Dhanesh Portfolio: Formwork Specialist

DHANESH DAS

portfolio

A concise selection of the works in formwork engineering

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CONTENTS 1.

Project 1:

Ocean Heights by Arabtec, Dubai, UAE.

2. Project 2:

Continental Tower by Kaveri General Contracting, Dubai, UAE.

3. Project 3:

Viaduct shoring failure, KVMRT SSP Line, Kuala Lumpur, Malaysia.

4. Project 4:

Retaining Wall formwork failure, KVMRT SSP Line, Kuala Lumpur, Malaysia.

5. Selected works for design review & auditing

6. Other Skills & Hobbies

7. Profile Overview

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OCEAN HEIGHTS Dubai Marina, UAE -

2010

Ocean Heights is a super tall residential skyscraper in Dubai Marina, Dubai, UAE. The tower stands 310 m tall with 83 floors. The building was completed in 2010.

Currently, Ocean Heights is the fifth-tallest residential building in the world and the fourth-tallest residential building in Dubai. The tower has unique curves and twisting motion as one ascends. PERI Dubai was chosen by Arabtec Constructions to provide formwork solutions for the RC elements like slabs, columns, lift walls and shear walls.

SYSTEM DESCRIPTION Typical slab Walls & Columns -

Custom made Multiflex Tables with TK head VARIO, CB240 self climbing system PERI internal shaft platforms

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SLAB TABLE & MULTIFLEX FOR TYP. FLOOR SLAB

BEAM & SLAB FORMWORK FOR 7TH TO 11TH FLOOR LEVEL - PLAN & SECTION

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CONTINENTAL TOWER Marina, Dubai, UAE -

2011 to 2017

Continental Tower is a 30-storey mixed-use building in Dubai Marina, Dubai. The development contains a total of 250 units.

Construction began in 2011 and was completed by 2017.

The project was developed by Continental Investments and the main contractor was Kaveri General Contracting Company LLC. PERI Dubai was chosen by Kaveri General Contracting Company LLC to provide formwork solutions for the RC elements like slab, columns, lift walls and shear walls in the year 2010-2011.

SYSTEM DESCRIPTION Typical slab Walls & Columns -

Multiflex Tables with TK head VARIO, CB240 self climbing system PERI internal shaft platforms

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SLAB TABLE & MULTIFLEX FOR TYP. SLAB

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CB240 EXTERNAL CLIMBING SYSTEM INTERNAL SHAFT PLATFORM & VARIO WALL FOR LIFT WALLS

SECTION-A

PLAN VIEW-CORE WALL(2) WALL FORMWORK ARRANGEMENT

PLAN VIEW-CORE WALL(2) CLIMBING PLATFORM ARRANGEMENT 8

INVESTIGATION ON VIADUCT SHORING FAILURE K u a l a L u m p u r , M a l a ys i a -

2020

Project

: PROJECT MASS RAPID TRANSIT (KVMRT Line 2) LEMBAH-JAJARAN SERDANG-SUNGAI BULOH-PUTRAJAYA Kuala Lumpur, Malaysia.

Work Package (WP) WP Location Date of Incident

: W10 Elevated : LONG SPAN CROSSING V204A (P13) : Sunday, 21st September 2019.

Main Contractor Work Package Contractor Specialist contractor Formwork Supplier

: MMC-GAMUDA KVMRT (PDP) SSP SDN BHD : WCT Berhad DETAILS HIDDEN : Giga Tegasan Sd. Bhd. : SGB Brandsafway

INCIDENT DESCRIPTION On Sunday 21st, September 2019 evening the Falsework supporting the Segment Box Girders (SBG) E17A, E18A & ED at P13 had failed to cause the SBGs to slip from the hydraulic jack. It was understood that at the time of this failure, the three SBGs were stitched together and its levelling & aligning were ongoing.

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SUMMARY OF CONTRIBUTORY FACTORS Multiple concerns discussed below were observed which could have actively or passively triggered the failure; • The crew involved in the end span construction were inexperienced and not adequately trained.

• The use of 5Ton jacks for the horizontal alignment of SBG will develop horizontal reaction forces with magnitudes that exceed the design horizontal load of falsework.

