slab formwork concerns

Hi Matt

Unfortunately your photos didn't load for your post.

It would be really handy to see your structural plan for the slab and the steel so I and others can answer your questions accurately. Are you able to screen shot those?

The good news is that there is a generally a fix for most things in construction, but again I say this without actually seeing how bad your situation is.

Here is my stab in the dark attempt to answer your questions without seeing the photos or structural plans ( which are vital at interpreting what is required/specified):

1. How flat should the pods be? Can they be this uneven? (see left in back ground, and right in foreground) I dont think the pods need to be perfectly flat provided there is the correct amount of concrete coverage ( normally 80-100mm) the steel is placed at the correct height.
2. the garage is set down but I believe by 70mm too much (error in plans). The frame will be steel and would be too short if the set down is too much. How can this be rectified? Are you using steel frames in lieu of timber or are you meaning your structural steel posts? Structural steel can easily be modified, steel frames can not and 70mm is too much to be legitimately packed in my opinion. This will need some engineering advice to see if something can be added to the slab like structural grout and or that section of frame will need to be remade
3. We have concrete piers. They haven't dug all the way down to the pier for the front steps - is there meant to be a thin dirt layer in between pier and slab or is it meant to be direct contact? I really need to see some photos and plans to answer this
4. Is it ok to have the gap under the boards like at the front? I really need photos for this one. I am imagining that there is a gap between the formboard/edgboard at the bottom and some concrete will leak out. If I am correct this happens and is easy to clean up later.

I hope you can post the missing items as I am curious to see what is happening

Cheers

Simeon

Hi Matt

Thanks for posting the update.

I can tell from the photo that the slab formwork and steel isn't finished . There is still a fair bit of work for them to do from the time that photo was taken ( I assume they might have even poured it by now?)

The only question I can answer is regarding the waffle. That waffle pod is in an area close to the drop edge beam and as long as you have the minimum concrete coverage it's perfectly fine not being flat. All it is doing is taking up space to reduce the amount of concrete.

As for your steel frames, your builder will have to find a solution. This is one of the many reasons I absolutely detest steel frames, but let's not forget that your step down heights should be following the plans, if not the builder will need to fix it.

Considering everyone seems to know about it before the slab pour there are 2 solutions:

1. The simplest thing would be to fix it before the slab is poured by adjusting the slab height on site.
2. Your builder can ask the frame manufacturer to make some adjustments to the frames before they are built

All the best

Simeon

K977

Its fantastic that you had a wonderful steel frame experience.

Having been through the process with around 4 builds here in Sydney I have found the process to be an absolute nightmare to get anything modified or even built for that matter.

Yes it can be done but if the frame company has already designed the frames and put them into production they need to redesign it, re-manufacture it and then deliver it to site which can take multiple weeks. And it is very expensive.

The other point to note is that by the time the slab is poured if the builder is half organised these frames should already be made so you are scrapping what you have built and redoing it.

And it is not until you work with timber where your carpenters custom frame on site and this process take a a couple of hours versus weeks.

So yes I think steel is a terrible product and I am definitely not misleading anyone but again, I am super happy that you love yours.

So if you think I am misleading, I invite you to fly up to Sydney and spend a week with me on my jobsites and I am more than happy to show you how much better timber is. But I might have to put you to work for a few days labouring.

That's a serious offer and sent with love

Cheers

Simeon

Thanks. Told the builders and the contractors seem to have put more fill underneath the garage slab to raise that level.

My main issue now is something our inspector didn't pick up so I'll have to argue it alone: slab mesh scratching a penetration, as well as no seal between the pipes:

1. scratching
right side of this photo
left side of this photo

Is there any standard that applies to having steel too close to the penetrations?
(there's also another penetration where the reo is 1cm clearance)

2. sealing:
Can see ground between these pipes
How can they seal between these?

Many thanks
Matt

Thanks Robert and Simeon. We got all of the prepour issues fixed for pour.

The slab looks overall ok but today I noticed 6 or 7 edge beam bar chairs are exposed, and 2 places with exposed reo. I'm thinking both are a concern. If I see a bar chair, probably the reo there doesn't have concrete cover, even if I can't see it, right?

I want the builders to do a proper job sealing these. Should I be pushing for something like injecting epoxy, rather than trowelling some grout over the facade which I worry they may well try to get away with.


Many thanks,
Matt