Hand Book on Foundation,

Formwork, Rebar &

Concrete

Building Structure
Competency Center
Introduction............................................................................................6
Worksite Management............................................................................6
Assembly & Dismantling Process..............................................................9
Flowchart for Aluform...........................................................................32

Introduction..........................................................................................34
Type of Slipform....................................................................................36
Assembly procedures............................................................................36
Tapering Slipform.................................................................................38
Assembly of stair tower..........................................................................39
Dismantling procedure..........................................................................40
Summary of Labour Productivity Norms..................................................43
Slipform Planning.................................................................................44

Aluminium Formwork Refurbishment......................................................47

Plywood...............................................................................................71
Form Release agent..............................................................................73
Formwork lift........................................................................................74
Automatic Climbing System...................................................................75
Hand tools required..............................................................................76
Guidelines for Formwork Engineer ........................................................33
Guidelines for Foreman/Charge hand...................................................78
System Formwork Functions, applications& Safety...................................79

Category of Reinforcements...................................................................91
Reference Indian standards...................................................................91
Reference International Standards..........................................................91

2
Hook & Bend Allowance........................................................................92
Bar bending Schedule Format................................................................93
Minimum diameter required for Bending Former....................................98
Cross-sectional area & Mass of Rebar....................................................99
Checks...............................................................................................100
Testing of Rebar..................................................................................101
Nominal cover....................................................................................104
Tips on Cover.....................................................................................104
Tolerance of cover...............................................................................104
Material for cover...............................................................................105
Photographs (Rebar)...........................................................................106
Prefabricated cage photos...................................................................109
Rebar tying machine...........................................................................109
Splicing methods................................................................................110
Precautions.........................................................................................110
Splicing strengths................................................................................110
Reinforcement couplers.......................................................................110
Coupler photographs..........................................................................111
Classification of test for Reinforcement couplers....................................112
Reinforcement Binding........................................................................113
Welding of Reinforcements..................................................................115
Precautions in Rebar activity.................................................................117

Pile....................................................................................................119
Classification......................................................................................120
Factor governing Pile selection.............................................................112
List of Reference Codes.......................................................................125
Installation sequence
Driven cast in-situ piles...................................................................126
Bore cast in-situ piles......................................................................127
Characteristics of Bentonite suspension for BCIS piles...........................128
Important things to be followed...........................................................130

3
 Driven cast in-situ piles...................................................................130
Bore cast in-situ piles......................................................................131
Driven precast...............................................................................132
Load test on Piles................................................................................134
Types of Arrangements........................................................................134
Vertical load test Arrangements.......................................................135
Lateral load test Arrangements.......................................................137
Pullout test arrangements...............................................................138
Pile Integrity test..................................................................................140
PDA Test.............................................................................................140
O Cell Test........................................................................................142

Cement..............................................................................................145
Physical requirement of Cement...........................................................149
Mineral Admixtures.............................................................................150
Fly ash..........................................................................................150
GGBFS..........................................................................................154
Micro silica& Metakoline.................................................................154
Aggregates.........................................................................................155
Mechanical Properties....................................................................158
Grading Requirements...................................................................159
Mixing of water...................................................................................161
Admixture...........................................................................................162
Concrete............................................................................................163
Grades of concrete........................................................................164
Exposure conditions.......................................................................165
Batching.............................................................................................168
Mixing Time........................................................................................170
Transporting Concrete.........................................................................171
Planning.............................................................................................172
Compaction.......................................................................................173
Vibration............................................................................................173

4
Points to remembered in Compaction..................................................174
Finishing............................................................................................175
Curing...............................................................................................177
Common defects in Concrete..............................................................179
Types of Surface defects.......................................................................180
Special concrete..................................................................................186

Introduction........................................................................................187
Definition...........................................................................................187
Advantages of Prestressing..................................................................188
Application.........................................................................................188
Materials management.......................................................................189
Reference Standard & codes................................................................191
Elongation & Modified Elongation Calculations....................................192
Jack Pressure calculations....................................................................192
Losses in Prestressing..........................................................................193
Properties of HT strand (IS: 14268-1995).............................................193
Methodology of Post Tensioning works.................................................194
Prestressing Equipments......................................................................197
Tendon Profile.....................................................................................198
Case study.........................................................................................199
Photos................................................................................................201

5
 Aluminium Formwork
Introduction

Site will be provided with a set of formwork drawings which entailed the
followings: -
Shell Plan Layout
Formwork layout drawings,
Wall panel Layout,
Slab Panel Layout,
Starter Block Layout,
Corner Layouts,
Beam Panel Layout,
Soffit Layout,
Staircase Layout,
Bracket and Soldier layout,
Miscellaneous Layout which includes sunken portion, upstand portion
etc,
Elevations and sections drawings indicating the location of formwork
panels and component,
Typical Fixing Detail drawings,
Location of Box outs and Transfer Box out drawings for transfer of
Formwork, etc.

