koto building technology information...

KOTO BUILDINGTECHNOLOGY INFORMATION

GUIDE

Housing Kenya

http://www.kotocorp.com/

mailto:[email protected]

Koto Components

Foundations:

a. K-Pod Foundation System for Raft Slabs. (1.2m x 1.2m x .140mm) b. Koto Spacers for accurate positioning of K-Pods (Plastic) c. Koto Screw Piles for Koto Amphibious Homes (Steel Type with

Stabilizer)

Koto IBS Energy Efficient Wall Panels:

a. Koto 8 150mm Standard Series b. Koto 8 200mm Standard Series c. Koto 8 Extreme Series d. Koto 8 Earthquake / Cyclonic Panel

K-Deck Flooring Panels:

a. 100mm Thick Standard K-Deck Panels b. Made to Order Panels

Koto Roof Panels:

a. Standard 100mm Thick Koto Roof Panels b. 125mm Thick Koto Roof Panels c. 150mm Thick Koto Roof Panels

Sundry Items:

a. Koto Joint Paste b. Koto Skim-Coat c. Koto Polymer d. Koto Helix Screw Fixings

K-Pods:

Step 1: Place plastic sheet over

properly prepared soil.

Step 2: Place plastic Spacers. These 4

way spacer insure the steel bar once

placed in in exactly the correct place.

Step 3: Soil to slop 1-2 degrees away

from the K-Pod Foundation

Step 4: All edge beams (perimeter

beam) to be wider than the Koto 8

panel.

Step 5: In Asia a 450mm wide

footpath is cast at the same time the

concrete is poured floor slab.

Step 6: Place appropriate formwork

so concrete can be poured.

Step 7: To prohibit termites from

entering into the house via the

plumbing pipe, place a square section

of stainless steel mesh and secure

with a stainless steel hose clamp

prior to pouring the concrete

Step 8:

Begin pouring concrete in

accordance to the building code.

It is more practical to concrete

from the edges to the centre and

work backwards to zero starting

point.

Step 9: While placing

concrete, insert the steel

bars that have a 150mm

long 90degree into the

substrate. The engineer

nominated size of bar to

extend into the centre of

the thickened edge beam

& 450mm above the

slab.

Step 10:

All Slabs to be finished

with:-

A: Helicopter

B: Vibrating screed This

procedure provides a good

surface so tiles will never

delaminate in the future.

K-Pods creates a perfect

raft slab by connecting a

network of beams to a

thickened edge beam around the perimeter of the slab.

K-Pod Spacer:

K-Pod Spacers are multi-directional and

when placed on the plastic ground cover

insures the foundation Pods support the

steel reinforcing in exactly the correct

position ready for concrete placement

and insure the network of beams are

exactly the same.

In the event of rain there are no

trenches to fill and clog with mud and debris making the K-Pod an excellent raft

foundation system.

Koto Steel Screw Piles:

Use in many applications and ideal for Koto Amphibious Housing,

Koto Zero Concrete housing and foundations in general.

For further information & advice please revert to Koto engineering:

Standard Dimension Koto Wall Panels:

150 Series:

Item Wide Length Height

1 150mm 1.2m 2.1m

2 150mm 1.2m 1.2m

3 150mm 1.2m .900mm

4 150mm 1.2m .600mm

5 150mm 1.8m 1.2m

6 150mm 1.8m .900mm

7 150mm 1.8m .600mm

Core Hole Information – 150mm series Panels:

Core Hole Dimensions are:- 120mm x .80mm @ 200mm centres

To calculate the m3 volume of concrete required to fill one core hole, multiply

the height of the wall x .120mm x .80mm.

