IRC: 87-1984 GUIDELINES FOR THE DESIGN AND ERECTION OF FALSEWORK FOR ROAD BRIDGES THE INDIAN ROADS CONGRESS 1996IRC: 87.1984 GUIDE LINES FOR THE DESIGN AND ERECTION OF FALSEWORK FOR ROAD BRIDGES Published by THE INDIAN ROADS CONGRESS Janmagar House, Shahjaban Road, ‘New Delhi-110 011 1996 Price Re, 36 (Ptus packing & postage)IRC 87-1984 IRC : 87-1984 First Published March, 1984 Reprinted : August, 1996 CONTENTS Clause No Page No. Introduction 1 1. Scope : 1 2. Definitions : 2 3. Materials ‘4 34. General 4 32, Specifications for Materials 5 3.3. New Materials 8 34, Formwork Accessories 8 3. Form Coatings or Release Agents and Sealants for Form 8 (Rights of Publication and of Translation are reserved) oo 5 4.1, General 9 42. Loads 10 43. Permissible Stresses 13 44, Overturning 4 4.5. Deflection Limits 4 4.6. Analysis 4 4.7. Lateral and Diagonal Bracings 15 48. Shores a 45 49. Proprietary tems 16 4.10, Foundation of Falsework 16 4.11, Special requirements for Prestressed Concrete : 7 4:12, Common Deficiencies in design ” 5. Plans 18 6. Site Operations 18 64, General é 8 62. Erection : 19 63. Concreting Operations and Application of Loads 21 Printed at M/s, Sagar Printers and Publishers 64, Removal of Formwork 2 "New Delhi-110003 (1000 copies)IRC : 87-1984, 65. Precautions for Special Structures 66. Re-use and Maintenance of Formwork 6.1. Check for Workmanship Special Formwork J. Slip Forms 7.2. Travelling Forms 73. Extreme Weather Condition Trusses or Girders used as Falsework Appendix 1: Information to be supplied by manufacturers of proprietary systems .. Appendix 2: Typical connection details of — falsework irc: 71984 GUIDELINES FOR THE DESIGN AND ERECTION OF FALSEWORK FOR ROAD BRIDGES INTRODUCTION wos et ofthe “Guidelines for the Design and Erection of (wongonntk for Road Bridges’ was prepared by a Subcoe etic. (Pergonnel given below) of the Bridges Committee and war eos bz, theam ia their meetings held on the 23rd, 24th and 25th Meee Bridges Comer eeeniatt of, the Guidelines were approved Sy ins Pewites Committee in their meetings held on the athe aise February, 29th & 30th December, 1981 and 6th March, tees G. Venkatesuiu Convenor SG Motwani “ Member-Seeretary KD. Balt ‘Rep of Ms, Gammon (India) Led. (S.8. Sivaswamys Rep of Ups La (Bijendra Singh) Rep. of Mis. Indian Plywood ‘Manufacturing Cow Ltd, AD. Narain Bombay (Lt. Col Gi. Singh) KK Suryanarayana Rao Rep. of NBC. (AL. Torsha) PS. Sandhaviata Rep. of CAL (EM: Menon}, ahi a8 Director General (Road Developmen) and Add, Secret toi ove of aie sea a These guidelines were Approved by the Executive Committee ‘moangit mecting held on 21st July, 1983 and by the Counce eee, {Ogth meeting held at Pondicherry on 21st August, 13t5 subject red by the Bridges Committee in thei Ihi on 16th December, 1983 and. theIRC: 87-1984 The guidelines prescribe only the minimum requirements and are to be supplemented by design judgement andexperienes 2. DEFINITIONS For the purpose of these guidelines, the following definitions shall apply : 2.1. Base Plate A device used to transfer the vertical load from a structural member to its foundation or foundation structure element ia such a ‘way as to distribute the load. 2.2. Bay Length The distance between the centre lines of two adjacent shores. 23. Blinding A layer of lean concrete 50 to 100 mm thick, put down on soil to seal it and provide a clean bed for construction wos, 2.4. Bracing ‘The system of members (diagonal and horizontal) which acts in compression or tension and stiffens a frame against deformation’ 2.5. Coupler or Clamp A device for connecting together the component parts of tubular shores and bracings. 2.6, Dead Load The self weight of a member being designed or analysed, 2.7. Falsework (The total temporary structure system including the formwork for the permanent structure during erection and until it booms self supporting, 2.8. Forkhead A‘U"-shaped housing to take joists or stringers, 2.9. Formwork/Forms A part of the falsework used as mould for the poured con: 2 IRC: 87.1985 Siiesindt Gotsists of the sheeting and its immediate supporting or stiffening members, . - . 2.10. Frame (eutattested principal unit of falsework made from timber or Steel (tubular or rolled steel sections) 211. Grade Stress The appropriate safe Working stress level of timber, 2.12, Guard Rail or Hand Rail exposed ide of ets “reent erans ee nse edge or losing their balance. 213, ite The height of concrete formed and cast in one pour, 2.14, Load Bearing Member toag, MY SOMPONERE Of asructure Which is directly subjected to 2.15. Prop/Shore Tadlvidval vertical or inclined member used to support loads, 2.16. Resboring or Repropping 4 {gstem used during the construction operation in which the I Shores are removed and replaced in @ planned Sequence to avoid any damage to partially cured concrete. 