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Application of Formwork for High-rise and Complex Building Structures – the Hong Kong Cases Raymond Wong Wai Man, Division of Building Science and Technology, City University of Hong Kong

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Page 1: Conditions and Constraints in the Application of …personal.cityu.edu.hk/~bswmwong/photo_lib/formwork...Application of Formwork for High-rise and Complex Building Structures – the

Application of Formwork for High-rise and Complex Building Structures

– the Hong Kong Cases

Raymond Wong Wai Man,

Division of Building Science and Technology,

City University of Hong Kong

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1. Introduction

• Formwork system is the key factor determining the success of a construction project in terms of- speed- quality- cost- safety of works

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2. Classification of Formwork

• Sizes• Location of use• Materials of construction• Nature of operation• Brand name of the products.

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2.1 Classification according to sizes

small-sized formwork

- operation by workers manually - timber and aluminium

large-sized formwork

- crane facilities are required in the operation- reduce the number of jointing and to minimize the number

of lift. - stiffening components - studs and soldier.

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2.2 Classification according to location of use

• Different elements in the structure have different design and performance requirements in the use of formwork.

• Some systems are more adaptive for specific location of use, such as

Irregular frame structure – traditional timber form or aluminium formCross Wall – gang form, climb form or jump form Floor – table formRepeated regular section – tunnel form

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Aluminium formwork system for residential housing block

Timber formwork for irregular-grid podium structure

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Steel panel form (Gang form) for constructing a core wall

Table form for the flat slab structure

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Gantry form/tunnel form system for the construction of station facilities

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Jump form system used in public housing project

Climb form in the construction of the 50-storey Manulife Tower

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2.3 Classification according to materials of construction

• Timber - most popular formwork material - low initial cost - high adaptability to complicated shape- labour intensive and environmental

unfriendly• steel - hot-rolled or cold-formed sections

- heavy weight - suitable for large-sized panels

• Aluminium - stiff and light weight- higher material and labour cost- excellent finish

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Detail of wall formwork using manual operable timber panels

The Festival Walk, a super-sized shopping mall constructed in traditional timber formwork system

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Examples of steel form in the form of large panel shutters

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Detail of a typical aluminium formwork system for apartment-type building

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2.4 Classification according to nature of operation

• Manually operated formwork

• Self-lifted formwork

• Crane-lifted formwork

• Gantry, traveling and tunnel type formwork system

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Climb form operated by the use of a series of synchronized hydraulic jack systems

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Jump form for the construction of a high-rise residential tower –lifting action is done by a series of screw jack systems

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• Construction of the 600m-long elevated expressway for theLantau Link using a type of traveling gantry form

• Structure of the ShuiHong Station of the West Rail projects

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2.5 Classification according to brand name of the product

Some common names in the market

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3. Considerations when using formwork

3.1 Design related considerations

• shape of the building• Architectural features on building exterior• Internal layout• Structural form• Consistence in building dimensions• Span and Headroom • Repetitive nature• Finishing standard

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3. Considerations when using formwork

3.2 Construction related considerations

• Complexity of the built environment• Speed of work• No. of possible reuses• Construction planning and arrangement• Area or volume of cast per pour• Involvement of other construction technique• Dependence of work• Provision of construction joint• Accessibility to work• Feasibility of introducing alternative design

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Examples of some crucial built situations

very large site

Sloped site

very crowded site

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Phasing arrangement to be considered

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Examples where special techniques are involved in the construction

Incorporation of precast elements

Incorporation of tensioning and complicated phasing arrangement

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Examples where complicated construction jointing requirement are involved

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Accessibility problems in formwork process

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Accessibility problems in formwork process– more examples

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4 Examples of Application4.1 Festival Walk – using traditional

manual-type timber formwork

• 21,000 sq m site. • 4-level basement and

7-level upper structure.

Features:• A 48m-span void

constructed of 8 numbers of cast-in-situ and post-tensioned beams, supported on the sides by bearers

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• large span structures up to 32m in length, cast-in-situ, some are post-tensioned.

• 3 atrium spaces, averaged 35m in span, and with 25m headroom

• Average headroom for each floor is about 4.5m.

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• Basement -- top-down approach.

• non-repeated layout

• structure subdivided into 6 main phases.

• great number of construction jointing

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Other complication/ features of the formwork system as shown in the project

Using the ground surface as formwork soffit

Formwork forming the shape of the drop panel of the flat slab using blinding concrete

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Other complication/features of the formwork system

Provision of complicated construction jointing in the formwork

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4.2 Belcher’s Garden – using traditional manual-type timber form

• situates on sloped site with area around 24,000 sq m.

• level difference about 65m.

