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L&T DOKA

FORMWORK SYSTEM
PRESENTED BY:

TUSHAR AKBARI (CPM0106)
SUBMITTED TO:
MR. DEBASIS SARKAR
DOKA FORMWORK Inc.
• leading European company
for concrete formwork.
• Doka formwork technology
makes a major contribution
towards getting concrete into
the desired ‘form’ - in an
economical way.
• EUR 394 Million Doka Group
is spreaded in more than 35
countries of world .
L & T-ECC in association with DOKA:
1985 Collaboration with M/s Doka of Austria
1986 Fabrication of steel components through
vendors commenced
1990 Production of timber beams at Chennai
commenced
1991 Marketing of formwork systems to external
clients
1997 Dedicated factory set up at Pondicherry for
manufacture of steel components
2000 1) Timber beam production facility at Chennai
shifted to Pondicherry
2) New line added for timber beam production
to enhance capacity
MERITS OF L&T DOKA!!!!!!
• Simplicity in assembly of system.
• The system is flexible, easy to understand
and versatile.
• can be made suitable for all applications,
requires little working skill and helps to
achieve uniformly good quality of finish.
• high labor and material productivity with
speed and safety.
• Investment need may be made on the
minimum quantity of formwork.
• More no. repetitive usage.
• Greater life span and less labor requirement.
• Able to resist more lateral pressure of liquid
concrete.
• Less chance of burglary & misuse due to
heavy weight & large size.
• Easily modifiable as compare to steel
formwork.
• accurate, safe and speedy construction
DEMERITS OF L&T DOKA !!!
• High initial investment.
• would be handicapped
without tower crane.
• Require more mechanized
setup at site.
• Handling and placing is very
difficult, it requires separate
shade to store them.
• In house training require to
increase labor efficiency.
• Proper storage space is
required when job is over
NEED FOR “SYSTEM”FORMWORK?
• Vertical growth
• Traditionally under mechanized &
labor intensive.
• Excessive use of reinforced
cement concrete.
• High quality surface finishes for
exposed R.C.C work
• Acute shortage of highly skilled &
competent formwork carpenter.
• Modular panel with high flexibility
LOADS AND DESIGN
• Density of concrete
• Slump of concrete
• Rate of pour
• Method of discharge
• Concrete temperature
• Vibration
• Height of discharge
• Dimensions of sections cast
• Reinforcement detail
• Stiffness of forms
• Transfer of loads from floor to floor during construction
Shuttering area of 3 to 5 sq m. is required for placing 1 cu.m of
concrete and formwork therefore contributes a major factor in
the cost, this being 25% to 70% of the total cost.
H-BEAM: BACKBONE OF L&T DOKA SYSTEM
• An engineered timber component
• Manufactured under strict quality control.
• The flanges are made of seasoned chemically
treated timber. The web is made of boiling
water proof plywood and joined with the flange
by unique finger joint.
• H–beams are light, dimensionally stable and
retain their structural properties over a period of
time even after repeated usage.
• The H – beams can be used more than 100
times and it consumes only 40% of timber
volume required.
• H-16 (16 cm depth) and H-20 (20 cm depth),
length varying from 1m to 4m.
– Reduces consumption of timber
– Minimizes work at site
– Consistent in strength.
– Cost ratio per use of H-16 beam to
conventional timber = 1: 3.5
– Economical and long-lasting.
• Components
FLEX SYSTEM
– H-Beam
– Floor Form
– Plywood
– Collapsible Telescopic
Prop
– Four way head
– Removable folding tripod
– Supporting head
– Assembly wedge clamp
FLEX SYSTEM
• Advantages
– Effective for slab and beam formwork upto floor heights of
4.4 m.
– Removable folding tripods make selected individual prop
self standing
– Flexibility in spacing between and heights of individual
props.
– Components are light enough for erecting and dismantling
manually.
– Lapping of standard lengths of H-Beams both in primary
and secondary layers avoid their cutting at site.
– Avoids skilled labour at site
– Enables re-propping and frequent reuse of materials.
– Simple deshuttering operation.
FLEX TABLE FORM
• Components
– H-Beam
– Plywood
– Collapsible Telescopic
Prop
– Table head / U-Head
– Assembly wedge clamp
• Advantages
– Can be transferred as complete set, hence no loss of
components
– Shifting trolley provides superb mobility in horizontal
direction
– Quick to shift, faster construction
– Easy fixing, high labour productivity
– Less props in relation to area
HEAVY DUTY TOWER SYSTEM
• Components
– Basic Frame – size of 0.9 m,
1.2 m, 1.8 m
– Horizontal Brace
– Diagonal Brace
– Foot Plate
– U-Head
– Tower spindle with lever nut
– Beam span 2230
– Beam span extension 1525
– Coupler
– Brace stirrup
– Short prop
HEAVY DUTY TOWER SYSTEM
• Advantages
– High load carrying capacity is
> 25 tons per tower.
– Rigid and stable with minimum
bracings.
– Easy to erect and dismantle
using unskilled labour.
– Tower as a whole can be
shifted using crane and
transport wheels.
– Ideal for heavy floors involving
greater heights.
– Can be converted into stair –
tower with additional standard
components.
– Heights upto 700mm can be
made by spindles at top and
bottom
Open Connection
Close Connection
WALL FORMWORK SYSTEM
• Components
– H - Beam
– CT Prop
– H-Beam Splice
– Foot Adapter
– Steel waler
– Connecting Pin
– Wing Nut
– Tie rod
– Head Adapter
– Anchor Plate
– Lifting Bracket
– Angle Plate
– Adjustable splice plate
– Splice plate
WALL FORMWORK SYSTEM
Lifting Bracket

