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4/19/2018 1
SYSTEM FORMWORK Larsen and toubro limited
4/19/2018 2
LARSEN & TOUBRO LIMITED
ECC DIVISION
LUDHIANA CITY CENTRE
CONSTRUCTION OF RCC BASEMENT STRUCTURE
By : A.K. Mishra
4/19/2018 3
THE CLIENT: TODAYHOMES AND INFRASTRUCTURE
JOINT VENTURE WITH LUDHIANA IMPROVEMENT TRUST
ARCHITECT: CP KUKREJA AND ASSOCIATES
CONTRACTOR : LARSEN AND TOUBRO LIMITED
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LUDHIANA CITY CENTRE
LOCATED IN HEART OF LUDHIANA
BUILT ON 25 ACRES OF LAND
4 SIDE OPEN PLOT
MAXIMUM NUMBER OF CAR PARKS UNDER ONE ROOF
ONLY DEVELOPMENT OF INDIA WITH 5 STAR HOTEL,SHOPPING MALL,IT/OFFICE SPACE,HEALTH CARE,LIBRARY,MUESEAM UNDER 1 ROOF
BIGGEST ATRIUM:2 LAKH SQUARE FEET
4/19/2018 5
LUDHIANA CITY CENTRECONSTRUCTION OF RCC BASEMENT STRUCTURE
Project Highlights
JOB VALUE : 12400 lacs
DATE OF LOI: 30:1:2006
DATE OF COMMENCEMENT: 15:02:2006
DATE OF COMPLETION: 14:02:2007
DURATION OF
PROJECT : 12 months
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THE WORK
FORMWORK PLANNING AND
DESIGN OF ITS VARIOUS
COMPONENTS
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WHAT IS FORMWORK? FORMWORK IS A MOULD USED TO SHAPE
CONCRETE UNTIL IT ATTAINS SUFFICIENT
STRENGTH TO CARRY ITS OWN WEIGHT
CAN BE ASSEMBLED BY UNSKILLED LABOUR
CONSTITUTES 30% OF THE COST AND
60% OF THE TIME IN CONCRETE
CONSTRUCTION
GOOD FORMWORK RESULTS IN
SPEED,QUALITY,ECONOMY AND SAFETY
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TRADITIONAL APPROACH
BALLIES USED AS SUPPORT FOR
SHUTTERING
UNSAFE AND UNRELIABLE
LOW REUSE VALUE
DOES NOT PRODUCE GOOD QUALITY
CONCRETE
4/19/2018 9
CHOICE OF RIGHT TYPE OF FORMWORK
FORMWORK SHOULD BE ABLE TO BE
DESHUTTERED AND DISMANTLED FAST
SAFETY TO BE IMPROVED BY SITE
PERSONNEL
OVERALL COST SAVINGS
GOOD SURFACE FINISH TO BE ACHIEVED
OPTIMUM STOCK OF FORMWORK FOR SIZE
OF WORKFORCE AND SPECIFIED TIME
SCHEDULE
4/19/2018 10
SYSTEM FORMWORK-L&T
EARLIER CALLED DOKA FORMWORK
INVERSIBLE
FAST ERECTION
MORE STABLE
SAFE IN USE
4/19/2018 11
FORMWORK PLANNINGSTEP1.)
CONFIRMING HQ ON THE NEW JOBS BAGGED
IDENTIFYING TIME AND MATERIALS FOR CONSTRUCTION PROJECT
STEP2.)
FINALIZING FORMWORK MATERIALS REQUIREMENTS FOR THE PROJECT
COLLATE THE REPORTS FROM RUNNING SITES AND CHECK SEPARABILITY FROM OTHER SITES WITHIN THE REGION
SENDING REQUEST FOR TRANSFER OF RESOURCES IF AVAILIBILIY IS CONFIRMED
4/19/2018 12
CONTD….
RECEIVING NEW TARGETS ON
PRODUCTIVITY FROM HQ
COMPARING THE RUNNING
LMP COST FROM THE ACTUAL
IDENTIFYING TRAINING NEEDS
OF STAFF
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COMPONENT DETAILING FOUNDATION FORMWORK
HDT TOWER
SLAB/BEAM FORMWORK
WALL/COLUMN FORMWORK
4/19/2018 14
FOUNDATION FORMWORK
STEEL PANELS OF STANDERED SIZES
MINIMIZE MAKING AT SITE
USE OF VERSATILE COMPONENTS LIKE
STEEL WALERS(2 ISMC BACK 2BACK) AND
ALIGNMENT PROPS
EASY ASSEMBLY WITH DIMENSIONAL
ACCURACY
4/19/2018 15
4/19/2018 16
FOUNDATION FORMWORK MATERIAL CONTD.
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CONTD…
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CONTD….
