Module 2: Specialized Formwork Systems
1. Climbing & Slipform Systems
These systems are designed for vertical structures requiring continuous or rapid construction, such as high-rises, chimneys, and silos.
Hydraulic Climbing Formwork for Towers:
Mechanism: Uses hydraulic jacks to lift the entire formwork system along pre-installed rails or guide rails as the concrete cures. Common in skyscrapers and bridge pylons.
Advantages:
Speed: Reduces cycle time by eliminating dismantling/reassembly.
Safety: Integrated guardrails and platforms minimize fall hazards.
Precision: Ensures consistent wall alignment in high-rise cores.
Examples: Doka’s SKE 100, PERI’s ACS (Automatic Climbing System).
Slipform Techniques for Chimneys/Silos:
Continuous Pouring: The formwork moves upward (typically 150–300 mm/hour) while concrete is placed, creating seamless vertical structures.
Key Components:
Yokes & Jacks: Support the formwork and provide controlled lifting.
Suspended Platforms: Allow workers to finish surfaces and install reinforcement.
Challenges:
Concrete Consistency: Requires precise slump control to prevent bulging or collapse.
Weather Sensitivity: Wind and temperature affect curing rates.
2. Jump Form & Self-Rising Systems
Ideal for repetitive vertical structures like elevator shafts and shear walls, these systems balance speed and safety.
Design & Safety Protocols:
Modular Panels: Steel or aluminum forms with integrated working decks.
Anchoring: Uses cast-in inserts or shear cones for stability.
Load Transfer: Each "jump" requires verification of concrete strength (typically 5–10 MPa before lifting).
Fall Protection: OSHA-compliant guardrails and harness points.
Case Studies of Mega-Projects:
Burj Khalifa (UAE): Used a combination of climbing and jump forms for its reinforced concrete core.
Shanghai Tower (China): Employed self-climbing systems to achieve its twisted geometry.
3. Modular & Panelized Systems
Designed for rapid, repetitive construction in large-scale projects like mass housing and commercial slabs.
Mivan/PVC Formwork for Mass Housing:
Lightweight Aluminum/PVC Panels: Prefabricated for quick assembly; ideal for repetitive layouts (e.g., apartment towers).
Advantages:
Speed: Reduces construction time by up to 40% compared to conventional formwork.
Cost-Effective: High reuse (500+ cycles) lowers long-term expenses.
Limitations: Requires precise planning for panel alignment.
Table Form/Flying Form for Slabs:
Mechanism: Preassembled deck sections (with falsework) are "flown" via crane to the next level after concrete sets.
Applications: High-rise flat slabs, parking structures.
Innovations:
Rolling Systems: Motorized trolleys for faster repositioning.
Adjustable Props: Accommodate varying slab thicknesses.
Key Takeaways:
Climbing/Slipform: Best for tall, continuous structures; requires skilled labor and real-time monitoring.
Jump Form: Balances speed and safety for mid- to high-rise cores.
Modular Systems: Optimize cost and time for repetitive projects.
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