Modern Formworks

Types and technologies

CHARUDATHAN M.B.

MBEM, SEMESTER 1, SPA NEW DELHI

MODERN FORMWORK TYPES AND TECHNIQUES

Contents
1 2 What is formwork? .................................................................................................................... 3 Classification of Formwork ......................................................................................................... 3 2.1 2.2 2.3 2.4 2.5 3 Classification according to size............................................................................................ 3 Classification according to the location of use .................................................................... 3 Classification according to materials of construction .......................................................... 3 Classification according to nature of operation ................................................................... 4 Classification according to brand name of the product ....................................................... 4

Aluminium Formwork ................................................................................................................ 5 3.1 3.2 3.3 Merits of aluminium formwork........................................................................................... 5 Comparison - Aluminium Formwork VS Conventional Formwork ........................................ 6 MIVAN Formwork............................................................................................................... 6 Background ................................................................................................................ 7 Construction with MIVAN ........................................................................................... 7

3.3.1 3.3.2 3.4

SPECIAL TYPES OF FORMWORK L&T DOKA ..................................................................... 11 Various types of L&T DOKA work .............................................................................. 11 MERITS OF DOKA SYSTEM ......................................................................................... 12

3.4.1 3.4.2 3.5

Table form/flying form ..................................................................................................... 13 Process efficiency ..................................................................................................... 13 Safety ....................................................................................................................... 14 Other sustainability features ..................................................................................... 14

3.5.1 3.5.2 3.5.3 3.6

Slip formwork ................................................................................................................... 15 Process efficiency ..................................................................................................... 16 Safety ....................................................................................................................... 16 Other sustainability features ..................................................................................... 17 Other considerations ................................................................................................ 17

3.6.1 3.6.2 3.6.3 3.6.4 4 5

Conclusion ............................................................................................................................... 18 References ............................................................................................................................... 18

MODERN FORMWORK TYPES AND TECHNIQUES

What is formwork?

A structure, usually temporary, used to contain poured concrete to mould it to the required dimensions and support until it is able to support itself. Basic three principles to be kept in mind while using formwork are 2 Quality - In terms of strength, rigidity, position and dimensions of the forms. Safety - for both the workers and the concrete structure Economy - the least cost consistent with quality and safety requirements.

Classification of Formwork

Formwork can be classified according to a variety of categories:      2.1 According to size. According to location of use. According to materials of construction. According to nature of operation. According to brand name of the product. Classification according to size In practice, there are only two sizes for formwork; small-sized and large-sized. Any size which is designed for operation by workers manually is small-sized. 2.2 Classification according to the location of use

There are different types of formwork designed for specialized uses such as for slabs, beams, columns etc. There are not many effective formwork systems for stairs and staircases. This is because of the complicated three-dimensional nature of the elements. 2.3 Classification according to materials of construction Materials used for formwork are traditionally quite limited due to finding the difficult balance between cost and performance. The usually used materials are as follows Wood based materials

MODERN FORMWORK TYPES AND TECHNIQUES

Metals

Particle board, Plywood

Steel, Expanded metal, Aluminium

Rubber, plastics Foamed and expanded plastics, Glass fibre reinforced plastic,

Polypropylene Rubber ,Plastic sheet Cement based materials

2.4

Classification according to nature of operation Formwork can be operated manually or by other power-lifted methods. Some

systems are equipped with a certain degree of mobility to ease the erection and striking processes, or to allow horizontal moment using rollers, rails or tracks. 2.5 Classification according to brand name of the product

Several patented or branded formwork systems have successfully entered the local construction market in the past decade. These include products from brands SGB, RMD, VSL, MIVAN, Thyssen and Cantilever. Each of these firms offers its own specialised products, while some can even provide a very wide range of services including design support or tender estimating advice.

