Design of Formwork and Scaffolding (BCV613B)

Module-4
TOPICS:

Modular and Special formwork, scaffolding: Modular and Special formwork- Advantages and
Limitations, Shuttering and de-shuttering, applications, Aluminium formwork - Drawings &
Components, Activities, High rise construction, Table lifting system. Scaffolding: Modular scaffold
Installation sequence, Tie and material specification, Ladder safety, Loading Classification,
application, Components of L&T Modular Scaffolding system, Access scaffold Do's and Don’ts.
Innovation and Global practices.

Introduction to Modular and Special Formwork

Modular formwork refers to pre-engineered, standardized formwork systems made up of panels,

frames, and accessories that can be quickly assembled and dismantled.
These systems are designed for speed, reusability, and high-quality concrete finishing.

Key Features:

.IN
 Made from materials like steel, aluminium, or plastic.
 Highly reusable (up to 200+ uses).
 Precise, factory-made sizes ensure accurate construction.
C
 Best suited for repetitive structures like residential towers, offices, and industrial buildings.
N
Special formwork is custom-designed for unique or complex structures where standard modular
systems are not sufficient.
It is used when the project has non-typical shapes, like curves, domes, inclined walls, or special
SY

architectural finishes.

Key Features:
U

 Made from steel, timber, fiberglass, or a combination.

 Customized to exact shapes and design requirements.

VT

Often used for bridges, flyovers, dams, high-end architecture, and iconic structures.
 Typically less reusable than modular formwork.

Introduction to Modular and Special Formwork Scaffolding

Scaffolding is a temporary structure used to support workers and materials during the construction,
maintenance, or repair of buildings and other structures.

Key Features:

 Provides safe access to high and hard-to-reach areas.

 Supports materials and workers simultaneously.
 Made mainly from steel, aluminium, or composite materials.
 Types include Tube and Coupler, Modular (Cuplock, Ringlock, Kwikstage), and Suspended
Scaffolds.

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 Design of Formwork and Scaffolding (BCV613B)
Main Applications:

 Construction of buildings and bridges.

 Painting and renovation projects.
 Infrastructure maintenance.

Difference between Modular and special formwork and Scaffolding

Aspect Modular Formwork Special Formwork Scaffolding

Standard repetitive form Worker and material
Purpose Custom complex form casting
casting support
Reusability High (many cycles) Low (few cycles) Temporary use
Building exteriors, interior
Examples Apartments, offices Bridges, domes, curved walls
maintenance
Main
Steel, Aluminium, Plastic Steel, Timber, Fiberglass Steel, Aluminium
Materials

.IN
 Modular Formwork = Fast + Repeatable
 Special Formwork = Custom + Artistic
 Scaffolding = Safe Access + Temporary Support
C
Advantages and Limitations of Modular formwork
N
Advantages:
SY

 Speed of Construction: Quick assembly and dismantling reduce overall construction time.
 Reusability: Can be reused multiple times (50–100 times or more), making it cost-effective
for large projects.
 Consistency and Quality: Produces uniform, smooth finishes and accurate dimensions.
 Labor Savings: Requires less skilled labor compared to traditional formwork.
U

 Safety: Often designed with built-in safety features like platforms and ladders.
 Reduced Waste: Minimal on-site cutting and adjustment.
VT

Limitations:

 Initial Cost: Higher upfront investment compared to timber formwork.

 Transportation and Handling: Heavy modular systems (especially steel) can be difficult to
transport and need cranes or lifting equipment.
 Design Flexibility: Best suited for repetitive structures; complex, unique designs may need
special modifications.
 Storage: Requires organized storage space to prevent damage between uses.

Advantages and Limitations of Special formwork

Advantages:

 Custom Shapes: Enables construction of architecturally complex and unique structures.

 Precision: High accuracy and finish quality for intricate designs.

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 Design of Formwork and Scaffolding (BCV613B)
 Efficiency for Unique Structures: Makes complicated pours feasible and faster than trying to
adapt modular systems.

Limitations:

 Cost: Very expensive due to one-off manufacturing and custom design.

 Time-Consuming: Design, production, and setup take longer than modular formwork.
 Limited Reusability: Often designed for a single use or very few uses, making it
uneconomical for standard projects.
 Technical Expertise: Requires highly skilled designers and workers for fabrication and
installation.