Standard Dimension Koto Wall Panels:

200 Series:


1 200mm 1.2m 2.1m

2 200mm 1.2m 1.2m

3 200mm 1.2m .900mm

4 200mm 1.2m .600mm

5 200mm 1.8m 1.2m

6 200mm 1.8m .900mm

7 200mm 1.8m .600mm

Core Hole Information – 200mm series Panels:

Core Hole Dimensions are:- 100mm x 100mm @ 200mm centres



Extreme Dimension Series Koto Wall Panels:

For Extreme Sub-Zero - 40 degrees OR + 60 degrees regions


1 250mm 1.2m 2.1m

2 300mm 1.2m 2.1m

3 350mm 1.2m 2.1m

4 250mm 1.2m 1.2m

5 300mm 1.2m .900mm

6 350mm 1.2m .600mm

The above Extreme Wall Panels are ideal for climates such as: Canada, Russia,

Europe etc OR, Saudi Arabia or extreme hot climates and OR, Fluctuating

temperature climatic conditions.

Optionally Koto Extreme panels can be used for “Special Buildings”, or any

extreme region desiring to minimise high energy costs.

Above: Extreme Wall Panel for Extreme Insulation in Extreme Climates.

Koto Earthquake Panels:

Note: These panels have been scheduled into the system of limited Koto

Manufacturing Facilities in 2014 due to the changes made in New Zealand and

Philippines building codes as a result of excessive increases in earthquakes and

tornadoes in both countries.


1 200 1.8 1.2m

2 200 1.8 .900mm

3 200 1.8 .600mm Item Wide Length Height

1 200 1.2 1.2m

2 200 1.2 .900mm

3 200 1.2 .600mm

Core Hole Information – Earthquake series Panels:

Core Hole Dimensions are:- 200mm x .100mm @ 300mm centres



Packaging Koto 8 Panel Forms:

Above: Koto 8 Product ex-factory stock is readily available for large projects.

Typical Koto 8 IBS Panel Forms:

Top: Typical 150mm Form Bottom: Typical 200mm Form

Koto Bond Beam Panel Forms:

Above: Koto Bond Beam Forms are placed on top of either the Vertical /

Horizontal Combo Option of installation, OR, the Horizontal Option of

Installation.

Below: All external core hole corners on perimeter walling will RC filled as

shown in the drawing below.

Koto Helix Fixing Screws:

Options of Fixing the Helix Screw

1: Screw in anywhere with the hex

head socket already provided

2: Drill an over-size hole, fill with Koto

joint paste and screw helix into paste.

3: Spread a construction adhesive to

the back of the Helix screw, flowed by

screwing into the wall section.

Popular “Rule of Thumb” when Designing with “Low

Dead Load Weight” Koto Panel Forms:

For normal conditions the general consensus is as a guide:-

150mm wide panels:- Single story homes, links houses, resorts etc

200mm wide panels:- Use from 2 stories to 5 stories

Multi-Story building of any height use either of the above as an infill

between columns and beam construction.

Always refer to your structural engineer for specific advice as there are large

savings to be enjoyed in multi-level construction with low dead load weight Koto

materials.

Benefits using Koto 8 construction methodology as a “Permanent Formwork” for

single and double story buildings include:- less transport, no cranes, can use

supervised unskilled work force, no plastering, easy M & E without the need to

hack, high-speed construction, cost effective foundations, early completion

schedules etc.

What is a Koto 8 Form?

KOTO 8 building system is light weight form panels which provide

permanent formwork to reinforced concrete columns for column and beam construction of buildings. The columns are produced by reinforcing and concrete filling vertical cores and horizontal beams in the KOTO panels.

For Single Story Houses where there are little vertical forces, the structure need be designed for racking forces only. For this the columns are spaced apart in the external walls and a bond beam built into the panels across the top of the walls. The KOTO 8 panels serve as the walls between the columns and the bond beams also serve as anchorage.

For Multi-Level Construction the system is also designed as column

and beam. The columns are produced by reinforcing and concreting all cores in

the Koto 8 panels give continuous rows of columns, which are connected to

concrete slabs. The columns carry the vertical loads and resist the racking forces

in flexure. The concrete slabs serve the same purpose as beams. The KOTO 8

panels infill between the columns and together serves the purpose of walls.