MODERN FORMWORK TYPES AND TECHNIQUES

Aluminium Formwork

The panels of aluminium formwork are made from high strength aluminium alloy, with the face or contact surface of the panel, made up of 4mm thick plate, which is welded to a formwork of specially designed extruded sections, to form a robust component. The panels are held in position by a simple pin and wedge arrangement system that passes through holes in the outside rib of each panel. The panel fits precisely, securely and requires no bracing. The walls are held together with high strength wall ties, while the decks are supported by beams and props. 3.1  Merits of aluminium formwork The formwork does not depend upon heavy lifting equipment and can be handled by unskilled labourers.  Fast construction is assured and is particularly suitable for large magnitude construction of repetitive nature at one project site.  Construction carried out by this system has exceptionally good quality with accurate dimensions.  System components are durable and can be used several times without sacrificing the quality or correctness of dimensions and surface.  Monolithic construction of load bearing walls and slabs in concrete produces structurally superior quality.  In view of the four day cycle of casting the floor together with all slabs as against 14 to 20 day cycle in the conventional method.  As all the walls are cast monolithic and simultaneously with floor slabs requiring no further plasters finish.  As the system establishes a kind of Assembly line production phase wise completion in desired groups of buildings can be planned to achieve early utilization of the buildings.

MODERN FORMWORK TYPES AND TECHNIQUES

3.2 

Comparison - Aluminium Formwork VS Conventional Formwork More seismic resistance: - The aluminium formwork can assure more seismic resistance to the structure due to the box type construction.  Increased durability: - thee formwork itself is much more durable when compared to the conventional wooden formwork. The durability of a complete concrete structure is more than conventional brick bat masonry.  Lesser number of joints: It has lesser number of neat and perfect joints thereby reducing the leakages and enhancing the durability.  Higher carpet area- Since the walls are made of concrete, the shear walls will be thin thus increasing area.  Integral and smooth finishing of wall and slab- Smooth finish of aluminium can be seen vividly on walls. It requires hardly any plastering to be done.  Uniform quality of construction Uniform quality of construction is maintained due to monolithic continous construction and use of uniform grade of concrete.   Negligible maintenance Strong built up of concrete needs no maintenance. Faster completion Unsurpassed construction speed can be achieved due to light weight of forms    Lesser manual labour- Less labour is required for carrying formworks. Simplified foundation design due to consistent load distribution. The natural density of concrete wall result in better sound transmission coefficient. MIVAN Formwork

3.3

The system of aluminium forms (MIVAN) has been used widely in the construction of residential units and mass housing projects. It is fast, simple, adaptable and cost effective. It produces total quality work which requires minimum maintenance and when durability is the prime consideration.

MODERN FORMWORK TYPES AND TECHNIQUES

3.3.1 Background Mivan is basically an aluminium formwork system developed by one of the construction company from Europe. In 1990, the Mivan Company Ltd from Malaysia started the manufacturing of such formwork systems.  In this system of formwork construction, cast in situ concrete wall and floor slabs cast monolithic provides the structural system in one continuous pour.  The concrete is produced in RMC batching plants under strict quality control and convey it to site with transit mixers.  The frames for windows and door as well as ducts for services are placed in the form before concreting.  Staircase flights, faade panels, chajjas and jails etc. and other pre-fabricated items are also integrated into the structure.  The method of construction adopted is no difference except for that the sub structure is constructed using conventional techniques.  The superstructure is constructed using MIVAN techniques. The integrated use the technology results in a durable structure. 3.3.2 Construction with MIVAN 3.3.2.1 Pre Concrete Activities  Receipt of Equipment on Site The equipments is received in the site as ordered.       Level Surveys Level checking are made to maintain horizontal level check. Setting Out The setting out of the formwork is done. Control / Correction of Deviation Deviation or any correction are carried out. Erect Formwork The formwork is erected on site. Erect Deck Formwork Deck is erected for labours to work. Setting Kickers kickers are provided over the beam.

After the above activities have been completed it is necessary to check the following.  All formwork should be cleaned and coated with approved realize agent.

