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L&T DOKA FORMWORK SYSTEM PRESENTED BY: TUSHAR AKBARI (CPM0106) SUBMITTED TO: MR. DEBASIS SARKAR
DOKA FORMWORK Inc. • leading European company for concrete formwork. • Doka formwork technology makes a major contribution towards getting concrete into the desired ‘form’ - in an economical way. • EUR 394 Million Doka Group is spreaded in more than 35 countries of world .
L & T-ECC in association with DOKA: 1985 1986
Collaboration with M/s Doka of Austria Fabrication of steel components vendors commenced
1990
Production of commenced
1991
Marketing of formwork systems to external clients
1997
Dedicated factory set up at Pondicherry for manufacture of steel components
2000
1) Timber beam production facility at Chennai shifted to Pondicherry 2) New line added for timber beam production to enhance capacity
timber
beams
at
through Chennai
MERITS OF L&T DOKA!!!!!! • Simplicity in assembly of system. • The system is flexible, easy to understand and versatile. • can be made suitable for all applications, requires little working skill and helps to achieve uniformly good quality of finish. • high labor and material productivity with speed and safety. • Investment need may be made on the minimum quantity of formwork. • More no. repetitive usage. • Greater life span and less labor requirement. • Able to resist more lateral pressure of liquid concrete. • Less chance of burglary & misuse due to heavy weight & large size. • Easily modifiable as compare to steel formwork. • accurate, safe and speedy construction
DEMERITS OF L&T DOKA !!! • High initial investment. • would be handicapped without tower crane. • Require more mechanized setup at site. • Handling and placing is very difficult, it requires separate shade to store them. • In house training require to increase labor efficiency. • Proper storage space is required when job is over
NEED FOR “SYSTEM”FORMWORK? • Vertical growth • Traditionally under mechanized & labor intensive. • Excessive use of reinforced cement concrete. • High quality surface finishes for exposed R.C.C work • Acute shortage of highly skilled & competent formwork carpenter. • Modular panel with high flexibility
LOADS AND DESIGN • Density of concrete • Slump of concrete • Rate of pour • Method of discharge • Concrete temperature • Vibration • Height of discharge • Dimensions of sections cast • Reinforcement detail • Stiffness of forms • Transfer of loads from floor to floor during construction Shuttering area of 3 to 5 sq m. is required for placing 1 cu.m of concrete and formwork therefore contributes a major factor in the cost, this being 25% to 70% of the total cost.
H-BEAM: BACKBONE OF L&T DOKA SYSTEM • An engineered timber component • Manufactured under strict quality control. • The flanges are made of seasoned chemically treated timber. The web is made of boiling water proof plywood and joined with the flange by unique finger joint. • H–beams are light, dimensionally stable and retain their structural properties over a period of time even after repeated usage. • The H – beams can be used more than 100 times and it consumes only 40% of timber volume required. • H-16 (16 cm depth) and H-20 (20 cm depth), length varying from 1m to 4m. – Reduces consumption of timber – Minimizes work at site – Consistent in strength. – Cost ratio per use of H-16 beam to conventional timber = 1: 3.5 – Economical and long-lasting.
• Components – – – – – – – –
FLEX SYSTEM
H-Beam Floor Form Plywood Collapsible Telescopic Prop Four way head Removable folding tripod Supporting head Assembly wedge clamp
FLEX SYSTEM • Advantages – Effective for slab and beam formwork upto floor heights of 4.4 m. – Removable folding tripods make selected individual prop self standing – Flexibility in spacing between and heights of individual props. – Components are light enough for erecting and dismantling manually. – Lapping of standard lengths of H-Beams both in primary and secondary layers avoid their cutting at site. – Avoids skilled labour at site – Enables re-propping and frequent reuse of materials. – Simple deshuttering operation.