2.17. Seaffold/Seaffolding ‘Jay temporary elevated platform and its supporting structure Contextor aeberting workmen or materials oF bothtasd we trembere, “He, guidelines is deemed to comprise wooden rats embers, It includes similarly constructed means of vcs and egress. 2.18. Shim & hin piece, usually, of wood, metal or stone’ used for adjust ing the formwork. 3IRC 87.1984 2.19. Shock Load ‘The load imparted to.a structure due to impact of material. 2.20, Sill or Sole Plate A footing or bearing (usually of wood) which distributes the vertical shoring loads to the ground or slab below. 2.21, Strut A member in compression, 2.22, Stud A vertical or horizontal stiffener fixed to the back of the form sheeting. 2.23, Superimposed Load or Imposed Load Any load that a member is required to support in addition to its on self weight. It includes loads such as that of concrete, forming material, faisework material, workmen, equipment and wind forces, etc. 2.24. Tier A unit or frame or shore erected one above another in a vertical direction. 2.25. Transom A cross beam or horizontal scaffold tube. 2.26. Wedge A piece of strong timber or metal which tapers in its. length and is used to adjust elevation or line to tighten or release form= work. Folding wedges comprise a pair of wedges laid one above the other with thiekends apart. 2.27. Yoke Ina vertical slip form, a yoke in the form of inverted which carries the wall forms and is itself carried and raised by a Jack or a screw arrangement, 3. MATERIALS 3.1. General The permitted materials for falsework in the context 4 IRC ; 87-1984 Graserese, Buidelines are timber, steel, plywood, concrete and 3.2, Specification for Materials fill the, materials shall conform to the specified quali consistant with the intended purpose and actual she conditioes applicable. Where materials or components and theit uses are covered. by existing IS or IRC Standards as shown in ‘Table 1, conformity with them subject to the satisfaction of supplementary Tequirements, if any, arising out of these guidelines shall be ensured. Tame 1 Material | Principal use | Minimum size [Specification Rema | 2nd den lestesoures | Oo @ e a oO Tinker Form 18:88 Soft woods of scatfolding, Rook are" recomended for foram ees fay dt aber tres eee then becomes versa geen inber nif cutand wap sing hot sean (9 For for deck to, beam des and omer erica Mites 250m os Gi Beam soit 50mm Colummatiss Soman ston Gi) Prope 75 100 mm es (9) Balls for ores 100 mm dia rorbrcings "99mm dia As. “IS : 883 Code of Practice for Use of Structural Timber in Building, 5IRC: 87-1984 IRC: 87-1988 o @ o o © o_ @ OS One! Farm work cme (b) Ply. | Formsand 6 mm 1S : 4980" Plywood Poneais such wood Form linings provides ange Plates, prop, Sheeting and dea of joint Frames asseso- panels 2mm free smooth Flee and trestes ete, Concrete aurface, Civ) Clasps isrrme@ easy in handling, Couplers for fight wet, tubular fexibie oF use, centering capacity to with: © Atm Lisht weight Manufac. Stand hot and um pinelsand turer's fold climates, no Alloys forming systems data Shrinkage owing sad capping oF alewor ‘yng high (©) Fibre Precast concrete Manufac- This material isa resistance to Glass construction turers" gle bre rene Iinpaet oad and {nd architectural sata” forced piace concrete roduc, excelent East concrete Surfaces cn be ; moulded t0 any (©) Steel) Sheet Plate Forms and Form Steel forms ean Shape without ‘ geste Bases ire ror —— (0 Prens 37mm i) Rolled Form supports Steel framing and () Asbes- Column forms Usually left in Scatlons and shoring & ISasg@juseyraming« fon Sad duct formers position and tubes framiag, shoring ‘ eement provides the fished surface (Lami rue column Manufac © gogtes Pressed for small ducts data 503506 mm Paper, i fate tubes 50x6 mm (card (iy tubes Board) 40 mm dia @ Hard Form panels and —do— somina Bore bere Ga ‘sth wal ‘minions 12 mm thickness Tiniag tisk 405mm © Plats: Formas, ~do~ (i) Proprietary Forms ean be Design data to be Folyete for decorative Systems” Sbeained Tor bialned from ee, Somer ‘oid ster ietnutitre Polyeus- ‘ectangular or of the pro i polygonal shapes, systems, oe on = de 11 IS 4980 Specification for Plywood for Concrete Shutting work (4 Rubber Form lining to 4,18 22 Speciation for Structural Steel (Seemeseg gad void ation for 715 : 2062 Speciation for Structural Steel (welaineccoaes 5 Bl Spectteation for Structural Stee (High Gehegy 1977 Specication for Structural Stel High Sak Tit Speci Tubes for Structural purposes. 