Basic Civil Engineering first year Notes- Chapter 4 Building.pptx
Construction Technology III (Group Assignment) - Semester 3
1. IBS FormworkSystem
ConstructionTechnology III
• Introduction
• Manufacturing &
Assembly
• Advantages &
Disadvantages
• Case Study
• Conclusion
0333129 Ang Toh Chuan 0328264 Isaac Wong Han Jack 0334776 Karen Lim Wan Yee 0330764 Wan Yee Len
2. Introductionof IBS Formwork System
Formworks are one of the most important
temporary works for construction of
reinforced concrete superstructure in
building projects.
Moulds used to retain the shape, size and
position of wet concrete as it sets.
Considered as the “least prefabrication” IBS
types as formworks still require site casting.
Examples are tunnel forms, tilt-up systems, beam and
columns moulding forms and permanent steel formworks
like metal decks.
Materials: Steel, aluminium, fiber-reinforced plastic and etc.
3. Project Cause Planning Phase Forming Phase Concreting Phase
• New construction
• Maintenance/repair
• Maintenance/
refurbishment
• 2D/3D planning
• Defining the formwork
system
• Defining the formlining
• Defining the
construction sequence
• Creating the logistics
concept
• Erecting the formwork
• Adjusting the formwork
• Moving the formwork
• Dismantling the
formwork
• Providing/distributing
of concrete
• Inserting of concrete
• Compressing of
concrete
• Curing of concrete
Work phases
4. Manufacture
Assembly
Steel formwork consists of panels fabricated out of thin
steel plates stiffened along the edges by small steel
angle. The panel is held together by using suitable clamps
or bolts and nuts.
1. Reinforcement bars are being tied and spacers are
attached to ensure the rebars are not exposed.
2. Before concreting, the steel panels must be oiled and
assembled with rebars passing horizontally through it.
3. Steel panels are aligned well before inserting the bolts
and nuts. The panel must be aligned and locked well
to prevent leakage when concreting.
5. Manufacture&Assembly
4. Pouring of concrete.
5. Struts are used as additional support so that panels will not fall easily.
6. Dismantling of steel formwork. Extra rebar are cut by hand-held cutter.
Manufacture&Assembly
6. Advantages
of Steel Formwork System
• Reusable
• Durable
• Can be fixed easily
• Provide uniform size and
surface
• No shrinkage of formwork
occurs
7. Disadvantages
of Steel Formwork System
• More expensive than
conventional timber formwork
• Handling process is more
difficult
• Limitation to the shapes and
sizes
• Steel can be dented easily
8. FormworkSystem
Conventional
Steel
TimberFormwork System
Steel formwork does not absorb moisture or water
vapour
Steel formwork does not shrink or warp
Steel formwork are more durable and can be reused
longer time than conventional timber formwork
Steel formwork can be installed and dismantled easily
and faster
Lesser construction waste produced
Steel formwork provides good quality of the exposed
surface
Modern
9. Setia City
Residence
s
Project Data
Setia City Residences is an epic development that is being eagerly awaited for in the prized township of Setia Alam. It is to be the first upmarket high rise
development to ever be built in the town from the leading developer of SP Setia.
Setia City Residences will be a very strategically-located home situated just next to the townships only shopping mall, Setia City Mall. The Gross Development
value (GDV) of this project is approximately RM500 million and will span 5.77 acres of land. There will be three towers to this project, all standing at 35 storeys tall.
Location: Shah Alam, Malaysia
10. SETIA CITY RESIDENCES
Formwork systems in use
Requirements
Compliance with the tight construction schedule.
Expected date of completion: 2019
Rail Climbing System
11. Rail Climbing System
Suitable for multi-storey vertical concrete
such as:
• Skyscrapers
• High Rise Buildings
• Airport ControlTowers
Climbing Rail
The universal steel profile for climbing applications. Available in
lengths from 1.48 m to 9.98 m.
Climbing Shoe
Guidance and bearing support for climbing rails with foldable
guidance skids and self-acting bearing pawl.
Climbing Device
For crane-independent climbing of RCS climbing units with 5 tonnes
lifting force.
