1.

High Volume Fly Ash Concrete RMC (Ready mixed concrete) Slip Formwork
It is used to replace a portion of the Portland cement used in Concrete delivered at site or in to the purchaser’s vehicle in a Slip forming, continuous poured, continuously formed, or
the mix. plastic condition and requiring no further treatment before slipform construction is a method in which concrete is poured
According to IS: 456 – 2000 replacement of OPC by Fly-ash up being placed in position in which it is to set and harden into a continuously moving form.
to 35% as binding material is permitted. RMC IN INDIA: In India RMC was first initially was used in • This technique is an alternative for conventional formwork
HVFAC is a concrete where excess of 35% of fly-ash is used as 1950 during the construction sites of Dams like Bhakra system which helps in continuous vertical and horizontal
replacement. Nangal, Koyna. construction. The process stops only when the required
Use of fly ash is because of many factors such as - At the construction the transportation of concrete is done by length of casting is completed.
• Abundance of fly ash i.e. 110million tons of fly ash is either manually or mechanically using ropeways & buckets or • It can be used to form any regular shape or core. The
produced in India every year. conveyor systems. formwork rises continuously, at a rate of about 300mm per
• Fly ashes from major TPP are of very high quality i.e. quality Factors Affecting the Choice Of RMC hour, supporting itself on the core and not relying on support
of fly ash. • Better quality concrete is produced or access from other parts of the building or permanent
• Economic factor i.e. Cost of fly ash with in 200 km from a • Elimination of Storage space for basic materials at site works.
TPP is as low as 10% to 20% of the cost of cement. • Elimination of Procurement / Hiring of Plant & Machinery Types
• Environmental factors i.e. reduction in CO2 emission. • Wastage of basic materials is avoided • vertical slip forming the concrete form may be surrounded
2.Silica fume concrete • Obtained fast Construction process by a platform on which workers stand, placing steel
Very fine non-crystalline silica produced in electric arc • Time saving Hassle free mixing reinforcing rods into the concrete and ensuring a smooth
furnaces as a by product. • Economical for Large Projects pour. Together, the concrete form and working platform are
Highly reactive pozzolan used to improve mortar and Materials Required for RMC raised by means of hydraulic jacks. Generally, the slip form
concrete. 1. AGGREGATE rises at a rate which permits the concrete to harden by the
Silica fume in concrete produces two types of effect viz. 2. SAND time it emerges from the bottom of the form.
• Physical effect 3. CEMENT • horizontal slip forming for pavement and traffic separation
• Chemical effect 4. ADMIXTURE(s) Air-entraining admixtures, Water-reducing walls concrete is laid down, vibrated, worked, and settled in
The transition zone is a thin layer between the bulk hydrated admixtures, plasticizers Retarding Admixtures Accelerating place while the form itself slowly moves ahead. This method
cement paste and the aggregate particles in concrete. admixtures was initially devised and utilized in Interstate
This zone is the weakest component in concrete, and it is also Advantages • Tapered slip-forming is also used in the construction of
the most permeable area. • RMC is more advantageous to the consumer from both the conical chimneys, cooling towers, piers and other tall concrete
Silica fume plays a significant role in the transition zone technical and economic aspects of concrete making structures involving constant or changing thicknesses in walls,
through both its physical and chemical effects. • Assures consistent quality through accurate computerized diameters and/or shapes. A form is used with sections which
5.Light weight concrete control of aggregates and water as per mix designs overlap so that one gradually slides over the other. This is
Structural lightweight concrete is similar to normal weight • It facilitates speedy construction through programmed commonly done in chimney construction but it is not
concrete except that it has a lower density. delivery at site and mechanized operation with consequent satisfactory for architectural concrete because the lap shows.
Made with lightweight aggregates. economy. Advantages
Air-dry density in the range of 1350 to 1850 kg/m3 • Elimination of material storage on congested building site- 1.Non-stop Method of Construction
28-day compressive strength in excess of 17 Mpa. no need to allocate place at site for storage of cement, 2.Increase rate of construction
Structural lightweight concrete is used primarily to reduce the aggregate, sand. 3.Increase the productivity
dead-load weight in concrete members, such as floors in high- • It minimizes cement wastage due to bulk handling and there 4.Provide more working space
rise buildings. is no dust problem and therefore pollution-free. 5.Creates safe work environment for the workers
Structural Lightweight Aggregates: • Save contractor’s time, usage of Labor’s energy to mix 6.Employs less accessory equipment
• Rotary kiln expanded clays, shales, and slates concrete and also saves project time. 7.Increase flexibility in construction
• Sintering grate expanded shales and slates • Multi transportation of raw materials. 8.Reduced Labor costs
• Pelletized or extruded fly ash • Creates a clean pollution free (noiseless and dust less) 9.Scaffolding and temporary works in construction is reduced
• Expanded slags environment. 10.Uniform wall sections and layouts are obtained
Advantages Disadvantages Disadvantages
• Rapid curing at ambient temperatures • Double handling results in additional cost and losses in 1.High cost for initial setup
• High tensile, flexural, and compressive strengths weight. 2.Requires Specialized workers and expertise
• Good adhesion to most surfaces • Requirement of godowns for storage of cement and large 3.Need sophisticated Equipment
• Good long-term durability with respect to freeze and thaw area at site for storage of raw materials. 4.Dimensional Accuracy can go low in certain conditions
cycles • Aggregate get mixed and impurities creep in because of Jump formwork
• Low permeability to water and aggressive solutions wind, weather and mishandling at site. Generally, JUMP FORM systems comprise the formwork and
• Good chemical resistance There are always the possibilities of manipulation, manual working platforms for cleaning/fixing of the formwork, steel
• Good resistance against corrosion error and mischief as concreting are done at the mercy of fixing and concreting.