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Forming the sloped beams on the formed slope

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Construction of the podium structure

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Other featurs:

• 10-level podium, used as carpark, shopping mall and recreational facilities

• Six 48-storeyresidential towers built on top of podium

• huge size of podium and sophisticated typographic environment of site, demands complicated phasing and sectioning arrangements

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Falsework to support the transfer plate

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Detail of transfer plate before concreting

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Superstructure

- irregularity in layout

- complicated architectural features in external envelops

- large amount of short-span slabs

- large amount of shear walls in the structure

- use of manuallyoperated timber panel forms

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Detail of the floor form layout from an elevated position

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Detail of the wall formwork

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Detail of wall and floor formwork arrangement as seen from the floor interior

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4.3 Lee Garden Hotel Redevelopment – Climb form for core, composite slab and structural steel outer frame

• 50-storey office building

• inner core constructed in reinforced concrete

• outer frame in structural steel

• RC core constructed using the VSL climb form -- self-lifting formwork system using hydraulic jacks

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Assembling of the climb form on the ground slab level

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The climb form at its trial operation

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Details of the Climb-form system

Gantry frame, shutters, rail tracks, and scaffold detail

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More detail on the rail track for the panel shutters

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Detail of the guide wheel and locking pin

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Resizing the form where the section of the core wall changed

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4.4 Cheung Kong Center –

• 62-storey office building

• Jump form system for core

•composite slab and concrete-filled steel tube as the outer frame

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Layout of the Jump Form rising from the foundation raft

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Overall layout arrangement of the Jump Form as seen from an elevated position

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Screw jack detail

Formwork arrangement as viewed from the side

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The gantry frame that mounted the panel shutters rigidly within the core wall layout

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Steel fixing inside the form

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Detail seeing the arrangement of the formwork system with the panel shutters in position

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Form system as seen from the inner shaft

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4.5 Gateway – Climb form for core and table form for slab

• 3 detached building towers each of 38-storey high• structure of towers –

central core with averaged 12m span RC columns around

post-tensioned flat slab system,

core wall - VSL climb form, partially in large panel gang forms

slab – aluminium strutted flying form system

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Some sections at the sides of the core wall are formed using large panel shutter

External view of the climb form for the construction of the core wall

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Floor slab as seen from various elevations

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Wall section of the core before the enclosing with panel shutters.

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Other Features

- slab is cast in two separated sections in a staggered manner with a lapse of 2 to 3 storeys to convenient tensioning works, as well as to obtain better operation arrangement in the handling of the formwork

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Flat slab and post-tensioning arrangement

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Dropped panel at the column head and detail for slab joining to the core wall

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4.6 Harbourfront Landmark – Steel panel form for shear walls & table form for slab

• 62-storey residential development with 3 attached towers on a 6,500 sq m site.

• Shear walls to form compartment units, centered with a core structure.

• Walls -- steel form system

• Slabs -- aluminium-strutted flying form system

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General detail of the steel form for wall

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Detail of large panel wall formwork

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The rear elevation with ellipse-shaped core wall serving as kitchen and store room

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The rear section with slab constructed using manual timber formwork

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• central cores -- constructed in form of vertical shaft. • inner structures – slab, lift walls & landings are cast-in-situ

using timber forms• stair flights -- prefabricated

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Releasing the table form

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Placing the table form

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Forming the inner walls and stair landing within the core shaft

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4.7 Park Avenue – Aluminium form• four 46-storey high

residential towers on transfer plate

• aluminium formwork -MIVAN system

• structure consist of a large number of shear wall

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Mock up of the Aluminium Form before installation in full scale

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General detail of the aluminium form –walls and beams

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General detail of the aluminium form –walls and beams

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General detail of the aluminium form –walls and beams

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General detail of the aluminium form – wall (view from interior)

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General detail of the aluminiumform – Floor

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General detail of the aluminium form – stair

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General detail of the aluminium form – stair

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General detail of the aluminium form –Plant box and external features

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General detail of the aluminium form – Plant box and external features

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General detail of the aluminium form – Plant box and external features

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Close up detail

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Close up detail

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Close up detail

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Problems encountered in the using of the Aluminium Form

• Too many formwork accessories that make installation very difficult

• Complicated external wall and spatial design magnify the installation problem

• Inconsistent in the major structural elements require frequent amendment to the formwork

• Resulted to a very long learning curve

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Problem of too many insistently sized components

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4.8 Nina Plaza• Climb form for the core wall (3 isolated cores)• Modified steel table form for floor slab• Traditional timber form for podium structure

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Arrangement of the climb form for one of the building cores

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The form in its opened mold

Side view of the form seeing the platform and the jacking rod

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Overview of the formwork arrangement for the core and the floor