Schematic Drawing:

Please Note the proper procedures for a permanent structure in accordance to

code is shown in the schematic drawing:-

1. K-Pod Forms

2. K-Pod Spacers

3. Thickened Edge Beam

4. Steel bar in accordance to engineers shops drawing

5. BRC to the top of the K-Pod

6. Starter bar extending down deep into the thickened edge beam

7. Koto Pre-Finished wall Panel Form

8. RC concrete filling the Koto Panel Form where specified

9. Power Float Finish to the concrete surface

Options for Installing Koto 8 Wall Forms:

The Vertical and Horizontal Combo Option of installing Koto wall

Forms

2.1m vertical Koto wall panels align to top of window & door frames.

The top horizontal bond-beam panel can be .6 - .9, or1.2 high, or cut to

suit application.

Tongue & groove connectors are on top, bottom, and each end of the

Koto Panels for easy and accurate installation

Lintels: Flip the panel upside down that will sit over the opening. Cut out

a section the depth of the required lintel. Push a rio bar into the form so

its self-supporting. Flip the panel back to the upright position. (this takes

about 1 minute ) When pouring concrete to the columns/bond-beam, the

lintel will automatically fill. The Koto panel is acting as a permanent form

making lintels a very easy task.

The above method is a fast efficient method of delivery with minimal joints

which is preferred by many western or European installers.

If using with a standard wall height this methodology is very fast to install as all

components are standard.

The Horizontal Option of installing Koto wall Forms:

Use any combination of Standard Horizontal Koto wall form panels such

as 600, 900 or 1.2m high by either 1.2m or 1.8m long to suit your module

size making designing with modules easy…...

The top Koto Form Panel will be a pre-cut Bond-beam Panel for super-

fast and easy installation.

Corners Panels to be are cut at 45 Degree (preferred method for point to

point accuracy and alignment), However, butt jointed method can also be

used on site as shown in the diagram right, but point to point is superior

allowing for 3 reinforcement bars to the corner.

Koto mono or flat roof Form Panels have in-built stiffeners that are fixed

into the exterior wall bond-beam and a centre support beam.

Where gable-end roof is specified, it can be supported off a longitudinal

beam, or extended height of the interior partition wall.

The horizontal method of installation is ideal in severe seismic and cyclonic

regions as each panel can be easily converted to a bond-beam panel if called up

by a professional engineer.

Another installer’s option if he has multiple, whole long walls, can be assembled

horizontally on the concrete floor slab, and then raised into position in one large

piece with a crane making the Koto 8 an extremely versatile Form.

Installing Koto 8 Wall Forms to the Floor Slab:

1) With a power float floor

and starter bar inserted deep

into the thickened edge beam

workers now check diagonals

and set out their dimensions by

flicking in a Chalk Line to the

inner side where the fist panels

Forms will be set. Mix the Koto

Joint paste and apply to the

substrate. Now place the Form

over the starter bar onto the

wet adhesive.

2) On the perimeter wall the

team will install the Koto

Windows as they go.

The cold rolled windows have

an allowance for the next form

to fit firmly into any side of the

window frame.

Each Koto 8 Form has a male

and female connection allowing

for easy and accurate

installation of window and door

frames.

3) Internal partition Door Frames are

also installed as you go. Installers must

check with a quality spirit level for

perpendicular and plumb.

Usually interior doors and Door Lock

Sets come with the package when

ordered.

Timber or aluminium window and

door frames can also be used,

however, we recommend fitting a

protective architrave to the frame

edges.

4) Double sliding doors in accordance

to the code are also installed as the

contractor goes.

Important Note:

RC columns with two steel bars are

fitted each side of any exterior

opening and one column minimum to

each side of the partition wall frames.

In most applications with a continuous

three corner RC pour and two RC cores

either side of an opening on the

perimeter wall will provide three (3)

times raking.

Right:

Standard Cold Rolled Metal

galvanised dipped Window and

Door Frames as shown in the above

affordable housing projects.