6 TormsIRC 871984 3.3. New Materials Several new materials like aluminium alloys, fibre glass, asbestos cement, plastics and rubber, etc, are now available Wl can be used for falsework. As ‘these materials are not yet in common use, it shall not be interpreted to exclude the use of any such, materials which can mest qualiy and safety requirements for the work. In the designs in which these new materials. are used, the manufacturer's specifications and data shall be adopted after tests are conducted on them to verify the parameters, if necessary 3.4. Formwork Accessories For the design of form ties, form anchors and form hangers permissible stress shall conform to the relevant standards as well as design data based on test evidence published by the manufacturers. 3.4.1. Form ties : A form tie is a tensile unit adopted for holding concrete forms against the active pressure of freshly placed plastic concrete. Form ties. are also. manufactured part of pro Brietary system. 3.4.2, Form anchors: Form anchors are devices used in the securing of formwork to previously placed concrete of adequate strength. The devices normally are embedded in the concrete during placement. Actual load carrying capacity of the anchors depends on the strength of concrete in which they are embedded, the area of contact between the concrete and anchor and the depth of embedment. Manufacturers also publish design data and test information to assist in the selection of proper form anchor devices. 3.4.3. Form hangers: Form hangers are often used to sts pend formwork from a supporting structure. 3.5. orm Coatings or Release Agents and Sealants for Formwork 3.5.1. Form coatings: Form coatings or sealants are usually applied to contact surface either during manufacture of in the field to Serve one or more of the following purposes: (@) 10 seal the contact surface and joints from intrusion of moisture or {oss of moisture and cement slurty. () to alter the texture of the contact surface. (6) to improve the durability of the contact surface. (@) to facilitate release of form from concrete during stripping. 3.5.2. Release agents: Form release agents are applied to form contact surfaces to prevent bond and thus facilitate stripping. 8 TRC : 87-1984 They may be applied permanently to form materials during manufacture or in the field or may be applied to. the form. before each use. The release agents. shall be checked for compatibility With form surfaces, plastic concrete including admixtures and requirements for the application of further materials to the hardened concrete. They shall be kept off construction joints surfaces and reinforcing steel by applying before the teinforcement is laid. “Care shall be taken to wasure that excessive application of release agent does not cause staining of concrete surface or retard curing. Where exposed aggregate work or other type of concrete surface finish is desired, release agents may be designed. suitably. 3.5.3. Manufacturer’s recommendations: Manufacturer's reco- mmendations shall be followed in the use of coatings, sealants and release agents, but independent investigation of their’ performance is recommended before use. 3.5.4. Form insulation: These are usually used for prote- ction of concrete in cold weather. These sball be used as per manufacturer's recommendations. 3.55. Sealants: In order to get smooth concrete surface finish and prevent escape of cement slurry, use of laminated tar Paper or similar sealant can be permitted. 3.5.6, Laminated tar paper (craft paper): These are_ mostly used to give a smooth surface and to prevent leakage of cement slurry. ‘These shall be used as per manufacturer's. recommen jations, 4. DESIGN 4.1. General 4.1.1. Falsework shall be designed to meet the requirements of the permanent structure, taking into account the actual conditions of materials, environment and site conditions. Methods of easy dismantaling and erection shall be catered for. 4.1.2, Falsework may be designed in accordance with relevant IRC Codes in force for design of permanent structures unless otherwise mentioned herein, 4.1.3. Careful attention shall be paid to the detailing of connections and function with a view to avoid gross errors leading to significant damage or failure. It shall be ensured that local 9IRC: 87-1986 failures do not lead to progressive collapse involving the entire structure. 4.2. Loads 4.2.1. Falsework shall be designed to cater for the vertical, horizontal and other loads as specified in the subsequent clauses. 4.2.2. Vertical loads: Vertical loads shall comprise (a) Dead oad, and (b) Superimposed load. 4.2.2.1. Dead load (@) Dead oad. shall include the self weights ofthe falsework structures including formwork. (b) Any ancillary temporary work connected to and supported by the falsework structure. (© Permanent structure supported by the falsework. Self weights shall be determined according to clause 205 of IRC except for the following items for which the unit» weights given in clause 4.2.2.1.1. shall apply. 