• Lighter weight (only somewhat less dense than traditional gangs, who manipulate the concrete mixes and water cement The formwork supports itself on the concrete cast earlier so
concrete, depending on the resin content of the mix) ratio. does not rely on support or access from other parts of the
• May be vibrated to fill voids in forms building or permanent works
• Allows use of regular form-release agents (in some Lift Slab Construction Jump form, often described as climbing form. It is suitable for
applications) • Lift slab construction is a method of constructing concrete construction of multi-storey vertical concrete elements in
• Dielectric buildings by casting the floor or roof slab on top of the high-rise structures, such as shear walls, core walls, lift shafts,
7.Self compacting concrete previous slab and then raising the slab up with hydraulic jacks, stair shafts and bridge pylons.
Self-compacting concrete (SCC) is an innovative concrete that so being cheaper and faster as it does not need forms & It is a highly productive system designed to increase speed
does not require vibration for placing and compaction. shores as it is needed for cast-in-place slabs. and efficiency while minimizing labor and crane time.
It is able to flow under its own weight, completely filling • Lift-slab construction can be more economic than Types
formwork and achieving full compaction, even in the presence conventional construction when the building is vertically 1-NORMAL JUMP/CLIMBING FORM: Units are individually
of congested reinforcement. uniform, such as for hotels, apartment buildings, and lifted off the structure and relocated at the next construction
The hardened concrete is dense, homogeneous and has the dormitories, and where the slab designs are repetitive. level using a crane. Crane availability is crucial.
same engineering properties and durability as traditional • After the slabs have cured long enough to reach a 2-GUIDED-CLIMBING JUMP FORM: Uses a crane but offers
vibrated concrete. prescribed strength, powerful hydraulic jacks mounted on top greater safety and control during lifting as units remain
Types: of the columns lift the slabs into their respective positions. anchored/guided by the structure.
1.Powder type of self-compacting concrete: This is • A console connected to each hydraulic jack synchronizes the 3-SELF-CLIMBING JUMP FORM: does not require a crane as it
proportioned to give the required self- compatibility by number of turns of the check nuts to assure that the concrete climbs on rails up the building by means of hydraulic jacks.
reducing the water-powder ratio and provide adequate slab is being raised the same amount at all points. Advantages
segregation resistance. • Lift slab can be used for heights up to about 16 stories. • Fast construction can be achieved.
2. Viscosity agent type self-compacting concrete: This type is Economical column spacing ranges from 22 to 32 feet. • The formwork system is easy to clean and reuse with little
proportioned to provide self-compaction by the use of Columns may be pipe, tubes or wide flange sections; concrete formwork waste generated compared to traditional
viscosity modifying admixture to provide segregation columns may be used in 3- to 4-story buildings. formwork.
resistance. Advantages • Climbing formwork systems offer simplicity, safety and cost
3. Combination type self-compacting concrete: This type is • Lift-slab construction method becomes more advantageous effectiveness for certain high-rise building structures.
proportioned so as to obtain self- compatibility mainly by in buildings with similar floor plans throughout the height of • The repetitive nature of the work, combined with the
reducing the water powder ratio. the building and where flush slab may be desired. engineered nature of the formwork, allows fine tuning of the
9. Fibre reinforced concrete: • This method eliminates the need for redundant formwork construction operations, which in turn leads to minimal
Fibre reinforced concrete (FRC) may be defined as a as only shuttering required on the edges, therefore casting concrete wastage.
composite materials made with Portland cement, aggregate, concrete slabs is the simplest stage in whole constriction • Many repeated uses of formwork are possible before
and incorporating discrete discontinuous fibres. process of lift-slab method. maintenance or replacement is needed, the number of uses
The role of randomly distributes discontinuous fibres is to • Lift-slab method may be employed with ribbed slabs not depending on the quality of the surface finish of concrete
bridge across the cracks that develop provides some post- only flat slabs with some compromise of the ease of casting. specified.
cracking “ductility”. Another advantage is reduced handling and hoisting of • Climbing forms can be designed to operate in high winds.