Understanding the Koto 8 IBS Insulated Energy Efficient

Wall Form:

Above Left:

Koto 8 Panel Form mounted in a Test Rig under load. As we have seen the Koto

Form is a Permanent Formwork that allows designers, engineers and

contractors to quickly calculate and install these as structural elements by

engineering the columns and beams inside.

Above Right:

R.C. Columns and Beams previously poured inside the Koto 8 Panel Form. This

is what a professional engineer is engineering.

Left:

This 200mm x 100mm earthquake column

shows 2 bars and stirrups, whereas, low

wind-speed or low seismic regions would

only require 100mm x 100mm columns

with 1 bar in accordance to a professional

engineers calculations.

Engineers are engineering the RC columns and Beams”

The drawings demonstrate RC placement to Corners

right, and Openings above.

Webs can be cut out between the core holes and two bars installed

demonstrating the versatility of the Koto 8 IBS system.

Right: Starter Bars on level

two bond beam are ready for

the next level to be added for

this commercial “Birds House”

Farm in Northern Borneo.

These 70m x 24 m x 3 level

building are completed in

remote locations in just 21

days and yield high volume

birds’ nests.

Joint Flushing:

Flushing Joints between two Koto

8 Forms is quickly and easily

performed by using Koto Joint

Paste while holding the trowel on

an acute angel and saturate a

100mm length of alkali resistant

fibreglass over the joint.

Above: Note the metal security window frames leave a protective architrave

around the window and Koto 8 panels Forms quickly mount directly into any

side of the frame. As no screws or tools are required these windows install in

30 seconds.

Koto 8 IBS Wall Panel Forms and High-Rise Construction:

Mega High-Rise Construction:

For multi-level buildings over 6 stories high the methodology to use Koto 8

Forms is simple.

Columns and Beam will be constructed and the Koto 8 Panels become Infill

Panels. These can be either Load Bearing OR Non-Load Bearing which the

engineer will calculate.

Large savings for foundations can be expected due to Koto Low Dead Load

Weight IBS Panel Forms.

K-Deck IBS Flooring Forms:

What is a Koto Floor-

Deck Form?

An engineered pre-stiffened, pre-

coated insulated energy efficient form

that allows for easy fast installation for

spans up to 4.8m long compatible with

Koto walling systems with a built in

“Creep Factor” for seismic regions.

For longer spans a professional engineer to update the basic engineering

for multi-story buildings which essentially is steel sizing and concrete after

live and dead loads are calculated.

Benefits of using an IBS Flooring Form:

Koto Floor-Deck Forms allow for the placement of forms

without the need for scaffold.

In many applications Koto Floor-Deck Forms simply span from

bond-beam to bond0beam.

In other applications Koto Beams and Columns can be set to

place the Koto Floor-Deck Forms on.

Contractors can immediately walk on the Koto Floor-Deck Form

as soon as they are placed.

Only minimum props are required just before pouring concrete

herein allowing for work to continue seamlessly

Koto Screw Pile or hand

formed Column & Beams to

the 45 degree mountain site

are the best options not to

damage a precious

landscape ready for the

platform to take shape.

Pre-factory made and pre-stiffened

Koto Flooring Forms are loaded onto

the column and beam structure.

Note: As soon as the Koto Flooring

Forms are place without scaffold

underneath workers can immediately

walk on top of the forms to prepare for

the next stage.

The only footprint of trees removed on

this 45-65 degree mountain site is the

actual land space to install the Koto 3

level home.

Practically zero scaffold was required.

Below:

Mountain Side Homes / Chalets completed with zero damage to the

environment.

Koto Beams, Flooring and Finishing ready for next level

on an Elevated Site:

Above:

I. Top Left: Koto Beams Ex-Factory are simply slotted into the Koto wall

Panel Forms. Steel is placed and ready for Concrete.

II. Top Right: The Pre-Stiffened Koto Flooring Forms complete with

services and BRC mesh positioned is receiving high speed concrete

pumping.

III. Bottom Left: Minimum props required for the concrete placement

above is a bonus as it allows for other trades to complete their scope of

works without having to wait for concrete to cure and removal of props

normally used in conventional construction.