4.2.2.1.1. The following unit weights shall be adopted in the absence of actual measurements: (a) Wet concrete including reinforcement 20 26 KNfeat () Timber (soft wood) 6KNim* (©) Formwork (sheeting main and secondary bearers) ... Actual weight (@) Scaffold tube 45Nim For falsework composed of scaffold tube fittings, the addi- tional weight of fittings may be estimated for by increasing the self Similely, in the case. of falsework. bul with fabcatee frames, the addtional weight of fttings may be estimated at Sper cent of the total weight of the frames and bracings. 4.2.2.2. Superimposed londs 42, Superimposed loads shall include the following : (@) Construction personnel (b) Plant and equipment including the impact and surge— Special consideration shall be given to items of plant which cause vibration and_to the effect on formwork of external bolt on vibra- tors and prestressing equipment. Large horizontal forces may 10 IRC : 87.1984 develop in pumped concrete pipe runs though surcharge will usually be smaller. The pipes shall be adequately anchored, specially at bends and the effect of blowing out the line shall also be considered. (c) Stacking of meterials—This normally occurs from stor- ‘age of hollow pots and reinforcement on the formwork prior to concreting. If there is likelihood that formwork will be used. for substantial storage of material, this shall be designed for and clearly indicated on the drawings, (4) Surcharge on concrete—This is of particular importance when the formwork has been designed to carry thin slabs of co grete, as it is common practice initially to deposit the concrete in heaps. (c) Impact due to deposition of conerete—This can be due to the deposition of concrete from over-head skips, but has generally @ local influence. Where formwork is particularly susceptible to this ‘type of over-load, and even greater general superimposed loads shall be used. However, deflection is frequently “the Fuling design criteria and a temporary over load which causes only teme orary excess deftection may be permissible. (f) Prestressing losds—The forces and deformation of the concrete associated with prestressing are often transferred to the supporting falsework, Allowance shall be made in the falsework design to accommodate either the force or the movement involved. 4.2.2.2.2. Uniformally distributed load of 3.6 N/m? of the forms area may be assumed to cater for the superimposed loads except in specified cases where actual estimation of individual elements shail be done, 4.2.3, Lateral londs : The lateral loads shall comprise : (a) Lateral pressure of fresh concrete (by Environmental loads (© Miscellaneous 4.2.3.1, Lateral pressure of fresh concrete 4.2.3.1.1, The factors effecting lateral pressure on forms are: (a) Density of concrete—Denser concrete increases the hydrostatic pressure, uIRC: 87-1984 (0) | Rate of placing-—The maximum lateral pressure is _pro- Portionate to the rate of placing, upto a limit equal to the full. hurd Pressure. (¢) | Vibration—Internal vibration results in increase of late- ral pressure locally. (4) Temperature of concrete—Higher lat from low temperature effecting the setting time, al pressure results (6) Slump—Concrete with high slump will cause larger lateral pressure. (1) | Method of discharge and compaction—If the concrete is Placed by pumps, the lateral pressure will decrease, (2). Width and depth of section—For thicker walls or columns ing Pressure may be reduced due to arching effects. The dept of the section influences the hydro-static pressure. 4.2.3.1.2. In general a minimum value of 20 kN/m? shall be adopted in the design. This value is valid for the tate of ive of foncrete at Im/h at 25°C and sump 40 mm without adminwres 1a case of significant differences, specialised literature may be referred to, 4.2.3.2. Environmental loads 423.21, | Wind—False work shall be designed for the same loads as specified for the permanent structures, 4232.2. Water—Where it is necessary for falsework, sup- Ports to be placed in flowing water, the effect of the forces caused by the flow shall be considered. These will include (@) Water forces (©) Forces from floating det The supports shall be protected against (b) above by provi- sion of fenders and cut waters, foundations shall be well protected against the effect of scour. 