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AFTER ERECTION
Steel panel
Pipe waler
Alignment
prop
welar
Pipe waler
clamp
4/19/2018 20
HDT TOWER BASIC FRAME
HORIZONTAL BRACE
DIAGNOL BRACE
TAKES LOAD OF 250KN
HIEGHT ADJUSTMENTS UPTO 800MM
POSSIBLE
TRANSPORT DEVICES CAN BE ATTATCHED
4/19/2018 21
COMPONENT DETAILING
4/19/2018 22
CONTD….
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AFTER ERECTION
Coupler and
spring lock pin
Foot plate
Tower
spindle
4/19/2018 24
WALL/COLUMN FORMWORK
SHOP MADE SHUTTER
ACCORDING TO THE HIEGHT OF WALL OR
COLUMN SPLICING CAN BE DONE
ISMC WALERS ARE USED FOR BEARING
4/19/2018 25
COMPONENT DETAILING
4/19/2018 26
CONTD….
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CONTD……
4/19/2018 28
COLUMN FORMWORK WORKING AT 4.8M HIEGHT
4/19/2018 29
COLUMN FORMWORK
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WALL FORMWORK 1.8M HIEGHT
4/19/2018 31
SLAB/BEAM FORMWORK
SHEATHING MEMBER
H-BEAM(SECONDARY MEMBER)
WELAR(PRIMARY MEMBER)
HDT TOWER
4/19/2018 32
AFTER ERECTION
tower
H-beam
Sheathing
welar
4/19/2018 33
DESIGN OF FORMWORK FORMWORK MUST SUPPORT ALL THE
VERTICAL AND LATERAL LOADS
ALL LOADS ARE ASSUMED TO BE
UNIFORMLY DISTRIBUTED
BEAMS SUPPORTED OVER 3 OR MORE
SPANS ARE TAKEN AS CONTINUOUS
APPROXIMATE FORMULAE ARE USED
4/19/2018 34
AN IMPORTANT POINT
SHEATHING SPAN DECIDES H-BEAM SPACING
H-BEAM SPAN DECIDES WALER SPACING
WELAR SPAN DECIDES TOWER SPACING
“SPAN” HERE MEANS THE DISTANCE BETWEEN
TWO REACTION POINTS
4/19/2018 35
DESIGN PROCEDUREEXAMPLE
LOADS TO BE TAKEN
DEAD LOAD(1)
(THICKNESS OF MEMBER*DENSITY OF
CONCRETE)
LIVE LOAD(2)
SELF WEIGHT(3)
DESIGN LOAD,W=(1)+(2)+(3)
4/19/2018 36
DESIGN PROCEDURECHECKS TO BE APPLIED
BENDING MOMENT CONDITION
SHEAR FORCE CONDITION
DEFLECTION CONDITION
THE MINIMUM OF ALL 3 SPANS IS TAKEN AS SPAN FOR THE MEMBER
ACCORDING TO HEIGHT OF WALL OR COLUMN THE REQUIRED LENGTH OF H-BEAM(AN I SECTION )
HIGH STRENGTH TIE SYSTEM BEAR LARGE CONCRETE PRESSURE
4/19/2018 37
DESIGN PROCEDURECONTD….
DESIGN DONE FROM TOP TO BOTTOM
1. SHEATHING MEMBER
2.H-BEAM(SECONDARY MEMBER)
3.WELAR(PRIMARY MEMBER)
HDT TOWER
4/19/2018 38
SELF WEIGHT OF CONCRETE WITH
REINFORCEMENT=25KN/M^3
SELF WEIGHT OF FORMWORK VARIES
BETWEEN 0.5KN/M^2 TO .75KN/M^2
MINIMUM LIVE LOAD =2.5KN/M^2
MINIMUM DESIGN LOAD=5.0 KN/SQM
4/19/2018 39
SHEATHING MEMBER:
END CONDITION ASSUMED TO BE A PROPPED
CANTILEVER
BM=W*L^2/8<=.2KNM/M
SHEAR=5*W*L/8<=6.16KN/M
DEFLECTION=W*L^4/(185*E*I)<=1.852*10^-3M
MINIMUM OF ABOVE THESE 3 SPANS IS TAKEN
AS SPACING BETWEEN H-BEAMS
4/19/2018 40
SECONDARY MEMBER(H BEAM):
END CONDITION IS ASSUMED TO BE SIMPLY
SUPPORTED
LOAD INTENSITY =DESIGN LOAD*SPAN OF
SHEATHING MEMBER
BM=W*L^2/8<=3KNM
SHEAR=W*L/2<=6KN
DEFLECTION=5*W*L^4/(384*E*I)
MINIMUM OF ALL 3 IS TAKEN AS SPAN FOR
H-BEAM
4/19/2018 41
WELAR (PRIMARY MEMBER)
SIMPLY SUPPORTED END CONDITION IS
ASSUMED
NOW WIDTH OF LOADING IS THE SPAN FOR