Worksite Management

Prior to the arrival of the containers from the disembarking point to the
project work site; a Stock Yard is to be properly allocated and set up for
the unloading of the formwork material and accessories.
This Stock Yard should preferably be located at close proximity or within
the compound of the project work site, properly fenced up and security

6
shall be of up most priority due to the high residue value in the secondary
market for aluminum formwork material.
A Workshop area for maintenance of formwork material is recommended
to be set up at the project site to minimize the downtime in requisition of
replacement panels.
The proposed Stock Yard and Workshop area shall be flexible and re-
adjustable to suit the working environment and project work site. As a
result of the far away Stock Yard or Workshop area the project progress
will affect the targeted construction cycle time. (Ref Layout Drg No.: )
Upon arrival of formwork panels at Project Site, Site personnel shall ensure
that the panels are stacked and stored according to sizes and marking using
proper separator such as pallets for easy identification and allocation for
subsequent distribution. (Dry Mockup will be assembled as per schemes
at factory; this will eliminate the usual problematic discrepancies of odd
size panels which need to be fabricated at project site).

BSCC - HQ shall provide the estimated manpower requirement for the

Project based on the quantity of formwork panels to be supplied to achieve
the required cycle time. This manpower requirement shall vary according
to the size of formwork use on the building.
However, the manpower requirement for other supplementary trades which
complement the formwork installation such as Mechanical & Electrical
(M&E) services and rebar works need to be taken into consideration also.
A joint effort of all operations from formwork installer, rebar, plumbing,
electrical and concreting workers need to be synchronized to achieve the
required cycle time.
Segregation and systematically allocation of duties for each formwork team
are required in ensuring optimization of productivity. Hence, each team
shall be delegated or assigned to do specific job tasks on a daily basis to
resemble a manufacturing production line. However, due consideration
should be used in determining the level of experience and compatibility of
persons when allocating tasks to minimize the risks.

7
Control measures should be taken to identify and minimize the hazards
associated with work involving the assembly and dismantling of formwork
equipment such as falls from height, slips, falling objects, noise, dust and
manual tasks.
The external working brackets/platforms or scaffoldings should not be
used to stack materials or equipment. This will lead to the persons working
on it expose to additional hazards in relation to trips and slips or collapse
of the external working brackets / platforms or scaffolding.
Minimize the working heights for persons performing the assembly and
dismantling formwork.
Mixing of formwork components should be avoided to prevent unsafe
installation such as mixing pins and braces which may lead to collapse of
the formwork.
Do not allow drop stripping of formwork as it is an unsafe practice.
Partially assembled or dismantled formwork should be secured during
break time to prevent against overturning or collapsing due to strong wind
or accidentally / unintentionally knock over by workers.
Electrical safety should be implemented for the safe use of electrical
equipment.
Protruding flat ties or projecting nails should be removed immediately
with appropriate tools at dismantling stage.
Use of personal protective equipment by all persons working at work
areas (such as safety hardness, safety helmets, eye protection etc) should
be strictly implemented.

Accessories (10%) extra will be supplied for the assembly and dismantling
of the formwork panels.
Sufficient tools required for assembling and dismantling will also be
supplied as per the attached list.

8
 Assembly Process
Setting Up Level & Marking Of Position
The project surveyor shall mark based on the approved construction drawings
to ensure that the gridline and level of the foundation level is properly set up,
marked for walls, column etc. Leveling must be checked prior to commencement
of formwork installation to ensure accurate positioning.

Cleaning of the surface and side panel of the formwork after each usage
shall be done immediately using proper tools.
Ensure that all front and side panel of formwork is properly coated with
recommended Form release agent that prevents from sticking and concrete
buildup aluminium form surfaces. It protects and prolongs the useful lives
of the aluminium formwork.
The following precautions shall be taken when applying the Formoil on
the aluminium panels.
The best results are obtained when a uniform application of Formoil is
applied immediately following stripping and subsequent cleaning of
the panels. Always ensure that the coated form surfaces are allowed
to dry prior to placing concrete.
Do not over apply. Excess Formoil can adversely affect performance
and should be picked up promptly with rags.
Prevent Formoil overspray from contacting reinforcing steel bars and/
or tensioning cables.

The support works such as rebar, Mechanical & Electrical (M&E) and
plumbing are to commence immediately once the set up is done. The
same is to be ensured before installing the Aluminium formwork.
The support works for the slab section commence after the slab formwork
panels are assembled.
Cover Blocks should be fixed on both sides of the rebar section for
positioning and eliminate the rebar from resting on the surface of the
formwork panels.