42.3.3. Miscellaneous loads : Other horizontal forces may result in from the following cases and may be catered for wherever appropriate. (@) Movements of the permanent structures imposed on 12 IRC: S798 He falsework due to thermal or other effects like post tensioning operations, (0) External ties and anchorages L234, Design values of total lateral load : Certain horizone wipforees are identibable and can be calculated but whine may be 2 ta tts8h value of the total lateral load however shall not be les than 3 per cent of the total design vertical load Ties Point farabplication of tne loading may be assumed at ave sons of the formwork, 4.3, Permissible Stresses Sig Att, Permissible stresses shall not exceed the basic values specified in relevant codes for permanent sticng. (a) Timber—The _permissibi form to IS : 883 or IS 3629, le stresses in timber shall con« (2) , Steel—The permissible stresses shall be those as recom= Tree a MIRG 24 a8 appropriate to the steel bemg “asc oy the use to which it is put. (©) Tubular seetions—Permissible stresses in tubular sections shall be those as recommended in IS : 806, a (4) Masonry —The permissible stresses shall be th recommended in IRC 40" n! ] (© Other materials—Where material chosen’ for the false ayy fe ober than those mentioned above, the permissible suse Ta pec etgke, a8 Fecommended by the manufacturer alee TAF Anover stress of 334 per cent shall be permitted for Panay, (1 in 40) out of plumb. In case any of the following defects are noticed, prop may be set aside, discarded or returned to workshops for depot foF attention or scrap : 20 IRC: 87-1984 (A tube with a bend, erease or any noticeable lack of straightness i) A tube with more than superficial corrosion, ii) A bent head or bate plate. ‘An incorrect or damaged correcting pin. 6.3. Concreting Operations and the Application of Loads 6.3.1, Points for check before and during these operations are: ) Whether proper pen O Nasbeen acoraed (ii) Whether the reinforcement and falsework have been checked ? (il) Whether the forms are clean and free from wood.shavngs, eit te? 0) Whether form i has been applied ? Form oil should be avoided for concrete surfaces on which plastering 10° be: done: ‘om ase surfaces, whitewash is desirable. I form oils applied, W should eo shepked| that form oil not applied or splashed eaflesy othe reinforcement or prestessing tendon and anghomsges (©) Where camber has been provided, the free (top) surface of the concrete should never be Hnished fat but shuld alse bs cassbered to the same exten asthe form, (i) Whether all forms are mortac tight ? (vi) Whether the sequence snd rate of concreting that i, of placement is as er the design oriet? * " (iil) Whether all precautions have been taken to prevent accidental impact and scouring/tooding of foundations * (x) Whether adequate precautions have Been taken to Keep unnecessary materais away from the falbework? : - (3) Whether adequate access ramps ete. in the correct positions have been provided for the smooth flow of men, materials had machines 3 (Gi) Whether the forms are inthe correct position in space and adequs- {ely braced so remain there and the forme are dintensionaly aceate {0 produce finished concrete of the requited dimensions? ‘The props and bracings shall be watched during. the placement of {ouerete and its vibration and any members whith may tend le work loose ‘or ‘wedges which shift should be attended (on agreed system of communication between the man below. and the mies ia charge of conereting operations should be established so that conerer ting éan be stopped instantly if at alle Becomes nocesary wo do sae i (ii) Platforms forthe movement of workers and mechanised. conercte Doggies (used in large works) shall be separate and should not piace load upon the reinforcing see. It this s unavoidable, ste) che shall "e placed under" the. reinforcement at wlequate spacing vo prevent deformation of the reinforcement iv) Arrangements for field adjustments and_ constant inspections of forms, ‘shores and foundations ‘dutiag. placing of concrete both by supervising 88 well as construction agents” (0: be ‘ensured (step 21 fon to commence the placement of concreteIRC : 87-1984 leaks, tightening wedges, and clamps, to adjust shores and for timely Action against distufbances, et). 6.4, Removal of Formwork 6.4 1. Forms shall not be struck off until the concrete has reached a strength at least twice the stress to which the concrete may be subjected at the time of removal of formwork. The strength referred to shall be that of concrete using the same cement and aggregates with the same proportions and cured under condi- tions “of temperature and moisture similar to those existing on the work Where possible, the formwork shall be left longer as it would assist the curing. Proper precautions shall be taken to allow for the decrease in the rate of hardening ‘of concrete that ‘occurs during cold weather. Note 1; In normal circumstances and where ordinary Portland cement is used, forms may generally be removed after the expiry of the following peroids : (@) Walls, columns and vertical 24.0 48 hours as_may be decided by Taoey ofall stracturaly the Engineers Chae members (©) Slabs (props left under) 3 days (©) Beams and arches softs (rope lett onde Taays (4) Removal of props under S slabs Pros ‘7-14 days (2) Removal of props under © Neti and aches 1421 days For other cements, the stripping time recommended for ordinary Portland cement may be suitably modified. cre Thao of rp ol dey n,n, al now Tegra rn aan cae SOLIS Caaicea, 6.4.2, Falsework shall be gradually and_uniformly lowered in such a manner so as to avoid any shock or vibration of injurious stresses in any part of the structure. 