• Advantages – Can be transferred as complete set, hence no loss of components – Shifting trolley provides superb mobility in horizontal direction – Quick to shift, faster construction – Easy fixing, high labour productivity – Less props in relation to area
HEAVY DUTY TOWER SYSTEM • Components – Basic Frame – size of 0.9 m, 1.2 m, 1.8 m – Horizontal Brace – Diagonal Brace – Foot Plate – U-Head – Tower spindle with lever nut – Beam span 2230 – Beam span extension 1525 – Coupler – Brace stirrup – Short prop
HEAVY DUTY TOWER SYSTEM • Advantages – High load carrying capacity is > 25 tons per tower. – Rigid and stable with minimum bracings. – Easy to erect and dismantle using unskilled labour. – Tower as a whole can be shifted using crane and transport wheels. – Ideal for heavy floors involving greater heights. – Can be converted into stair – tower with additional standard components. – Heights upto 700mm can be made by spindles at top and bottom
WALL FORMWORK SYSTEM USED IN CEMENT SILO WITH WORKING PLATFORM AND HEAVY DUTY TOWER SYSTEM
WALL FORMWORK SYSTEM USING ALUMINUM PROPS AND SCAFFOLDING
Advantages – Ideal system for speedy construction. – Wall panels can be dismantled and handled manually. – Minimizes the number of sheathing joints. – Simple shuttering and de-shuttering operation. – Wall Formwork panels facilitates fixing of working platform and alignment system
Basic Frame – 1.2 m Foot Plate Tower spindle with lever nut Coupler Spring locked connecting pin Horizontal Brace Scaffolding pipe Swivel coupler Stair Bracket Intermediate Railing Inner hand railing Connection Angle Grid Iron
STAIR TOWER
ELEVATION
STAIRCASE IN HEAVY DUTY TOWER SYSTEN WITH SAFETY NET HT. 40 ft.
TOP VIEW
NUCLEAR POWER PLANT FORMWORK : KAIGA UNIT 3&4
PROJECT BREAK DOWN STRUCTURE
Major Consultants for 1&2 •Stup Consultants •Development consultants pvt. Ltd. •Mecon (eng. & drg. Consultant)
Client is itself the designer of the project as this project is repetition of Kaiga 1 & 2.
CLIENT: NUCLEAR POWER CORPORATION OF INDIA LTD. (NPCIL)
CONTRACTOR FOR INTAKE TUNNEL
MAIN CONTRACTOR FOR CIVIL WORKS
CONTRACTOR FOR EXCAVATION WORKS
M/S L&T , ECC DIVISION
M/S GAMMON INDIA LTD.
M/S AFCONS INFRASTRUCTURE
SUB CONTRACTOR FOR TB3,TB4,SRPH,FWPH M/S IVRCL (I. VENKAT REDDY CONSTRUCTION LTD.
CONTRACTORS FOR MECHANICAL WORKS
CONTRACTORS FOR PUMP HOUSE
M/S BHEL
M/S EPCIL(ENGG. PROJECTS INDIA LTD.)
SUB CONTRACTOR FOR FABRICATION AND FIXING OF EP’S •M/S NSG FABRICATION •M/S SUVARNA FABRICATION
SUB CONTRACTOR FOR MACHINARY & EQUIPMEN SUPPLY M/S SETHIA EQUIPMENT
• • • • •
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• • • • • • • •
JOB: Construction of main plant civil works package II for Kaiga unit 3 & 4. AIM: Generation of power using stem from PHWR type nuclear reactor . PROJECT TYPE : Infrastructure CONTRACT TYPE: Item rate contract CLIENTS: Nuclear power corporation of India ltd. (NPCIL) Kaiga Atomic Power Project 1,2,3&4 Post: Kaiga,Karnatka – 581400 CONTRACTOR: Gammon India Ltd. Civil Engineers and Contractors Gammon House Veer Sarvarkar Marg,Mumbai – 400025 PROJECT COST: 254.82 Crores (for civil works only) CONTRACT PERIOD: 56 Months (including monsoon) STARTING DATE: 1st October 2001 EXPECTED COMPLITION DATE: 30th June 2006 SCHEDULED COMPLITION DATE: 40 Months (16 months Or earlier) DEFECT LIABILITY PERIOD: 12 Months PLANT AREA: 25 Hectare SITE AREA: 200 X 200 m2
FORMWORK OF OUTER CONTAINMENT WALL FROM EL. 93.870 TO EL 96.07 OF RB3