9
Positioning of outlets for electrical switch boxes to its correct alignment can
be done by riveting the appropriate fit size mould to the formwork panels.
The electrical switch boxes are then securely cap to the fit size mould and
fasten by way of wiring to the formwork panels. Ensure that it is properly
secured to prevent grouting from building up in the switch boxes.

Always commence wall erection from the external corner of the wall
section to ensure both joint external corner wall panels will support each
other for standing position. Pin and wedges are to be used to secure the
panels together. Always insert the pin from the inside out for easy removal
of pin after concreting.
The formwork panels wall positioning is securely placed on the marked
gridlines and level by way of fixing timber stoppers at the base of the
outer side of the formwork panels at interval of one (1) meter. This would
ensure that the formwork panels are not disposition during the concreting
process.
Once the initial wall corner panels are assembled, place the wall corner
panels on the allotted set up position.
Commence to erect simultaneously the balance of the wall panels from
either side of the external wall panel.
Proceed to assemble the internal wall corner. Place these panels into the
correct position on the lines which were set up by the surveyor. Proceed to
assemble the balance of the internal wall at both sides.
The internal and external walls are to be held together by flat wall tie with
wall tie sleeve and PVC cover. These wall tie sleeve and PVC cover are
to be cut for the exact length of the wall thickness. Flat wall tie are to be
coated with the Form Oil before each usage.
To determine and achieve the vertical accuracy of the formwork panels
assembled before concreting process, several methods such as plumb
bob, spirit level, theodolite equipment etc can be used. The simplified
method of using a plumb bob with a string attached to it which is then
suspended from the upper part of the formwork panels is used as a guide
to determine the deviation from the vertical alignment of the panels.
Additional wall panels or starter blocks (kickers) are fixed on the external
wall panels in accordance to the required height for the formation of the
10
slab concrete. Check to ensure that the verticality of the Starter Blocks
(kickers) is correctly aligned.
The Starter Blocks (kickers) shall remain at its position for the subsequent
forming of next level wall.

Fix the slab corner on top of the wall panels with round pins and wedges.
The position of the pins should be from top down to ease the dislodging
process.
The prop length and prop head is to be connected together for beam and
slab support.
Alu span mid beam and Alu span cantilever end beam are connected to
the Slab prop head using Beam Splice Bars. They are connected together
by long pins and wedges at bottom section.
The Aluspan mid beam sections are accurately position to enable the slab
panels to be connected systematically.
Commence to assemble the slab panels from the corner section of the
slab. Subsequently, fixed the whole slab area by pinning the slab panels
together with the Aluspan mid beam.

External working platform brackets are used to provide a work area at the
external wall section.
Once the first level is completed and external formwork panels are
removed, fix the external working brackets to the first floor level at position
slightly below the kickers which are fixed on first floor external slab.
The external working brackets are secured to the external wall section
from the inside using tie rods, nuts and bolts.
Once all the external working brackets are put in place, timber planks
and strips are placed on the floors and railings respectively to create an
external working platform for the assembly of the subsequent level of the
external formwork panels and kickers.
Another set of external working brackets are later fixed on the subsequent
level using the method as prescribed above.
Once the subsequent level of external formwork panels are fixed, the

11
external working brackets at one level below are removed and moved to
the subsequent level. This process is repeated until the completion of the
subsequent floors.

A numbering sequence / stenciling shall be given for each panel and is

identified in accordance to unit area such as living rooms, Kitchens, Bed
rooms, bathrooms, common areas etc.
Color identification scheme while numbering on each section or area will
also eliminate the confusion that may arise due to the size. It can be
identified such that Blue is for Room 1, Red is for Room 2, Green is for
Living area etc.,
By practicing the use of numbering system in combination with the color
identification scheme, it have been proven to avoid confusion and assist
in the process of identification of panels position once they are transferred
to the next level/floor.

Ensure that the position of the walls and column formwork are in
accordance with the set up marking.
Check to ensure correct spacing of props for slab formwork.
Check the verticality and horizontality level of the wall and slab panels
respectively.
Ensure that all pins, wedges and ties are properly secured and tightened.
Re-check the opening such as door and window panels are correct.
Re-check all propping stands to ensure its height are in accordance to
drawings.
Adequate bracing (if necessary) to ensure stability.
Ensure cover blocks are placed correctly.

Ensure site coordinators are available and on stand-by during the

concreting process.
Always ensure that concrete pouring is distributed evenly throughout the

12
wall sections before commencing to cast the slab level areas. This is to
prevent loading pressure on the formwork panels due to uneven casting.
Recheck the areas whenever cement slurry leakage is noted to determine
the cause of it. Remedy work should be done immediately to ensure the
concreting process is not affected.
During concreting, always ensure that immediate step is taken to remove
/ clean all the excess concrete that is stuck on the back of the formwork
panels. Non removal will result in the formwork panels getting too heavy
and also the scrapping task after the concrete has dried up becomes more
tedious.

