Scaffold Teaching

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Scaffolders are the masters of looking ahead Posted on May 10, 2013 by admin Comments off •In your first few months of scaffolding you realize that scaffolding trains you to think ahead. This is how it works: •You grab 2-4 items, lock them together and carry them on your shoulder with its natural center of gravity •You walk these items to its destination in about 1-2 minutes and place them ready for assembly •On your walk back you think about what area next needs more items and what items to get •On the way back though you notice fellow scaffolders carrying those items so you decide to cart a different scaffold item •You repeat the above process and every time you think ahead at least every 5 minutes •The assembly of the scaffold starts with the forethought of bay positioning and identification of obstacles already done •Once the base is done the next round of scaffold is pumped around the sight, again with constant forethought of what and where scaffold items are needed for topping out Many experienced scaffolders need only a brief word to each other at the beginning of a day and hardly talk about the scaffold because the forethought they get on their return runs to gather more items is enough for most of the day. The rest of the talk and chatter is whatever scaffolders want to. So does this make scaffolders good chess players?

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Scaffold Teaching

Transcript of Scaffold Teaching

Page 1: Scaffold Teaching

Scaffolders are the masters of looking ahead

Posted on May 10, 2013 by admin

Comments off

•In your first few months of scaffolding you realize that scaffolding trains you to think ahead. This is how it works:

•You grab 2-4 items, lock them together and carry them on your shoulder with its natural center of gravity

•You walk these items to its destination in about 1-2 minutes and place them ready for assembly

•On your walk back you think about what area next needs more items and what items to get

•On the way back though you notice fellow scaffolders carrying those items so you decide to cart a different scaffold item

•You repeat the above process and every time you think ahead at least every 5 minutes

•The assembly of the scaffold starts with the forethought of bay positioning and identification of obstacles already done

•Once the base is done the next round of scaffold is pumped around the sight, again with constant forethought of what and where scaffold items are needed for topping out

Many experienced scaffolders need only a brief word to each other at the beginning of a day and hardly talk about the scaffold because the forethought they get on their return runs to gather more items is enough for most of the day. The rest of the talk and chatter is whatever scaffolders want to. So does this make scaffolders good chess players?

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Bracing – Why is it important?

Posted on December 17, 2012 by admin

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Bracing are extra lengths used to add structural strength. They offer strength by resisting against a structure wanting to bend, providing rigidity.

Modular scaffold like Kwikstage and Cuplok have diagonal bracing to resist horizontal forces such as wind. Do not think that wind is irrelevant, especially when shade clothe is used to cover the scaffold, as this will greatly increase the surface area of wind force, like a boat sail. Bracing will connect from node to node across a bay normally covering a height of 2 to 3 metres depending of the length of the bay. Successive braces are used from top to bottom, normally in a zig-zag fashion, reaching all the way to reach above the top working deck. This is done every fourth bay, but some systems will allow up to every eighth bay.

How the forces work on scaffold is this: when a force is exerted on a scaffold, such as wind, the scaffold verticals or standards will want to bend one way or the other, horizontals or ledgers moving with it. Scaffold in general is quite rigid but not at its nodes where they connect. If the nodes where welded together instead of hooked or wedged it would be a different story. However, when diagonal bracing is in place, those horizontal forces change direction through the diagonal direction of the brace and dispersed in a vertical direction through the verticals or standards down to the ground, causing rigidity. This is why bracing is important.

Where scaffold is used as falsework in a birdcage design, put together like a chessboard layout, bracing should be on all sides and each bay with bracing should be braced through to the other side of the falsework. Bracing goes from the bottom node to the very top node, ideally from the bottom jack to the top fork head or U-head. The best use of bracing is connecting at the nodes where the ledgers connect. Bracing is critical in falsework and must not be neglected. It can be really tedious to install but be mindful that by far, lack of bracing is the primary reason for failed falsework.

So bracing is important because it keeps scaffolding stiff and rigid, a critical facet of any structure.

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Base Jack

Posted on August 9, 2012 by admin

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Screw Jack: A foundation for 48.3mm diameter tubular scaffold. Adjustable wing nut on a 38mm outer diameter and 36mm inner diameter (2mm deep thread) threaded steel rod and a 150mm squared base plate welded on the bottom.

Weight: 6.2kg / 13.6lb (based on dimension below);

Dimension: 0.605m (height);

Note: Base Jacks can come in different weights and dimensions according to the manufacturer. The above description and figures are typical only.

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Dead Load

Posted on February 25, 2013 by admin

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What is Dead Load? It is the force or weight an object has, generally known as self-weight. In scaffolding, it is the self-weight of individual or collection of gear.

In a constructed scaffold, dead load is calculated through a standard leg. The dead load would include the weight of the standards, half the weight of ledgers and transoms connected to that standard leg, a quarter of the weight of internal bay boards, half the weight of hopup boards, the weight of hopups connected and half the weight of mesh guards. The full weights are items solely connected to that standard leg. Half weights are from items whose weight is shared between two legs. Quarter weights are from items shared between four standard legs. Add all those weights together to get a dead load.

The dead load is calculated in kilonewtons(kN). 1 kilonewton equals 100 kilograms, represented as 1kN=100kg. So a weight of 630kg is equal to 6.3kN.

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Scaffold Prejudice

Posted on July 19, 2012 by admin

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When our view is based on a limited or flawed knowledge, prejudice can stop us from discovering more ideas and better solutions. This does of course apply to scaffolding.

