formwork handbook dlf capital greens

Upload: anupam-ghosh

Post on 07-Aug-2018

222 views

Category:

Documents


0 download

TRANSCRIPT

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    1/48

    1  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Handbook On Methodology for Formwork System

    For DLF, Capital Greens

    L&T ConstructionPrepared by: - Formwork Dept., RB&F, DLCLDoc Ref:-SOP/DLF Capital Greens/R0 

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    2/48

    2  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    INDEX 

    SL. Topic

    1) General Information / Formwork strategy 

    2)  Methodology for formwork systems proposed

    HY-RIB Stopper use for construction joints

    Column formwork

    Wall formwork

    Flex Formwork system

    Cup lock system

    Access Scaffold system

    CB 150 A

    3)  L&T Stair tower system

    4)  Form release agent & Plywood

    5)  Roles & Responsibilities of site Engg. / Foreman and charge hand

    6)  Standard allowable deviation as per IS 456:2000

    7)  Formwork: hand tools

    8)  Do’s & Don’ts in formwork  & stacking

    9)  Stacking (Housekeeping)

    10) Water jet for efficient cleaning of Shutter panels

    11) Shuttering oil sprayer machine

    12)  Formwork safety

    13) Accident Prevention

    14) Slab & Beam striking time as per the IS 456

    15) Formwork Check List

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    3/48

    3  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Formwork Strategy

    Structure  System proposed  Total scope

    (Sqm)

    Catering area

    (Sqm) 

    Isolated footings Wall / Column FW  4838  227

    Column square/ rectangle  Wall / Column FW  443544  7819 

    Retaining Wall  Wall / Column FW  5155 254

    Beam & slab Conventional  Cup lock system  400697  10595 

    Peripheral/ Heavy beams  Flex System 447817 11841

    Staircase Flex System 23524 871

    Total FW Scope  1325575 31608

    CLUSTER BSCC IN-CHARGE  SITE PLANNING IN-CHARGE 

    As per the formwork ACE

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    4/48

    4  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    METHODOLOGY FOR FORMWORK SYSTEMS PROPOSED 

    HY-RIB Stoppers for construction joints: 

    Hy-rib stoppers shall be used in the foundation where mass construction of concretehas to be done with-out any construction joints or heavy dense reinforcement is usedwhere it is difficult to erect vertical formwork shutter.

      Hy-rib permanent formwork comprises of Zinc-coated steel which areformed into a ribbed expanded mesh.

      It is a lost type formwork item to form construction joints in concrete &Stopper ends for retaining walls, columns & beams. It can also be used tosupport horizontal slab flooring.

      It will produce a surface which will bond directly with the next pour.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    5/48

    5  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    COLUMN FORMWORK SYSTEM

    SYSTEM DESCRIPTION: 

    Column Formwork is a complete ColumnFormwork system, mainly consists of plywoodsheathing backing by timber H-Beams and Steel

    Waler which can be erected manually & also can behandled by crane.Besides giving smooth concrete finish thisSystem comes with inbuilt safety and working acces-sories platform.

    Lifting Bracket

    Pl

     AlignmentSystem

    H-Beam

    orkPlatform 

    Steel

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    6/48

    6  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Method Statement for Column Formwork:

    Formwork Erection: 

    Making of shutter panels

    1)  Drill holes in H-beams for fixing beam clamp, lifting

    bracket & Working platform bracket.

    2)  Make shutter panels (without/with fixing of walers

    and accessories) of required size including cutting

    plywood for stitching with H-beams.

    3)  Fix of wooden planks (40mm) at top & bottom sides

    of shutters. Minimum size of column that can be

    done is 300mm x 300mm.4)  The shutter panels can be combined as an ‘L’

    shaped panel using angle plate& lifted to next loca-

    tion.

    5)  Fix starter suitable to column size.

    6)  Remove the forms for starter after concreting is

    over.

    7)  After concreting clean the shutters with water jet for any excess / over concreting.

     Assembly of formwork:

    1)  Fix both shutter panels in position.

    2)  Fix tie rod, anchor plates and wing nuts at the corner of shutters in each waler level.