13
 Dismantling Process

Formwork panels shall be removed without damaging the concrete.

Reinforcement Bars or other tools shall not be used as a lever against the
concrete in removing the formwork panels. Only panel puller shall be
used for removing the wall panels.
The appropriate time for the stripping of formwork panels will vary
according to the environment and type of concrete used. The formwork
panels of the wall, column and beam section can be usually dismantled
after 12 hours. However, this process shall subject to approval of the
project structural engineer after taking into consideration the grade of
concrete used, additional props stand ordered, etc.
lways ensure that the wall section panels are removed first follow by the
A
column and beam sections.
For precautionary step, ensure that formwork panels are removed
systematically and due care is to be taken to prevent any damages to the
formwork panels and also finish surface of the concrete whenever possible.
or safety reason, ensure that no workers are facing the pin and wedges
F
when removing using hammer. Pin and wedges removed are to be
collected and placed in containers to minimize lost and replacement.
he dismantle formwork panels shall be transferred to the next level/floor
T
for subsequent assembly process via the slab opening or staircase areas
in an orderly manner and to the appropriate section/area immediately.
This will eliminate the confusion and congestion in the dismantling area
or level as a result of too many dismantled formwork panels lying on the
floor area.
s the formwork panels are pre-numbered and if color identification
A
scheme is implemented, the transfer of panels can be determined and
planned ahead according to the various sections / areas of one level/floor
to the subsequent level/floor.
lways ensure that all the formwork panels are to be properly cleaned
A
and applied with the Form release agent to protect the surface of the
formworks before re-used.

14
 or the external wall section, the Starter Blocks (kickers) on the upper
F
portion of the floor level shall remain intact to support and align the
next level/floor of formwork panels that are going to be assembled.
The assembly of the external formwork panels can be done by using the
external working platforms that are fixed to the wall areas.

he appropriate time for the stripping of formwork panels will vary

T
according to the environment and type of concrete used. The formwork
panels of the slabs section are usually dismantled after 36 hours. However,
this process shall subject to approval of the project structural engineer
after taking into consideration the grade of concrete used, additional
props stand ordered, etc.
he Aluspans mid beams / end beams have to be removed first after
T
dismantling the wall panels. Proceed by removing the long pins and
wedges on the joint bars for the end and middle beams. However, the
prop lengths are to remain undisturbed during this process to lend support
for the weight of the concrete slab.
here shall be 2 sets of prop lengths to support the concrete slab. The first
T
set of the prop stands will only be removed when the assembly of the third
level/floor commences and also upon approval and consultation with the
project structural engineer.
roceed to dismantle the slab panels by commencing from the end of the
P
slab area. Once the slab panels are dismantled, continue to remove the
slab corners.

Flat wall Ties are used for the purpose of ensuring the thickness of the walls
and column are consistent. Flat wall ties are to be removed by using special
called Wall tie remover / extractor.

Subsequently, proceed to remove the wall tie sleeve which is embedded in the
walls and columns section by using nose player.

15
 Assembly Process

Form Release agent (Solvent based) to be applied on the surface of all the
panels before the assembly process.

16
 Assembly Process

Outer Corner is fixed to External Wall Corner panel by round pin and
wedge.

17
 Assembly Process

Inner Corner is fixed to the Internal Wall panels by round pin & wedge. The
Internal and External Wall Panels are hold by Flat Tie with Tie Bar Shield in
between the panels.

VERTICAL CORNER INTERNAL

18
 Assembly Process

Repeat Sequence No. 3 to complete the assembly of both the Internal and
External Wall Panels.

19
 Assembly Process

Install Slab Corner on the top portion of the Wall Panels with round pin &
wedge.

Slab Corner Internal

20
 Assembly Process

Aluspans mid beams / end beams and Prop head are combined by Beam
splice bar with long pin and wedge at the bottom section.

BEAM SPLICE BAR

Aluspan cantilever

BEAM SPLICE BAR

Aluspan

21
 Assembly Process

Start the assembly of the Slab Panels from the Slab corner Internal.
Subsequently, fill out the whole slab area by pinning the slab panels together
with the Aluspans (Comprises of Aluspans and cantilevers). Mid Beams / End
Beams

Slab corner Internal

22
 Assembly Process

Additional Wall Panels (or Kickers) are fixed to the external Wall Panels to raise
to the appropriate height to contain the slab concrete when it is poured.