When I first started out scaffolding, Kwikstage scaffold was used. I came to enjoy scaffolding very quickly due to the hard work ethic, the physical strength I gained and the satisfaction I felt in ensuring a safe workplace. However, my enjoyment of scaffolding become linked almost permanently with Kwikstage scaffold and when I was first exposed to Cuplok scaffold I was quick to find fault with it due to my prejudice. I saw it as difficult to carry, a pain to put together and unsafe to use. This prejudice remained for several years.

This all changed when I started scaffold design where I learned many benefits of Cuplok over Kwikstage. Cuplok certainly comes to its own when designing falsework to support the pouring of concrete slabs and headstocks. Cuplok is about 30% stronger than Kwikstage. This allows less gear to be used due to a greater width and length of bays to be allowed resulting in a quicker tool time and cheaper client charges. These benefits are invaluable to winning jobs and client satisfaction.

Basically, Cuplok can be seen as the stronger brother who stands by until little brother, Kwikstage, can’t handle the workload. This does not necessarily mean Kwikstage will lose its place in scaffolding. It highlights that all scaffold systems have a purpose and we shouldn’t allow a limited view to stop us from exploring other ideas and better solutions that maybe offered.

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Civil Engineering .

Thursday, June 10, 2010

FORMWORK

What is Formwork

Formwork is a die or a mould including all supporting structures, used to shape and support the

concrete until it attains sufficient strength to carry its own weight. It should be capable of carrying all

imposed dead and live loads apart from its own weight.

INTRODUCTION TO FORMWORK

 Formwork has been in use since the beginning of concrete construction.

 New materials such as steel, plastics and fiberglass are used in formwork.

 greater attention is being given to the design, fabrication, erection and dismantling of

formwork

DEFENITION:

 As a structure,

 Temporary which is designed to contain fresh fluid concrete.

 Form it into the required shape and dimensions.

 Support it until it cures sufficiently to become self supporting.

The term ‘formwork’ includes the actual material contact with the concrete, known as form face, and

all the necessary associated supporting structure.

REQUIREMENTS OF A GOOD FORMWORK SYSTEM

  How formwork can be erected and de-shuttered fast.

  How good concrete quality and surface finish can be achieved.

  What is the optimum stock of formwork required for the size of work force, the specified time schedule

and flow of materials.

  What is the overall cost savings that can be achieved using the right type of formwork.

  How SAFETY can be improved for the site personnel.

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In order to successfully carry out its function, formwork must achieve a balance of following

requirements:

 Containment

 Strength

 Resistance To Leakage

 Accuracy

 Ease Of Handling

 Finish And Reuse Potential

 Access For Concerted

 Economy

Containment: formwork must be capable of shaping and supporting the fluid concrete until it cures.

Strength: formwork must be capable of safely withstanding without distortion or danger the dead

weight of the fluid concrete is placed on it, labour weight, equipment weight and any environmental

loadings.

Resistance to leakage: all joints in form work must be either close fitting of covered with form tape to

make them grout tight. If grout leakage occurs the concrete Will leak at that point. Leakages cause

honeycombing of the surface.

Accuracy: formwork must be accurately set out so that the resulting concrete product is in a right

place and is of correct shape and dimensions.

Ease of handling: form panels and units should be designed so that their maximum size does not

exceed that which can be easily handled by hand or mechanical means. In addition all formwork must

also be designed and constructed to include facilities for adjustments, leveling, easing and striking

without damage to the form work or concrete.

Finish and reuse potential: the form face material must be selected to be capable of consistently

imparting the desired concrete finish (smooth, textured, featured or exposed aggregate etc.) At the

same time it should also achieve the required number of reuse.

Access for concrete: any formwork arrangement must be provide access for placing of the concrete.

The extent of this provision will be dependent on the ease of carrying out the concrete operations.

Economy: all the formwork is very expensive. On average about 35% of the total cost of any finished

concrete unit or element can be attributed to its formwork; of this just over 40% can be taken for

material for formwork and 60% for labour. The formwork designer must therefore not only consider the

maximum number of times that any form can be reused, but also produce a design that will minimize

the time taken for erection and striking.

FORMWORK BASED ON MATERIALS

MATERIALS FOR FORMWORK

                                                Formwork can be made out of a large variety of materials.

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 The material most commonly being used to date is timber. However, due to the

depleting forest reserves and increasing cost of timber the use of alternate materials

such as plywood and steel has become prominent.

 More recently, materials such as plastics and fiberglass are also being used for pre-

fabricating formwork.

 The type of material to be used depends on the nature of construction as well as

availability and cost of material.

 The constraints on the project such as overall cost, time of completion also play a

major role in the use of a particular material for formwork.

TIMBER FORMS

Timber is required for practically all jobs of formwork. The timber bring used for formwork must satisfy

the following requirements:

I. It should be durable and treatable

II. It should have sufficient strength characteristics

III. It should be light weight and well seasoned without warping,

IV. It should hold nails well.

Advantages of using timber forms:

I. It is economical for small construction jobs

II. It is design flexible and easy to erect

III. It has good thermal insulation which makes it useful to be used in colder

            Regions

Iv.      It can easily be made into any shape or size

Plywood forms (in combination with timber)

Concrete shuttering plywood is bwp grade plywood, preservative treated and specially suited

for use in concrete shuttering and formwork.