• The primary beams, secondary beams and layer 1 beams were loosely laid without any connections between them. Layer-1 steel UB sections directly beneath the SBGs were not designed to cater eccentric loading. However, during the horizontal shifting of SBGs using the 5T baby jacks, the 50T hydraulic jacks meant for vertical alignment will slide over the greased shim plates leading to eccentric loading on layer-1 steel UB sections. Hence, in the event of eccentric loading, the steel UB sections could have overturned triggering the failure.

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Vertical alignment of SBGs on 50T jacks if not done properly can cause overloading of jacks due to the intermediate jacks getting redundant. This could lead to local failure of falsework standards or head jacks.

RECOMMENDATIONS 1.

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For complex temporary works activities, a design coordination meeting should be arranged between various parties (Contractor’s operation team & Designer) involved to discuss the work sequences, load criteria, erection & dismantling of temporary work structures etc. Thereafter, the design requirement should be captured in a Design Brief by the contractor and should be issued to the Designer.

The Design Brief should be checked and verified by the TWC before issuing it to the Designer.

Any changes from the original design that the operation team intends to make which was not originally captured in the approved MS or Design Brief should be informed to the Designer, PE & ICE. Erection & dismantling of Temporary work structures should only be performed by fully trained/competent persons.

The methodology of the work should be captured in a drawing whether sequencing and loading limits are specified. This document should be subject to ICE checking and approval.

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INVESTIGATION ON RETAINING WALL FORMWORK FAILURE K u a l a L u m p u r , M a l a ys i a -

2020

Project

: PROJECT MASS RAPID TRANSIT (KVMRT Line 2) LEMBAH-JAJARAN SERDANG-SUNGAI BULOH-PUTRAJAYA Kuala Lumpur, Malaysia.

UG Station Date of Incident

: CHAN SOW LIN : 17th January 2020.

Main Contractor Sub Contractor Formwork Supplier

: MMC-GAMUDA KVMRT (T) SDN BHD : SP Mega SDN BHD DETAILS HIDDEN : FORMWORK SUPPLIER Formwork Malaysia SDN BHD

INCIDENT DESCRIPTION On Tuesday, 17th January 2020 two of the Single-sided wall formwork panels for a 58m long and 7.6m high retaining wall inside the station box excavation gave way while the concreting was ongoing. At the time of failure 450cu.m concrete had been poured. The bottom portion of the panels got deformed forming a gap between the panels. Roughly 9 cu.m of concrete was lost before the failure was mitigated onsite.

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7450 mm CASTING HEIGHT

SYSTEM WALL FORMWORK

7600 mm

7700 mm FORMWORK HEIGHT

TYPICAL SECTION (EXTRACT FROM SUPPLIER DRAWING)

FRAME SB-A+SB+SB-C PUSH-PULL PROPS RS450 (FOR STABILITY)

DW26 TIE RODS ANCHOR SYSTEM DOUBLE U160 ANCHOR WALER

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CONTRIBUTORY FACTORS 1.

The formwork was designed to cater for a maximum concrete pressure of 30 kPa based on the concrete parameters assumed by the Formwork designer in their design. However, the actual concrete parameters differed from that of the Formwork designer’s assumptions and thus, the formwork was under-designed. The concrete pressure adopted in the design is only 40% of the actual. It was noted that the Formwork designer did not refer to the concrete parameters specified in the design brief issued by MGKT at the early stages of the concreting works. Also, MGKT’s Temporary works coordinator & the site team failed to check and verify the design assumptions made by the designer before the concreting works. (a) Concrete pressure based on SUPPLIER assumptions

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(b) Concrete pressure based on actual concrete parameters

The anchor forces given by FORMWORK SUPPLIER in their design were meant for a 6.5m high wall extracted from their standard datasheet. This approach is not accurate as the pressure diagram for the 6.8m wall and 6.5m wall is not similar. Thus, a separate frame analysis using suitable to determine the anchor forces would have been more appropriate.

