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
- 12. How it works
- 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
- 16. works How it
- 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.
Editor's Notes
- #4: Project phases for the construction, maintenance and repair of concrete structures
- #7: Can be reused up to 100 times Strong and have the ability to carry heavy load
- #8: - Handling is more difficult due to heavy weight of steel
- #10: 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.
- #11: The formwork in use for this project is the rail climbing system, With the reason that this project has a tight construction schedule.
- #12: 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.
- #13: 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.
- #14: 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.
- #15: 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.
- #16: 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.
- #17: 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.
- #18: 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.
- #19: 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.
- #20: 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.
- #21: 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%.
- #22: 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.
- #23: 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.
- #24: 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.