IV. Bottom Right: Concrete floor completed with Power Float Finish,

Services positioned for level two and Steel Starter Bars in position with

next course of Koto wall panels already bonded to the substrate.

Installing with Koto Roof-Deck Forms:

Koto IBS Roof Panels are pre-Stiffened Forms that allow for workers to span

them across to roof area without interior scaffolding

As soon as they are placed a Double Acting Roof Tie is inserted into the bond

beam and fitted off against wind up draughts.

Metal sheeting can be immediately screwed to the stiffeners or the Roof-Deck

can be waterproofed as is. In the interior the ceiling becomes the roof and fans

or lights can be fitted to the stiffeners.

Below:

The Roof is the Ceiling – only it’s insulated from the hot sun to maximise

energy efficiency in the home.

Left: The Roof is the Ceiling. Right: Simple way for drop-down ceilings

Right: A Koto Dual Roof Panel Bracket for

fixing 2 panels to the bond beam. Usually pre-

drilled, to screw into the metal stiffener.

Bracket for Standard Steel or Timber Roof Trusses:

Traditional Roof Tie-Down

Brackets are used when using

galvanised steel trusses.

Brackets to be placed into wet

concrete at the consulting

engineer’s specification.

Koto Pre-Stiffened & Pre-Coated Roof Panels:

Koto are easy to position into place “without” the need for

underside scaffolding.

Soon as you place the Koto Roof-Panels into position you can

immediately walk on them.

No need to pay for false ceiling.

Fans and lights can be fixed directly into the in-built stiffeners.

As the Koto Roof Panels are pre-finished – flushing and painting is

all that’s required.

Choices of thicknesses are available to suit the specific U-value

requirement – Koto Roof Panels prohibits heat transfer to the

interior.

Contractors have the choice of laying roof sheet to the inbuilt

stiffeners, 30-40mm of concrete to the substrate or

waterproofing the Koto Roof Panel.

Mono roofs tie into the bond-beam, whereas a gable roof ties to

a beam extended from each end of the building.

In some countries contractors use the Koto Roof Panels as a

ceiling and install a traditional truss roof on top.

Additional stiffeners can be embedded should a water tank be

installed, however, Koto has various water tank designs that are

flat and form part of the substrate.

There are a number of fixing methodologies

for the Koto Roof Panels.

In sub-zero temperatures adverse Koto

Roof Panels are recommended.

The advantage of a Koto Roof Form is its

ability to change to suit the environment

albeit it cyclonic or seismic regions.

Shingles are easily fixed to the Koto Roof

Panel

Koto Super Solar Film panels adhere directly to the panel – that

work far more efficiently than the usual crystalline cells.

Koto Roof Panels can Harvest water

Koto Walling Panels and Koto Roofing Panel provide the most

energy efficient home in the market place today

These homes are ideal for “Off-the-Grid” housing

In Europe 60% of pensioners money is wasted on heating in severe

winters – by using Koto energy efficient housing their energy cost

in severe winters would be approximate 2% of their pension.

Notation for Designers:

Koto urges designers to design to the modules shown in the wall dimensions

grid.

This way zero waste is reconciled for the client and add to the other in-build

savings.

One of the many tie

down options when

tying to a R.C. bond

beam.

Others include pre-bent

steel over lashing, metal

brackets or simply

reinforcing steel driven

over the roof panel

stiffeners.

Another typical method of tying down

roof trusses to the RC Bond beam as

found in conventional construction

Koto 8 IBS for High Seismic Applications:

Above: The combination of Koto 8 Wall Forms and K-Deck connections

provides a significant high “Creep Factor” for these adverse conditions.

Typical Koto 8 Contractors Tool Kit:

All these tools fit into a 60 litre plastic rubbish bin doubling as a tool box.

When using Koto JP Paste or Skim-Coat the bin can be used to store Koto Polymer for easy access and fast mixing.

www.kotohousingkenya.co.ke [email protected]

http://www.kotocorp.com/

mailto:[email protected]

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