    3)  Fix Alignment props/supporting brackets with Head adaptor assembly and

    foot adaptor assembly on the adjacent sides of the shutters.

    4)  Plumb the shutter panels as required and checking the column size as per requirement.

    5)  Fix the stop anchor, anchor cone with PVC sleeve to facilitate for fixing of climbing

    bracket for next lift.

    Deshuttering of column formwork:

    1)  Remove side panels in after removing the alignment props, tie rods/accessories only.

    2)  Clean, apply oil and shift.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    7/48

    7  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    WALL FORMWORK  

    SYSTEM DESCRIPTION: 

    Wall Formwork is a completeFormwork system, which main-ly consists of plywood sheath-ing backed by H-Beams andSteel walers (ISMC 100 B/Bchannels). The support is givenby double nut alignment propswhich can be used toalign the shutters to the re-quired angle and position.These shutters can be erectedmanually &also can be handled

    by crane.Besides giving smooth concretefinish this system comes withinbuilt safety and workingaccessories.

    Method statement for Wall Formwork: 

    Formwork Erection: 

    Making of shutter panels

    1)  Lay waler @ distance (or) predetermined location over the leveled surface. (Either a

    timber platform or with lean concrete to accommodate the size of the shutter panel)

    2)  Drill holes in H-beams for fixing beam clamp, Lifting bracket & working platform bracket

    at predetermined locations using suitable power drill.

    3)  Drill holes in H-beams with Drilling plate & safe guard for fixing M 6 x 70 bolts with

    waler.

    4)  Place the H-beams above the waler and connect the same with beam clamp / M6 bolts.

    5)  Place the Plywood (the grains should be perpendicular to the timber beams) and ensure

    proper butting of plywood with the Assembly.

    6)  Use only screws (1.5” long) for fixing plywood with H-beams. (approx. 8 no’s for 8’ x 4’

    plywood size )

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    8/48

    8  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    7)  Fix wooden planks (40mm thk. x 160 mm) at top & bottom sides of shutters. Provide slot

    in the top plank of lifting bracket location.

    8)  All the above should be done with an accuracy of ( + or -) 2mm

    9)  Any lengths of panel to suit the required dimension of walls can be formed using the

    available lengths of waler, splice plate & connecting pins, if the system is to be crane

    handled.

    Erection of wall formwork:

    1)  The wall panels should be placed on the outside first and all the gaps to be filled

    appropriately using fillers/sponge etc. for maintaining the form finish, then reinforce-

    ment can be tied and inner shutters be placed.

    2)  The wall panels should be placed alongside each other & aligned properly; edges

    checked using plumb bob and line threads.

    3)  The joints of the wall panels should be filled with sponge or appropriate filler material

    so that the slurry leakage is arrested.4)  The tie rod hole locations shall be made prior to erection of shutters so that the

    alignment &pattern of hole locations is to be maintained uniformly. No other holes

    should be allowed to drill later.

    5)  The grout check has to be fixed to the shutters at the top so that the concrete level can

    be maintained in a straight line for the pour and it also acts as a starter for the second

    pour above.

    6)  Fix timber spacers to maintain the wall thickness at top.

    7)  High strength tie system bears large concrete pressures and avoids load-bearing struts.

    8)  Panels can be made in large units for handling by crane and in smaller ones to facilitatemanual handling.

    9)  Panels can be used along with Climbing Formwork system for the more height.

    De-shuttering of wall formwork: 

    1)  First remove Wing nut, Anchor plates, Tie rods, Head adaptor assembly, Alignment

    struts, Supporting Brackets, Foot adaptor assembly.

    2)  Remove shutters (each separately) with the help of crane or manually.3)  In case of subsequent lifts remove climbing brackets, Suspended platforms handrail post,

    accessories.

    4)  In case of shutter being used for subsequent lifts the Alignment struts head adaptor

    assy., Foot adaptor assy., Supporting Brackets need not be removed.

    5)  Stacking of wall shutters shall be done vertically with fabricated steel racks (Ref. fig ver-

    tical stacking of formwork).

