquire

Holding Down Bolt (grade 8.8) High Tensile.

Also available:

Galvanised & Stainless

Grade 4.6 Mild Steel

SPECIALS manufactured to order. CONTACT US.

Part Number Thread Length (mm) Finish Grade

431-16x0300 M16 300 Self Colour 8.8 (HT)

431-16x0375 M16 375 Self Colour 8.8 (HT)

431-16x0450 M16 450 Self Colour 8.8 (HT)


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431-20x0375 M20 375 Self Colour 8.8 (HT)

431-20x0450 M20 450 Self Colour 8.8 (HT)

431-20x0600 M20 600 Self Colour 8.8 (HT)

431-20x0750 M20 750 Self Colour 8.8 (HT)

431-20x1000 M20 1000 Self Colour 8.8 (HT)


431-24x0375 M24 375 Self Colour 8.8 (HT)

431-24x0450 M24 450 Self Colour 8.8 (HT)

431-24x0600 M24 600 Self Colour 8.8 (HT)

431-24x1000 M24 1000 Self Colour 8.8 (HT)

431-24x1250 M24 1250 Self Colour 8.8 (HT)


431-30x0450 M30 450 Self Colour 8.8 (HT)

431-30x0600 M30 600 Self Colour 8.8 (HT)

431-30x0750 M30 750 Self Colour 8.8 (HT)

431-30x1000 M30 1000 Self Colour 8.8 (HT)

431-30x1250 M30

1250

Self Colour

8.8 (HT)


431-36x0450 M36 450 Self Colour 8.8 (HT)

431-36x0600 M36 600 Self Colour 8.8 (HT)

431-36x0750 M36 750 Self Colour 8.8 (HT)

431-36x1000 M36

1000

Self Colour

8.8 (HT)

431-36x1250 M36 1250 Self Colour 8.8 (HT)


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Tapered Waxed Cone

The use a void former allows easier adjustment of the bolt, after the concrete is set.

Also available:

Polystyrene Cones

Expanded Mesh Parallel Tubes

Part Number Taper (mm) Length (mm)

434-20x228x70 25 x 70 228

434-20x305x92 25 x 92 305

434-24x380x108 27 x 108 380

434-24x450x114 32 x 114 450

434-30x535x118 32 x 118 535

434-30x610x133 27 X 133 610


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434-30x760x133 32 x 133 760

Square Hole Plate Washer

Standard stock sizes listed below.

Specials made to order in our own workshops. Click "DESIGN YOUR FABRICATION" to enquire.

Part Number Bolt Size Square (mm) Thickness (mm)

522-100x06xM16 M16 100 x 100 6

522-100x06xM20 M20 100 x 100 6

522-100x06xM24

M24

100 x 100

6

522-100x10xM16 M16 100 x 100 10

522-100x10xM20 M20 100 x 100 10

522-100x10xM24 M24 100 x 100 10

522-150x10xM30 M30 150 x 150 10

522-150x10xM36 M36 150 x 150 10

casting bigger than usual bolts into concrete

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