ADDITIONAL WALL
PANEL / STARTER
BLOCK

23
 Assembly Process

Upon completion of the installation and fixing of the Wall and Slab Panels,
a numbering sequence will be made for each of these panels with colour
identification scheme to differentiate each of the unit area such as bedrooms,
living room, bathroom etc. This numbering and colour identification scheme
will ensure that each panels can be determined as to their exact location once
they are tansferred to the next level for installation.

Always ensure that wall ties, pins and wedges are properly installed and
secured before pouring concrete into the forms. Ensure that concrete pouring
is distribute evenly throughout the Wall Panels section before commencing to
cast the slabs level area.

24
 Dismantling Process

After 12 hours, remove the Internal Wall panels by knocking out the wedges
and pins. The Wall Panels are to be moved to upper floor through the slab
opening as shown. The transferring of the panels should be done in a
systematically and orderly manner to ensure that the next cycle or level is not
affected. Since all the panels are numbered with different colour identification
scheme, these transfer process can be determined and planned in advance
according to section of the building such as Room 1, Room 2, Bathroom are
etc.

25
 Dismantling Process

After removing the External Wall Forms (the starter Block (kicker) should
remain undisturbed), the dismantled wall forms are moved to upper floor.
Access Scaffolding is use for transferring of external wall panels from the
ground floor level. For level 1 and above, an external working platform is
fixed to the external wall. The external wall forms from level 1onward shall
be supported by the kickers. (These steps are to be repeated from one floor
to another floor.)

Starter Block

Super plate

26
 Dismantling Process

After removing the Wall Panels, proceed to the Slab Panels after 36 hours
by removing the long pins and wedges on the joint bars the end and middle
beam section.

27
 Dismantling Process

Upon removing the Aluspans Mid Beams and Aluspan cantilevers End Beams,
the prop shall remained undisturbed during this process to support the
concrete slab.

28
 Dismantling Process

Proceed to strip the Slab Panels and transfer to the next level according to the
designated area and installation sequence.

29
 Dismantling Process

Strip the Slab Corner.

30
 Dismantling Process

Pull out Wall flat Tie using Wall Tie puller and remove the Wall tie sleeve using
Nose player.

When the cube tests show that the slab concrete is sufficiently strong, the prop
together with the prop heads are removed and transferred to the next level.

31
 Flow Chart for
Aluform Work at Site
FLOW CHART FOR ALUFORM WORK AT SITE:-

1 1a, 1b, 1c

If not suitable
2a, 2b 2 3 3a

If suitable If not suitable

5 4 4a

7 7a
`
8

If work front is not ready

9 12

If work front is ready 10

11

13

14 15 15a

16a 16 17 18

19a, 19b, 19c, 19d 19

23 22 21 20

32
 Activity for the Flow
Chart Numbers
1. Receive Aluform materials.
1a. Packing list, BOQ, and Formwork layout.
1b. Tools.
1c. Additional accessories.
2. Visual inspection.
2a. Packing list & schemes.
2b. Acceptance criteria.
3. Inform concern for any defects
3a. Details of report.
4. Collect modification details.
4a. Fabrication drawings.
5. Stock the material as per packing list.
6. Room wise segregation.
7. Dry mock-up.
7a. Schemes.
8. Room wise numbering for identification.
9. Dismantling of mock-up.
10. Setting out.
11. Shift to work location.
12. Shift to stock yard.
13. Actual assembly at work location.
14. Slab rebars & M&E works.
15. Final checking (Pre pour check)
15a. Check list.
16. Concreting.
16a. Pour card.
17. Post pour check.
18. Leveling and finishing.
19. De-shuttering
19a. Removing pins and wedges.
19b. Removing wall ties.
19c. Removal of wall panels.
19d. Removal of deck panels.
20. Cleaning of panels.
21. Fixing of working platforms with brackets.
22. Erection of Safety posts / rails.
23. Applying Form release agent.

33
 Slipform
Introduction
Slipform has been accepted as a precise construction technique within a
comparatively short period of time an indication of its considerable popularity.
This popularity has in turn encouraged further research ensuring the adoption
of new methods and modern materials, which have firmly established
slipforming as an economical, rapid and accurate form of construction.
Now that it is properly developed, the technique can be applied to many
different forms of structure, including tapering formations with straight
or parabolic profiles incorporating constant reductions in wall thickness.
Traditional applications for slipforming are silos, chimneys, bridge piers,
water towers, special application like construction of pylons, lift core wall of
building, lining for tunnel shaft, framed structures etc.,

Slipform construction, also referred to as sliding form construction, is similar

to an extrusion process. Plastic concrete is placed in the forms, and the forms
act as moving die to shape the concrete. Once the form has been filled with
fresh concrete and hardening has started the form is gradually raised by the
lifting devices on which it is suspended. The rate of movement of the form
is regulated, so that the forms leave the concrete after it is strong enough to
retain its shape while supporting its own weight. Pouring of concrete, tying of
reinforcement, fixing of openings/inserts etc are performed gradually from a
working platform.
An average sliding speed of 200mm an hour is common, rising to 300mm
an hour under the best conditions and 100 to 150mm an hour when large or
complicated structures are being slipformed.

