DEVELOPMENTS IN FORMWORK

LARSEN & TOUBRO LIMITED

ECC Division
 FORMWORK

• Is a mould or die to create a particular shape

• It may be compared to a “baking tin” in the
shape which the structure is to have, which
holds the concrete in this shape until it has
hardened.
 SYSTEMS FORMWORK
DEFINITION…
A range of pre-engineered Formwork
components which can be freely combined
with each other and used for a variety of
applications
 WHY AT ALL SYSTEM
FORMWORK?
• To ensure quality ,safety , speed

and economy

• Ensured by the use of standard formwork

systems
 • FLEXIBILITY
• EXPERTISE / SKILL
CONVENTIONAL
• REUSE VALUE.
VS • QUALITY OF MATERIALS.
PROPRIETARY • COST OF MATERIALS / MAKING.
• WORKMAN SHIP.
SYSTEMS
• LABOUR PRODUCTIVITY.
• EFFECTIVE PLANNING.
 • SIMPLICITY IN FABRICATION
• EASY TO UNDERSTAND FOR
MERITS OF TRADITIONAL CRAFTSMEN
• VERSATILITY OF COMPONENTS
SYSTEMS • FLEXIBILITY
• SYSTEM FOR ALL MAJOR
FORMWORK APPLICATIONS.
• HIGH PRODUCTIVITY - LESS
SKILL
• QUALITY OF FINISH
 MECHANISATION

• Use of equipment for better end product

• Construction industry under pressures from
deadlines and cost
• Need to resort to faster mode of construction
– solution mechanisation
FORMWORK SYSTEMS

• FOUNDATION FORMWORK
• WALL / COLUMN FORMWORK
• FLEX SYSTEM
• HEAVY DUTY TOWER
• CLIMBING FORMWORK
FOUNDATION FORMWORK

FLOOR FORMS SYSTEM

• timber-steel combination
• easy-to-use
 FLOOR FORMS SYSTEM

APPLICATION IN
FOUNDATION

WHEN TIE RODS ARE NOT USED THE TIE ROD HOLES
IN FLOOR FORMS TO BE PLUGED USING FORM PLUGS
FOUNDATION
FORMWORK
 Doka column formwork

Doka
Framax/Alu-Framax Doka
column formwork RS
universal panels column formwork
Top 50

Doka Doka
column formwork KS column formwork Alu
ST-04-2001e
 Steel walings and
corner connecting plates

Steel waling
WS 10 Top 50
up to 70 x 70 cm
Steel waling
WU 12
up to 120 x 120
ST-13-93e
COLUMN FORMWORK
 LIFTING
BRACKET WORKING
PLATFORM

STD. STEEL
TIE SYSTEM WALER

H16 - BEAM

STEEL WALER ALIGNMENT

12 MM SYSTEM
H-BEAMS PLY

12 MM THK PLY.

PLAN C /S ELEVATION

WALL FORMWORK SYSTEM

WALL FORMWORK
 The Doka Floor System
Dokaflex 1-2-4 Heavy Duty Tower
system
Doka load-bearing
Dokaflex tables Staxo

Hand

Hand,
crane
Hand,
Crane
crane
D4-35-99e
 DOKA-FLEX 1-2-4
• For slab and beam floor up to floor
heights of 4.4 m
• Removable folding tripods make
selected individual props self-standing
• Flexibility in spacing between and
heights of individual props
• Enables re-propping and frequent reuse
of materials
FLEX SYSTEM
CONSTRUCTION OF RC FLOOR
USING FLEX SYSTEM
TYPICAL ARRANGEMENT OF L&T-DOKA FLEX SYSTEM
FOR INCLINED R.C.FLOORS

FILLER PANEL

H-16 BEAM (SEC.)

FOURWAY 12 MM PLY.
HEAD
TIMBER
PACKING

H-16 BEAM
CT PROP (PRI.)

TRIPOD
TYPICAL ARRANGEMENT OF L&T-DOKA FLEX SYSTEM

12 MM PLY
AS SHEATHING
H-16 BEAMS (SEC)

H-16 BEAMS
FOURWAY (PRIMARY)
HEAD
H-16 BEAMS
BEAM (PRIMARY)
FORMING
HEAD CT PROPS

TRIPOD
BEAM FORMING SUPPORT SYSTEM
H-20 BEAM
B.F.S. EXTN.
12 MM THK. PLY BEAM FORMING SUPPORT

19 MM PLY

H-16 BEAM H-20 BEAM

CT PROP FOURWAY HEAD

RE-PROPPING STRIP IN POSITION APPROX.
AT THE CENTRE OF THE SPAN.

PROPS PLACED BELOW

THE RE-PROPPING
STRIP.

