Prefabrication

ARN - 303- Building Construction - IV

STAY IN PLACE FORMWORK SYSTEM A3 REPORT Professor: Ram Sateesh Pasupuleti

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

TYPES OF STAY IN PLACE FORMWORK

Sismo Building Technology Structural Stay-in-Place Formwork System (Coffor) Insulating Concrete Forms (ICF) Monolithic Insulated Concrete System (MICS) Lost-in-Place Formwork System – Plaswall Panel System Lost-in-Place Formwork system – Plasmolite Wall Panels Stay-In-Place PVC Wall Forms

Permanent Wall Form (PVC)

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

Sismo (patented) Building Technology is an insulating shuttering kit for a whole building unit based on a three-dimensional lattice made of galvanized steel wire and EPS panels.

These are formwork systems which are left in the structure after concreting and act as insulation.

Plaswall Panel System is a lost in place formwork (patented system of M/s FTS Buildtech Pvt. Ltd), where two fiber cement boards (FCB) of 6mm thickness each are bonded through HIMI (High Impact Molded Inserts) spacers.

This is a prefinished wall formwork from M/s Novel Assembler Pvt. Ltd. comprising of rigid PolyVinyl Chloride (PVC) based polymer components that serve as a permanent stayin-place durable finished form-work for concrete walls.

It is a patented structural stay in place formwork system to build loadbearing monolithic concrete wall structures based on shear wall concept.

Monolithic Insulated Concrete System (MICS) is a patented system of M/s Maiwir Ecotech Pvt. Ltd.. It is a formwork system for reinforced concrete made with a rigid thermal insulation that stays in place as a permanent interior and exterior substrate for walls, floors and roofs.

Plasmolite Panels are lost in place formwork system (patented system of M/s FTS Buildtech Pvt. Ltd), where two fibre cement boards (FCB) of 6 mm thickness are bonded together through High Impact Molded Inserts (HIMI) spacers.

“Permanent Wall form” of M/s Kalzen Realty Pvt. Ltd. is an innovative permanent structural walling system consisting of rigid Poly-Vinyl Chloride (PVC) formwork that serve as a stay in place finished form-work for concrete walls.

STAY IN PLACE FORMWORK

WHY SIP?

In order to fast-track delivery of affordable houses using sustainable emerging housing technologies for example under pradhan mantri aavas yojna urban , formwork systems have shown potential to be viable alternative system of construction. These systems not only bring speed and economy in construction but also provide quality durable structures.

After concrete pouring and hardening this type of formwork systems remain in place as an integral part of the structure and contribute to the structural integrity ,durability and even aesthetics of concrete elements.

ADVANTAGES

Stay in place formwork systems are quicker requiring less manpower and machines. These are used to form loadbearing walls, eliminating need for columns and beams. With the use of stay in place formwork, need for separate formwork is eliminated. It brings overall economy and speed in construction.

Page No: ARN - 303- Building Construction - IV Date: 23-09-2021 Professor: Ram Sateesh Pasupuleti

STAY IN PLACE : COFFER SYSTEM The formwork is composed of two filtering grids comprising of rib meshes made of galvanized plain steel GP sheets with herringbone mesh pattern Riblet. Reinforced by C profile GP sheet vertical stiffener, these grids are further connected by articulated horizontal ms rebound loops in one direction and cold rolled closed annealed plate GP horizontal connectors in other directions. After the erection of formwork panels in alignment over strip foundation, closing of corners edges of doors and windows frames rebar positioning concrete of required greatest pod inside the panels either using pump bucket or with Chauvel loader. The inside and outside walls are finished with cement plaster of suitable grade. The Coffer system brings a unique technology called a structure stainless formwork system. Compared to the conventional there is a time saving of 50 to 60 percent. Coffer provides facility to pour concrete on coffer walls and slab in one go. So you have a unique monolithic structure. .

