Scaffolders are the masters of looking ahead

Posted on May 10, 2013 by admin

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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?














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.











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.



















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.


















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,
cant 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 shouldnt allow a limited
view to stop us from exploring other ideas and better solutions that maybe offered.












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.


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.
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
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
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
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
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.
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.
Permanent formwork can also be utilized as the facing materials of in situ reinforced
concrete. They can be of two typesparticipating 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.
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
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


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/m
Bonding: Boilproof and weatherproof phenol-resin glue (BFU 100) to DIN 68705-T3
Edges: Dispersion
Thickness: 21 mm

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.

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

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.


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

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
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

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.

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.

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/m
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
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/m


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.

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

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 :)
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
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
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
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?
Reply
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