The plywood is built up of odd number of layers with grain of adjacent layers perpendicular to

each other.

Plywood is used extensively for formwork for concrete, especially for sheathing, decking and

form linings.

There are two types of plywood - internal and exterior.

The interior type is bonded with water resistant glue and exterior type is bonded with water

proof glue.

Hardboard forms

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 Hardboard is a board material manufactured of wood fiber, which is then refined or

partly refined to form a panel having a density range of approximately 50 to 80

pounds per cubic foot.

 Hardboards are standard / non-tempered or tempered.

 The tempered one being used for formwork. Tempered hardboard is solid or

perforated hardboard panels impregnated with resin under high pressure to make

them stronger and more resistant to moisture and abrasion.

 The boards available in large sheets have a hard, smooth surface that produces a

concrete whose surface is relatively free of blemishes and joint marks.

 The thin sheets can be bent to small radii, which is an advantage when casting

concrete members with curved surfaces.

ALUMINIUM FORMS

 Forms made from aluminum are in many respects similar to those made of steel.

 However, because of their lower density, aluminum forms are lighter than steel

forms, and this is their primary advantage when compared to steel.

 As the strength of aluminum in handling, tension and compression is less than the

strength of steel, it is necessary to use large sections.

 The formwork turns out to be economical if large numbers of reuses are made in

construction.

 The major disadvantage of aluminum forms is that no changes can be made once

the formwork is fabricated.

PLASTICS

      These forms have become increasingly popular for casting unique shapes and patterns being

designed in concrete because of the excellent finish obtained requiring minimum or no surface

treatment and repairs.

            Different types of plastic forms are available like glass reinforced plastic, fiber reinforced

plastic and thermoplastics etc.

   Fiberglass-reinforced plastic is the most common and has several advantages such as

I. The material allows greater freedom of design

II. Unusual textures and designs can be molded into the form

III. It   allows   the   contractor   to   pour   structural      and   finished   concrete

            Simultaneously

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IV. Because sections can be joined on the job site in such a way so as to eliminate joints, there is

no size limitation

If carefully handled, a number of reuses are possible making it highly

            Economical

Vi.      It is lightweight and easily stripped

          The disadvantage of using plastic forms is that it does not lend itself to field fabrication  Hence,

the design and planning of this form must be carefully carried out. Also care must take not to damage

the plastic by the heat applied for accelerated curing of the concrete. Trough and waffle units in

fiberglass are used in construction of large floor areas and multistoried office buildings.

STEEL FORMWORK:

            Mostly used in large construction projects or in situations where large number of re-uses of the

same shuttering is possible. Suitable for circular or curved shaped structures such as tanks, columns,

chimneys. Etc. & for structures like sewer tunnel and retaining wall.

Advantages of steel formwork over timber form:

I.             strong, durable & have longer life

II.             Reuses can be assumed to vary from 100 to 120 wares timber varies from 10 to 12.

III.             Steel can be installed & dismantled with greater ease & speed resulting in saving in

labour cost.

IV.             Excellent quality of exposed concrete surface obtained. Thus saving in the cost of

finishing        the  conc. surface.

V.             no danger of formwork absorbing water from the conc. & hence minimizing

honeycombing

CONSTRUCTION OF FORMWORK:

•          propping and centering

•          shuttering

•          provision of camber

•          cleaning & surface treatment

Propping and centering:

                        The props used for centering may be of steel, timber post or ballies.pillars made up of

brick masonry in mud mortar are also sometimes used as props.

Shuttering:

                        can be made up of timber planks or it may be in the form of panel unit made either by

fixing ply wood to timber frames or by welding steel plates to angle framing.

Provision of camber

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                        Certain amount of deflection in structure is unavoidable. It is therefore desirable to give

an upward camber in the horizontal member of conc. Structure to counteract the effect of deflection.

Surface treatment

 Before laying conc. The formwork should be cleaned of all rubbish particularly the

sawdust savings & chippings etc.

 Before laying conc. the face of formwork in contact with conc. shall be cleaned &

treated with release agent like raw linseed oil or soft soap solution as to prevent the

conc. getting struck to the formwork.

Order and method of removing formwork:

 Shuttering forming vertical faces of walls, beams & column sides should be removed

first. Shuttering forming sofit to slab should be removed next.

 Shuttering forming soffit to beams, girders or other heavily loaded member should be

removed in the end.

DURATION TAKEN FOR REMOVAL OF FORMWORK

1        WALLS COLUMNS & VERTICAL SIDES

            OF BEAMS                                                                            1-2 DAY

2        SLABS                                                                                   3 DAYS

3        BEAM SOFFIT                                                                      7 DAYS

4        REMOVAL OF PROPS TO SLABS

            A) SLAB SPANNINIG UPTO 4.5M                                    7 DAYS

            B) SLAB SPANNINIG OVER 4.5M                                   14 DAYS

5        REMOVAL OF PROPS TO BEAMS

            AND ARCHES

            A) SPANNING UPTO 6 MTS                                              14 DAYS

            B) SPANNING OVER 6 MTS                                              21 DAYS                   

TYPES OF FORMWORK

                        There are different types of formwork available for different purposes. Generally, the

formworks for vertical concreting are called wall forms and those for horizontal concreting are called

slab or floor forms. The various types of formwork available today in the market are discussed in

detail.