NAME : Shreyes Gupta (19110025) Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002)

STAY IN PLACE : EPS DOUBLE WALL SYSTEM

STAY IN PLACE : INSULATED CONCRETE FORM SYSTEM

It is an insulating shuttering kit made in a factory for whole building based on a three-dimensional lattice made of high-tensile galvanized steel wires.

At the exterior side of the lattice, a high-density fire-resistant grade of expanded polystyrene panels is inserted which transforms the lattice into a closed structure that can be filled with concrete.

Other materials like mineral board can also be used depending upon the requirement and cost economy. The steel bars also act as a and anchoring for the finished materials and it holds reinforcement bars in place during concreting. The panels are erected on foundation using dowel bars and exterior surface is finished with cement plaster of appropriate grade. EPS base stay in place formwork system has high heat resistant property and brings down energy consumption required during winter and summer for heating and cooling.

An American initiative is used in Europe America Africa and Southeast Asia. Insulated concrete forms ICF system comprises a panel of two walls of selfextinguishing expanded polystyrene EPS of density 24 kilograms per cube meter separated by a nominal distance of 150 millimeters by hard plastic tiles. The forms are open-ended hollow polystyrene blocks that fit tightly together to form a shuttering system. These are assembled at the site to hold reinforced concrete.

The concrete of the desired grade is poured into the hollow space to form a continuous wall, when hardened the wall supports the structural loads from floors and roofs and shuttering provides thermal insulation. Reinforcement, as required from the design, is also placed. The Upper and lower surfaces of the polystyrene panels are castellated and the vertical mating surface of our tongue and grooved to form a tight fit when joined together. The rigid form does not require support in falsework.

STAY IN PLACE FORMWORK

Page No: ARN - 303- Building Construction - IV Date: 23-09-2021 Images From BTMPC manuals and videos

STAY IN PLACE: PVC WALL FORMS

EXTRUSION OF PANELS

Stay in Place PVC Wall Form is a typr of SIP which is already in use in Australia and Canada . The technique involves using rigid poly-vinyl chloride (PVC) based polymer components serve as a permanent stay-in-place finished formwork for concrete walls. The formwork System being used acts as pre-finished walls requiring no plaster and can be constructed instantly.

Raw materials in screw barrels

Screws push molten raw material

Extrusion through the die

Two water cooled vaccums

Measured and cut

Belt Puller

Hardened PVC panels

Passing through the vacuum coolers

ERECTION OF PANELS Each wall component automated cutting saw.

cut

with

Course begins with box connector, and placing two adjacent pannels.

JOINERY PANELS The box connector slid down between the two panels and is located over the foundation dowel.

Main Panel

Connector

Connector

Panel

Corner Panel 3 way Connector Basic Frame Jointer Connector

Window Frame

Azteca Frame

Starter

Jointer Panel

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

Checking of correct component, proper pieces and correct alignment.

Bracing done at top and bottom, components screwed, and assembly plumbed.

Erection continued sequentially, according to drawing layout

1. MAIN PANEL 2. CONNECTOR 3. CONNECTOR 4. PANEL 5. CORNER PANEL 6. 3-WAY (T- CONNECTOR) 7. JOINTER PANEL 8. JOINTER CONNECTOR 9. BASIC FRAME 10. WINDOW FRAME 11. AZTECA FRAME 12. STARTER

STAY IN PLACE FORMWORK

Page No: 2 ARN - 303- Building Construction - IV Date: 24-09-2021 Images From BTMPC manuals and videos

STAY IN PLACE: PVC WALL FORMS There are certain specifications given in the BMTPC manual regarding the attachment of panels for doors and windows.

First, the side panels are placed and screwed on the top then the leveling is checked and then the top panel for the window all door is fitted. Some construction detail designs are also given in the BMPTC manuals.

PLACING OF REINFORCEMENTS

POURING OF CONCRETE

Reinforcing steel bars are provided as specified on the structural drawings for the project.