MODERN FORMWORK TYPES AND TECHNIQUES

  

Ensure wall formwork is erected to the setting out lines. Check all openings are of correct dimensions, not twist. Check all openings are of correct dimensions, not twist.   Check all horizontal formwork (deck soffit, and beam soffit etc.) in level. Ensure deck and beam props are vertical and there is vertical movement in the prop lengths.    Check wall ties, pins and wedges are all in position and secure. Any surplus material or items to be cleared from the area to be cast. Ensure working platform brackets are securely fastened to the concrete. On concrete activities At least two operatives should be on standby during concreting for checking

3.3.2.2

pins, wedges and wall ties as the pour is in progress. Pins, wedges or wall ties missing could lead to a movement of the formwork and possibility of the formwork being damaged. This affected area will then require remedial work after striking of the formwork. 3.3.2.3 The post-concreting activities 3.3.2.3.1 Cleaning All components should be cleaned with scrapers and wire brushes as soon as they are struck. Wire brush is to be used on side rails only. The longer cleaning is delayed, the more difficult the task will be. It is usually best to clean panels in the area where they are struck. 3.3.2.3.2 Transporting  There are basic three methods recommended when transporting to the next floor:  The heaviest and the longest, which is a full height of wall panel, can be carried up the nearest stairway.  Passes through void areas.  Rose through slots specially formed in the floor slab for this purpose. Once they have served their purpose they are closed by casting in concrete filter.

MODERN FORMWORK TYPES AND TECHNIQUES

3.3.2.3.3 Striking Once cleaned and transported to the next point of erection, panels should be stacked at right place and in right order.

3.3.2.3.4 Erecting formwork for Construction The use of the software along with the experience and skill of the designers ensures an efficient construction process by incorporating the optimum assembly procedures, economical panel selection and ultimately minimizing capital and operational costs.

MODERN FORMWORK TYPES AND TECHNIQUES

3.3.2.4 Work cycle MIVAN is a system for scheduling & controlling the work of other connected construction trades such as steel reinforcement, concrete placements & electrical inserts. The work at site hence follows a particular sequence. The work cycle begins with the de shuttering of the panels. The system usually follows a four day cycle: Day 1: -The first activity consists of erection of vertical reinforcement bars and one side of the vertical formwork for the entire floor or a part of one floor. Day 2: -The second activity involves erection of the second side of the vertical formwork and formwork for the floor Day 3: - Fixing reinforcement bars for floor slabs and casting of walls and slabs. Day 4: -Removal of vertical form work panels after 24hours, leaving the props in place for 7 days and floor slab formwork in place for 2.5 days.

MODERN FORMWORK TYPES AND TECHNIQUES

3.4

SPECIAL TYPES OF FORMWORK L&T DOKA

DOKA form work is known for the simplicity in assembly of system. The system is flexible, easy to understand and versatile. It can be made suitable for all applications, requires little working skill and helps to achieve uniformly good quality of finish. System gives high labour and material productivity with speed and safety. Investment need be made on the minimum quantity of formwork. 3.4.1 y y y y y y Various types of L&T DOKA work Flex System -For R.C.Floors upto 4.40m. Beam Forming Support system - For R.C.Beams 300mm to 1200 mm deep. Column Formwork system - For R.C.Columns min. size - 15cm x 15cm. Wall Formwork Systems - For R.C.Walls. Heavy Duty Tower System - For staging / scaffolding. Capacity 6.25MT per leg. Stair Tower System Access to heights - Plan size - 1525 x 2250 mm. Access Scaffolding System for Scaffolding. y Climbing formwork System - For Tall structures 3.4.1.1 Flex beam forms This type is best suited for different types of floors with varying shapes and thickness. The main

components are as follows y The light weight H-16 can any H-16 light be point

beams: weight

The beam at

supported

along the length, with no restriction of spacing.

Hence it can be easily adapted for varying floor thickness and changing room dimensions.

Four way heads: The four way heads hold the light weight beams whether they are kept continuously, joined or overlapping, this can be adapted to varying room dimensions without the head to cut the H-16 beams.

