Challenging the status quo – Sleeve form process improvement
By: Javier Glatt On: February 27, 2014 Comment: are off for this post.
Hardstone Construction’s Tivoli Village project in Las Vegas, NV, is a complex $720 million mixed use shopping mall development with a total of eighteen buildings, nine of which are on top of two levels of parkade. While providing live 3D parametric modeling services using the CATIA platform, current CadMakers Company Inc. co-founder and engineer Nicolas Cantin encountered a problem. When laying the 6”, 8” and 12” PVC sleeve forms that house conduit and piping into the concrete, the off-the-shelf, standard solution provided (shown below) consisted of tied PVC sleeves to the stirrups using steel wire. These would often come loose during the concrete pour (risking a code violation by sliding too close to the rebar) and needed to be removed after the concrete cured (shown below) causing the process to be extremely labour intensive. Furthermore, since they were attached to the stirrup, coordination between rebar and concrete personnel was required to determine where to stop the stirrup in relation to the Z-bar. Once the rebar was installed, the concrete team needed to slide the sleeves in between the rebar and had to hope the rebar team left enough clearance for the sleeves. This had been the “typical” and acceptable process and had not been challenged. However, with over 1 million square feet of sleeve beam on the podium, the typical process was slow and costly.
3D modeled sleeve form installation – Final view of process improvement
3D sleeves coordinated with Plumbing installation
Sleeve form installation – Visual of old process
Sleeve form removal – Visual of old process
Tasked with the challenge to find a better way, Nic used his technical skill-set to design detailed shop drawings of an innovative two screw steel system (shown below). It allowed the concrete personnel to install the sleeves directly on the form-work prior to the rebar installation; thus eliminating any potential coordination issues between the two trades. The result was a simple installation process for the field, guaranteed code compliance and no need for removal after the concrete had cured. This new design was created directly from the live 3D parametric model. Leveraging CATIA automation tools, the drawings went direct to the fabricator and drafting time was reduced by 80%. This process improvement reduced field labour time from approximately one hour per sleeve form to about five minutes, resulting in savings to the project of approximately $300,000.
Sleeve form shop drawing using CATIA Automation tools
At CadMakers Company Inc. we are relentless in our approach to process improvement. This example shows that the combination of challenging the status quo and applying cutting edge technologies in a unique way, has the potential to result in significant value to the project.