Vertical steel reinforcement (re-bar) placed in the box connectors or in the cells of the panels at regular intervals Horizontal bars shall be installed after the vertical bars . spacing of performed cores can be adjusted as per the structural requirement of spacing of horizontal bars The horizontal bars are lapped with the previous bars At the first corner, the hooked horizontal bars are installed from both directions Horizontal hooked bars are installed at the ends of straight walls prior to installing the next corner and are installed at intersections after erecting a sufficient length of wall.

Bracing must be re-checked to ensure that all members are properly installed and that the Novel System components are located, aligned and plumbed.

A highly workable, free-flowing concrete mix has to be used for the pouring.

The concrete specified shall be highly workable, free flowing mix 13 poured from the top into the cavities using a small hose to go down at least 1.5 to 2m into the cavities for directly pumping the concrete from ready mixed concrete truck.

For small building construction, concrete can be poured manually using a funnel.

Concrete mix directly poured from ready mixed concrete truck There is no need to use vibrator because gravitational pressure acts to selfcompact the concrete inside the water tight cavities when selfcompacting concrete is used.

Filling the panels with concrete shall be done in three layers of 1m height with an interval of 1 hour between each layer.

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

STAY IN PLACE FORMWORK

Page No:3 ARN - 303- Building Construction - IV Date: 24-09-2021 Images From BTMPC manuals and videos

STAY IN PLACE : PVC WALL FORM

TESTING/ VERIFICATION PROCESS

SOME IMP CODES AND STANDARDS USED IN ASSESSMENT

TEST PERFORMED AND TEST RESULTS Testing of samples by RDH Building Engineering Ltd., USA Air Leakage Rate and Water Ingress Resistance Tests These tests were performed by constructing a wall of 1994 mm x 2032 mm using light weight EPS by Plasti-Fab Advantage ICF as formwork for the steel reinforced 150 mm thick concrete. A 584 mm x 584 mm fixed window was installed within the wall assembly.

Air Tightness Test in accordance with ASTM E283 When tested to the standard of ASTM E283 at a pressure differential of 75 Pa, the specimen, as prepared, achieved an Air Leakage Rate per fixed area (qA) of less than 0.0039 L/s.m2.

Water Ingress Resistance Test in accordance with ASTM E331 When tested to the standard of ASTM E331, no water ingress resistance was observed through the specimen at differential pressures of 150, 300, 700, 1400 & 5000Pa. Engineering Evaluation of Logix ICF Water Vapour Transmission Test by Intertek Testing Services NA Ltd., USA Intertek has conducted an engineering evaluation of Logix Insulated Concrete Forms Ltd., on Logix ICF to determine if the Logix ICF meets the 2005 National Building Code as a vapour barrier. The analysis showed that Logix ICF meete the water permeance requirements and can be installed without a vapour barrier

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

STAY IN PLACE FORMWORK

Page No: 4 ARN - 303- Building Construction - IV Date: 24-09-2021 Images From BTMPC manuals and videos

STAY IN PLACE : COFFER SYSTEM

SIZE OF PANELS

ELEMENTS AND PANEL ASSEMBLY The formwork system comprises of two filtering grids made of rib mesh reinforced by vertical stiffeners called ‘C’ channel which is made up of galvanized sheet having zinc coating .The grids are connected by rebar which acts as horizontal stiffeners and connector which act as a shear link.

The vertical steel channels and horizontal steel bars act as steel reinforcement for load bearing wall. The connectors help to fold the formwork for easy transportation. Concrete is poured into these gaps between ribmehses. The panels are prefabricated which when arrive on the construction site are installed and ready for concreting. The Formwork System is generally used for residential buildings upto G+4 storey, Industrial buildings, Underground Tanks, Water retaining structures, Storm water drains, Compound walls etc. and also as shuttering material for slabs.

