Is DCS a "stay in place" form?
Yes. DCS is a true "stay in place" forming system. The polymer cells, forming the wall structure, remain in place after the concrete has been placed, leaving a bright, durable and clean wall surface.
How do the DCS components fit together?
DCS forms interconnect by simply snapping together, either vertically (building structures restrained by floors) or horizontally (warehouse type buildings covered with metal roofing). This patented ‘snap together’ connection mechanism makes DCS superior to any similar product available worldwide and achieves safer, faster installation.
What are the standard module dimensions of DCS?
Dincel profiles are available in 110mm and 200mm thickness
Do I need any special tools?
No. Standard hand held rechargeable battery tools are all that is needed for most projects.
How do I brace the DCS forms?
The bases of the forms are restrained by channel shaped guides (P-G) or by 2 x 100mm x 50mm timber walers which also establish the location of the walls. The tops of the forms can be braced with either steel or timber bracing. Most of the bracing can be eliminated if the floor formworking trade also installs the DCS forms from the floor decking, by utilising the decking as bracing for the top of the DCS forms. In building structures, this is the most beneficial method of installation for both the formworking trade and the builder.
How is steel re-bar placed into the form?
The unique design of the DCS forms, as certified by the University of New South Wales, enables steel reinforcement to be eliminated for the majority of applications.
When vertical re-bar is required, its placement is simple and straightforward. Dincel Reo-Clip ensures that the vertical bars can be placed in a fixed position at the centre and/or either faces of the 200mm Dincel Profile.
Do I have to use a special concrete mix?
No. Refer to the Concrete Mix Specification within the Dincel Construction Manual.
Can I use 20 Mpa with DCS in lieu of 40 Mpa concrete to cater for exposure to weather conditions?
Yes. Australian Standard AS 3600 requires engineers to specify a minimum of 40 Mpa concrete for surfaces exposed to weather if the structure is located within 1km of the coastal zone. The reason for this is to achieve low porosity concrete to eliminate concrete cancer. The waterproof (Download - Dincel Wall Waterproofing Warranty)
DCS system provides superior protection for concrete by its permanent polymer forms which eliminates the need for higher grade concrete above 20 Mpa for durability purposes.
Should a concrete pump be used?
Yes. The system is designed to work best with a concrete pump, and the use of boom pumps is especially recommended. Concrete can also be placed with crane buckets, elevators or other typical placement methods.
Do I have to pour more slowly than with conventional systems?
No. The DCS forms allow concrete placement at a nominal rate of 1.5 vertical metres per hour. Concrete should be placed in no more than 2m lifts provided that the first pour layer is not more than 1m for a wall of minimum 3m height.
Can I vibrate the forms?
Yes. We recommend using a 25mm vibrator used by an experienced operator. Refer to the Dincel Construction Manual for more detail.
Do I need to use superplasticisers in the concrete mix design?
This depends on the circumstances. If a 50mm pump discharge pipe is used, superplasticisers are not recommended due to their limited working times. However, water reducers which don’t affect concrete working setting time may be used.
Do DCS forms ever blow out?
No. Provided the end corners of the walls are properly secured and braced and the DCS recommended method of installation is followed, it is virtually impossible to have blow outs. Bulging of the forms can occur if the wet concrete mix is dropped into the forms from excessive heights. It is therefore recommended that the concrete pump discharge is directed to one of the internal webs of Dincel profile to slow down the free fall of aggregate, avoid segragation and hydrostatic impact pressure. Refer to the Dincel Construction Manual for guidance.
Do I get uplift at the base of DCS wall forms during concrete pouring? And do i need to fix the bases of the wall forms to the wall bottom tracks?
No. This uplift phenomenon occurs with pervious formwork surfaces such as plywood or fibre-cement sheets. Since cement slurry does not bond due to water absorption to the polymer surface of DCS forms, the formwork uplift which is normally experienced with common formworking systems does not occur with the DCS wall systems.
In addition, the round, horizontally aligned web holes of the vertically placed DCS modules prevent the free fall of coarse aggregate, hence eliminating concrete segregation. The same phenomenon, commonly called elephant-trunk action, pushes the forms down against the potential uplift caused by the wet concrete mix.
For the above reasons no physical connection is required between the bottom tracks and the wall forms. However, in order to prevent the forms from being displaced by wind or accidental disturbance by impact, it is recommended that the forms should be connected to the bottom guide tracks by gluing and/or screwing if they are to be left overnight prior to concrete pouring.
Do I get pockets or voids in the walls?
