L&T DOKA L&T DOKA

FORMWORK SYSTEMFORMWORK SYSTEM

PRESENTED BY:PRESENTED BY:

TUSHAR AKBARI (CPM0106)TUSHAR AKBARI (CPM0106)

SUBMITTED TO:SUBMITTED TO:

MR. DEBASIS SARKARMR. 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 Collaboration with M/s Doka of Austria

1986 Fabrication of steel components through vendors commenced

1990 Production of timber beams at Chennai 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

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 constructionShuttering 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 SYSTEMH-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 plywoodboiling 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.

FLEX SYSTEM• Components

– 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.

FLEX TABLE FORM• Components

– H-Beam– Plywood– Collapsible Telescopic

Prop– Table head / U-Head– Assembly wedge clamp

• 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

Close Connection Open Connection

WALL FORMWORK SYSTEM• Components

– H - Beam– CT Prop– H-Beam Splice– Foot Adapter– Steel waler– Connecting Pin– Wing Nut– Tie rod– Head Adapter– Anchor Plate– Lifting Bracket– Angle Plate– Adjustable splice plate– Splice plate

Lifting Bracket

Timber Plank

Scaffold bracket

Head Adaptor

Steel Waler

Working Platform

Supporting Bracket

Foot Adaptor

WALL FORMWORK SYSTEM

WALL FORMWORK SYSTEM

Lifting Bracket

Timber Plank

Working Platform

Scaffold bracket

Steel Waler

CT Prop

Supporting Bracket

H-Beam

Foot Adaptor

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

COLUMN FORMWORK SYSTEM• Components

– H - Beam– CT Prop– H-Beam Splice– Foot Adapter– Steel waler– Connecting Pin– Wing Nut– Tie rod– Head Adapter– Anchor Plate– Lifting Bracket– Angle Plate– Adjustable splice plate– Splice plate

Plan

Section

Working Platform

Scaffold bracket

Foot Adaptor Supporting Bracket

H-Beam

Tie Rod

Anchor Plate

H-Beam Plywood

Steel Waler

CT Prop

CT Prop

COLUMN FORMWORK SYSTEM

Typical Column Formwork System

MODIFIED FORMWORK AS PER REQUIREMENT (DOKA + CONVENTIONAL FORMWORK)

ACCESS SYSTEM• Components

– Scaffold Frame – 0.9 m, 1.2 m, 1.8m

– Spring Locked connected pin

– Foot plate– Coupler– Scaffold Coupler– Scaffold Spindle– 2H-225 Bracing– Scaffold Board

TYPICAL HAND SKETCH SHOWING DETAILS OF ACCESS SCAFFOLDING WORK WITH BRACING TO PERMANENT

STRUCTURE

STAIR TOWER• Components

– 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

STAIRCASE IN HEAVY DUTY TOWER SYSTEN WITH SAFETY NET HT. 40 ft.

ELEVATION

TOP VIEW

NUCLEAR POWER PLANT FORMWORK : KAIGA UNIT 3&4

CLIENT: NUCLEAR POWER CORPORATION OF INDIA LTD. (NPCIL)

CONTRACTOR FOR INTAKE TUNNEL

M/S L&T , ECC DIVISION

CONTRACTORS FOR MECHANICAL WORKS

M/S BHEL

MAIN CONTRACTOR FOR CIVIL WORKS

M/S GAMMON INDIA LTD.

CONTRACTORS FOR PUMP HOUSE

M/S EPCIL(ENGG. PROJECTS INDIA LTD.)

CONTRACTOR FOR EXCAVATION WORKS

M/S AFCONS INFRASTRUCTURE

SUB CONTRACTOR FOR TB3,TB4,SRPH,FWPH

M/S IVRCL (I. VENKAT REDDY CONSTRUCTION

LTD.

SUB CONTRACTOR FOR FABRICATION AND FIXING

OF EP’SM/S NSG FABRICATIONM/S SUVARNA FABRICATION

SUB CONTRACTOR FOR MACHINARY & EQUIPMEN

SUPPLY

M/S SETHIA EQUIPMENT

Major Consultants for 1&2Stup ConsultantsDevelopment consultants pvt. Ltd.Mecon (eng. & drg. Consultant)

Client is itself the designer of the project as this project is repetition of Kaiga 1 & 2.

PROJECT BREAK DOWN STRUCTURE

• 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&4Post: Kaiga,Karnatka – 581400

• CONTRACTOR: Gammon India Ltd.Civil Engineers and ContractorsGammon HouseVeer 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

THANK THANK YOU!!!!!!!!!!!!!!YOU!!!!!!!!!!!!!!