RE-PROPPING
STRIP
ALONGWITH
PROPS AT THE
CONSTRUCTION
SITE.
 HEAVY DUTY TOWER
SYSTEM
• Rigid and stable with minimum bracings
• Height adjustment upto 700 mm is made
possible by adjustable Spindles at the top
and bottom
• Easy to erect and dismantle using
unskilled labour
• Tower as a whole can be shifted using
crane or transport device
CONTD..
• Ideal for heavy floors involving great
heights
• Can be converted into stair - tower with
additional standard components
• This system has high flexibility in height
adjustment and arrangement in plan
• HDT can be erected up to 100 m and
load carrying capacity is 25 tons for the
basic tower
TYPICAL ARRANGEMENT OF L&T-DOKA HDT SYSTEM

H-16 BEAMS

BEAM BOTTOM
AND SIDES USING
CONVENTIONAL
SYSTEM

STEEL WALER U-HEAD

SHORT PROPS

H.D.TOWER
SYSTEM FOOT PLATE

TOWER SPINDLE
HEAVY DUTY TOWER
SYSTEM
 HEAVY DUTY TOWER
SYSTEM IN USE AT SANTA
CRUZ AIRPORT
TABLE FORM
USING HDT
CLIMBING FORMWORK 150 F
• Climbing Formwork was used for the
elliptical core portion
• These are usually meant for tall structures
• Stripping of Formwork and repositioning
for next pour consume minimum
operations
• Saves space and equipment time
 CLIMBING FLOOR PROP CT WITH HEAD
ADAPTOR AND FOOT ADAPTOR

FORMWORK

Simple climbing
Formwork CLIMBING BRACKET 150A

SUSPENDED PLATFORM 80A

TRAVELLING CLIMBING FORMWORK SYSTEM

VERTICAL WALER

ROLL BACK SHIFTING OF PANEL

OF SHUTTERS TO NEXT LEVEL USING
CRANE

150F climbing
Formwork
CLIMBING FORMWORK
 ACCESS SCAFFOLDING

• Used for scaffolding purpose up to 40 m

height
• uses lighter frames compared to those in
HDT
 ACCESS SCAFFOLDING
Application
ACCESS SCAFFOLDING
ACCESS SCAFFOLDING
 STAIR TOWER

• Safe and convenient access up to

100 m
• can be handled as a single unit
with a crane
Raysut Cement
Project
- Cement Silo -
at Oman.
NEW FORMWORK
SYSTEMS
 AUTOMATIC CLIMBING
EQUIPMENT SKE-50
Doka automatic climbing scaffold SKE 50:

Lifting capacity:50 KN per unit

Can be inclined up to:+/- 15 Grad

Pouring heights:Variable from 2.5 to 5.5 m

Number of possible working-platform levels:up to 6

Used for stairs and lift cores in high-rise building and

on bridge piers.
 STAGE - 4
STAGE - 3
STAGE - 2
STAGE - 1

Pour the Fix the suspension- Strip out formwork, Raise the
1st shoe, suspended fix the upper climbing scaffold
concrete- climbing-scaffold with suspension-shoe, by hydraulic
step 1st suspension- insert the climbing- power.
platform.pour the 2nd profile.
concrete-step
 STAGE -7
STAGE - 6
STAGE - 5

Assemble the 2nd Strip out formwork, fix the upper Raise climbing-scaffold together
suspension-platform, suspension-shoe, raise and fix with the formwork by hydraulic
close the formwork. Pour the climbing-profile, remove the power, close the formwork. Pour
the 3rd concrete-step. lower suspension-shoe. the 4th concrete-step.
OUTER VIEW OF NATURAL
DRAFT COOLING TOWER
CONSTRUCTED USING
AUTOMATIC CLIMBING
FORMWORK AT NEYVELI,
TAMILNADU
 INSIDE VIEW OF THE
NATURAL DRAFT
COOLING TOWER
CONSTRUCTED USING
AUTOMATIC
CLIMBING SYSTEM AT
NEYVELI, TAMIL NADU
COLUMN FORMWORK SYSTEM
FRAMI SYSTEM
FRAMI IN USE
Pre-engineered Aluminium Formwork
•Generally used for mass housing
•Components are light in weight and hand shifted
•System does not depend on crane
•Components are tailor made to suit to the room dimension
•Large number of repetitions
•Components are corrosion free
•Slabs and walls are cast together
•Investment cost is high and cost per use is low
•Good resale value for the formwork materials (Aluminium)
•Can achieve good accuracy, straightness, verticality, right
angles and levels
PRE-ENGINEERED ALUMINIUM FORMWORK
MIVAN FORMWORK
ASSEMBLED MIVAN FORMWORK
OTHER SYSTEMS
 SLIPFORM
Slipform means a continuously moving form
moving at such a speed that the concrete
when exposed has already achieved enough
strength to support vertical pressure from
concrete still in the form as well as to
withstand lateral pressure caused by jack rod,
wind etc.
Principle of Slipform

 The entire assembly connected with yokes can

be lifted using hydraulic jacks.