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    9/48

    9  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    FLEX SYSTEM

    SYSTEM DESCRIPTION:

    The forms shall be made with plywood backed by H-beam & supported by using props. Props

    take the load and shall be erect in position using tripods for lateral stability. The spacing be-

    tween the timber beams shall be in accordance with design criteria & should be properly

    screwed to the plywood and safely placed over the props to avoid toppling.

    The props are designed to take care of the vertical loads which are tested under maximum

    loading conditions. The spacing of CT prop will be decided based on the thickness of the slab

    i.e. load coming from the slab & the prop height required. More the height, the lesser will be

    the capacity so it should be ensured that use of props in the fully extended condition should

    be avoided.

    Method statement for FLEX FORMWORK: 

    Formwork Erection: 

    Erection of FLEX SYSTEM: 

    1)  Mark Props location.

    2)  Place main Props – I step, Tripods, - II step, Four way heads – III step.

    3)  Use four way heads over props at the lapping joints of primary H-beams.

    4)  Place primary & secondary layers of H-beams.

    5)  Place plywood’s and screw with H- beams.

    6)  No need to place tripod at all the prop Location but should provide at ends and joints

    of primary H-Beam

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    10/48

    10  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    7) Maintain the required level of slabs by adjusting the props.

    8)  Apply shutter release agent over plywood surface & fix masking tape in joints ofplywood to avoid slurry leakage. 

    De-shuttering of flex formwork: 

    1)  Lower the props height by collapsing.

    2)  Remove secondary beams and parallel remove plywood.

    3)  Remove primary beams.

    4)  Remove four way heads and Intermediate props.

    5)  Remove main props, four way heads, Tripods.

    6)  Clean and stack the plywood’s and H-beams for next portion.

    7)  Shift the materials to next location.

    8) Use Stacking pallets for the shifting. 

    CUPLOCK SYSTEM 

    SYSTEM DESCRIPTION:

    Sequence for Assembling: 

    1.  Level the ground and compacted the earth.

    2.  Mark the Scaffolding location on the ground/floor.

    3.  place the concrete sill or wooden sleeper above ground ( 300 x 300 x 150 mm )

    4.  Provide gap 300 mm between the scaffolding and permanent structure.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    11/48

    11  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    5.  Erect Scaffold Screw jack.

    6.  Erect Vertical leg over screw jack and connect with horizontal bracing both directions at

    every cup location.

    7.  Rotate the cup by hammering gently to tight the bracing.

    8.  Level the Scaffold after fixing the first level of the leg with water level.

    9.  Fix the working platform over the horizontal bracing ( 50 mm thick Timber planks )

    10. Fix the next level of scaffold leg.11. Brace the scaffolding with permanent structure and between towers

    at every 4.0 m height intervals.

    12. For fixing of bracing with permanent structure to scaffolding, use 150 x 150x 6 mm thick

    insert plate welded with NB 40 mm pipe.

    13. Use Anchor fastener 12 mm at 4 corners.

    14. Use scaffold up to a maximum height 40 meters.

    15. If Cup lock is used as staging, then place adjustable screw jack with U-head followed by

    other formwork components above it.

    STEP-1 STEP-2

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    12/48

    12  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Sequence for dismantling :

    1.  If used as staging remove the above formwork arrangement by lowering the adjustable

    screw jack with U-head.

    2.  Route the cup by hammering.3.  Remove horizontal bracing (above the working level).

    4.  Remove the Vertical legs simultaneously at same level as mentioned above.

    5.  Remove the working platforms (scaffold board the level above the working level).

    6.  Remove the Bracing between towers / with permanent structure when dismantling work

    reaches level below.