The real contribution of the fibres is to increase the toughness materials and supplies that can simply be placed on top of the • precise adjustment of the formwork in all planes.
of the concrete under any type of loading. slabs and lifted with them. • Some formwork systems can be used at an inclined angle.
The fibre reinforcement may be used in the form of three – • Jump Formwork System is the better solution in the case of
dimensionally randomly distributed fibres throughout the Cross Wall Construction Multistory structures rather than conventional formwork
structural member when the added advantages of the fibre to • Construction of series of walls perpendicular to lateral axis Disadvantages
shear resistance and crack control can be further utilised. of building • Costly to installs compared to traditional form work.
The most common applications are - • These walls are load bearing in nature • Required skilled workmanship.
1. pavements • Doesn’t need steel framing for building • Shortage of cranes resulting in unable use of normal form
2. tunnel linings • Construction of customized panels as per the requirements type.
3. pavements and slabs of building • Not economical to use in four storey building.
4. shotcrete Features Tunnel Formwork
5. shotcrete also containing silica fume, • Walls are prefabricated as per the design requirements This is mainly used where the building has many rooms, and
airport pavements, bridge deck slab repairs. • Cross walls also act as structural members for buildings modules that are repeated many times.
• Cross walls resist the forces parallel to the plane of wall Tunnel formwork reduces the construction time of a building
Modular Coordination Is Based On: • This method is feasible for construction in buildings having hugely, since both the vertical and horizontal elements are
○ the use of modules (basic modules & multi modules) same floor plan up to five stories. poured together at the same time.
○ a reference system to define coordinating spaces and zones • This also known as box wall construction A tunnel formwork system is composed as shown in figure 18
for building elements and components Advantages of deck panel, which is a thick steel skin used to form the
○ rules for positioning of building elements within the • Viable solution for sturdy construction ceiling, and a wall panel, which is also a thick steel skin, used
reference system • Because of prefabrication onsite construction time reduced to form the walls between two adjacent modules;
○ rules for sizing of components in order to determine their • Safe due to box type construction Also, one of the most components of a tunnel formwork
work sizes • Initial cost of construction is inexpensive in comparison to system is the waler and the waler splices which is used to
○ rules for defining preferred sizes conventional method create a stiffer deck and wall panels so as to minimize the
○ communication between participants in the building • Site coordination becomes easy deflection due to the concrete lateral pressure,
process • Structure becomes unbending and substantial in addition; a diagonal strut assembly is used to provide
• Highly efficient for acoustic purpose additional support for the floor slab and keep the wall and the
• Highly resistant to fire floor perpendicular to each other.
• Provides good thermal mass Limitations
• Not suitable for small projects, and if there are many
variations in design
• High initial investment of formwork and other machineries.
• Imported formwork, need 5 to 6 months early finalization of
plan.
• Dependent of formwork supplier for amendments in form
work and accessories.
Types of Formwork
1) Conventional Type of Formwork:
• This is the most traditional type of formwork and this uses
timber, bamboo, masonry and carpentry to complete
construction.
• Low initial cost, low experience factor and low weight are
some of the advantages while high floor cycle, poor finish,
and high labour requirement are the disadvantages of this
formwork type.
• This formwork type is still in practice in two-three storey
building construction projects.
2) Fiberglass formwork:
• The use of fiberglass as a material to make forms for
concrete work has increased rapidly within the past two
years.
• Among the reasons are:
• Fiberglass forms provide a means of producing a
concrete surface that is architecturally acceptable without
rubbing and grinding
• Special patterns and designs can be readily moulded
into the material. -Large areas or sections may be made
without joints or seams
• When repeated usage is possible, fiberglass is often
the most economical form material.
3) Plastic Formwork:
• It comes as an individual structural element like columns
and walls Various sized columns and walls are available in the
market.
• The formwork is very easy to install and uninstall and has a
very high repetitive nature.
• The ease of application makes it very useful where faster
completion of work is a criterion.
4) Fibre-reinforced polymer (FRP) formwork system:
• FRP formwork is used where unique configuration required
for the arches and columns or any other structural parts.
• The FRP formwork pieces were produced using the hand
layup method using moulds fabricated by means of a
computer numerical control (CNC) machine.
• On site, the size and weight of the formwork required the
use of forklifts and scissor lifts for assembly
5) Aluminium Panel System Formwork:
• System formwork has prefabricated modular components
with casting panels.
• The system form can suit the required shape of concrete
structure.
• The speedy and quality construction is the biggest
advantage in this type while high initial cost is the main
disadvantage and hence this is nut economical to use in low
else buildings.
• But this is the most economical form of formwork type to be
used in