MODERN FORMWORK TYPES AND TECHNIQUES

y Props along with folding tripods stand: simple and quick to use as they can stand firmly on their own without additional bracings. The props are telescopic and adjustments can be made in height. 3.4.1.2 Column formwork system y Combines H-16 beams with steel wallers to produce an accurate tight weight wall panel, y The system can be easily adopted for wall with complicated sections, thick walls and extremely tall walls, with the same components and addition of a few accessories, y y Column formwork can also be made to suit any required dimension Full size plywood sheets can be used for shuttering without cutting them into smaller panels. y This minimizes the number of joints and helps in achieving good quality concrete surface. y With this System, preassembled panels can be easily joined

vertically to change heights and width with standard circular

formwork, walls of different radii can be easily built to suit any requirement.

3.4.2

MERITS OF DOKA SYSTEM The system is flexible and is simple in assembly/ dismantling of system. It requires lesser overall stock and also offers reduced cycle time and hence ensures labour saving. The system gives high material productivity with speed and safety. It combines the flexibility of timber with the strength of steel. The whole process is easily understandable for Traditional Workmen hence requires very little working skill. Components are versatile and suitable for all major applications

MODERN FORMWORK TYPES AND TECHNIQUES

3.5

Table form/flying form

A table form/flying form is a large pre-assembled formwork and false work unit, often forming a complete bay of suspended floor slab. It offers mobility and quick installation for construction projects with regular plan layouts or long repetitive structures, so is highly suitable for flat slab, and beam and slab layouts. It is routinely used for residential flats, hotels, hostels, offices and commercial buildings. Generally, a series of individual falsework components including primary beams and props are connected to form a complete table, with plan area of up to about 100m2. Trusses are often used, linked by cross-bracings. The formwork can be mounted on castor wheels or trolley units, allowing it to be moved horizontally. The basic construction sequence using this formwork is as follows: The assembled table formwork units are rolled in to position and sealed along the joints to form the floor to be cast. Steel reinforcement is fixed in place. Concrete is placed and cured. Once struck, the formwork units are lowered and rolled out from underneath the newly formed slab. They are then taken by crane and placed at the next position or level.

3.5.1 y y

Process efficiency Speedy construction for large floor layouts. Fully assembled units can be manoeuvred quickly into place, rather than transporting individual components from one location to another and reassembling.

MODERN FORMWORK TYPES AND TECHNIQUES

High quality surface finishes can be achieved when appropriate quality control is used.

The individual components of the formwork system are highly engineered and can be precisely adjusted.

As the tables create large bay sizes the need for infill areas and decking joints is minimised. The high degree of repetition simplifies work practices.

Reduced workforce requirement on site. However, the initial assembly of the formwork can be labour intensive depending on the size of the table unit.

y 3.5.2 y

It is easier to plan construction activities due to the repetitive nature of the work.

Safety Table formwork systems can include standard health and safety features, such as guard rails. Edge protection is normally fixed after or during the assembly of the table form units.

Table top decking and guard rails can be assembled at low levels and lifted on to the table false work when complete. The false work units can also be assembled at ground level, minimising work at height.

y y

Decking with non-slip surfaces can be used to enhance safety. Interconnected truss members provide a reasonably robust assembly and create a stable working platform.

y 3.5.3 y

The repetitive nature of the work ensures that site operatives can quickly become familiar with health and safety aspects of their job. Other sustainability features The formwork system is reusable with little waste generated compared to traditional formwork. The assembled units are intended for use throughout the duration of a project without dismantling.

y y

Increased speed and time efficiency on-site. Table form systems have been found to be very cost effective for structures with flat slabs.

The repetitive nature of the work, combined with the engineered nature of the formwork, allows site teams to finely tune their operations, which in turn leads to minimal concrete wastage.