    7.  Remove Screw jack.

    8.  Shift the materials to next position.

    STEP-3 STEP-4

    STEP-5 STEP-6

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    13/48

    13  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Electrical safety guidelines:

    Scaffolds shall not be erected, used, dismantled, altered, or moved such that they or any

    conductive material handled on them might come closer to exposed and energized power

    lines than as indicated in the chart that follows:

    Insulated lines voltage Minimum distance Alternatives Less than 300 volts 3 feet (0.9) 2 times the length of  

    300-15 kv 10 feet ( 3.1m)  the line insulator  

    More than 50 kv 10 feet (3.1m) plus 4

    inches

     but never less than 

    10 cm for each 1 kv

    over 50 kv

    10 feet (3.1M ) 

    Un Insulated lines volt-

    age 

    Minimum distance Alternatives 

    Less than 50 kv 10 feet (3.1m)

    More than 50 kv 10 feet (3.1m) plus 4

    inches

    2 times the length of

    the line insulator

    10 cm for each 1 kv over

    50 kv

     but never less than 10

    feet (3.1m)

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    14/48

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    15/48

    15  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    CB150A & CB150F FORMWORK SYSTEM for the Highrise vertical 

    Column / Wall 

    SYSTEM DESCRIPTION:

      The L&T-Formwork Climbing System are used for tall structures like cooling towers,etc. where very uneconomical & unsafe to provide staging or scaffolding for supportingthe external or internal wall formwork.

      In this system bracket is hanged on anchors called lost stop anchors provided in the al-ready casted wall and supports/alignments are taken from these brackets. The bracketsare suitably braced to prevent any sway and are provided with walkways/working plat-

    forms / handrails etc. for safety and ease of working.

    CLIMBING BRACKET 150A

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    16/48

    16  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    17/48

    17  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    CLIMBING BRACKET -150A  -- SEQUENCE

     Assembly of Simple Climbing Formwork  

      After dismantling the shutters from the 1st pour of concrete, remove anchor cone using DK spanner

    and fix climbing cone in the stop anchor.

      Assemble Climbing bracket 150 A –  2 no's (max distance should be 2.0 to 2.40 m) and brace with NB

    40 pipes and couplers to form as a unit.

      Provide working platforms with 4“X 4” (or) timber as supporting member and 2” thick planks.

      Brace the primary member and climbing bracket with brace stirrup.

      Fix Handrail post on each bracket and hand railing at 2 levels should be done with NB 40 pipes &

    couplers.

      Lift the entire assembly of climbing bracket 150 A with the help of crane and place over the climbing

    cone correctly and lock the pin.

      Follow the procedures described in the assembly of wall formwork; however the alignment props to be

    fixed in the climbing bracket platform.

     

      Suspended platform 80 A should be fixed in the predetermined holes provided in the climbing bracket

    and brace the suspended platforms with NB 40 pipes and couplers. Provide 2” thick planks as wor k-

    ing platform.

      Cover the open face of suspended platform with safety net.

      Check the verticality of the shutter using plumb bob.

    Dismantling

      Remove the wall panel assembly and keep it on the ground.

      Remove Climbing bracket set and lift to the next location and place over Climbing cone already fixed

    in position.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    18/48

    18  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    L&T –  STAIR TOWER SYSTEM 

     Assembly of stair Tower:

    1.  Mark the Heavy-Duty tow-

    er location on the

    ground/floor (1525X2250systems)

    2.  Erect H.D. Tower spindle

    with Foot plate and spring

    lock pin 16 dia.

    3. Erect Basic frames 1.20 mheight with 1525mm X

    2250 mm Configuration

    over spindles and connect

    the frames with Diagonaland Horizontal bracing.

    4.  Level the basic frames af-

    ter fixing the first level.

    5.  Fix Connection angle with

    frames and connect it with

    spring lock pins and click

    and pawl.

    6. Fix the stair brackets (left

    & right) over horizontalmember of the frames and

    clamp them.

    7.  Fix the Grid Irons over

    Stair brackets using bolts

    & nuts.

    8.  Fix Inner hand railing, In-termediate railing.

    9.  Fix Diagonal bracing 12-

    225 with connection anglein each tier.

    10.  Fix Horizontal Bracing H-152 with connection angle in landing location.

    11.  Brace stair towers at every 6-m heights with the permanent structures.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    19/48

    19  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Dismantling of stair Tower:

    1. Remove intermediate railing and inner hand railing from Top.

    2. Remove Grid irons.

    3. Remove the stair brackets (both left & right)

    4. Remove Diagonal bracing, Horizontal Bracing

    5. Remove connection angle.

    6. Remove Bracing and frames.7. Remove the Bracing between towers / with permanent structure when disman-

    tling Work reaches that level.