6.4.3. Immediately after removal of the formwork, the concrete shall be carefully inspected, Defects, if any, shall be made good as soon as practicable. 6.4.4, Where the side shutters also support the fiange of the 2 IRC: 87.1986 T-Beam, such shutters shall be removed only after the flange concrete attains sufficient maturity. 6.4.5. For prestressed units, the side forms shall be released as early as possible after 9 hours, but within 24 hours, at the latest, and the sofit forms shall permit without restraint deformation of the member when prestress is applied. Form supports and. soffit forms for cast-in-situ members shall not be removed until sufficient prestress has been applied to carry the dead load, any formwork Supported by the member and anticipated construction loads. 6.4.6. All fromwork shall be removed without impact or shock likely to damage the concrete. Removal operations shall be carried out in proper sequence so that the structure is not subjected fo excessive or eccentric loads. Soffit fromvwork shall not be allowed to fall to the level below (a practice known as'erash Striking’) but shall be lowered in a controlled manner to prevent probable damage to structure as well as formwork. 6.4.7. Where the shape of the member is such that the form- work had re-entrant angles, the formwork shall be removed as soon 88 possible after the eoncrete has set to avoid shrinkage eracks “due to the restraint, 6.4.8. Where internal metal parts are permitted, they or their removable parts shall be extracted without causing any damage to the concrete and remaining holes filled with mortar, ‘No permanently embedded metal part shall have less than 25 mm cover to the finished concrete surface. 6.4.9. Premature release of props to allow soffit formwork to be removed, followed by replacement of the props, is normally advisable only’ when careful control can be exercised. Such Procedures shall be effectively supervised and subject to the approval of the Engineer responsible for the design of the structure. 6.5. Precautions for Special Structures 6.5.1. Prestressed concrete structures : The falsework shall be 0 arranged as to ensure no stress reversal in the permanent member on prestressing. The foundation shall be adequate for the Joads expected to be transferred on prestressing. The falsework shall be set at a higher level to allow for defiection and shortening of the end supports. 23TRC :87-1984 6.5.2. Arch superstructure : The sequence of erection and removal of centering shall be as per the design. Normally wedges should be struck in pairs from the crown outwards to the springings, loosening them gradually without shock to the arch rings. 6.5.3. Marine works : Due provision shall be made for 1g to forces specific to. marine environments such as tides, waves, adverse wind conditions, etc, Timber shuttering or false- work which are likely to be affected by marine borers. shall be avoided and if at all used for very short periods shall be inspected and the material examined at close intervals to detect the presence of these borers. ‘The formwork materials shall be protected aganist corrosion. The frequency of inspection shall be suitably increased. 6.5.4. Composite construction; Falsework of members which are parts of a composite construction shall be erected with due care to ensure proper bearing, rigidity and lightness, to prevent settlement or deflections beyond allowable limits. Wedges, shims, Jacks, etc. should be provided so asto permit adjustment, if required during concreting, 6.5.5. For special structures requiring complicated formwork of the type not already used, it may be desirable to test a mock-up of the scheme to ensure satisfactory results. 6.6, Re-use and Maintenance of Formwork The number of reuses of formwork is entirely the responsibi- lity of the contractor, subject to the condition that it continues to produce the specified result. Forms which are to be reused shall be carefully cleaned and properly repaired between uses. Concrete ‘or mortar film sticking to the form face or the joining surfaces shall be completely removed after each use. When not required for immediate reuse, the formwork materials shall be properly stored. Wooden components in particular shall be protected from adverse weather conditions during storage. Metal components. shall. be cleaned and painted periodically.” Threaded parts shall be oiled sreased after thorough cleaning and removal of dirt or slurry. Free movement of the telescopic components shall be ensured by periodic cleaning/oiling. 