• Elevator Shafts
• Bridge Pylons
used as climbing formwork as well as a climbing protection panel.
Climbing unit is securely connected to the building at all times which makes the
climbing procedure fast and safe also in windy conditions
13. Almost
completely
crane-
independent
Can sustain
high winds
Safer
lifting and
handling
Faster
construction
Customised
configurations
Minimizes
labour and
better
productivity
AdvantagesRailClimbingSystem
Why not the
conventional system?
Speed of construction: Min. cycle time is of 21
days
Bad quality of surface finish, plastering is
required
Great amount of wastage of formwork
material
Less accuracy in construction compared to
the modern system
Re-usage value of formwork, maximum 50
while modern formwork is 250-300
Not suitable for high rise construction
Economy on small scale construction
Timber, plywood, bamboo
14. RedevelopmentofEquatorialHotel,KualaLumpur
Equatorial
Plaza
Hotel Equatorial Kuala Lumpur, one of the city's
oldest landmarks was opened in 1973, ceased its
operations on April 1, 2012 to make way for
redevelopment phase. The construction will take 36
months involves the construction works of the
podium block, office and hotel towers.
Requirements
To work without interruptions
by IJM Construction Sdn Bhd
Formwork systems in use
Panelized Slab Formwork
50-storey commercial
development
consisting of hotel and
office
Green Building Index:
Gold rating
TargetedCompletionQuarter32018
15. Main system components
Panel
for standard fields measures 1.50mx0.75m. The
lightweight aluminium frame is covered with
9mm thick formlining.
Cover strip
is made of plastic and is used with the drophead
system.
Main beam
for standard fields is 2.25 m long. It
provides the support for 3 panels each with a
width of 75 cm.
Drophead
accommodates the main beam and is
covered by the cover strip. The drophead can
be lowered by 6 cm and allows early striking to
take place.
4PanelizedFormwork
Slab
Range of applications extends from residential construction
through to industrial construction projects with thicker slabs.
Ideally suited for markets with very high safety standards.
Material : Lightweight aluminium
17. Effortless working
with lightweight and easy to
handle components
As safety levels are
enhanced, site personnel do
not tire so quickly.
Fast forming
With a simple, systematic
assembly sequence and
fewer slab props
• Slab props no longer need to be
set out
• Determination main and
secondary beam spacings is not
needed
• No taking into account the load-
bearing capacity of the formlining
Low on-site material
requirements
Due to early striking with the
drophead and fast
development of the panels
and beams in the next storey
Easy cleaning
Through powder-coated
elements, components made
of plastic, and undercut panel
edges
High level of safety
on all sides
After a simple positioning
procedure, it is immediately
fixed against tipping or
moving.
Advantages
By utilizing this formwork system in the project,
work could be efficiently carried out at all heights
in 10 days cycle.
18. Conventional Slab Formwork
Modern Slab Formwork
Cleaner, neater and safer working environment
Additional supports obstruct working space
19. The Paramount at Buckhead,
Atlanta
At 44 stories, it’s the tallest residential structure ever
constructed using tunnel forms. This project has a footprint of
approximately 13,400 square feet.
Construction start, 2002; Completion, 2004
Formwork system in use: Tunnel Forms
Construction Technique: Cast walls and slabs in one operation
Tunnel form is widely used in the construction of cellular structures
with high degree of repetition such as:
• Prisons
• Hotels
• Student Accommodation (Hostels)
• Private Housings
• Commercial Developments
20. Tunnel formwork come in
half units, in the form of
inverted “L”. Bolted together at
the top to form each tunnel
Jacks help the
formwork to
adjust to the
final height
Inbuilt wheels
help the
formwork to
move in and out
of the position
Tunnel
Form
21. 1. Wall reinforcement
2. Tunnels are craned into place, bolted together and ties are added.
3. Slab reinforcement.
Casting
Process
of Tunnel Formwork
22. 4. Wall and slab concrete are
placed. Butane heaters are used
to maintain a sufficiently high
temperature for the concrete to
reach its striking strength
overnight.