Shuttering and De-shuttering

Modular Formwork

Shuttering (Erection):

 Assembly: Panels are assembled quickly using clamps, pins, or bolts.

.IN
 Alignment: Systems come with alignment accessories (props, beams) ensuring verticality and
plumb walls.
 Handling: Lightweight materials like aluminum may allow manual handling, but heavy steel
systems may need cranes.
C
 Speed: Very fast compared to conventional formwork because panels are standardized and
labeled.
N
De-shuttering (Removal):
SY

 Timing: After concrete achieves sufficient strength (typically 1–2 days for walls, longer for
slabs).
 Process: Panels are removed easily by detaching clamps/pins.
 Care: Panels must be cleaned immediately after removal to prolong life.

U

Storage: Panels are stacked systematically to avoid damage and prepare for reuse.

Special Formwork
VT

Shuttering (Erection):

 Custom Setup: Since it's designed for unique shapes, assembly can be slow and requires
detailed fitting.
 Precision Work: Often involves intricate support systems (like custom props, braces) to
maintain the complex form.
 Heavy Equipment: May require cranes or other lifting devices for large or oddly-shaped
formwork.
 Skilled Labor: Specialized knowledge is essential to assemble without damaging the complex
geometry.

De-shuttering (Removal):

 Timing: De-shuttering needs extra caution because the special concrete shapes can be delicate
initially.
 Dismantling: Must follow a planned sequence to prevent cracking or damaging the structure.

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 Design of Formwork and Scaffolding (BCV613B)
 Inspection: Both the concrete surface and the formwork are carefully inspected — often forms
are retired after use.
 Reuse: If the special formwork is robust and the project requires repetition, it might be reused
a few times, but usually, it's a one-off.

Note:

 Modular formwork focuses on speed and reusability.

 Special formwork focuses on precision and customization, but is slower and costlier.

Applications

Modular Formwork Applications:

 Residential Buildings:
o Mass housing projects (like apartments, row houses).
o Ideal for repetitive room layouts (bedrooms, kitchens, etc.).
 Commercial Buildings:
o Office complexes and malls where floors and columns are repetitive.

.IN
 Industrial Structures:
o Warehouses, factories where standardized shapes are needed.
 Infrastructure Projects:
o Retaining walls, boundary walls.

C
High-rise Buildings:
o Especially useful for fast floor-to-floor construction (e.g., modular slab and wall
systems).
N
 Tunnels and Shafts (with modular tunnel forms):
o Semi-specialized modular forms adapted for underground structures.
SY

Special Formwork Applications:

 Architectural Projects:
o Curved walls, domes, arches, unique facades.
U

 Bridges and Flyovers:

o Special pier, abutment, and deck formwork.
VT

 Dams and Water Retaining Structures:

o Complex shapes and massive concrete pours.
 Sculptural Concrete Work:
o Iconic structures (e.g., museums, auditoriums) needing artistic concrete shapes.
 Towers and Chimneys:
o Tall, tapered or specially profiled structures.
 Marine and Offshore Structures:
o Complex molds for caissons, dock walls, etc.
 Stadiums and Arenas:
o Complex tiered seating and large-span roof supports.

Note:

 Modular formwork = Fast, repetitive, cost-effective structures.

 Special formwork = Custom, iconic, or very complex structures.

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 Design of Formwork and Scaffolding (BCV613B)

Aluminium Formwork

 Aluminium formwork is a lightweight, strong, and reusable formwork system made primarily
from aluminium alloy.
 It is used to cast entire structures (walls, slabs, beams, columns, stairs) in a single pour.
 Systems like Mivan formwork are a popular type of aluminium formwork.

Key Features:

 Lightweight: Easier to handle manually compared to steel formwork.

 High Reusability: Can be reused up to 250–300 times with proper care.
 Precision: Offers very high accuracy and a smooth concrete finish.
 Speed: Greatly speeds up construction — ideal for mass housing or high-rise projects.
 Monolithic Construction: Walls and slabs are cast together, making structures stronger and
more durable.

Advantages of Aluminium Formwork:

 Fast Construction: Quick assembly and dismantling.

.IN
 Durable: Long lifespan if handled properly.
 Smooth Finish: Minimizes plastering work after de-shuttering.
 Labor Efficiency: Less skilled labor needed after initial training.
 Structural Strength: Monolithic concrete structures resist seismic forces better.
C
Limitations of Aluminium Formwork:
N
 High Initial Cost: Expensive to manufacture or purchase.
 Design Rigidity: Not flexible for changes once formwork is set.
SY

 Damage Sensitive: Aluminium is softer than steel, so panels can dent if mishandled.
 Skilled Setup Required: Needs proper planning and trained labor to avoid mistakes.

