FORMWORK

Larsen and toubro limited

Presentation by:
Rachna Rajput
(1030227)

08/28/09 1
 LARSEN & TOUBRO LIMITED
ECC DIVISION
LUDHIANA CITY CENTRE
CONSTRUCTION OF RCC BASEMENT STRUCTURE

08/28/09 2
By : A.K. Mishra
THE CLIENT: TODAYHOMES AND
INFRASTRUCTURE
JOINT VENTURE WITH
LUDHIANA
IMPROVEMENT TRUST

ARCHITECT: CP KUKREJA AND

ASSOCIATES

CONTRACTOR : LARSEN AND TOUBRO

LIMITED

08/28/09 3
 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
08/28/09 4
 LUDHIANA CITY CENTRE
CONSTRUCTION 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
08/28/09 5
 THE WORK

FORMWORK PLANNING AND

DESIGN OF ITS VARIOUS
COMPONENTS

08/28/09 6
 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

08/28/09 SPEED,QUALITY,ECONOMY AND SAFETY 7
 TRADITIONAL
APPROACH
 BALLIES USED AS SUPPORT FOR
SHUTTERING

 UNSAFE AND UNRELIABLE

 LOW REUSE VALUE

 DOES NOT PRODUCE GOOD QUALITY

CONCRETE
08/28/09 8
 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

08/28/09 9
 SYSTEM
FORMWORK-L&T
 EARLIER CALLED DOKA
FORMWORK
 INVERSIBLE
 FAST ERECTION
 MORE STABLE
 SAFE IN USE

08/28/09 10
 FORMWORK
STEP1.) PLANNING
 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

08/28/09 11
 CONTD….
 RECEIVING NEW TARGETS ON
PRODUCTIVITY FROM HQ

 COMPARING THE RUNNING

LMP COST FROM THE ACTUAL

 IDENTIFYING TRAINING NEEDS

OF STAFF

08/28/09 12
COMPONENT DETAILING
 FOUNDATION FORMWORK

 HDT TOWER

 SLAB/BEAM FORMWORK

 WALL/COLUMN FORMWORK

08/28/09 13
 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

08/28/09 14
08/28/09 15
 FOUNDATION
FORMWORK MATERIAL
CONTD.

08/28/09 16
 CONTD…

08/28/09 17
 CONTD….

08/28/09 18
 AFTER ERECTION
Steel panel
Pipe waler
clamp
Pipe waler

Alignment
prop

welar

08/28/09 19
 HDT TOWER
 BASIC FRAME
 HORIZONTAL BRACE
 DIAGNOL BRACE
 TAKES LOAD OF 250KN
 HIEGHT ADJUSTMENTS UPTO 800MM
POSSIBLE
 TRANSPORT DEVICES CAN BE ATTATCHED

08/28/09 20
 COMPONENT
DETAILING

08/28/09 21
 CONTD….

08/28/09 22
 AFTER ERECTION

Coupler and
spring lock pin

Foot plate

Tower
spindle

08/28/09 23
 WALL/COLUMN
FORMWORK
 SHOP MADE SHUTTER

 ACCORDING TO THE HIEGHT OF WALL OR

COLUMN SPLICING CAN BE DONE

 ISMC WALERS ARE USED FOR BEARING

08/28/09 24
 COMPONENT
DETAILING

08/28/09 25
 CONTD….

08/28/09 26
 CONTD……

08/28/09 27
 COLUMN FORMWORK
WORKING AT 4.8M
HIEGHT

08/28/09 28
 COLUMN FORMWORK

08/28/09 29
 WALL FORMWORK 1.8M
HIEGHT

08/28/09 30
 SLAB/BEAM
FORMWORK
 SHEATHING MEMBER

 H-BEAM(SECONDARY MEMBER)

 WELAR(PRIMARY MEMBER)

 HDT TOWER

08/28/09 31
 AFTER
ERECTION
Sheathing
H-beam

welar

tower

08/28/09 32
 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

08/28/09 33
 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

08/28/09 34
 DESIGN PROCEDURE
EXAMPLE
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)

08/28/09 35
 DESIGN PROCEDURE
CHECKS 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
08/28/09 36
 DESIGN PROCEDURE
CONTD….
 DESIGN DONE FROM TOP TO BOTTOM
 1. SHEATHING MEMBER
 2.H-BEAM(SECONDARY MEMBER)
 3.WELAR(PRIMARY MEMBER)
 HDT TOWER

08/28/09 37
 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

08/28/09 38
  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

08/28/09 39
 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

08/28/09 40
  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

08/28/09 41
08/28/09 42
 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
08/28/09 43
  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)

08/28/09 44
 PRESSURE DISTRIBUTION DIAGRAM

Pmax/D

P max

08/28/09 45
 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
08/28/09 46
 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

08/28/09 47
 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

08/28/09 48
 Ladder Safety
Follow the 4:1 rule when using extension ladders

6 m (20 ft)

1.5 m (5 ft.)

08/28/09 49
 –Erect First Tower – Adjust and ensure the
top level is same. Connect all pin bracing

08/28/09 50
08/28/09 51
08/28/09 52
 Use of lifeline
above 2m

08/28/09 53
 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

08/28/09 54
 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

08/28/09 55
  ACTUAL PRODUCTIVITY IS
TAKEN AS AVERAGE STOCK
LEFT

 PRODUCTIVITY IN %=
(ACTUALPRODUCTIVITY/STANDE
RED PRODUCTIVITY)*100

08/28/09 56
 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

08/28/09 57
 BATCHING OF
CONCRETE
 PAN TYPE BATCHING PLANT
 CAPACITY OF 60M^3/HR
 WEIGHED BATCHING
 MIXING
 TRANSPORTATION
 PLACING

08/28/09 58
 THANK YOU

08/28/09 59