5. Tunnel forms are removed next
day.
6. The process is repeated.
23. Conclusion
Modern formwork system is not exactly better than the conventional formwork
system in every aspects.
Conventional formwork system is still preferable in small scale construction as it is
beneficial in terms of cost.
Hinweis der Redaktion
Project phases for the construction, maintenance and repair of concrete structures
Can be reused up to 100 times
Strong and have the ability to carry heavy load
- Handling is more difficult due to heavy weight of steel
Case study 1 – Setia City Residences, located at Shah Alam
The construction of this project begins in November 2015, and is expected to be complete by next year.
The formwork in use for this project is the rail climbing system,
With the reason that this project has a tight construction schedule.
The rail climbing system can be considered as a cost saving method because it combines the features of formwork and scaffolding systems.
It is also an effective solution for structures that require seamless walls, or their form is very repetitive.
This formwork system is generally and more suitable to be used on structures with more than 20 floor levels, such as skyscrapers and high rise buildings.
The formwork is connected to the perimeter of the building.
This formwork is mainly use in the construction of reinforced concrete wall.
Climbing device that will lift the formwork upwards. It is also why the rail climbing system is know as the self-climbing formwork.
The main advantage of this formwork system is that it is almost completely crane-independent, because it can move by itself with the function provided by the climbing device.
This formwork system also speeds up the construction time as the vert. and horiz. part of the building can be built concurrently.
But this is also one of the limiting factor. If the floor slab is not completely done, the construction of the wall for next level cannot begin.
Overall, the complete construction cycle of one level will take around 3-5 days.
Case study 2 – Redevelopment of Equatorial Hotel, now known as Equatorial Plaza
It is a 50 storey commercial development of hotel and office.
This construction will take 3 years and target to be completed by this year, around September.
One of the formwork system used is the panelized slab formwork.
This formwork system is designed for standard use in constructing slabs with the maximum thickness of 109cm.
It can be applied in both residential and industrial construction projects.
One of the components is the drophead. What’s so special about it is that it will allow early striking and will reduce the on-site material requirements.
First, is the early striking of drophead.
Then comes after is the main beam, which will support the formwork panels.
The panels will create a large surface area to form a decking to construct suspended floor slab.
Actually this formwork system is quite similar to the conventional slab formwork system.
Just that the material used in this system is lightweight aluminium, which is more durable than timber and plywood.
The components of this system are all prefabricated in the factory, so it will increase the construction speed.
By using this formwork, the construction can be carried out at all heights in 10 days cycle while the conventional method will take minimum of 21 days.
If we compare the modern and traditional slab formwork.
The modern system has a cleaner and neater working environment, while the conventional system will require additional supports which will obstruct the working space.
Case study 3 – The Paramount at Buckhead, Atlanta
This building has 44 stories and it is the tallest residential structure to be constructed using tunnel forms.
Tunnel form is widely used in the construction of cellular structures, and the construction technique is that it builds monolithic wall and slab in one operation.
By using this formwork system in this project, the complete construction of the shell is one month earlier than it is stated in the contract.
Overall construction period, takes only 2 years to be completed.
Tunnel formwork comes in half units, and bolted together to form one unit.
The formwork comes together with jacks that will help to adjust the height, and inbuilt wheels for them to move easily.
But this system still requires tower crane in the beginning to assemble the formwork.
When compared with traditional construction, it reduces the cost of frame by 15% and construction time by 25%.
The casting process is very simple.
First step – placing wall reinforcement then the installation of tunnel form.
After that, slab reinforcement is placed above the formwork and concrete is poured to form the wall and slab.
The curing process can be done overnight with the use of butane heaters to maintain a sufficient high temperature.
Then the tunnel formwork will be removed the next day and the process is repeated for next level.
Although there are now a lot of steel or aluminium formwork suppliers in Malaysia, and some of the companies have their own innovative systems and provide a lot of benefits in a construction, it doesn’t mean that the conventional formwork system is not good.
Because in some ways, the conventional method is cheaper than the ibs method, for example in a small scale construction.
Therefore, some of the construction projects out there are still using the conventional formwork system.