MODERN FORMWORK TYPES AND TECHNIQUES

3.6

Slip formwork

Slip form is similar in nature and application to jump form, but the formwork is raised vertically in a continuous process. It is a method of vertically extruding a reinforced concrete section and is suitable for construction of core walls in high-rise structures lift shafts, stair shafts, towers, etc. It is a self-contained formwork system and can require little crane time during construction. This is a formwork system that can be used to form any regular shape of core. The formwork rises continuously, at a rate of about 300 mm per hour, supporting itself on the core and not relying on support or access from other parts of the building or permanent works.

Commonly, the formwork system has three platforms. The upper platform acts as a storage and distribution area while the middle platform, which is the main working platform, is at the top of the poured concrete level. The lower platform provides access for concrete finishing. The basic construction sequence using this formwork is as follows: The formwork and the access platform are assembled on the ground.
y y

The assembly is raised using hydraulic jacks. As the formwork rises continuously, continuous concrete and rebar supply are needed until the operation is finished.

y y

At the end of the operation the formwork is removed using a crane. The entire process is thoroughly inspected and highly controlled.

MODERN FORMWORK TYPES AND TECHNIQUES

3.6.1

Process efficiency

Prudent and careful planning of construction can achieve high rates of production. The slip form does not require a crane to move upwards so the need for crane time is reduced. Concrete supply, on the other hand, can be heavily dependent on crane time or lift availability since volumes required are well below the capacity of normal concrete pumps. As this formwork operates independently, formation of the core in advance of the rest of the structure takes it off the critical path. This can help to provide stability to the main structure during its construction. The availability of the different working platforms in the formwork system allows the exposed concrete at the bottom of the rising formwork to be finished, making it an integral part of the construction process. Certain formwork systems permit construction of tapered cores and towers. Slip form systems require a small but highly skilled workforce on site. 3.6.2 y Safety Working platforms, guard rails, ladders and wind shields are normally built into the completed system. y Reduced use of scaffolding and temporary work platforms results in a less congested construction site. y The completed formwork assembly is robust and provides a stable working platform.

MODERN FORMWORK TYPES AND TECHNIQUES

The strength of the concrete in the wall below must be closely controlled to achieve stability during operation.

The uniform and continuous nature of the work ensures that site operatives can quickly become familiar with health and safety aspects of their job.

y y 3.6.3 y

Formwork suppliers provide materials and resources to help train the labour force. High levels of planning and control mean that health and safety are normally addressed from the beginning of the work. Other sustainability features The repetitive uniform nature of the work, combined with the engineered nature of the formwork, allows fine tuning of the construction operations, which in turn leads to reduced concrete wastage.

The formwork system is reusable with little waste generated compared to traditional formwork.

y 3.6.4 y

Slip form systems can offer safe and cost effective solutions for certain high-rise building structures. Other considerations This formwork is more likely to be economical for buildings more than seven storeys high.

Extensive planning and special detailing are needed as the process has little flexibility for change once continuous concreting has begun.

Standby plant and equipment should be available though cold jointing may occasionally be necessary.

The structure being slip formed should have significant dimensions in both major axes to ensure stability of the system.

The setting rate of the concrete has to be constantly monitored to ensure that it is matched with the speed at which the forms are raised.

Assembly and operations require personnel to be comprehensively trained to ensure competence. It is necessary to understand and comply with suppliers method statements at all times.

MODERN FORMWORK TYPES AND TECHNIQUES

Conclusion

Modern formwork systems for concrete structures have evolved to help meet the demands of the construction industry and its clients. These include demands such as cost, speed and efficiency, which have always been important to industry and will continue to be so. However, more recent drivers for sustainability have widened the demands to also embrace environmental and social concerns. Modern engineered formwork solutions have achieved step-change improvements in most of these areas compared with the bespoke timber-based types of formwork widely used up to the early 1990s.

References 1. Rohan Rupasinghe, Eanna Nolan, Formwork for modern efficient

construction 2. M.K.Hurd, Climbing formwork system goes horizontal 3. www.doka.com