 The jack climbs upon the jack rod, which is

located within the wall to be cast.

 The movement of jacks lift the yokes, which in

turn is attached with other components of
shutter assembly.
Types of Slipform

1. Straight slipform.

2. Tapered slipform.

3. Slipform for special applications

Applications of Slipform
 Straight Slipform
 Silos
 Chimneys (cylindrical)
 Water towers
 Central core for office blocks
 Columns

 Tapered Slipform
 Chimneys (conical)
 Ventilation stacks
Slipform for special applications

 Blocks of flats, Lifts & Stairwell

 Bridge piers

 Pre-heater Building

 RCC pylons for boiler supporting structure

 Framed structures with beams and columns

Advantages of Slipform

Accuracy
Monolithic construction
Lends itself to almost any shape in plan
High quality surface finish
Labour saving in long term
Saves formwork materials
Economical above a certain height.
Produces aesthetically pleasing structures
Limitations of Slipform
• Good co-ordination at all levels and site
organization is required.
• Day and night shifts must be organized.
• Operation during unsuitable weather.
• High initial expense.
• Need for 24 hours service facilities (e.g.,
Canteen, material supply, maintenance crews).
• Social problems created by long working hours
SLIPFORM IN
USE AT RPL,
JAMNAGAR
 275M HIGH CHIMNEY FOR
NORTH MADRAS THERMAL PROJECT DAHANU CHIMNEY
CHENNAI.
SCOPE TOWERS, NEW DELHI -
CORE WALL
NATIONAL STOCK EXCHANGE
BUILDING
AT MUMBAI, MAHARASHTRA
ICICI BUILDING AT
MUMBAI.
CEMENT TERMINAL - COLOMBO
BRIDGE PIERS - KONKAN RAILWAY
RAYSUT CEMENT PLANT - OMAN
 THE THREE “Ws” AND ONE
“H” OF TUNNEL FORMS

 TUNNEL FORM IS A FORMWORK SYSTEM

WHAT ? WHERE SLABS & WALLS OF A BUILDING IS
CAST IN A CONTINUOUS POUR USING
ROOM SIZED STRUCTURAL STEEL MOULD.
  STRUCTURAL DESIGN CARRIED OUT
KEEPING IN MIND THE APPLICATION OF
TUNNEL FORM
WHERE ?  REPEATING MODULE OF WALLS AND
SLABS IN PLAN.
 TOTAL NUMBER OF REPETITION POSSIBLE
IS ABOVE THE BREAK-EVEN VALUE.
 AVAILABILITY OF TOWER CRANE.

 IT IS THIS FORMWORK SYSTEM THAT

WHY ? SCORES THE MAXIMUM POINTS ON
VARIOUS ASSESSMENT PARAMETERS
FOR A MULTISTORIED BUILDING
HOW ?

VIEW SHOWING
TUNNEL FORM
SYSTEM OF
CONSTRUCTION
CROSS-SECTION OF TUNNELFORM
 DIFFERENT TYPES OF TUNNEL FORM

SECTRA TUNNELFORM - PORTICO

SECTRA TUNNELFORM
WINDWALL PANEL
 DIFFERENT TYPES OF TUNNEL FORM

SECTRA TUNNELFORM
ROLLING TRACK

OUTINORD TUNNELFORM
HALF TUNNEL
 DIFFERENT TYPES OF TUNNEL FORM

OUTINORD TUNNELFORM
HALF TUNNEL

OUTINORD TUNNELFORM
REPROPPING
PRECAST YARD -TISCO JAMSHEDPUR
FACADE WALL
BLOCK WORK -
SOUTH CITY
BANGALORE
 SUMMARY

• The use of systems Formwork minimises

the time required for erection as well as
deshuttering
• Economises since skilled labour required is
minimum
Contd.….

• Use of equipment enables considerable

reduction in project completion time
• Systems Formwork is more amenable for
pumped concrete
 QUALITY

• The surface appearance of the concrete will

depend on the surface of the Formwork.

 SAFETY
Is ensured if
• Components are light in weight for
handling and placing
• Less making is involved at site
• Loose or hanging components are minimal
• Minimum operations are involved in each
repetition
• working platforms are provided to work at
heights
 SPEED

• Accounts for 60% of the total project time

• Use of standard Formwork enables

considerable reduction in time

 ECONOMY

• Repetitions obtained is much more than that

of conventional Formwork

• Cost effective when more number of

repetitions are obtained