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DESIGN REVIEW & AUDITING: SELECTED WORKS KVMRT LINE 2

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ELEVATED & UG

A) TRESTLE SUPPORTS FOR THE SBG ERECTION AT VARIOUS LOCATIONS IN KVMRT LINE 2 ( ELEVATED )

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B) BACK PROPPING FOR STATION SLAB TO RECEIVE THE TBM AFTER BREAK THROUGH ( UG )

D) SELF CLIMBING PLATFORM TO CAST INTERNAL WALLS OF INTERVENTION SHAFT ( UG )

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E) TRAVELLING FORM AND GANTRY FOR VIADUCTS ( ELEVATED )

F) SLAB FORMWORK FOR STATION SLAB ( UG )

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SKILLS & HOBBIES TRAINER Provided training and conducted TWs forums to the TWCs with the aim of developing and improving their competency level in TWs management. This training was extended to the CMs, PMs, QA/QC, SHE, SUBCONs, etc. for awareness in TWs. (Pictures from the various forums & training sessions in temporary works )

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LIAISE WITH MULTI DISCIPLINARY DEPARTMENTS PLANNING CONTRACTS

GEOTECH

BIM TEAM

QA/QC

TEMPORARY WORKS CICE & SC

SHE

SITE TEAM

SURVEY

SUB-CONS

DESIGN CONSULTANTS

MODEL MAKING

Understanding Shukov’s Tower or hyperboloid

Experiment with Tensegrity structure

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PHOTOGRAPHY Night view at the Gardens by the Bay, Singapore.

Old city view Prague, Czech Republic.

FINE ARTS

Landscape: Water Colour

Portrait: Charcoal pellet 22

Profile overview

DHANESH DAS THOPPIL Formwork Specialist

ABOUT ME A self-motivated Formwork Specialist with experience in the design, management & coordination of formwork, falsework, scaffolding, and other Temporary Works structures. Over this period of my tenure, I have achieved extensive knowledge in the core principles of formwork technology and the technical know-how of proprietary formwork systems of various companies like PERI , DOKA, SGB, HUNNEBECK, RMD Kwikform, etc.

I have good exposure to various codes and standards involved in the formwork & scaffolding design, temporary works management, and HSE. Also, I have a proven track record in leading, managing, and mentoring a team of young and experienced engineers.

EXPOSURE IN CODES & REGULATIONS BS 5975: 2008+A1:2011 BS EN 12812:2004 DIN 4421 BS EN 12811 ( 1/2/3 ) TG20:08 (V1 & V2)

Temporary works procedures and falsework design Falsework design Falsework design Scaffolds / Information on materials / Load testing Guidance on scaffolding with tubes & fittings

BS 5950-1:200 BS 8118-1:1997

Steel design Concrete design

CIRIA 108 DIN 18218 BS 8539:2012

Concrete pressure on wall formwork Concrete pressure on wall formwork Post installed anchors in concrete

BOOKS

Formwork a guide to good practice (3rd Edition) 23

PROFESSIONAL EXPERIENCE MMC GAMUDA KVMRT (T) Kuala Lumpur, Malaysia

Sr. Temporary Works Engineer (Asst. Manager D&T)

GHI FORMWORKS Dubai, UAE

Design Team Leader

PERI LLC. Dubai, UAE

Design Engineer

HARSCO India Pvt. Ltd. Hyderabad, India.

Sr. Design Engineer (Team Leader)

Cape East WLL. Doha, Qatar.

Planning & QS Engineer Scaffolding

FORESHORE Technical Solutions Calicut, India (Back-office to PERI Dubai.)

Design Engineer

EDUCATION 2002-2006

Bachelor’s Degree (4-year course) in Civil Engineering from the University of Calicut, India.

SOFTWARE SKILLS Drafting & Modelling Basic: Analysis:

AutoCAD 2D & 3D MS Office, STAAD Pro, RSTAB, etc.

OTHER ATTRIBUTES o BIM certification: BIM Level 2 Essentials (ISO 19650) completed from ‘bre ACADAMY

o CITB: Hands-on training in ‘Scaffolding erection and its safety aspects’ by the invited delegates from CITB UK at KL, Malaysia. .

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