Applications:
U

 Mass housing projects (like government housing schemes).

 High-rise residential and commercial towers.
VT

 Townships and repetitive apartment layouts.

 Infrastructure projects needing repetitive, fast construction.

Fact:
The "Mivan" system (developed by a European company) popularized aluminium formwork across
the world, especially in India, the Middle East, and Southeast Asia.

Drawings & Components

Typical Drawings Include:

 Layout Drawings (Plan view showing wall and slab layout)

 Elevation Drawings (Front and side views for wall height and window/door openings)
 Sectional Drawings (Cross-sections for slab thickness, beam depths)
 Component Assembly Drawings (Guides for placing each formwork panel)
 Table Form Layout (If using table lifting system)

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 Design of Formwork and Scaffolding (BCV613B)
Main Components:

Component Purpose
Wall Panels To form vertical walls
Slab Panels To form horizontal slabs
Beam Side and Bottom Panels To form beams' sides and bottoms
Deck Panels Slab forming panels
External Corner/ Internal Corner Panels For wall junctions
Prop Heads / Drop Heads To support slab panels with props
Kicker Forms Starter forms at floor level
Staircase Forms For casting in-situ stairs
Window / Door Boxouts Pre-made frames to cast openings
Accessories (Pins, Wedges, Clamps) For fixing panels

Activities in Aluminium Formwork Construction

.IN
1. Shuttering layout marking (Setting out on slab)
2. Fixing wall panels (Vertical forms first)
3. Placing beam sides and bottoms
C
4. Installing slab panels (Decking panels + slab props)
5. Fixing external and internal corner panels
N
6. Plumbing and Leveling (Ensuring alignment)
7. Pouring concrete
8. De-shuttering (Slabs removed first with drop heads, walls after strength gain)
SY

9. Cleaning, Repairing, and Stacking (For reuse on next floor)

U

High Rise Construction with Aluminium Formwork


VT

Fast Cycle Time: Achieves 4–5 days per floor cycle with trained crews.
 Monolithic Construction: Walls and slabs are poured together — very strong and reduces
joints.
 Uniformity: Ideal for repetitive high-rise towers (residential, commercial).
 Labour Efficiency: Can reduce manpower by ~30–40% compared to conventional shuttering.
 Surface Finish: Smooth concrete finish; often no need for internal plastering (only putty).
 Challenges: High initial setup cost, need for careful planning, and skilled supervision.

Table Lifting System

A system where large assembled slab formwork units ("tables") are lifted as a whole unit by crane
instead of dismantling every time.

How it Works:

 Entire floor slab formwork (slab panels + beams) is pre-assembled as a "table."

 After concrete sets:
o Props are removed.
o Table units are rolled out using wheels or trolley systems.

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 Design of Formwork and Scaffolding (BCV613B)
o Lifted by crane to the next floor and repositioned.

Advantages:

 Massive Time Saving: No need to dismantle and re-assemble slab formwork each floor.
 Safety: Reduces working at height and handling of individual panels.
 Better Quality: Less risk of damage to panels and better slab alignment.

Used in:

 High-rise towers with repetitive floor layouts (e.g., residential apartments, office skyscrapers).

Summary:

Feature Aluminium Formwork

Speed Very fast (4–5 days/floor)
Surface Finish Very smooth
Reusability 200+ times

.IN
Best for High-rise towers, repetitive layouts
Cost High initial cost, low overall cycle cost
C
Scaffolding
N
 Scaffolding is a temporary structure used to support workers, materials, and tools during the
construction, repair, or maintenance of buildings, bridges, and other structures.
SY

 It allows workers to reach heights and positions that would otherwise be hard to access safely.

Main Components of Scaffolding:

U

 Standards: Vertical pipes that transfer the entire load to the ground.
 Ledgers: Horizontal pipes that connect between standards.

VT

Braces: Diagonal pipes that provide stability.

 Platforms (Planks): Surfaces where workers stand and place materials.
 Couplers/Clamps: Fittings that join parts together.
 Base Plates: Plates placed under standards to spread the load.