The slipform should be designed so that the loads to which its various
component parts are subjected are uniformly distributed, and the yokes are
loaded as uniformly and axially as possible to avoid their overturning. The
jacks should not be located in wall openings as for as possible. The loading
should not exceed the lifting capacity of the jacks. The loads acting on slipform
can be classified as follows,

34
 Dead load due to the components
Live loads due to Concrete
Friction between form and concrete
Workmen
Materials
Machinery
Other installations
Auxiliary load due to the way of application of live loads,
Crowds of workmen
Piles of materials
Shocks produced by material unloading

Wind pressure
Adhesion between concrete and form due to long interruption.
Friction due to incorrect position of form
Failure of one jack

Breaking of certain members of the slipform

Failure of two adjacent jacks

2 Kgf / cm 2 - when releasing the form.

4 Kgf / cm 2 - when coming out from the form.

20 Kg / cm 2 - after 24 hours since pouring.

200 Kg / cm2 - after 28 days.

35
Type of Slipform
The slipform can be broadly classified into,
Straight slipform.
Tapering slipform.
Slipform for special applications

Typical structures that are constructed using straight slipform technique are,
Silos
Cylindrical chimneys
Water tank shafts
Columns

Typical structures that are constructed using Tapering slipform are,

Conical chimneys
Ventilation stack
Tapered bridge piers

Typical structures that are constructed using Special slipform are,

Lift cores
Framed structures
Preheater building
RCC Pylons

Construction of block of flats, lifts and stair- well, bridge piers, preheater and
RCC pylons for boiler supporting structure using slipform techniques comes
under special applications because of their complex sizes, shapes and loads
to be lifted along with slipform, like walkway trusses, etc. which is essential
for construction.

Assembly Procedures

Position the vertical and horizontal reinforcement with correct cover.

Casting of the starter. (min: 150 - 200mm)
36
Check starter for the correctness in level and diameter.
Fix the inside and outside staging brackets/erect scaffold pipes, if
required.
Fix timber runners connecting the walkway brackets. / Level the surface
using cement mortar.
Check the level.
Tie the vertical and horizontal reinforcement upto shutter top height.
ark the position of inside and outside yokes in the starter, starting from
M
the tower location.
nsure that three sets of yokes are located in between two tower
E
verticals.
lign the panels and introduce steel washers at regular intervals to
A
maintain
4mm slope both inner & outer faces.
ix top and bottom waler pipe. Fix external supports, both horizontal and
F
inclined to align the shutter.
Fix filler panels.
Repeat the operation 10 to 12 for outside and make sure that washers are
introduced at the bottom of shutters to achieve 4mm slope towards inside.
ix the waler shoes, inside and outside yoke legs. Adjust waler shoe and
F
check the verticality on both faces
Keep timber supports between top & bottom walers at yoke location.
Align the form panel by external supports.
ix the yoke beam generally two numbers at the bottom and one number
F
at top.
Check the level of yoke beams with spirit levels.
Fix the inside and outside walkway brackets.
inish the final alignment by suitably adjusting the waler shoe bolts. Ensure
F
that all walers are touching the form panels. Provide packing wherever
required.
Fix the flying tie rod assembly and support the center rings. Ensure uniform
tightness is maintained in all the spokes.

37
Tapering Slipform
Position the vertical and horizontal reinforcement with correct cover.
asting the starter. (Provide pocket or pipe sleeve in yoke locations to
C
accommodate tapered sleeves )
heck starter for the correctness in inclination level and diameter. Chip
C
and finish the same, if required.
rect central tower using L&T HDT system and fix planks on the top after
E
aligning the top construction accurately.
Fix the centre frames with the help of scaffold pipes, if required.
re assemble the trusses and spiders after marking the location of inside
P
yoke leg, assemble with yoke legs, yoke beams, adjusting screws as per
initial setting diagram , erect them and provide support.
Check the level of truss.
ark the position of inside and outside yokes in the starter starting from
M
the tower location.
ssemble the panels along with
A form supports with pre assembled
condition.
ix top and bottom waler. Fix external supports both horizontal and inclined
F
to align the shutter.
ix inside and outside consoles and upper outside console and fix
F
planks.
Fix the yoke beams at top & bottom.
Check the level of yoke beams with spirit levels.
Fix the top platform pipes with guard railings.
Fix the jacks & turnbuckle jacks and finish the hydraulic connections.
Test for leakage in the line and jacks and replace, if required.
Fix water level tubes & check the platform level. Adjust if required.
Check the the final adjustment as per the initial setting diagram.
Fix the handrails.
Fix the tapered sleeves & jack rods.
nergise the slipform before filling the form and removing temporary
E
supports.