6.7. Cheek for Workmanship 6.7.1. Checking shall be thorough and records of checks carried out should be maintained for important works, Checks 24 IRC: 87-1988 should be made at critical stages of erection and it is suggested that checking be done when: (@) the foundation for the falsework is prepared and before vertical members are erected, (®) the falsework strocture has attained a height of one and a half times its Teast plan dimension, (©) the falsework reaches the level of support of formwork, aud (@) immediately before the loads ace applied, 6.1.2. Checking shall be timely and shall never be burried up. Such checking shall be based on a system concept with check lists suitably standardised, The check list ia general shall cater to the following functional areas: (The structure isin accordance with the detailed drawings; (i) The structural dimensions are within agreed tolerances; (li) The foundations are adequate and fully bedded; (Gv) The verticals are true; (0) Beaciags ané tis are provided and properly connected; (Gi) The component materials are free from defects; (si) The planned sequence of conceting is fully understood. and appre ciated, Including placement of concrete ia layers; (iy Facies shall be provided tothe safety supervisor in exercising. his ‘ormal functions; (Gx) The falsework shall be maintained, in a serviceable state until rendered redundant by the maturity of the concrete, (6 In case the timber posts need to be spliced are the ends made square {0 abut against cach otber, (i) Js the splicing done with timber plates and using proper nuts and ‘oits? (iy Are suitabie cleats provided at crossings or junctions of any two members? (sil) Are, proger lateral supports of scantlings sven tothe vertical faces ‘ofthe webs of beams ? (iv) Ig every individual beam supported independeatly right up to the ground level? (0 Whether oop ole, or wbatr hole, cean out holes and tempo: ary openings for placing ‘concrete ‘upto height of opening aa {nspection windows are provided ? (wi) Whether safe scaffold platform is available for workmen to reac forms (xvi) Whether Sittings for form vibrators are provided ? i) Whether, adequate lighting arrangements have been made, if . required ? and 2sIRC: 87-1984 (six) Whether requirements of safety regulations have been met with at the working area’? 7. SPECIAL FORMWORK 7.1. Slipforms 7.1.1. General : Slipforms can be used for vertical structures, fuch as beams, piers and wells etc. Thesesforms are usually moved by jacks riding on steel rods or pipes embedded in or attached to the hardened concrete. The movement of forms may be conti- uous process until the structure is completed or in a phased sequence of finite placements. Slipforms shall be designed, constructed and the sliding operations carried out under the supervision of persons experienced in slipform work. Jacking rods or pipes may be left in place or withdrawn as conditions permit. The design of the yokes must provide for adequate clearance to instal horizontal reinforcing bars and embedments in. their correct locations prior to concreting. For ttallbs of about one metre eight and may be. of timber, plywood or steel. Special care must be taken in building the forms and arranging the jacks so that the forms ‘will drag straight without twist. Forms shall be constructed with a slight batter so that they will be self-clearing as they slide. A range of 6 mm to 8mm ina height of 1 m of form is indicative of current practice, 7.1.2. Sliding operations : The sliding speed is determined by the rate of setting and hardening of the freshly placed concrete, the rate at which ‘the concrete can be supplied, placed and compacted, and the rate at which reinforcement steel can ‘be supplied and fixed. When using ordinary Portland cement, the average sliding speed is in the range of 150 mm — 300 mm per hour. Alignment and plumbness of the structure shall be checked at the beginning and at least once in eight hours of operation, 7.2, ‘Travelling Forms 7.21. Travelling forms consist of formwork mounted on 26 TRC: 87-1984 moveable frames or scaffolding called travellers, After the purpose ofthe formwork is served at one section of the. structure, the forms are released and moved along the structuretto the next secs tion to be concreted, 7.2.2. Travelling forms are suitable for many types of bridges particularly where a number of repetitions are involved, These forms can be used both for members of constant cross section and variable cross section. 7.2.3, Each set of forms and travellers shall be designed for the particular job. Forms are attached to the traveller mounted on wheels, skids, etc, Jacks are generally used for deshuttering and for adjustment to profile at the next section. 