PVC STAY IN PLACE FORMWORK SYSTEM

GROUP MEMBERS

DIVYA
KAVYA
BHAVIKA
SRISHTI
MEHR
RITHIK

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

CONCEPT
 SYSTEM MECHANISM

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 STRUCTURAL FRAME MADE OF HOT ROLLED STEEL SECTIONS PREFABRICATED WALL PANELS AND HOT ROLLED SECTIONS

THESE MEMBERS ARE TRANSPORTED ON SITE AND THEN ERECTED AS A FRAMEWORK OF STEEL SECTIONS AND
FITTED PVC PANELS USING CRANES.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 PVC SIP FORMWORK SYSTEM ACT AS PRE-FINISHED WALLS REQUIRING NO FLOOR IS INSTALLED USING DECKING SHEET
PLASTER

ONCE THE FLOOR AND FRAME IS INSTALLED AND ALIGNED, WALL PANELS ARE FIXED AS PER DESIGN ON THE
DECKING FLOOR

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 TYPES OF PANELS

Types of panels are given below: i. Standard single

panels – These panels shall be used for slab shuttering
but may also be used as shuttering option for RCC wall
having thickness of more than 350mm. Double panels
– Double panels shall have inbuilt steel and not require
extra reinforcement. In double panels, the grids shall
be connected by articulated rebar loops and
connectors that fold. These panels are of two types:
(a) Standard double panels shall be of fixed size and
need to be cut on site for openings etc.
(b) Customized double panels from the factory shall
have required cutting for openings as per drawing and
no need to cut on site.
(c) These panels create a monolithic structure as it
allows pouring of walls and slab together.
These panels shall be used for load bearing walls,
retaining walls and shear walls. Insulated Double panel
– These panels shall have an integrated insulation on
the exterior side. The insulated material shall be of
polystyrene or polyurethane of required thickness as
per design.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

ELEMENT AND PANEL ASSEMBLY

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 WALL PANELS BEING FIXED POST ALIGNMENT OF BASIC FRAMEWORK PREFABRICATED PANELS HAVE PROVISIONS FOR SERVICES LIKE CONDUITS
ETC.

ONCE THE WALL PANELS ARE ALSO FIXED, THE CONDUITS ARE FIXED ALONG THE REINFORCEMENT.

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 CONCRETE FILLING INSIDE WALL PANEL CAVITIES FINISHING WORK EXECUTION POST INSTALLMENT OF WALL AND INITIAL
FRAMEWORK

THE FINISHED PRODUCT TAKES LESS TIME IN CONSTRUCTION, AS COMPARED TO CONVENTIONAL. IT ALSO
REQUIRES LESS CURING TIME AND REDUCES WATER REQUIRED (IN CASE OF CONCRETE).

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

FLOORING SYSTEM

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 FLOORING SYSTEM

COMPOSITE FLOOR

Decking sheets are placed upon the galvanised steel section in a direction perpendicular to the section.
These sheets are fixed with shear studs.
The floor slab and the beam beneath acts compositely.
The beam depth are therefore also, less than non composite slabs

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

FLOORING SYSTEM

PRECAST FLOOR

Precast slabs are placed along side the galvanised steel beams. These panels can be fitted in two
ways, one is fitted upon the beam and the second inserted between the flange of the beams.

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 WALL SYSTEMS

● Wall System consists of rigid polyvinyl chloride (PVC) based polymer components that serve as a permanent stay-in-place durable finished
formwork for concrete walls.
● The extruded components slide and interlock together to create continuous formwork with the two faces of the wall connected together by
continuous web members forming hollow rectangular components.
● The web members are punched with oval-shaped cores to allow easy flow of the poured concrete between the components.
● The hollow Wall components are erected and filled with concrete, in situ, to provide a monolithic concrete wall with enhanced curing capacity
due to water entrapment, as the polymer encasement does not allow the concrete to dry prematurely with only the top surface of the wall being
exposed to potential drying.
● The polymer encasement provides crack control vertically and horizontally for the concrete, and provides vertical tension reinforcement thus
increasing the structural strength of the wall.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

WALL SYSTEMS

This system is adaptable to any building design

i.e. residential, commercial, industrial, low and
high rise buildings. Novel Wall is very efficient in
terms of acoustic performance, weather proof
and highly resistant to termites attack, and is
virtually maintenance free.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 ELECTRIC AND PLUMBING DUCTS

The Electric and Plumbing Ducts The electric and

plumbing ducts etc. shall be placed inside the ducts. For
connectors, small openings shall be made in the
expanded metal.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT
USES AND LIMITATIONS

USES

As high capacity vertical and shear load bearing structural walling in

multi-storey construction: the Novel Wall shall be filled with reinforced
concrete suitably designed to resist the combined effect of lateral and
gravity loading.