38
 tart the concreting after completion of all activities and checking the
S
availability of all materials as given in the planning for slipform.
Fix the inside and outside hanging scaffold and do the decking.
Tie the safety net.

Assembly of Stair Tower:

The verticality of the stair tower shall be checked only with plumb bob.

Stair tower shall be checked for verticality at every support location. If any
deviation is found it shall be corrected then and there, by adjusting support
length. The deviation in verticality shall not be more than 10mm for every
10M of height and maximum 50mm for the overall height.

1. Uniform layer of concreting.

2. Regular cleaning of shutters.
3. Penetration testing of concrete, for setting time.
4. Freeness of tapered sleeves.
5. Periodical plumb readings.
6. Adjustment for tilt & twists.
7. Prevent overflowing of concrete.
8. Maintain a free board of 100 mm.
9. Uniform distribution of load on the platform.
10. Lowering of unwanted materials periodically.
11. Proper handling of lasers.
12. Cooling of jacks where the temperature is very high.
13. Protection of high pressure hose.
14. Protection of turnbuckle spindles.
15. Greasing of all moving parts / outside the shutters.
16. Ensure free movement of shutters, walers, intermediate form supports,
planks and handrails.

39
17. Consistent quality of concrete.
18. Periodical checking of concrete slump.
19. Fixing of required setting time for concrete based on slipping speed.

Dismantling Procedure

1. Provide coil nuts in the final layer of concrete approximately 300 mm

from top of concrete.
2. Fix dismantling brackets, handrails, finish planking and transfer the load
of slipform assembly to the brackets.
3. Remove the flying tie rod assembly and lower the same.
4. Remove the inside and outside hanging scaffold and shift the planks to
the staging brackets.
5. Remove the jacks and sleeves.
6. Remove the yoke assembly, which consists of yoke legs, yoke beams
and waler shoes.
7. Remove inside & outside walers.
8. Remove the wall forms, while removing the waler.
9. Extract the jack rods and grout the holes.
10. Remove dismantling brackets after completing other works.

1. Provide coil nuts in the final layer of concrete.

2. Fix dismantling brackets, handrails, and fix the planks.
3. Remove and re-locate the R.G.Hoist to the required location(if it is
there).
4. Transfer the load of slipform assembly and main truss to the wall.
5. Remove & re-fix the safety net with the temporary platform.
6. Remove the inside & outside hanging scaffolding.

40
7. Remove all the hydraulic hoses, manifolds and the jacks.
8. Remove the intermediate form supports, spindles, turnbuckle, shutters,
form supports, wall thickness screws, radius screws and yoke beams.
9. Remove inside & outside yoke legs.
10. Dismantle the truss assembly.
11. Extract the jack rods and grout the hole
12. Lower the materials then and there.
13. Remove the dismantling platform.

The progress of slipform is mainly determined based on the time consuming

for concrete pouring speed and reinforcement tying. if any delay in these
two the progress will affect drastically. As the space available for tying the
horizontal is restricted in slipform, it is very essential to plan all the activities
well in advance and to be prepared before starting of slipform.

The following points have to be considered while making the schedule.

The length of vertical/horizontal bars should be restricted to 5 mtr. due to
the constraints in lifting and handing at heights.
The diagonal bars around openings should be avoided.
Wherever stirrups are used it should be in 2 pieces only.
I t is not possible to have verticals in yoke locations and hence alternate
bars should be placed nearby.
herever concrete is taken through a chute the verticals below the chutes
W
have to be lapped with smaller lengths by means of welding.

The total requirement of reinforcement should be cut / bent and kept near
the slipform structure before starting slipform. The stocks should be kept with
proper tag for easy identification.

1. ACI 318- Building code requirements for reinforcement concrete.

2. ACI 304- Recommended practice for measuring, mixing, transporting
and placing concrete.

41
3. ACI 313-77 R83 - Recommended practice for design and construction
of concrete bins, silos and bunkers for storage of granular materials.