Types of Scaffolding:

 Tube and Coupler Scaffolding:

o Traditional type using pipes and clamps.
 Frame Scaffolding:
o Prefabricated frames; quick to assemble (common in building construction).
 System Scaffolding (Modular):
o Pre-engineered systems like Cuplock, Ringlock, Kwikstage.
 Suspended Scaffolding:
o Platforms suspended by ropes from the roof; used for painting and repairs.
 Cantilever Scaffolding:
o Scaffolding supported on a series of needles coming out from a structure.
 Trestle Scaffolding:
o Used indoors; working platform supported on ladders or tripods.

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 Design of Formwork and Scaffolding (BCV613B)
Advantages of Scaffolding:

 Provides Safety: Secure working platforms at any height.

 Increases Productivity: Easy movement for workers and materials.
 Access to Difficult Areas: Essential for tall or awkward structures.
 Versatility: Can be adapted to fit complex structures.

Limitations of Scaffolding:

 Cost: Can be expensive for large, long-term projects.

 Time-Consuming to Erect: Especially traditional tube-and-coupler types.
 Space: Needs clear space around a structure.
 Risk: If poorly erected, it can cause accidents.

Applications:

 Construction of buildings (residential, commercial, high-rise).

 Repair and maintenance work (painting, cleaning, façade repairs).
 Bridges, chimneys, dams.

.IN
 Industrial plants (power plants, oil refineries).
C
Modular Scaffold Installation Sequence
N
(Modular scaffolds = prefabricated components like Cuplock, Ringlock, Kwikstage)
SY

Step-by-Step Sequence:

1. Site Preparation:
o Level and compact ground; use sole boards if needed.
U

2. Base Setup:
o Place base plates and adjustable screw jacks.
3. Erect Vertical Standards:
VT

o Fix the vertical uprights (standards) into base jacks.

4. Attach Ledgers (Horizontals):
o Connect horizontal members at required heights using locking systems (cups, rings,
etc.).
5. Add Bracing:
o Diagonal bracing for stability in both directions.
6. Platform Installation:
o Place planks or decks between ledgers for working platforms.
7. Install Guardrails and Toe Boards:
o For worker safety on every working platform.
8. Tie Scaffold to Structure:
o Every certain height/width (depends on loading class) to prevent tipping.
9. Inspection:
o Before first use and periodically afterward.

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 Design of Formwork and Scaffolding (BCV613B)

Tie and Material Specification

Ties (Connecting scaffold to the building):

 Types:
o Anchor ties, box ties, lip ties, through ties.
 Spacing Guidelines (Typical):
o Every 4 m horizontally and 4 m vertically for normal scaffolds.
o More frequent for heavy-duty scaffolds.

Purpose:

 Prevent scaffold swaying, collapsing, or moving away from the structure.

Materials for Modular Scaffolds:

Component Material Specification

Standards (Verticals) Galvanized steel (typical diameter 48.3 mm)

.IN
Ledgers (Horizontals) Galvanized steel/aluminum
Planks/Platforms Steel decks or Aluminum/plywood composite
Base Plates/Adjustable Bases Hot-dip galvanized steel
C
Bracing Steel tubes with couplers

� Steel Grade Example:

N
 Tubes: EN 39 standard, 48.3 mm diameter, 3.2–4 mm thickness.
SY

Ladder Safety in Scaffolds

U

 Proper Access:
VT

o Internal ladders preferred to avoid external climbing risks.

 Ladder Angle:
o ~75° (1 m out for every 4 m up — "4:1 rule").
 Secured Ladders:
o Top and bottom fixed firmly to scaffold.
 Landing Platforms:
o Provided at maximum every 9 meters vertical height.
 Fall Protection:
o Ladder cages or use personal fall arrest systems for very tall scaffolds.
 Inspection:
o Ladders must be inspected daily and after any incident.

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 Design of Formwork and Scaffolding (BCV613B)

Loading Classification (Scaffold Classes)

Class Purpose Load Capacity (kN/m²)

1 Inspection / Light Duty 0.75 kN/m²
2 Light Work (painting, etc.) 1.5 kN/m²
3 General Work (bricklaying) 2.0 kN/m²
4 Heavy Work (masonry, tools) 3.0 kN/m²
5 Very Heavy Work (stonework) 4.5 kN/m²
6 Storage Loading (materials only) 6.0 kN/m²

Important:
Design and spacing of standards, ledgers, and ties depend heavily on the loading class.