TRADITIONAL FORMWORK

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 This usually consists of standard framed panels tied together over their backs with

horizontal members called waling.

 The waling is provided with the basic function of resisting the horizontal force of wet

concrete.

 One side of the wall formwork is first assembled ensuring that it is correctly aligned,

plumbed and strutted.

 The steel reinforcement cage is then placed and positioned before the other side of

the formwork is erected and fixed.

Plywood sheet in combination with timber is the most common material used for wall

formwork.

 The usual method is to make up wall forms as framed panels with the plywood facing

sheet screwed on to studs on a timber frame. This allows for the plywood to be easily

removed and reversed and used on both sides so as to increase the number of

reuses.

 The wall forms are susceptible to edge and corner damage and must be carefully

handled.

 Special attention must be given to comers and attached piers since the increased

pressures applied by wet concrete could cause the abutments to open up, giving rise

to unacceptable grout escape and a poor finish to the cast wall.

CLIMBING FORMWORK

 Method of casting walls consists of a climbing formwork, the climbing of which may

be manual or crane assisted.

 It employs a common set of forms used in a repetitive manner for casting walls in set

vertical lifts.

 After each casting the forms are removed and raised to form the next lift until the

required height has been reached.

 These forms are widely used in the construction of industrial chimneys, silos, high

rise towers & building cores, bridge piers & pylons, airport control towers,

telecommunication, towers etc.

The climbing form has many advantages such as the following

  Staged construction process allows balance of site resources.

  Anchor accessories can be reused after each pour, reducing material costs on

current and future construction programs.

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  In case of trolley mounted formwork, the panel retracts from the face, providing

space for cleaning and fixing of concrete.

 Formwork & access platforms lifted as one, minimizing crane support, reducing

labour and material costs.

  fine adjustments of the form face can be made during construction, providing

accurate alignment of the form face vertically & laterally.

SLIDING FORMWORK OR SLIPFORMING

 slip form means a continuously moving form, moving with such a speed that concrete

when exposed has already achieved enough strength to support the vertical pressure

from concrete still in the form as well as to withstand lateral pressure caused by wind

etc.

 Thus, the slip form concreting technique is a rapid and economical construction

method that can be applied with great advantage to many types of construction

projects such as chimneys, silos, water towers, bridge-columns, lift shaft cores and

shaft lining etc.

The technique is based on movable forms which are gradually lifted by hydraulic

jacks.

 It is a continuous process where wet concrete is added to wet concrete. Reinforcing

steel and/or post tensioned cables are continuously fixed as the normal slipping

speed is 3 to 6 meters per 24 hours. The slip form construction is designed for each

project depending on the structure of the project. The advantages of slip forming are

Minimum consumption of timber and steel plates.

Total elimination of traditional scaffolding

Minimum requirements of carpenters for assembling.

It gives a monolithic structure.

The concrete surfaces can be treated and finished while concrete is green,

Depending on the weather conditions, it is possible to achieve a vertical rise to the

tune of 4 to 5 m in summer and 2 to 3 m in winter.

The procedure of continuous slipping is applied to making both inner and outer walls

as well as columns of a building.

Form climbs.

PERMANENT FORMWORK

Permanent form or stay-in-place formwork is one in which the form is left as an

integral part of the structure.

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Permanent formwork can also be utilized as the facing materials of in situ reinforced

concrete. They can be of two types—participating and non-participating.

The material used for these forms must be durable and of sufficient strength.

Commonly used materials include polyvinyl chloride (pvc), galvanized coiled sheet

steel, fabricated steel, carbon/epoxy thin shell.

   The high initial cost of design and installation, lack of familiarity for installation and

maintenance and more specified form design are some of the barriers to the use of

this form.

   However, there are various advantages like low cost of transportation and

installation, precise form design, maximum flexibility, greater durability with reduced

long term maintenance and versatility.

SPECIAL FORMS

            These are those forms that are specially designed and manufactured for a particular kind of

construction. The need for a special formwork may arise due to several factors such as

•         when the contract demands the highest class of dimensional tolerance to be followed

•         Where the form work shape required becomes uneconomical or impracticable for site fabrication

•         Where the formwork is required to be self-contained i.e. self propelled,

•         Where rate of concreting, admixtures or types of concrete are such that concrete pressure developed

within forms and stresses in the forms demand special attention where a substantial number of re-

uses is envisaged

TABLE FORM

 This is a special formwork designed for use in casting large repetitive floor slabs in

medium to high-rise structures.

 The main objective of reducing the time required re-erecting, striking and re-erecting

slab formwork.

 A system which can be put as an entire unit, removed, hoisted and repositioned

without any dismantling.

GANGED PANEL FORM

 The increasing pace in the construction of multi-storey and massive concrete

structures, and the parallel progress in development of cranes and other mechanical

methods of transporting forms have made the use of ganged prefabricated forms for

the concreting of large sections of high walls very common.

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Ranging up to 30x50 ft, their size is limited only by the mechanics of handling. Large

panels can be assembled flat on the ground where it is easier to work. Delay and lost

motion are avoided in stripping because the gang forms are stripped as a unit.