4. ACI 347-78 - Recommended practice for concrete formwork.

5. ACI 313-77 - Allowable tolerance.

6. ASTM C 403-70 - Penetration resistance method of concrete setting.

42
 Summary of Labour
Productivity Norms

1 Erection of Access Tower (2.5 X 2.5 M) RM 32

2 Dismantling of Access Tower (2.5 X 2.5 M) RM 15
3 Erection of Stair Tower (2.5 X 2.5 M) RM 16
4 Dismantling of Stair Tower (2.5 X 2.5 M) RM 8
5 Straight Slipform Assembly YOKE SET 75
6 Straight Slipform Dismantling YOKE SET 55
7 Slipform Operation - Straight Slipform M2 1.22
8 Assembly of Pre-Stressed Silo YOKE SET 92
9 Slipform Concrete - Manual M 3
22
10 Slipform Concrete - Rmc With Pump M3 15
11 Slipform Concrete - Rmc With Hoist M3 25
12 Slipform Reinforcement - Straight Slipform MT 65
13 Extraction of Climbing Rod RM 0.34
14 Taper Slipform Assembly - Upto 24 Yoke Set MT 56
15 Taper Slipform Assembly - 16 To 48 Yoke Set MT 49
16 Taper Slipform Dismantling - Upto 24 Yoke Set MT 49
17 Taper Slipform Dismantling - 16 to 48 Yoke Set MT 46
18 Re-Assembly of Slipform - Taper Slipform MT 78
19 Re-Assembly of Slipform - Straight Slipform YOKE SET 90
20 Slipform Operation - Taper Slipform M 2
2.45
21 Slipform Reinforcement - Taper Slipform MT 90
22 Erection of R.G.Hoist NOS. 827
23 Re-Location of R.G.Hoist NOS. 1365
24 Dismantling of R.G.Hoist NOS. 675
25 Pre-Stressing Works in Silos MT 170
Note: The productivity norms will vary based on volume of work involved and number
of structures to be constructed in the project.

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 Slipform Planning
The execution of slipform job requires a complete and detailed preparation
as many simultaneous and successive operations are involved. The method
of construction, preparation of scheme drgs., calculating the requirement of
slipform materials, equipment, tools & tackles, consumable, manpower etc
needs thorough planning.

It also involve mix design, admixtures to be added for the concrete,

reinforcement around openings and planning for other related works on the
slipformed structure.

On large site with several structures built with the same slipform, planning
includes
Work below slip form level
Detailed programme for the wall
Work involved in intermediate floors, if any.
Embedment/ pockets and other installations during slipform

The number of yokes for each silo is calculated based on the diameter of the
silo. The yoke to yoke distance is normally kept between 1.25 and 1.35 m.
Once the number of yokes required is calculated the list of materials can be
prepared from the master list. The requirement of jack rods depends on the
height of structure. Always keep 5% extra material as spare.

Normally 2Nos. Yoke beams at the bottom and 1 at the top are fixed.
Wherever yokes are used for supporting some lifting arrangements, there the
top yoke beams also shall be 2 no back to back.

The capacity of Jacks to be deployed is depends on the following loads:

Dead weight of yokes,

44
Dead weight of Concrete lifting arrangements

Weight of Platform with 40thk plank

Weight of wooden Runners 125*75mm

Total Dead Load =X

Live load over platform @ 200kg/sqm

Weight of Concrete 0.5 cum

Weight of Steel (reinforcement, jack rod stacked on platform)

Total Live load Y

Frictional forces @0.173kg/m (length along the wall sides) Z

Total Load on Slipform L = (X+Y+Z) * t

Required Jacking Capacity (W) should be with 1.4 factor

Note:- Jack shall not be loaded more than 80% of its capacity.

Concrete Equipment
The quantity of concrete required per meter height should be calculated
first. The slipping speed can be assumed based on the quantity of concrete ,
reinforcement, pre-stressing and other related items. Rate of rise depends on
the above and setting time of concrete. Once the slipping speed is assumed
the concrete requirement per shift can be calculated.

Once the quantity per shift is known, with 25% spare capacity, the size and
number of mixing and lifting equipment shall be decided.

Consumable:
The standard list of consumable is given along with master material list. The
quantity of electrodes, gas, grease, oil etc. can be given approximately. The
45
wire rope required for hoisting to be calculated separately based on height of
the structure.

Timber Requirement
The requirement of timber is for the following areas.
1) Working platform 2) Masons platform 3) Runners for supports
4) Planks for the bracket platform if assembly is taken up from higher
elevation.

Working Platforms
Timber platform consisting of four parts
a) Supporting runners 5x 3x7 long & 6 long
b) Wooden planks 6 x 1 x 6 long.
c) Toe board size: 4 x 1 x 6 long

Manpower Requirement:
The requirement of labour for various activities can be calculated based on the
productivity norms, site conditions and type of structure.It is preferable to engage
one single agency for the entire slipform works in a project to have better control
over productivity and also optimum use of workmen with multi skill.

46
 Tunnel Form
Description of Half Tunnel Form

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