Timber Plank

Scaffold bracket

Working Platform

Head Adaptor

Steel Waler

Supporting Bracket

Foot Adaptor
WALL FORMWORK SYSTEM
Lifting Bracket

Timber Plank

Scaffold bracket

Working Platform

H-Beam

Steel Waler

Supporting Bracket

Foot Adaptor
CT Prop
• Advantages
– Ideal system for speedy
construction.
– Wall panels can be dismantled and
handled manually.
– Minimizes the number of sheathing
joints.
– Simple shuttering and de-shuttering
operation.
– Wall Formwork panels facilitates
fixing of working platform and
alignment system
WALL FORMWORK SYSTEM USED
IN CEMENT SILO WITH WORKING
PLATFORM AND HEAVY DUTY
TOWER SYSTEM

WALL FORMWORK SYSTEM
USING ALUMINUM PROPS AND
SCAFFOLDING
COLUMN FORMWORK SYSTEM
• Components
– H - Beam
– CT Prop
– H-Beam Splice
– Foot Adapter
– Steel waler
– Connecting Pin
– Wing Nut
– Tie rod
– Head Adapter
– Anchor Plate
– Lifting Bracket
– Angle Plate
– Adjustable splice plate
– Splice plate
COLUMN FORMWORK SYSTEM

Steel Waler Anchor Plate
Tie Rod
H-Beam
Plywood
Working Platform
CT Prop
Scaffold bracket

H-Beam
Plan
CT Prop
Foot Adaptor Supporting Bracket

Section
Typical Column
Formwork System

MODIFIED FORMWORK AS
PER REQUIREMENT (DOKA
+ CONVENTIONAL
FORMWORK)
ACCESS SYSTEM
• Components
– Scaffold Frame – 0.9 m,
1.2 m, 1.8m
– Spring Locked
connected pin
– Foot plate
– Coupler
– Scaffold Coupler
– Scaffold Spindle
– 2H-225 Bracing
– Scaffold Board
TYPICAL HAND SKETCH SHOWING DETAILS OF ACCESS
SCAFFOLDING WORK WITH BRACING TO PERMANENT
STRUCTURE
STAIR TOWER
• Components
– Basic Frame – 1.2 m
– Foot Plate
– Tower spindle with lever nut
– Coupler
– Spring locked connecting pin
– Horizontal Brace
– Scaffolding pipe
– Swivel coupler
– Stair Bracket
– Intermediate Railing
– Inner hand railing
– Connection Angle
– Grid Iron
STAIR TOWER
ELEVATION

STAIRCASE IN HEAVY DUTY
TOWER SYSTEN WITH SAFETY
NET HT. 40 ft.

TOP VIEW
NUCLEAR POWER PLANT FORMWORK :
KAIGA UNIT 3&4
PROJECT BREAK DOWN STRUCTURE
Major Consultants for 1&2
•Stup Consultants Client is itself the designer of the project
•Development consultants pvt. Ltd. as this project is repetition of Kaiga 1 & 2.
•Mecon (eng. & drg. Consultant)
CLIENT: NUCLEAR POWER CORPORATION OF INDIA LTD.
(NPCIL)

CONTRACTOR FOR MAIN CONTRACTOR CONTRACTOR FOR
INTAKE TUNNEL FOR CIVIL WORKS EXCAVATION WORKS

M/S AFCONS
M/S L&T , ECC DIVISION M/S GAMMON INDIA
INFRASTRUCTURE
LTD.

CONTRACTORS FOR CONTRACTORS FOR
MECHANICAL WORKS PUMP HOUSE

M/S BHEL M/S EPCIL(ENGG.
PROJECTS INDIA LTD.)

SUB CONTRACTOR FOR SUB CONTRACTOR FOR SUB CONTRACTOR FOR
TB3,TB4,SRPH,FWPH FABRICATION AND FIXING MACHINARY & EQUIPMEN
OF EP’S SUPPLY
M/S IVRCL (I. VENKAT •M/S NSG FABRICATION
REDDY CONSTRUCTION •M/S SUVARNA M/S SETHIA EQUIPMENT
LTD. FABRICATION
• JOB: Construction of main plant civil works package II for Kaiga
unit 3 & 4.
• AIM: Generation of power using stem from PHWR
type nuclear reactor .
• PROJECT TYPE : Infrastructure
• CONTRACT TYPE: Item rate contract
• CLIENTS: Nuclear power corporation of India ltd.
(NPCIL)
Kaiga Atomic Power Project 1,2,3&4
Post: Kaiga,Karnatka – 581400
• CONTRACTOR: Gammon India Ltd.
Civil Engineers and Contractors
Gammon House
Veer Sarvarkar Marg,Mumbai – 400025
• PROJECT COST: 254.82 Crores (for civil works only)
• CONTRACT PERIOD: 56 Months (including monsoon)
• STARTING DATE: 1st October 2001
• EXPECTED COMPLITION DATE: 30th June 2006
• SCHEDULED COMPLITION DATE: 40 Months (16 months Or earlier)
• DEFECT LIABILITY PERIOD: 12 Months
• PLANT AREA: 25 Hectare
• SITE AREA: 200 X 200 m2
FORMWORK OF OUTER CONTAINMENT WALL
FROM EL. 93.870 TO EL 96.07 OF RB3
THANK
YOU!!!!!!!!!!!!!!