LIMITATIONS
Limitations for using Novel System on the basis of performance, safety,
geo-climatic Conditions:
● Stay in Place PVC Forms Walls shall need preplanned & installed
MEP/Services for concealed network.
● Door and Window position shall not be changed after pouring of
concrete.
● Erection of panels shall be under supervision of trained staff.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 ASSEMBLY OF WINDOW OPENING

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 DOOR ASSEMBLY

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT
COLUMN ASSEMBLY

COLUMNS AND BEAMS:

Materials: wrought iron(fibrous and resists tensile stresses), cast iron(compressive members) and ,mild steel( all structural
members

Structural steel offers numerous advantages over galvanized steel thanks to its flexible composition. For instance, structural
steel is mostly composed of iron but can also have chromium, carbon, and other metals added to it to adjust for tensile and
shear strength.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

CASE STUDIES
CASE STUDY-1
Demonstration Housing Project at Hyderabad, Telangana
Telengana State Housing Corporation Limited (TSHCL), Hyderabad had allotted 1085
sq.mts. of land at Nirmithi Kendra, Gachibowli, Hyderabad for the Demonstration Housing
Project.
In order to demonstrate different emerging technologies, the Council constructed, two blocks
for 32 Demonstration Houses (G+3) using two different technologies i.e (i) STAY IN PLACE
FORMWORK SYSTEM - Structural Stay In Place Steel Formwork System (16 houses)
and (ii) LIGHT GAUGE STEEL STRUCTURAL SYSTEM (16 houses) under this project as
part of PMAY(U).
The project also includes on-site infrastructure work like internal road, pathways, Septic tank,
external electrification and water supply work, horticulture work, drainage & disposal, etc.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

Project Profile

● No. of houses : 32 (G+3)

● Carpet area of each unit :
38.74 sqm. and 39.50 sqm.
● Built up area of each unit
including common area :
53.18 sqm. and 53.10 sqm.
● Technology: (i) STAY IN
PLACE FORMWORK
SYSTEM - Structural Stay In
Place Steel Formwork
System (16 houses) and (ii)
LIGHT GAUGE STEEL
STRUCTURAL SYSTEM (16
houses)
● Each Unit consists of One
living room, two bedroom,
kitchen and two Bath with
WC.
● Includes Earthquake
Resistant Features.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

Structural Stay In Place Steel Formwork System
This patented structural stay in place formwork system is known as ‘Coffor’ to build load bearing monolithic concrete wall structures based on shear wall concept. The formwork
system comprises of two filtering grids made of rib mesh reinforced by ‘C’ channel vertical stiffeners. The grids are connected by rebar which act as horizontal stiffeners and connector
which act as a shear link. The grids on both faces act as sacrificial formwork in which concrete is poured in-situ.

After the erection of formwork panels in alignment, corners, edges of doors and windows frame are closed with rebar positioning & concrete of required grade is poured in the panels.
The concreting is done with a pump, bucket or with a shovel loader. The inside and outside walls are finished with cement plaster of suitable grade.
The panels are prefabricated according to a structural plan (based on architectural plans) designed by structural engineers.

Light Gauge Steel Structural System

Light Gauge Steel Framed Structures (LGSF) is based on factory made galvanized light gauge steel components, designed as per codal requirements. The system is produced by
cold forming method and assembled as panels at site forming structural steel framework of a building of varying sizes of wall and floor. The assembly is done using special types of
screws and bolts. LGSF is a well-established technology for residential construction in North America, Australia and Japan and is gaining ground in India.

LGSF is typically ideal for one to three storey high buildings, especially for residential and commercial buildings. Due to its flexibility, fast construction and durability, this technology
has great potential for counties like India. LGSF can be combined with composite steel / concrete deck resting on light steel framing stud walls.

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT
18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT
18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT
18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT
18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT
 CASE STUDY-2

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 CASE STUDY-3

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 CASE STUDY-4

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

CASE STUDY- INFERENCES

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 DESIGN
IMPLEMENTATION
INITIAL LEVEL-1
 DESIGN INTERVENTION

MEZZANINE FLOOR
ARCH METAL ROOFING

GIRDER

I SECTION COLUMN
GABLE END

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 PVC WALL PANELS

PVC PROFILES

ft
50

CONCRETE FILL

90ft

REINFORCEMENT
POSITION

GROUND FLOOR DETAIL

This is cement concrete flooring in rich ratio normally 100 to 150 mm thick with nominal reinforcement. The top layer of 10–12 MM thickness is laid with Iron chips or granules mixed with the concrete to
make the top layer more hard. The floor finishing is done with the vacuum dewatered process and the top layer is finished with mechanical trowel finish. This is used in the heavy material factories to
Minimize the damages to floor.

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 OTHER ELEMENTS

ROOF UPVC BI FOLDING DOOR AND WINDOWS

SKYLIGHT

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT

 DESIGN INTERVENTION

18BAR-2BC41P/ADVANCE BUILDING CONSTRUCTION & MATERIALS CONCEPT REPORT