Applications of Modular Scaffolding

.IN
 Building Construction:
o External façade work, brickwork, plastering.
 Industrial Maintenance:
o Power plants, refineries, chemical plants.
C
 Infrastructure Projects:
o Bridges, flyovers, tunnels.
N
 Event Structures:
o Temporary stages, grandstands.
 Facade Access Systems:
SY

o Window cleaning and cladding installation on skyscrapers.

 Shipbuilding:
o Repair and painting work.
U

Note:


VT

Modular scaffolding = faster installation + safer than traditional tube-and-coupler scaffolds.

 Ties = essential to prevent collapse.
 Ladder safety = critical for worker protection.
 Loading class must match actual work + storage needs.

L&T Modular Scaffolding System

(Larsen & Toubro — L&T uses a Cuplock / Ringlock type modular system, heavily in building and
infrastructure projects)

Main Components:

Component Purpose
Standards (Verticals) Upright tubes with cups or rings at intervals
Ledgers (Horizontals) Horizontal tubes connecting standards
Base Jacks Adjustable screw jacks for leveling on uneven ground
Diagonal Braces Provide stability in vertical and horizontal planes

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 Design of Formwork and Scaffolding (BCV613B)

Component Purpose
Steel Planks (Decks) Working platforms for labor and materials
Transoms Additional support under platforms
Top Cups / Rosettes Locking devices at nodes for connecting ledgers and braces
Toe Boards Safety barriers to prevent material fall
Guardrails Mid-rails and top-rails for worker fall protection
Access Ladders / Stair Units Safe vertical movement between scaffold levels
Staircase Towers Modular staircases integrated into scaffolds
End Brackets / Hop-Ups Platform extensions for working over edges

Access Scaffold Do’s and Don’ts

� Do’s:

 Use only certified scaffold materials.

.IN
 Inspect scaffolds daily (before use, after modifications, and after bad weather).
 Install proper guardrails, midrails, and toe boards on every working platform.
 Use proper ladder access — no climbing the scaffold frame!
 Secure scaffold ties properly at specified intervals to the building.
 Maintain clear access paths — no storing materials on ladders or stairs.
C
 Wear full PPE (helmet, harness if needed).
 Ensure correct loading — follow the loading class limits.
N
SY

� Don’ts:

 Don't overload platforms with workers or materials.

 Don't modify or remove any braces, ties, or ledgers without authorization.
U

 Don't climb or jump across scaffolding frames.

 Don't use damaged or bent scaffolding materials.
VT

 Don't leave incomplete scaffolds unguarded.

 Don't work on scaffold in high winds or rain without checking stability.

Innovation and Global Practices in Scaffolding

Innovations:

 Self-climbing Scaffold Systems:

o Scaffolds that "climb" along the building without needing cranes (hydraulic or
motorized).
 Aluminum Modular Systems:
o Lighter than steel; easy to assemble/disassemble by hand.
 Integrated Staircase Modules:
o Quick access inside towers without external ladders.
 Digital Monitoring Systems:
o IoT sensors installed to monitor scaffold load, stability, and vibrations in real time.

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 Design of Formwork and Scaffolding (BCV613B)
 Prefabricated Scaffold Modules:
o Preassembled units crane-lifted into place (speeds up setup).
 Lightweight Composite Planks:
o Fiberglass or composite planks instead of heavy steel/wood — non-slip and durable.

Global Best Practices:

 Advance Planning:
Scaffold design is done by qualified scaffold engineers and approved by a competent person
before erection.
 Tagging Systems:
o Green Tag = Safe for use
o Red Tag = Unsafe / Do not use
o Yellow Tag = Safe with restrictions
 Mandatory Scaffold Training:
o Workers must be trained and certified before use (ISO standards, OSHA guidelines).
 Weather Monitoring:

.IN
o Scaffolds are assessed after heavy winds or storms.
 Weekly Third-party Inspections:
o Especially on mega projects.
 Digital Scaffold Management Software:
o Used to track scaffold erection status, inspections, load conditions, and dismantling.
C
Topic Key Point
N
Components Standards, ledgers, braces, planks, ladders
Access Scaffold Do's Inspect, tie properly, load carefully
SY

Access Scaffold Don'ts No overloading, no tampering, no unsafe climbing

Innovations Self-climbing systems, IoT monitoring
Global Practices Training, tagging, digital tracking, inspections
U
VT

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