TUNNEL FORM

            The tunnel formwork is a room sized structural steel fabricated form which is used to cast the

rcc walls and floor slabs of a building as a monolithic structure in a continuous pour. The forms are

then heated using hot air blowers for accelerated curing of the concrete. This system is most

economical when the structure consists of large number of identical units. There exist two versions of

this type of formwork. They are:

A.        The half tunnel formwork used to cast only one wall and slab simultaneously

B.        The full tunnel formwork used to cast two walls and a slab simultaneously

            The sequence of construction involves placing of reinforcement, electrical and sanitary

conduits along with the tunnel forms. Concrete is then poured and the open side of the forms is

covered and hot air blowers placed inside. The forms are removed the next day and placed on the

next site using cranes. The optimum use of tunnel form is in multiunit shear wall structure with

identical floor layout at each level.

DOKA FormWork System.

I. Doka System Components

            The various basic components that make up the various DOKA system are as follows:

1. Doka formwork beams

2. Doka formwork sheets

3. Dokadur panels

4. Doka floor props

5. Form ties and suspension cones

6. Multi-trip packaging

1. Doka formwork beams

           

            The core of the system lies in the usage of an Engineered timber component, the  H-Beam.

The H-beams are manufactured in a modern automated plant at Pondicherry under strict quality

control the flanges are made of seasoned chemically treated timber. The web is made of boiling water

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proof ply wood and joined with the flange by the unique finger jointing method. The H-beams thus

manufactured are  light, dimensionally stable and retains its structural properties over a period of time

even after repeated usage. It is more predictable, easy to design and use, The number of reuses of H-

Beams is more than 100 times (8 times that of conventional timber) and it consumes only 40% of

timber volume required.

The H-beams are available in two size namely in H-16 - 16 cms  depth &  H-20 - 20 cms  depth, 

length varying between 1m to 6m.

Salient Feature

•          Reduction in consumption of timber.

•          Making work at site minimized.

•          No. of reuses more than 8 times that of conventional timber.

•          Dimensionally stable, uniform in size and consistent in strength.

•          Cost ratio per use H-16 beam : conventional timber = 1:3.5

•          Economical and long - lasting.

•          Light weight 6kgs per RMT.

Doka beam H20

Innovative end reinforcement .

For less damage to the ends of the beams

For outstanding durability

Outstanding production level.

Ensures uniformly high quality and load-bearing strength for safe and dependable usage

Is the basis for the reliability of the Doka beam formwork and Dokaflex floor formwork

From mechanical strenght grading

Practical marks for all standard lengths.

Max. Shear Force Max. Bending

Moment

EI

11 KN 4 KN/M 170 x 106 KG.CM2

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  As a grid for easy installation and checking of the Dokaflex 1-2-4 system

Doka beam H20 eco

Ends of beams bevelled for more strength but has no end reinforcement.

2. Doka formwork sheets

Doka has an extensive range of formwork sheets for the most varied areas of application. All sheets

are made of glue-bonded layered wood and are extremely strong and dimensionally stable.

Formwork sheet 3-S Plus

Three-ply concrete-formwork sheet, made of European spruce (picea abies), designed specially for

building. Produces a uniform concrete surface.

  Surface: Synthetic melamine resin glue with PU sealant and light corundum sanding on one side

  Bonding: Boilproof and weatherproof

  Edges: Impregnating emulsion,

Doka yellow

  Thicknesses: 21 and 27 mm

Formwork sheet 3-SO

Three-ply concrete-formwork sheet, made of European spruce. Produces a uniform concrete surface.

  Surface: Synthetic melamine resin glue

  Bonding: Boilproof and weatherproof

  Edges: Impregnating emulsion,

  Doka yellow

  Thicknesses: 21 and 27 mm

Dokaplex Multi-ply sheets

High-grade multi-ply sheet made of Finnish birch hardwood for use again and again. Produces a high-

quality, smooth concrete surface.

Surface: Phenol-resin coating, 120 g/m²

Bonding: Boilproof and weatherproof phenol-resin glue (BFU 100) to DIN 68705-T3

Edges: Dispersion

Thickness: 21 mm

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3. Dokadur panels

Dokadur panels are the state of the art for floor-slab panels. All-round edge and surface sealing

dependably protects the panel against the wear and tear of everyday construction work.

Maximised number of reuses and best-quality concrete surfaces.

From special surface sealing by means of PUR varnish and melamine resin coating with

precision-metered corundum sanding

For improved safety at work, because risk of slipping is reduced

From significantly reduced moisture absorption for much-reduced discolouration, structuring

and cracking

Big savings on costs

From easy cleaning of the surfaces, ready for the next use

From all-round edge protection made of high-grade PU

For exact edges with minimal cleaning

For low costs on account of easy and fast reconditioning of the edge

4. Doka Floor Props.

Doka floor props are the right choice for every application. High load-bearing strength plus many

practical details that help to make handling easier.

The props are available in various sizes viz. CT-250,CT-300,CT-340 & CT-410. The number

indicates the extended length of props in cms.

Carrying capacity is rated from 20 kN to 30 kN.

The tripods make the props self standing for  easier and faster erection of the shuttering

system. The adjustments in height are obtained by operating the prop nut. The required

dimension in plan is obtained by side-lapping of the H-Beams in the primary or secondary

layer.

A very accurate and convenient shutter is ready for tying of reinforcement and concreting.

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The system also facilitates re-propping. By adopting the method of repropping it is possible to

reduce the total quantity of formwork materials significantly. The system is very well adapted

for use alongwith the L&T-Doka Beam Forming Supporting system.