    8. Remove Tower spindles with Foot plates at bottom.

    9. Stack the small components in the stacking pallet

    Description:

    Stair tower’s outer frame has been modified to accommodate mesh so as to prevent both menand material from falling.

    STAIRTOWER WITH NET

    COMPONENTS

      STFR 152 (Replacement of basic frame 1.2)

      STFR 225 (Replacement ofall bracings)

      STFR 225 OP (Half openfor entry)

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    20/48

    20  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Stair tower assembly 

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    21/48

    21  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    FORM RELEASE AGENT AND PLYWOOD 

    APPROVED FORM RELEASE AGENT

      FOSROC MAKE - REEBOL ( 20 – 60 SQM/LT)

      BASF MAKE – RHEOFINISH 202 ( 30 – 70 SQM/LT)

      DON MAKE – SET RELEASE RTU ( 22 –  30 SQM./LT) CICO MAKE – CICO LEASE ( 20 – 60 SQM/LT) 

    PLYWOOD IS CODES

    PLYWOOD FOR CONCRETE SHUTTERING WORKS – IS 4990:1993

      RESIN TREATED COMPRESSED WOOD LAMINATES (

      PLYWOOD FOR GENERAL PURPOSES (THIRD REVISION) IS 303-1989 

    Sl.no Description Specifications Reference / Remarks

    1Moisture con-

    tentMoisture content not15%

    For testing procedure referIS 1734 (Part 1) :1983

    2DimensionalTolerances

    Length=+6mm,-0mm,Width= +3mm, -0mm,Thk. tol.=for > 6mm = +/-5% & for < 6mm = +/-10%Edge straightness & squareness 2mm per 1000mmi.e 0.2%,

    Refer IS 12049 : 1987 fortolerance limits andthickness tolerance shallbe as perIS 303 : 1989

    3Thickness offace veneer

    layernot < 1.2 mm

    4 Timber Any Plantation timber shall be used as raw material

    5 Mass

    for 6mm - 3.90 kg/Sqm.

    for 9mm - 5.85 kg/Sqmfor 12mm - 7.80 kg/Sqmfor 19mm - 12.35 kg/Sqmfor 25mm - 16.25 kg/Sqm

    The accuracy of the massspecified can be taken onlywithin a tolerance of +/-10%

    6 AdhesivesShall be of the hot press synthetic resin (phenolformaldehyde)

    Shall conform to IS 848 :1974

    7No. of ply in

    a board7-ply / 9-ply

    8Tensile

    Strength

    not < 32.5 N/mm2 parallel to grain direction of theface veneersnot < 22.5 N/mm2 right angles to grain direction ofthe face veneerssum of the tensile strength in both directions shallbe not < 60.0 N/mm2

    9Water Re-sistant Test

    Shall conform to IS 1734(Part 4) :1983

    10 Test ReportEach consignment shall be supplied along withTest Report on the above parameters

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    22/48

    22  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    ROLES & RESPONSIBILITY OF FORMWORK ENGINEERS AT SITE 

    1.  Preparation of formwork strategy based on the overall construction programme

    & GFC drawing.

    2.  Finalization and coordination of shuttering scheme and should execute as per

    the FW scheme drawings and design.

    3.  Ensuring effective and proper utilization of shuttering and staging material

    4.  Planning and allocation of materials/labour/plant & machinery for formwork ac-tivities in coordination with concerned persons at site.

    5.  Educating sub-contractor on system formwork.

    6.  Making mock-up of various system formwork.

    7.  Periodical reconciliation of formwork materials

    8.  Preparing FW schedule (requirement/release) within the ACE provision and

    sending the same to cluster office.

    9.  Preparing stock statement of formwork materials both in units and in nos. with

    area of shuttering done category wise/Plywood/Timber procured during the

    quarter/till date and productivity report.

    10. Maintain close interaction with stores and site people for proper accounting of

    materials.