No. This problem only exists with forms made from fibre-cement, masonry blocks or plywood. Due to the water absorption of forms such as fibre-cement, masonry blocks or plywood, wet concrete adheres to the form face and this builds up on the surface causing air pockets. This does not occur with DCS due to the impervious, slippery polymer surface.
How often do I need to provide joints in DCS walls?
The system incorporates in-built crack inducers which act as shrinkage movement joints for the DCS wall. The theoretical total relative movement of a vertically placed DCS wall for a temperature variation of 40°C is calculated to be 8mm for a 100 metre length of straight wall. This indicates that walls rarely need joints. However, we recommend incorporating the joints of the suspended concrete slabs in the walls as well. Refer to the Dincel Construction Manual, Dincel Wall allows pour strips in a continuous Dincel Wall which can be filled together with the floor slab pour strip.
How soon can I install DCS forms after foundation or slab concreting?
- The next day – after pouring of the in-situ foundations or slabs
- Achievement of necessary concrete wall strength is required by the design engineer prior to the installation of precast flooring
How are electrical and plumbing services installed in DCS?
DCS consists of in-built service conduits at 125mm centres in each face of the main module, which can accommodate all electrical power/communication needs without chasing the walls. Where applicable, the service holes are also big enough to accommodate 20mm diameter water pipes.
How are windows installed?
Any type of window system, vinyl, aluminium or timber can be installed from the interior of the building with DCS. The system provides a rebate within the wall to prevent wind driven water penetration to the interior of the building environment. The system incorporates more than adequate tolerances so the windows, balcony doors, etc. can be pre-ordered even during the planning stage.
Can I use DCS as a direct replacement for a column-slab frame system?
Yes. DCS can be used as columns or walls. It offers faster and cheaper column forms in comparison to conventional concrete blade columns.
Is DCS more advantageous to use than a frame structure consisting of slab-columns with infill walls in multi level residential construction?
Yes. if the following key points are considered:
- Conventional Column-slab frame structures generally consist of non-load bearing façade, party, corridor and partition walls with the following disadvantages:
- Non-load bearing walls provide additional loads to carry at each floor level resulting in more expensive floor slabs.
- More stringent structural/engineering serviceability requirements (deflection, shrinkage and thermal movement) associated with non-homogeneous infill wall material use, resulting in more expensive floor slabs.
- Columns as structural load carrying members normally result in higher load concentrations on the transfer floor slab, hence thicker and costlier transfer slabs.
- Internal works cannot start until at least the perimeter building walls and glazing are in place for trades to work.
- The infill façade, party and corridor walls of frame structures are costlier and take more time to build than DCS.
- More trades and many different materials result in the various trades being dependent upon each other and all trades being on the critical path. Increased numbers of workers present at any given time in comparison to DCS.
- DCS is an advanced development of the column-slab frame structure. The only difference is that all or some façade, party and corridor walls are employed as load bearing elements. Internal partition walls of sole occupancy units are the only lightweight walls. Blade columns are linked to each other to form walls rather than individual structural load carrying elements. The advantage of DCS in comparison to a conventional frame structure can be summarised as follows:
The abovementioned advantages of DCS illustrate that with minimal planning, building with DCS can be significantly faster and cheaper than a conventional frame structure.
- DCS walling can be installed much faster than conventional formed columns due to extremely simple and quick installation.
- DCS walls are cheaper to build, and being solid have great market appeal.
- DCS walls support slabs rather than being supported by slabs, thus resulting in lower cost floor slabs.
- The walls and slabs are all made from the same material, i.e. concrete. This homogeneity achieves similar behaviour of both slabs and walls. The polymer covered walls are of a non-brittle material, hence less stringent serviceability requirements, i.e. cheaper floor slabs.
- Reinforcement of the floor slabs with DCS requires significantly less time and less steel.
- DCS walls can be employed as deep beams thus resulting in substantially cheaper transfer slabs than in conventional frame systems.
- DCS offers waterproof and ready finished basement walls.
- DCS walls can be used as footings to eliminate conventional strip/pad footings.
- DCS walls constructed with concrete slabs require one trade only. The concreting trade can complete the entire building shell without leaving the construction site and the water pipes, power/communication cables etc can be installed at any time without interfering with the concrete trades. The DCS system also allows pre-ordering of the windows prior to construction. Windows can then be installed from the interior of the building which provides an additional benefit in terms of faster, safer construction.
- DCS requires fewer workers, less site amenities, and more importantly eliminates a significant number of dependent trades, taking them off the critical path.