H-BEAM AND W=DESIGN LOAD*WIDTH OF
LOADING
BM=W*L^2/8<=12.67KNM/M
SHEAR=W*L/2<=103.4KN/M
DEFLECTION=5*W*L^4/(384*E*I)<=6.67*10^-3
MINIMUM OF THESE 3 IS TAKEN AS THE
DISTANCE BETWEEN 2 TOWERS
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4/19/2018 43
DESIGN FOR WALL/COLUMN FORMWORK
CONCRETE EXERTS A FLUID PRESSURE Dh
ON THE FORMWORK
Pmax=
D[C1*R^.5-(C2*K*(H-C1*R^.5)^.5) OR
Dh
whichever is smaller
VALUE OF C1
FOR WALLS=1
FOR COLUMNS=1.5
4/19/2018 44
VALUE OF C2 DEPENDS ON CONSTITUENT
MATERIALS OF CONCRETE
D=WEIGHT DENSITY OF CONCRETE
H=VERTICAL FORM HIEGHT
h=VERTICAL POUR HIEGHT
K=TEMPERATURE COEFFICIENT TAKEN AS
(36/T+16)^2
R=RATE OF RISE M/H
T=TEMPERATURE OF CONCRETE AT PLACING
(degree celsius)
4/19/2018 45
PRESSURE DISTRIBUTION DIAGRAM
H
P max
Pmax/D
4/19/2018 46
DESIGN OF WALER –DESIGNED AS LATERALLY UNSUPPORTED BEAM
SIGMAbc=.66*Fcb*Fy/(Fcb^n+Fy^n)^1/n
Fcb=ELASTIC CRITICAL STRESS(N/MM^2)
Fy= YIELD STRESS OF STEEL IN( N/MM^2)
N=FACTOR TAKEN AS 1.4
Fcb=K1*(X+K2*Y)*C2/C1
PERMISSIBLE SHEAR STRESS=0.4*Fy
PERMISSIBLE DEFLECTION=L(SPAN)/325
BENDING STRESS=M/Z
SHEAR STRESS=F/Aweb
4/19/2018 47
STRIPPING TIME FOR FORMWORK
VERTICAL FORMWORK TO COLUMN, WALL
AND BEAM :16-24HOURS
SOFFIT FORMWORK TO SLABS(PROPS TO BE
REFIXED AFTER REMOVAL OF FORMWOK) :3DAYS
SOFFIT FORMWORK TO BEAMS :7DAYS
4/19/2018 48
SAFETY IN FORMWORK
BEFORE ERECTION OF STEEL FRAME STAGING THOROUGH INSPECTION
DIAGNOL BRACES SHOULD BE IN PROPER POSITION
ALL CONNECTING DEVICES SHOULD BE IN PLACE
BRACING SHOULD BE PROVIDED IF TOWER HEIGHT INCREASES 6M
AT HIEGHTS SAFETY BELTS SHOULD BE USED BY WORKMEN
4/19/2018 49
Ladder Safety
Follow the 4:1 rule when using extension ladders
6 m (20 ft)
1.5 m (5 ft.)
4/19/2018 50
–Erect First Tower – Adjust and ensure the
top level is same. Connect all pin bracing
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Use of lifeline above 2m
4/19/2018 54
LABOUR PRODUCTIVITY
PRODUCTIVITY IS MAXIMUM OUTPUT FROM MINIMUM INPUT
UNITS ARE SQM/MANDAY
WORKING OF 8 HRS=1MANDAY
PRODUCTIVITY=
SHUTTERING AREA ACHIEVED DURING THE MONTH/MANDAYS
4/19/2018 55
MATERIAL PRODUCTIVITY
MATERIAL PRODUCTIVITY IS COMPARED
WITH STANDERED PRODUCTIVITY
STANDERED PRODUCTIVITY CALCULATED
ON THE BASIS OF SHUTTERING AREA
COMPLETED AND KG MONTH PER SQM
TOTAL REQUIRED KG=
SHUTTERING AREA *KG MONTH PER SQM
4/19/2018 56
ACTUAL PRODUCTIVITY IS
TAKEN AS AVERAGE STOCK
LEFT
PRODUCTIVITY IN %=
(ACTUALPRODUCTIVITY/STANDE
RED PRODUCTIVITY)*100
4/19/2018 57
RATE ANALYSIS
ON THE BASIS OF NUMBER OF CARPENTER
KHALASI AND HELPER,NUMBER OF HOURS
OF WORK AND RATE/HR THE TOTAL AMOUNT
IS CALCULATED FOR SHIFTING ,FIXING AND
REMOVING
PRODUCTIVITY IN SQM/MANDAYS IS
CALCULATED
4/19/2018 58
BATCHING OF CONCRETE
PAN TYPE BATCHING PLANT
CAPACITY OF 60M^3/HR
WEIGHED BATCHING
MIXING
TRANSPORTATION
PLACING
4/19/2018 59
THANK YOU
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