    11. Dispatch and receipt notes to be sent to cluster office in the regular basis.

    12. Making of purchase requisition for plywood and timber after thoroughly analyz-

    ing the number of repetitions.

    13. Receipt of plywood/formwork materials to be acknowledged after quality

    checks to cluster office on monthly basis.

    14. 100% materials reconciliation at the end of the job.15. Looking after pre-dispatch maintenance.

    16. Ensuring that dispatched materials are in usable condition.

    17. Sending monthly reports to cluster office.

    ROLES & RESPONSIBITY OF SITE FOREMAN/CHARGEHANDS 

    1.  Material accountability right from the materials receipts at site to dispatch toother site after completion of the job.

    2.  Small items have to be issued to the subcontractors form the stores and make

    them responsible for those items. For their sake, tool-box can be issued. These

    items have to reconcile after completion of the job.

    3.  Ensure the Proper utilization of the formwork materials and avoid the misuse &

    wastage of particularly H-Beam and Bracing.

    4.  Ensure proper housekeeping at site as well as the maintenance (greasing/oiling

    after De shuttering etc.) of the formwork materials.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    23/48

    23  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    5.  De-shuttering in right time to achieve maximum number of repetitions of form-

    work materials.

    6.  Optimum use of screws & Accessories of formwork.

    7.  Quality in works carried out at site so that the tolerance should be within the

    tolerance limit.

    8.  Formwork labour productivity should be monitored closely to achieve the man-

    agement goal.

    9.  Training of labour and sub-contractor workmen at site either by mockup or

    classroom programme by drawing sketches.

    10. Adoption of safety standards while working by fully equipped with PPE and us-

    ing the complete system at site (do not miss any bracing/connecting pin/locking

    pin etc.).

    11. Use of stacking pallets

    STANDARD ALLOWABLE DEVIATION AS PER IS 456:2000

    The tolerances on the shapes, lines and dimensions shown in the drawing shall be within the

    limits given below as per IS 456:2000

    a) Deviation from dimensions

    of footings

    + 12 mm

    - 6mm

    1) Dimensions in plan + 5omm

    - 12 mm

    2) Eccentricity 0.02 times thewidth of the footing

    in the direction

    of deviation

    but not more than

    50mm

    3) Thickness + 0.05 times the

    specified thickness

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    24/48

    24  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    L&T FORMWORK –  HAND TOOLS 

    .

    MEASURING

    TAPE

    CLAW

    HAMMER

    TRY

    SQUARE

    SPIRIT

    LEVELPLUMB

    BOB

    TUBE LEVEL LINE

    THREAD

    HAND

    SAW

    CHISEL

    AUGUR SCREW BAR ADJUSTABLE

    SCREW

    SPANNER

    DOUBLE END

    SPANNER

    RING

    SPANNER

    WORK

    BENCH

    HAND

    PLANNER 

    TWO WAY

    RATCHET

    PLYWOOD

    TRY SQUARE

    ( BIG)

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    25/48

    25  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    L&T FORMWORK – MACHINERY & POWER TOOLS 

    HEAVYDUTY DRILLING

    MACHINE

    HEAVY-DUTY HSS

    DRILL BITS

    HAND SAW CUTTING

    MACHINE

    DRILLING MA-

    CHINE UPTO 13.5

    MM

    TABLE PLANNER CIRCULAR SAW CUT-

    TING MACHINE

    ELECTRIC SCREW DRIVER & BITS JIG SAW RING

    SPANNER

    DOUBLE END

    SPANNER

    CONCERETE

    DRILL BITS 

    WOODEN

    FLAT DRILL

    BITS 

    ( HSS ) DRILL

    BIT

    HAND PLANNER

    (ELECTRIC)

    COUNTER SUNK

    DRILL BITS

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    26/48

    26  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    DO’S & DON’T’S 

    Flex system: 

      Use tripods only where the H-beams are lapping and at the ends.

      All the legs of the tripods to rest on firm ground.

      Props to rest on the ground firmly and should be compacted.

      Ensure sufficient lap of H-beam in primary & as well as in secondary.