5. Form ties and suspension cones

Doka has a complete range of tried-and-tested formtie solutions and dependable suspension points

for wall formwork, single-sided formwork and climbing formwork in uncompromising quality for

maximum safety.

Doka tie rods and anchor accessories

  Provide safety through superb manufacturing quality

  Reduce labour costs for installing ties, because a hammer is all that is needed for easy installation

  Are durable, robust and unaffected by dirt

Robustly dimensioned universal climbing cones

  ensure firm connections between structure and formwork

  for safety on high structures

  for all kinds of climbing formwork

Safe suspension solutions for working and protection platforms

  With different attachments to suit the application

  Ideally matched to the carrying capacity of Doka working and protection platforms

  Easy to install and reusable.

6. Multi-trip packaging

Multi-trip packaging such as containers, stacking pallets and skeleton transport boxes  keep

everything in place on the site, minimise time wasted searching for parts, and streamline the storage

and transport of system components, small items and accessories.

Savings on material overheads and labour costs.

Through faster loading and unloading of system components, small items and accessories

Through easy relocation to the next point where the parts are needed

Through safe storage in stacks, particularly when space is at a premium

Page 20: Scaffold Teaching

Stacking pallets 150 and 120 simplify the storage and transport of floor props, removable folding

tripods, formwork beams and Dokadur panels. The clamp-on wheels make the stacking pallets

mobile, so they can easily be steered through standard door-size openings in residential

accommodation projects.

Page 21: Scaffold Teaching

II. DOKA Floor System

No matter what the room height, the shape of the layout or the slab thickness, with Doka you always

have exactly co-ordinated formwork in one single consistent system, comprising a conveniently small

number of easy to manage system components.

Dokaflex 1-2-4

            Dokaflex 1-2-4 is the fast, versatile floor formwork for floorplans of any shape, for beams, slab

overhangs and semifinished floor elements – and the ready reckoner is ideal for calculating the

quantities of materials, so there's no need for formwork planning. The free choice of formwork sheets

leaves nothing to be desired when it comes to the finished structure of the fair-face concrete.

The L&T-Doka Fex system is suitable for RC-floors upto 4.40 m high.

The plywood sheathing is supported by a layer of secondary H-Beams at the designed

spacing. The primary layer of H-Beams  are supported with necessary accessories over the

collapsible telescopic props fitted with tripods to ensure lateral stability.

Defined positioning grid with full flexibility in floorplan geometry

For quick erection of the formwork, because the positioning points are clear

Enables rapid adaptation to walls and columns by simply telescoping the transverse and

longitudinal beams

Speedy progress and simple logistics

Because there is only a small number of matched individual components

With high-grade Eurex floor props with consecutively numbered pegging holes and low

release forces

With high-grade Eurex floor props with consecutively numbered pegging holes and low

release forces

Because the ready reckoner makes it easy to calculate the quantities needed

Because dispensing with planning and preparatory operations cuts costs by a significant

margin

Because the maximum pitches for longitudinal and transverse beams and props are marked

on the beams - for floor-slab thicknesses up to 30 cm

Page 22: Scaffold Teaching

Safety and economy

From durable and robust individual components

Because the panels can be rented

With high-grade polyurethane surround for first-class concrete surfaces and reduced

investment costs

With non-slip surfaces for significantly enhanced safety at work

With high-grade Eurex floor props with consecutively numbered pegging holes and low

release forces

With the new, much-improved longitudinal and transverse beams for significantly reduced

post-use costs

Every requirement for fair-faced concrete fulfilled

By free choice of formwork sheets

By the sealed surface of the rentable panels

Dokamatic table

The innovative design of the Dokamatic table makes for even faster formwork handling whenever

large floor slabs have to be cast. Standard functional components can be installed for straightforward,

speedy adaptation to changing requirements on the construction site.

Fast repositioning reduces labour costs

Because fully assembled units are manoeuvred quickly into place - no laborious carrying of

individual components from one location to the next

Because practical shifting devices makes for virtually fatigue-free operations

Because easier to handle and safer than hand-operated formwork, particularly as room

heights increase

The Dokamatic table helps save on labour and on crane time: One man using the shifting trolley with

attachable drive unit can move the tables to the next casting location on the same level. The system is

optimised for minimal forming times on large-area projects and deals easily with varying requirements

in terms of statics and geometry.

Dokamatic table sizes

Comes in 4 rentable standard sizes with grid logic: 4.0 x 2.0 m, 4.0 x 2.5 m, 5.0 x 2.0 m and

5.0 x 2.5 m

Page 23: Scaffold Teaching

Special sizes for special applications can be supplied at any time

Made up of high-grade system components such as the sturdy Dokamatic table waling 12 and

Doka beams H20 top for outstanding durability and minimum post-use costs

Fully assembled Dokamatic tables delivered to your site right on time

Load-bearing tower Staxo

Staxo is a high-strength load-bearing tower made of robust steel frames for high shoring and heavy

loads. Integrated connectors for rapid assembly. This modern load-bearing tower system comprises

only a few individual parts and is extremely versatile. A comprehensive range of safety accessories

completes the system.

