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General Question

What is COFFOR?
COFFOR is a lightweight structural formwork system to build load bearing wall. It is a stay-in-place formwork that reinforces the construction.

What can you build with COFFOR?
COFFOR is used for building walls in all types of construction: single-family homes, multi-unit apartment buildings, lavish residences, luxurious building and all types of industrial/commercial buildings. Slabs and roofs (horizontal or inclined) can be built with COFFOR. It is also used for radius walls, blind walls, retaining walls, slabs, floors, inclined or flat roofs, infrastructures, foundations, rehabilitation, swimming pools, water tanks, civil works and much more.

How high can I build?
There is no height limitation. COFFOR can be optimally used for regular G+5 structures considering lightly reinforced wall, nominal reinforcement are required at junctions & openings as per EURO Codes. For higher floors, wall reinforcement may be required as per structural design requirements.

Do the forms stay on after the concrete is poured?
Yes, the COFFOR panel stays in place and stability enhances of structure.

Does a COFFOR building cost more?
In all cases, COFFOR construction is considerably cheaper than traditional constructions with column and beam (frame structures). Savings range up to 20% for regular structures, apart from the qualitative advantages that translate into cost savings described in the previous chapter.

  • Steel reinforcement is reduced compared to frame structures.
  • Time required to build, is 4 times less than frame structures. With Frame structure, it generally takes 1 month to build one floor. With COFFOR, it takes one week. And since no qualified labor is necessary with COFFOR the total labor cost is dramatically reduced.
  • Overhead cost is reduced since duration of the construction is less.
  • There is more usable area. Load bearing walls with COFFOR use less space than bricks that fill column and beam. The additional usable space varies from 3% to 6% depending upon the design. This is particularly advantageous for the developer since the increased available space is sold at the selling price.
  • The contactor has the opportunity to take on more jobs during the same time span: with the same equipment, the same infrastructure and the same team. His return on capital investment is double.
  • Overall, COFFOR buildings provide a better value. Lower recurring costs and potentially higher resale values pay for sometimes slightly higher construction costs within a few years.

Is building with COFFOR considered "green building"?
COFFOR technology helps protect nature reduces the depletion of natural resources and saves energy.

  • Forests are preserved as the intensive consumption of wood is reduced.
  • Pollution brought about by the burning or dumping of wood debris from construction sites is decreased.
  • Potentially polluting oil to clean metal sheeting is eliminated.
  • Use of bricks is decreased; reducing the amount of natural resources used as well as the energy to make them (China has banned the use of the bricks for this reason).
  • For low rise buildings, it is possible to use other filling materials than concrete.
  • The external placement of thermal insulation provided by COFFOR INSULATED makes it far more efficient than bricks in eliminating cold bridges, saving heating and air conditioning energy.
  • COFFOR builds concrete structures that last and do not require maintenance and repairs like other construction systems (wood, bricks, etc.).

How is a COFFOR wall different from Masonry / Wooden wall?
High-mass, reinforced concrete walls built with COFFOR are much stronger than masonry wall. They also provide monolithic structure, better resistant to natural disasters, more energy efficient; they reduce air infiltration and the thermal mass of the concrete keeps inside temperatures more even.

Is building with COFFOR easy to learn for a builder?
Yes, every step of the construction process is simplified:

  • Placement, alignment, bracing.
  • Setting of openings.
  • Rebar insertion (if necessary).
  • Service conduit penetration.
  • Concrete pour.
  • Visual inspection of the pour enables control of the concrete setting and eliminates segregation risks.
  • It is possible to pour concrete in the walls and upper slab at the same time.
  • COFFOR offers detailed instructional and technical materials for builders, such as the COFFOR installation video, product manual, installation guide and technical bulletins.
  • Workers are trained on the COFFOR technology in just 2-3 days: training is performed quickly and directly on-site. In addition, workers are keen to learn since COFFOR is by far less physically demanding than other construction methods such as heavy formworks, bricks, concrete blocks, etc.
  • COFFOR offers detailed instructional and technical materials for builders, such as the COFFOR installation video, product manual, installation guide and technical bulletins.
  • COFFOR also provides technical assistance via phone, fax, email, and in some cases on-site.

Will it take longer to build my house with COFFOR?
Experienced COFFOR crews can actually build COFFOR structures in less time compared to conventional construction. Compared to conventional way, COFFOR requires less shuttering, centering and removing shuttering for walls and wall and slab can poured with concrete in one pass.

Can COFFOR be used without concrete?
Yes, COFFOR can be used without concrete, different filler material can used with prior approval of structural engineer and COFFOR Technical Department.

Are COFFOR panels reusable?
NO, COFFOR panel are not reusable.

Can COFFOR be used for low cost housing?
Yes, COFFOR can be used in low cost housing.

How to use COFFOR in corrosive areas?
Main COFFOR components are galvanized which can resist corrosion. Just like any reinforced concrete structure that is exposed to corrosive area, depending on the site conditions COFFOR recommends water-proofing or damp-proofing with peel & stick membranes and/or drainage boards.

What are safety requirements to be taken care during construction?
It is necessary to wear gloves for all persons working with COFFOR panel during construction.

COFFOR System & its characteristic

What are COFFOR's physical dimensions?
Standard widths of COFFOR are 1100 mm (44’’), 900 mm (36”), 700 mm (28”), 500 mm ( 20”) and 300 mm (12”).
Height is available from 300 mm to 4000 mm in multiple of 100 mm according to order.
Standard thickness of COFFOR is 150 mm (6”), 200 mm (8’’) and 250 mm (10’’). Other thickness is available on request.