      Ensure the Correct spacing of H-beam & Props. According to FW design (FW Scheme

    drawing).

    Cup Lock system:Ensure

      Ground should be fully compacted and uniform.

      All the horizontal bracings should be in position.

      Bracings between towers / tower and permanent structure, required at four times the

    minimum width of scaffold in height.

      Adjustable screw jack with base plates and adjustable screw jack with U-head are pro-

    vided at the bottom and

    top of vertical leg respec-tively.

      Cup lock should be

    straight/vertical

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    27/48

    27  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Normal Lifting Position 

     Angle shouldnot be less

    than 60º 

    40mm thick

    Timber plank ascompression

    strut

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    28/48

    28  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    STACKING (Housekeeping)

    It helps…… 

    In easy reconciliation

    Faster retrieval of material & reconciliation.

    Better space management

    Improves work culture

    Avoids wasteful expenditure

    Safety- prevention & loss of material

    Protection to materials- improves life of materialsEnables easy maintenance

    Stack the materials properly when not in use & protect them. 

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    29/48

    29  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    30/48

    30  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    31/48

    31  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Water jet for efficient cleaning of shutter panels: 

    Application Area

    • Removal of rust, markings and concrete from plywood & steel surfaces.

    • Remove lime scale deposits and marine growth.• Deck cleaning.

    • Dust free sand blasting.

    USEFUL

      Easy and fast removal of dust particles, rust and plastic papers.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    32/48

    32  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Shuttering oil sprayer machine :

    Shuttering oil sprayer machine can be used for easy application of shuttering oil on both hori-

    zontal and vertical shuttering panels. It sprays oil when compression pressure is maintained by

     pumping. It is easy handling for workers; they can hold it in hand or hang on their back. 

    Benefits:

      Better productivity (saving cost and time)  Less wastage   No separate rollers/brushes, containers required.  Protect shuttering plywood from damage as in case of conventional application method.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    33/48

    33  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    FORMWORK SAFETY: 

    Inbuilt safety features in L&T System Formwork

    Flex System

    Clear passage for workmen & inspection, self-standing with tripods. Beam Forming Support 

    Safe and easy fixing removal mechanism, no loose components.

    Column Wall /Formwork system 

    Walkway Passage for tying of reinforcement, concreting & vibrating. Lifting hooks for

    mechanical handling, double nut props for alignment in both directions.

    Cup Lock System 

    Simple connections- no loose components, easy vertical alignment on uneven ground

    also, self-locking pins.

    Stair Tower System

     Access to heights up to 100 m with adequate tying to structure at 6.0 m. Handrail at

    all locations, Regular and comfortable risers, Uniform Head room, Proper arrange-

    ment of landing at regular intervals, Multiple entry possible on sides of buildings .

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    34/48

    34  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    SCAFFOLD Tag system

    This should be installed by the Safety persons after inspected by the

    formwork Engineers & safety authority together.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    35/48

    35  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Columnstaging arrangement 

    •  Proper access 

    •  Guard rails 

    •  Intermediate Landing 

    •  Workmen equipped

    with all required 

    Personal Protective

    equipment. 

    Safety Net

    provided

    to protectfrom fall of

    workman

    & Material

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    36/48

    36  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Workers working with their safety belts

    connected to horizontal life line. They are

    protected from fall even while moving from

    place to place.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    37/48

    37  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Approach walkway 

    Flex System 

      All the main props should be fitted with folding tripod 

      Do not use tor steel in place of locking pin in CT Prop.

      In ground level work, proper earth compacted andnecessary bearing below the prop should be done. 

    Do not useReinforcement instead of lock-ing pin

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    38/48

    38  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Working Platform 

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    39/48

    39  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

      Every work-platform shall be provided with guard-rails as shown. 

      Height of the guardrail shall be from 900mm to1200mm. 

      Intermediate guardrail and toe-board are provided.Height of toe-board is minimum 100mm. 

      Scaffold boards should be well secured without anyplay.

      Work-platform shall be provided with proper access,

    like a ladder secured to the scaffold. 