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Floor formed in staggered manner

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Propping arrangement and the layout of the table form as seen from the underside

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4.9 Some advanced self-climbing systems used in various forms of development - IFCII

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Building frame and core wall layout

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Formwork at its opened mold

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Close up view of the hydraulic jack

Jack for external panels

Jack for inner panels

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Operation of the Climb Form (Panels in the inner shaft)

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Operation of the Jack System

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Setting up of the climb form at the deck level

Deck at the topping out level

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Gantry frame, scaffold and Panel shutters as seen in the form interior

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Linking the core and the inner wall/slab construction

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4.10 Some advanced self-climbing systems used in various forms of development –

Residential Development at Repulse Bay

Formwork Features• A curved apartment-

type tower structure of 28-storey high

• 5 stair-core in parabolic-shape elevation, constructed using climb form

• Modified steel table form for the floors

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Detail of the staircase core

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Junction detail between core and the floor slab

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The table form for the casting of floor

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The hydraulic jack mounted on the external face for the lifting of the climb-form system

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4.11 Some advanced self-climbing systems used in various forms of development –

Residential Development at Stubb Road

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External view of the Jump form

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The form system as seen on the deck level

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Detail of the screw jack and the motor gear

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Detail of the shuttering arrangement

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Panel shutters inside the form system

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Panel shutters inside the form system

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4.12 Some advanced self-climbing systems used in various forms of development –Chartered House

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Large panel formwork for the ground floor core wall

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Modifying the large panel form into the climb form by adding in the gantry frame and jack system

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Overview of the climb form

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Arrangement between the core wall and the floor

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Layout of the core wall and the gantry/jack system within the core wall shaft

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Placing a section of the table form onto the floor slab

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Material hoist for the lifting of the table form units

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The floor slab and the tensioning arrangement

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4.13 Some advanced self-climbing systems used in various forms of development –

Urban Renewal Authority Mong Kong Redevelopment

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Forming the transfer plate and the lower section of core wall using manual timber form

The lower section of core wall below the transfer plate

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Erection and trial operation of the slip form system

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Erection of the slip form on top of the transfer plate

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Arrangement for the core wall and floor formwork

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Layout/gantry frame arrangement above and below the deck level

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Close up detail of the hydraulic jack system

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4.14 Some advanced self-climbing systems used in various forms of development –

Concord Project in Fanling Wah Ming Estate

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Detail of the jump form for constructing the core wall

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Detail and layout of the jump form for constructing a typical wing

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Close up seeing the operation detail of the jump form and the guide rail for the panel shutters

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4.15.1 Formwork Systems used in Civil Jobs –Ma Wan Elevated Expressway

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Complicated falsework is required in the forming of the elevated expressway section

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Gantry-type traveling formwork for the casting of the repeated expressway section

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4.15.2 Formwork Systems used in Civil Jobs –West Rail Sui Hong Station

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Setting-up of the gantry form for the construction of the station structure

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A suspended soffit supported by hangers from the gantries. The soffit will be used to cast the suspended slab of the station structure

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Detailed view of the gantry system and the suspended station slab

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The construction of the station’s superstructure using usual large-panel gang form from the suspended slab

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4.15.3 Formwork Systems used in Civil Jobs –West Rail Depot at Pat Sheung

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Traveling form for the casting of the repeated station structure/deck

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4.15.4 Formwork Systems used in Civil Jobs –Airport Ground Transportation Centre

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Traveling form for the forming of the passenger access linking the Airport Terminal Building and the Ground Transportation Center

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Detail of the double-decked passageway – waffle floor for the upper deck

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Forming the hollow-section curved roof of the GTC

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Gantry supporting the roof soffit that formed the under-side of the roof structure

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The roof portion above column head that formed using normal soffit panel supported by props

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Comparing some formwork cases for circular structures

Circular ramp in Festival Walk

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Comparing some formwork cases for circular structures

Circular ramp in IFC-I

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Comparing some formwork cases for circular structures

Circular ramp in IFC-II

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Comparing some formwork cases for circular structures

Circular ramp in Festival Walk

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A spiral-shaped stair

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Formwork Collapse Cases – The Festival Walk

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Formwork Collapse Cases –a portal beam in the Ma On Shan Station of the KCR East Rail Extension

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A portal beam formwork similar to the one collapsed

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Formwork Collapse Cases -Industrial Building in Kwai Fook Rord, Kwai Chung, 1995

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Summary

The structural form of the building is one of the critical factors to determine the choice of formwork

System products contribute much in the success of formwork application

The choice and arrangement of utilizing formwork is highly depended on individual site/project environment

More collaboration between client, design teams and contractor can help in the effective use of more advance formwork systems