7.2.4. Travelling cantilever formwork for cantilever bridges is a particular example of use of travelling forms for bridge deck construction, Such formworks, because of their importance ‘and large loads involved, are designed with the same care as that for s permanent structure, (7.2.5. Cantilever formwork eliminates falsework altogether. The deck is constructed as a series of segments progressively cantilevering out of the pier. The forms are suspended from 4 Structural frame anchored to the already concreted segment of the deck and cantilevering out to sustain the forms forthe next segment, 7.26. The cantilever forms shall be so arranged as to facili- {ate continuous concreting of the entire segment in one operation, Necessary provision shall be made to enable adjustrients in profile to cater io the camber requirements of the bridge deck, 7.3. Extreme Weather Conditions Falsework/Formwork in extreme weather conditions shall require supplemental design and specification depending upon the necessity in each case which are outside the purview of these guidelines, 8. TRUSSES OR GIRDERS USED AS FALSEWORK The design criteria, the permissible stresses and deflection limits shall conform to those specified in IRC : 24.IRC : 87-1984 Appendix-1 (Clause 4.9) INFORMATION TO BE SUPPLIED BY MANUFACTURERS ‘OF PROPRIETARY SYSTEMS General The information which the manufacturer is required to supply shail be in such detail as to obviate unsafe use of the equipment due to the intention of the manufacturer not having been made clear or due to wrong assumptions on the part of the user. Acl.2. The user shall refer unusual problem or problems of erection/assembly not in keeping with the intended use of the equipment, to the manufacturer of the equipment. A+2, Information required Ac2.l. The manufacturers of proprietary systems shall ‘supply the following information : (@) Description of basic functions of eauipment. ) List of items of equipment avaiable, sving range of sizes, spans and ‘ such ke, "with manufacturers identnenion numbers or ether (©) The basis on which the safe sind whether the factor of safety (@) Whether the supplier's data are based on calculations or tests. This shall be clearly” stated as there may be wide variations between results obtained by either method. (©) Instructions for use, and, maintenance, including any points which requlre special atention during erection, eapecaly where seiy is (0 Detaited dimensional information, as follows ( Overall dimensions and depths and widths of members (Line drawings including perspectives and photographs showing Gi) Seif weight. (Gv) Full dimensions of connections and any special positioning arrangements (¥) Sizes of members, including tube diameters and ‘thicknesses of material (01) Any permanent camber built in to the equipment, (vil) Sizes of holes and dimensions giving their positions. 28 rking loads have been determined fn applies t0 collapse or yield. IRC : 87.1984 (Data relating to strength of equipment a follows (0 Average failure toads as determined by tests, (i) Recommended maximum working lads for various conditions Working resistance moments derived from tess (Gv) Workin shear capacities derived from tess, () Recommended factors of safety used in asesing. recommended Toads and defections based oa fest resuls, (Wi Detestions under load together with recommended pre-amber and limiting detections. . (vip If working. loads depend on calculations, working. srsses should be sated,” It defections depend on theoreic! moments offneria or equivalent moments ef inertia Taler than Tots, {hin should be noted: (itp Information on the design of sway bracing against wind and other horizontal loadings: moe ae (ix) Allowable loading relating to maximum extension of ‘bases angjor heads. 29Appendix.2 ‘TYPICAL CONNECTION DETAILS OF FORMWORK cece Fillets inserted to form ‘chamfers sometimes allow grout to infiltrate behind feathered edges and so form bad fins which hhave to be repaired ‘Staggering joints to Tactics fgidlty of formwork (SKETCH NO. 1) (SKETCH NO. 3) Groursighe pits achived “cramping” ation between boards and integra let Folding wedges with aguare Shoulders (SKETCH NO.) 31 (SKETCH NO, 2) 0IRC : 37-1984 ‘Typical details of, struts bearing against runners of blocks (SKETCH NO. 5) Jute or rubber packing oxme used as gaskets to prevent F ‘rout leakage (SKETCH No. 6) ZS Te Rebate in forms to allow tight joint (SKETCH NO. 7) (SKETCH NO. 8) LL, “Typical support arrangements for inclined struts = Ground Typical aivange- ment of fan offset inform work ‘Typical arran- gement of an {inclined shoreIRC: 87-1985 IRC : 871985 Placing of runner in a forkhead TT] Weds (SKETCH NO. 11) (SKETCH NO. 12) 35Elevation Section Bracing to be parallel to ground line Position of bottommost horizontal bracing (SKETCH NO. 13) ‘Timber bearer Forkhead ‘Timber wedge cut to correct angle Forkhead detail at inclined deck (SKETCH NO. 14) 36