    Working Platform 

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    40/48

    40  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Floor Openings 

    • Cover the openings • Provide guard rails • Safety net with fishing net

    to trap falling materials • Provide toe-guard to pre-

    vent materials fallingthrough openings

    Unprotected sides and edges must have guardrails or equivalent 

    Guarded Edge 

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    41/48

    41  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Access to Work Platform LADDER 

    1. Ladder shall be of soundquality usable in construc-tion having rungs equallyplaced.

    2. Ladder shall be secured tothe scaffold as shown. 3. Ladder shall be extended

    at least 1m above thework-platform. 

    4. Horizontal distance be-

    tween the base of the lad-der and the work-platformshall be ¼ of the height ofthe work-platform. 

    5. Length of ladder should notbe more than 10m 

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    42/48

    42  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Safe Access  –  for the Concreting of wall / Column with the help of

    brackets & NB i e 

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    43/48

    43  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Dismantling of  Scaffold 

    1. Cordon off the area and deploy

    only experienced men. ProvideRed Tag 

    2. Start dismantling from top. 3. Each tier shall be completely

    dismantled and the material low-

    ered to the ground before begin-ning to dismantle the next tier. 

    4. Use Derrick and Pulley for lower-

    ing materials if at heights. 5. While removing jammed or rust-

    ed scaffold components, anchor-ing safety belt is essential. 

    6. At the end of the day, if a scaf-fold is going to be left half-

    dismantled, it is essential to low-

    er all the loose scaffold materials

    down and ensure that the scaf-fold is braced adequately to thebuilding. 

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    44/48

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    45/48

    45  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

     Accident Prevention 

    1. Elimination of unsafe acts and conditions2. Inclusion of Safety Aspects in the design itself

    3. Integrating Safety into Systems & Work Methods4. Should Confirm the Scheme drawing before doing any formwork

     Activity in site.

    Safe Design   Adequate Factor of Safety for Formwork System and individual Com-

    ponents  Components can be inspected easily to check design adequacy and

    acceptance criteria  Consideration of concrete pressure and rate of pouring in formwork

    design  Formwork System is self-aligning and self-standing  Easy to fasten accessories  System integrated aligning and bracings

      Work-platform with handrails for the works at heights  Integrated climbing arrangements  Study components which are light in weight for easier handling

      System-integrated handles / lifting hooks for easier handling

      Proper Slinging and Rigging Practices should be followed whilelifting the formwork assembly.

      Strength and Location of lifting hooks should be checked.  No loose materials should be kept on the formwork panels or top

    platforms.

      Panels should be pre-checked before lifting

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    46/48

    46  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    Slab & Beam striking time as per the IS 456

    Re-propping has to do if early striking of formwork. For re-propping has tofollow the scheme drawing & design criteria.

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    47/48

    47  SOP –DLF Capital Greens

    Released by :- Formwork Dept., RB&F, DLCL L&T Construction

    CHECK LIST FOR L & T FORMWORK SYSTEM

    Tolerances : Dimensions = ( + or - ) - 1 mm , Plumb = ( + or - )-1 mm & Level = ( + or - ) - 5mm.  

    SL .

    NODESCIRIPITION

    Allowable

    ToleranceOK NOT OK REMARKS

    Wall / Column Formwork System 

    1 Verticality ( plumb )

    2 Tightening of tie rods

    3 Tie rod Tube inner dia. 22 mm

    Thickness of tube - 2.5 mm

    4 Tie rod tube both end using of tie rod cone

    5 maintain of wall thickness timber spacer to be fixed at top level

    6 Wall Thickness checked Every Joint

    7 Compression strut in Shutter panel top with 2" thk planks 

    8 protective Timber planks @ Shutter panel bottom

    9 Connection of H-beam With steel waler Using of m6 bolts

    SLAB ( Flex system ) 

    1 All the main props should be fitted with folding tripod

    ( H - Beam lapping location ) 

    2 All intermediate prop should be fitted with four way head

    ( or ) supporting bracket 

    3  Locking pin For Props ( No Alternative to be use ) 

    4 Verticality of props

  • 8/20/2019 Formwork Handbook Dlf Capital Greens

    48/48