FORM WORK / SHUTTERING WORK

SHUTTERING WORK

1.    OBJECTIVE: 

The objective of this method statement is to carry out the Formwork works by meeting the technical specification and complying with Standards.

2.     SCOPE:

The scope of this method statement includes at all areas at CTSIL, CTSIL site while executing it in accordance with Technical specifications.

3.    REFERENCE 

·         IS-Codes

·         Technical Specification

4.    TOOLS AND TACKLES

·         Shuttering material – Props, Cup locks, Base plates 

·        U HEADS 

·        TIE ROD

·      HOLLOW SECTION

·        SHUTTERING PLYWOOD

·         JACKS

·          BRACING PIPES

·    Swivel coupler and Column boxes

·       HAMMER

·        LINE DORI

·         Hand saw  

·         Spirit level, 

·         Tube level, 

·         Plumb bob, 

·         Poly foam

·         Shutter  releasing agent, 

·         Shuttering Tape, 

·         Right angle, 

·         Crowbar

·         Measuring tape, 

·         Spirit levels 2 – 3m, 

·         Total station  

·         Right angle template

·         “ Good for Construction ” drawings

5.    MATERIAL USED:

·         Ply wood

·         Shuttering oil

·         Cleaning agent

6.    PROCEDURE:

a)    General:

·         Ensure Material approval prior to start work

·         Ensure cleaning to be done properly.

·         Ensure proper surface preparation.

·         Ensure necessary safety precautions are in place prior to start.

b)    Sequence of Work:

·         All the staging materials should be visually checked at site before erection.

·         Formwork shall be so erected to support safely the worst combined effects of all loads within acceptable dimensional tolerance and without causing bulging or deflection.

·         Formwork is designed and constructed to the shapes, lines and dimensions shown on the drawings with the tolerances given below.

·         Tolerance for cross-sectional dimensions of cast in-situ: as per specifications /approved drawings.

·         For cast in-situ elements, the deviation of level of any point from the intended level: as per specifications/ approved drawings.

·         Tolerance for penetration/ opening for services: +10mm for size and +25mm for location.

·         Tolerance for plumb: 3mm / m, maximum 20mm.

·         Formwork should be: 

·         Strong enough to bear the self–weight of formwork, wet concrete, reinforcement, and dynamic effects of placing and compacting, construction traffic and wind load.

·         The staging should rest on firm ground or strong brackets anchored well to the concrete structure below.

·         Scheme for formwork / staging should be submitted for approval wherever required by the Site Manager/PMC.

·         Water tight to avoid grout loss

·         Formwork must be free from defects

·         Before concreting, the interior must be free from debris.

·         All formwork joints must not have gaps to prevent leakage.

·         There must be adequate support, bracing and tie-back for the formwork to prevent bulging or displacement of structural elements.

·         Easily removable without any damage and should be re – usable.

·         It should be dimensionally accurate and give the desired finish to the contact surface.

·         Staging shall be true, rigid and thoroughly braced, shuttered and propped.

·         To achieve desired rigidity, adequate bracing is to be provided

·         Check the shuttering work for vertical and horizontal alignment, level, surface cleanliness, water tightness, and ability to withstand loads without distortion.

c)    Scaffolding: 

At the ground level, walk round the perimeter of the scaffolding and check for

·         Subsidence of the ground.

·         Cavities underneath sole plates

·         Dislocation of base plates.

Rectify with adjustable base plates or fill with concrete.

d)    Formwork:

The formwork oil basically serves the purpose of a specification medium. It acts as an intermediary that avoids any damage to the concrete. It also helps keep the formwork clean & ensures easy maintenance. 

·         The application of oil should be done with the help of foam or a similar soft medium and should be applied after cleaning the form.

·         Burnt machine oil or used oil is totally unsuitable and is unacceptable. It is recommended to use a water based formwork release agent. 

·         All spans in excess of 5 meters for beams and slabs should be kept within a pre camber of 2mm per 1 meter .For cantilever, give a camber at the end of span of 5 mm per 1 meter.

·         The quality of finished concrete is largely dependent on the quality of formwork.

·         Erection of casing and shifting of formwork shall be done under the personnel Striking time for formwork is as follows under normal conditions.

Walls, Columns, Starters etc            12 hours

Slab (span < 5mtrs)                            7 days

Beam (span < 5mtrs)                          14 days

Slab beam (span > 6mtrs)                   as per Consultant’s instruction

Props to cantilever                              as per Consultant’s instruction

Due to weather conditions if the concrete is not sufficiently hardened, the striking time to be extended after discussing with the project in charge. Obtain the 7th day cube test results before the removal of formwork for beams.

e)    Inspection methodology 

·         Check the shuttering work for surface cleanliness, and ability to withstand loads without distortion. Stability, safety, dimensional correctness, levels and alignment are the key factors.

·         All rubbish, particularly, chippings, shavings, and saw dust to be removed from the interior of the forms before the concrete is placed.

·         Check for plumb and parallelism at various points.

·         All formwork in the periphery of the building to be plumb.

·         For all required cut outs and shaft opening :

·         Are as per drawings

·         Inner right angles at all 4 corners checked using right angle

·         Check of diagonals using a measuring tape.

7.    RESPONSIBILITIES.

·         Construction Manager: He shall be responsible for overall management of construction activities.

·         Site Engineer: He shall be responsible for Executing in safe work method as per drawings and guide the supervisors and work men.

·         Site Supervisor: He shall be responsible managing all plant and machineries and labour and safety of the workers.

·         QA/QC In charge: He shall be responsible for ensuring the quality of work as per the specifications and standards.

·         HSE Manager/Engineer: He shall be responsible for assisting to engineer/supervisor to ensure the safety of workers during the progress of work. Safety inductions of each staff and workers shall be done and daily PPE check to be done and tool box talk shall be carried out before the start of work. General safety awareness as well as particular safety precautions and guidelines for activity to be carried out in that particular day shall be discussed.

·         Stores officer: He shall be responsible for storing of all materials. Also responsible for maintaining the record of incoming and outgoing and up to date stock details of materials.