What is COFFOR made of?
COFFOR is made of rib lath, C shaped profiles (both produced from hot galvanized cold rolled steel in coil) and articulated rebar loops (produced from steel rebar). COFFOR INSULATED is made with the same components but includes an insulation material such as polystyrene or polyurethane.

What happens to COFFOR walls in a fire?
Concrete structures are far more likely to remain standing through a fire than structures built with wood. COFFOR walls have been tested and shown to be an effective 4 hour firewall due to the solid concrete within.

Can I remodel or add to a COFFOR building later?
Yes. After consulting Structural engineer / COFFOR executive openings can be cut into concrete walls with tools obtainable from most tool rental stores. You can also add more walls by connecting them to existing walls.

How to insulate COFFOR from heat & electricity, as skin (rib lath) of COFFOR is good conductor of heat and electricity?
COFFOR is equivalent to shuttered walls with regards to heat according to EUROCODE and tests conducted. With regards to electricity, it is assumed that electric wires are inserted into conduit like in shuttered walls.

Design, Engineering & Building Codes

How do I determine what size COFFOR wall to build?
This is a decision to be made by your local building department, designer, or engineer. The local building department may allow you to follow pre-approved prescriptive designs.

Does the job need to be engineered?
In today's regulatory environment, many buildings require some engineering, but check with your local building department. COFFOR monolithic concrete walls may conform to pre-approved prescriptive designs available from the local building department.

Do I need to provide additional reinforcement in COFFOR wall?
For lightly reinforced wall, nominal reinforcement .are required at junctions & openings. For other type of wall reinforcement may be required as per local code requirements.

Does COFFOR comply with local building codes requirements?
COFFOR is a lightweight structural formwork system to build load bearing wall, load bearing walls needs to be designed as per local codes.

Doing business with COFFOR

How much does COFFOR cost?
Actual cost can be derived after redesigning structure, so that we can optimize use of COFFOR in structure. For redesigning, we'll need your plans (floors and elevations) or exact wall dimensions - incl. wall lengths, heights, and thicknesses; sizes of all wall openings; numbers of corners/angles/T-walls etc

Can I see an actual COFFOR project?
Yes. Contact COFFOR Representative or look through our photo & video gallery.

How do I find skilled labor to construct my COFFOR building?
Contact COFFOR for referrals to contractors experienced with COFFOR. COFFOR conducts training seminars for contractors to ensure your project's success.

How do I find an Architect or Engineer familiar with COFFOR?
Contact COFFOR and they can usually recommend an architect or engineer in your area who is familiar with designing with COFFOR. COFFOR’s Technical Library online, on DVD, or in print makes it easy for design professional to incorporate COFFOR.

How will my COFFOR project be supported?
Not only is COFFOR equipped to answer your questions and assist at the jobsite but your COFFOR Field Representative is also ready to assist with quantity 'take offs', job site training, product seminars and dealer & contractor training.

What kind of warranty does COFFOR provide?
We offer a limited product warranty for defective products.

COFFOR during Construction

How much bracing is needed?
Enough to keep the wall aligned during stacking and pouring, generally every 6-8' [1.8-2.4m] depending on the size of the wall. The corner and angle brackets eliminate the need for structural bracing of corners and angles. Refer to the COFFOR installation video, product manual or COFFOR Representative for more details.

Is a special concrete mix used?
No, all type of concrete mix can be used. Preferable "COFFOR Mix" is:

  • The specified compressive strength from the building plan;
  • A maximum 6" [150mm] slump (between 5" and 6" preferred);
  • The need for highly "flowable" concrete (e.g. with super plasticizer);
  • Aggregate Size of 3/8" [10mm] or 3/4" [20mm] (for walls 8" thick or more)

When concrete is poured from 3.0 m height inside panel, how segregation of concrete will be taken care?
Experience shows that there is no segregation when concrete is poured from 4.50 m.

Can 3.0 m or more height panels be filled in single pass for water retaining structures?
Yes, 3.0 m or more height panels can be filled in single pass for water retaining strictres.

Do the walls need to be vibrated?
Use proper placement and consolidation techniques, including rodding by hand, using a mechanical needle vibrator with a small diameter (maximum 1¼" [32mm]) or surface vibrator can be used. Do not over-vibrate.

How are doors and windows installed?
A wooden or vinyl frame (or "buck") is built to the specified size of the window or door rough opening and then inserted into the COFFOR wall. The buck is secured into place and concrete is poured around it.

How & when are electrical and plumbing installed?
Most electrical and plumbing conduit is set into panel prior to the placement of concrete. Electrical boxes, supply lines, and drain lines are affixed directly to the panel after cutting the COFFOR panel (Rib lath). Refer to the installation video and product manual for suggestions.

How are exterior & interior finishes done?
Plastering is required at exterior side of wall. For interior wall stucco (acrylic or cementitious) is adhered directly to the COFFOR after rasping it. Plaster board, wood, plastic or metal cladding is mechanically fastened to panel. Stone and brick are attached according to design specifications (e.g. with brick ledges and brick ties).

Do COFFOR walls below grade need water-proofing or damp-proofing?
Yes, just like any concrete structure that is exposed to moisture. Depending on the site conditions COFFOR recommends water-proofing or damp-proofing with peel & stick membranes and/or drainage boards. In addition, COFFOR recommends following all other accepted methods for water management, such as proper drainage, compaction of backfill, and management of run-off for the entire site.

 
     
 
 
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