Highly stable and highly versatile

  With 1.52 m wide frame with non-buckling vertical sections

  With 50 cm grid for setting the frame spacing

  With the tower unit's large footprint

  Because horizontal loads are safely dissipated

  Load-bearing capacity up to 70 kN/leg

Speedy assembly, even when the towers are high

  Because there are only a few individual parts, they are light and easy to handle

  Because the vertical adapters for the next lift are integrated, without loose parts or add-ons

  With drop-in assembly battens and integrated climbing rungs

Less crane time needed

  Because the towers can be pre-assembled on the flat, then hoisted into position

  With shifting carriages for horizontal repositioning

Staxo frame

Extremely strong, galvanised steel frame for straightforward height adjustment in a 30 cm

grid; choice of three heights 0.90, 1.20 and 1.80 m

Frame spacing with diagonal crosses from 1.00 to 2.50 m adjustable in 50 cm grid

Reliably withstands horizontal forces such as wind loads

Integrated next-lift frame adapters for ergonomic handling even high above the ground - no

tools required

Integrated climbing rungs and drop-in assembly battens support safe assembly and

disassembly

Page 24: Scaffold Teaching

Diagonal cross

Timesaving integration of horizontal and diagonal braces in a single component

Different lengths for variable frame spacing

Colour clips and stamping for clear marking of the lengths

Safe assembly with captive gravity catches

Setting the next lift is always quick and safe: no time is lost looking for parts, because the locking

springs (1),

 (3) and connecting sleeves (2) are captive, integrated into the frames.

No additional parts or loose parts, so even high above the ground handling is still straightforward.

Height adjustment

Height adjustment accurate to the millimetre, even under load. By means of screw-jack U-spindle at

the top, screw-jack foot or heavy-duty screw jack at the bottom. The heavy-duty screw jack 130 has

an extension height of 130 cm and is available for jobs requiring maximum versatility.

           

Page 25: Scaffold Teaching

Beam forming  support system

The L&T-Doka Beam Forming Support system is suitable for RC-Beams of depth between 30 cm to

120 cm.

Beam bottom

The plywood sheathing is supported by a layer of secondary H-20 Beams at the designed spacing to

form the beam bottom. The primary H-Beams in turn support the secondary layer.

Beam sides

The plywood sheathing is supported by H-Beams at the designed spacing running along the length of

the RC-beam  to form the beam sides. The H-beams are supported by the beam forming support

which are clamped onto the H-20 beams provided for the Beam  bottom. The beam forming support

ensures the right angle between the beam bottom and sides. The BFS extn. provides the necessary

adjustment in depth.

The beam forming support with extension are available in three sizes viz.BFS with extn.600mm long,

900mm long & 1200mm long. 

III. Wall Formwork System

The L&T-Doka  Wall formwork system is suitable for casting of RC-Walls  including water tight

structures.

The plywood sheathing is supported by H-Beams which are in turn supported by the steel walers. The

wall formwork facilitates fixing of working platforms for access, checking of reinforcement, concreting

etc., the panels also have provision for fixing for alignment system which ensure verticality. The 

pressure due to concrete  are sustained by High strength  tie system.

The walers are available in sizes of 0.8m, 1.2m, 1.6m, 1.8m, 2m & 2.4m the inside corners are formed

by “universal inside corner” and the outside by universal outside fixing or angle plates. The high

strength tie system can be through tie system or lost anchor system depending on the structure. The

H-Beams can be butt jointed to form larger size of panels.

The formwork panel along with the working platform and alignment systems can be lifted as a single

unit using a crane thus the labour involved in each operation of erection and deshuttering is reduced

to a minimum. The panels are formed in the carpentry workshop at site and the number of

operations/assembly of components at each location is minimal and hence accuracy is maintained.

Since large panels are handled as a single unit, the damage/loss of small components is eliminated 

contributing to very high material productivity. In the absence of a crane the panels can be dismantled

and handled separately. The wall formwork system can handle very large pressures generated due to

pumping of concrete.

Page 26: Scaffold Teaching

The planners place the Doka formwork beams H 20 (1) and the bracing, which consists of steel waling

(2) to suit the anticipated load. The sheeting (3) is freely selectable – your choice of smooth fair-faced

concrete, wood-textured surface, and so on.  

Doka framed formwork Frameco

The Frameco formwork system

Forms wall heights up to 3.00 m without stacking

Has sturdy, galvanised steel frames to produce smooth concrete surfaces

Permissible fresh-concrete pressure 70 kN/m²

Only 2 anchors up to a height of 3.00 m

Means fewer anchors have to be set, so forming work is faster

Reduces labour costs for post-casting work on the anchorage holes

End-to-end 15 cm grid with only 5 panel widths

Simplifies planning, forming and logistics on the construction site

Reduces the number of cost-intensive closures

Means matching panel formats for best possible utilisation of formwork

Reduces quantities in stock and costs for rental, because of effortless adaptation to any floor

plan

  Makes for compact lifting units for fast positioning and short crane times

Page 27: Scaffold Teaching

IV. Column Formwork System

The L&T-Doka  Column formwork system is suitable for casting of columns of minimum 15cm *

15cm .

In the Column formwork system the H-Beams along with steel walers and accessories makeup the

assembly. The Column formwork facilitates fixing of working platforms for access, checking of

reinforcement, concreting etc., The formwork panel along with the working platform and alignment

systems can be lifted as a single unit using a crane thus the labour involved in each operation of

erection and deshuttering is reduced to a minimum. The panels are formed in the carpentry workshop

at site and the number of operations/assembly of components at each location is minimal and hence

accuracy is maintained. Since large panels are handled as a single unit, the damage/loss of small

components is eliminated  contributing to very high material productivity. In the absence of a crane the

panels can be dismantled and handled separately. The column formwork system can handle very

large pressures generated due to pumping of concrete.

Any column size, straight from the modular system ...

For speedy forming of any column cross-section with standard parts

For optimum adaptation to any special geometry up to 5 m in diameter

For column cross-sections up to 120 x 120 cm with only one splice plate

For first-class concrete surfaces with any sheeting

Permissible fresh-concrete pressure 90 kN/m²

Some of the possible cross-sections of column

V. Climbing Formwork System

The L&T-Doka Climbing System are used for tall structures like cooling towers, etc where  it is very

uneconomical to provide staging or scaffolding for supporting the  external or internal wall formwork.

In this system a bracket is hooked on to anchors called lost anchors provided in the already cast wall

and supports/alignments are taken from these brackets. The brackets are suitably braced to prevent

any sway and are provided with walkways/working platforms / handrails etc for safety and ease of

working.

Page 28: Scaffold Teaching

Varying degrees of sophistication are available in the

Climbing formwork systems, a few of which are as listed.

CB - 150 A - Simple Climbing, Crane handled - platform width 1.50 m.   The brackets & wall formwork

are to be handled separately.

CB - 150 F- Traveling Climbing, Crane handled - platform width 1.50 m.  roll back arrangement  for

deshuttering & cleaning of shutters. The wall formwork and climbing bracket are lifted as one unit.

Automatic climbing formwork, the wall formwork along with the climbing brackets slide along the wall

using motors, thus eliminating the need for crane. This system is very often used for natural draught

cooling towers.

MF - 240 - Simple  Climbing, Crane handled - platform width 2.40 m. these brackets can also be fitted

with automatic climbers SKE-50 which is a hydraulic system with 5T carrying capacity or SKE-100

with 10T carrying capacity.

The MF 240 system

    * Travelling unit MF (1):

      Platform is 2.40 m wide for safe and convenient manipulation of the formwork. 75 cm retraction for

easy cleaning of the formwork and for working on the reinforcement.

    * Climbing bracket MF (2):

      Combines with beam and frame formwork, high load-bearing capacity (50 kN per climbing

bracket), angle of inclination ± 15° from vertical.

    * Working brackets (2):

      Modular principle for versatility: these brackets can be used as pouring, intermediate and

suspension brackets.

The SKE system

The modular system for automatic climbing

    * Free positioning of brackets and automatic climbers as single-section climbing scaffold

    * Lift heights up to 5.50 m

    * Formwork systems:

      • wall formwork FF 20 and large-area formwork Top 50

      • framed formwork Framax and Alu-Framax

    * Climbing speed 5 min/m

Page 29: Scaffold Teaching

SKE 50

    * Load-carrying capacity 5 metric tons per bracket

    * Ideal solution for a huge number of climbing tasks

    * Up to 40 automatic climbers per hydraulic unit

                       

SKE 100

    * Load-carrying capacity 10 metric tons per bracket

    * Platform system for simultaneous work at different levels

    * Extremely strong brackets permit wide, variable spacing

at 5:40 PM

13 comments:

1.

indianidol.007February 16, 2011 at 10:12 PM

Hey I am looking for total concrete formwork produced or manuctured every year. Do you have any idea where I can get those data from ?

Reply

2.

zamaSeptember 23, 2011 at 12:00 AM

Thanks....this really is helpful.

Reply

3.

Girish KSeptember 11, 2012 at 12:11 AM

Thanks very informative :)

Page 30: Scaffold Teaching

Reply

4.

uniscaffDecember 8, 2012 at 11:12 AM

Hi indianidol.007@ We can buy a shuttering systems like Flexible & Adjuster Panel, Form work System for RCC wall Etc. at Uniscaff Engineering

Reply

5.

Sakshi ChemSciencesDecember 12, 2012 at 5:05 PM

This comment has been removed by the author.

Reply

6.

Ali ZakourDecember 29, 2012 at 1:52 AM

Page 31: Scaffold Teaching

thanks

Reply

7.

sipilworldApril 1, 2013 at 10:40 AM

thanks

Reply

8.

AdminMay 9, 2013 at 10:41 PM

This comment has been removed by the author.

Reply

9.

AdminMay 9, 2013 at 10:44 PM

Txs for sharing good knowledge about shuttering. For practical construction guide one can visit to construction guide

Reply

10.

Madhubani Parasmani TravelMay 17, 2013 at 6:00 PM

Construction is important part of building design and material use and strength any nathural disaster situation no collaps any building Concrete Formwork

Reply

Page 32: Scaffold Teaching

11.

rengkat johnJune 10, 2013 at 2:41 PM

thanks

Reply

12.

Joecy RayahApril 30, 2014 at 3:14 PM

This article piqued my interest in the latest products available on the market, and I found a great resource here: http://www.directindustry.com/industrial-manufacturer/formwork-79428.html

Reply

13.

_Priya Raj_May 17, 2014 at 2:51 PM

Page 33: Scaffold Teaching

Hi there!I am a student of Construction Management from India and i am currently researching on different types of formwork systems and precast technologies available in India.. A Cost-Benefit-Analysis.

Does anyone here, have experience/useful information in this field?

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