'C’ Channel

ReBar

Rib Mesh Connector

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

TYPES OF PANELS

Standard double panel Standard single panel

Insulated double panel

These panels shall be used for slab shuttering but may also be used as shuttering option for RCC wall having thickness of more than 350mm.

Insulated Double panel – These panels shall have an integrated insulation on the exterior side. The insulated material shall be of polystyrene or polyurethane of required thickness as per design.

Used for main walls in structures.

STAY IN PLACE FORMWORK

These shall have inbuilt steel Fibre cement double panel and not require extra reinforcement. shall be of fixed These panels shall size and need to be cut on site have its interior face for openings etc but there are as fibre cement board also Customized double panels which has smooth from the factory that shall surface and avoid have required cutting for plastering of walls. openings as per drawing and These panels may be no need to cut on site. used for water These panels shall be used for retaining structures. load bearing walls, retaining walls and shear walls.

Page No:5 ARN - 303- Building Construction - IV Date: 24-09-2021 Images From BTMPC manuals and videos

STAY IN PLACE : COFFER SYSTEM

MANUFACTURING/INSTALLING MACHINERY

MANUFACTURING PROCESS FLOW CHART Marketing

PPC

Panel Designer

Plant store, Issue of raw material

Coffer panels on pallets

Production of Components 'C' Profile production line

Mesh Production line

Connector Machine

'L' and 'U' bar machine

CONSTRUCTION ACCESSORIES

Rib lathe

Crimping Machine Production of Single panerls Assembly Machine

studs and scews Single coffer panels

Horizontal steel C profile and scaffholding

Production of Double panels Quality check Packing and Dispatch

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

Construction tools and vertical saw

Steel wire

STAY IN PLACE FORMWORK

Rebars, U bars and Right angle C profiles

Page No: 6 ARN - 303- Building Construction - IV Date: 24-09-2021 Images From BTMPC manuals and videos

STAY IN PLACE : COFFER SYSTEM 1.

LAYOUT AND BLOCKING

CONSTRUCTION OF THE PANELS - ON SITE ASSEMBLY

2.

ERECTION AND POSITIONING OF PANELS

TRACING ON GROUND The alignment shall be traced with chalk on the two sides. Boards/battens shall be nailed on the ground to indicate the positioning of of the panels.Then the vertical reinforcing starter bars are projected on this alingnment after checking the verticality.

4.

INSTALLING REINFORCEMNET BARS AT THE EXTREMITIES AND NEXT TO OPENINGS

TEMPORARY PLACEMENT The Structural formwork panels shall be fitted over projecting vertical reinforcing starter bars. On a provisional basis, each panel shall be positioned vertically with the help of c channel of wooden battens or metal bars. Then, the small left over gaps after placing all panels is adjusted by cutting a panel with a vertical saw and is fixed in accordance with the width of that gap.

5.

CLOSING THE EDGES OF OPENINGS Once the panels are correctly stabilized, reinforcement bars shall be installed . Details of the reinforcement elements in the angles and around the openings shall be the same as for traditional walls of reinforced concrete. Vertical bars and horizontal bars in U-shape, shall be placed in the angles and openings- bound together and tied by a steel wire.

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

3.

CONSOLIDATING THE PANELS

HORIZONTAL ALIGNMENT

VERTICAL ALIGNMENT SCAFFOLDING

When all the panels are installed, these shall be consolidated with horizontal steel profiles fixed(Screwed) on single side at every 80 cm and which ensures a perfect alingnment of coffer panels that are bound together by these profiles. Also, Scaffolding ensures the vertical alignment of panels and serves as a work platform that are fixed to the panels.

CLOSING THE EXTREMITIES/ANGLES

BENDING THE PANEL ON SITE The angles shall be closed with Formwork angle panels delivered from the factory. In the absence of angle panels delivered from the factory, panels of expanded metal shall be press-formed on the site.

STAY IN PLACE FORMWORK

The angle panels shall preferably be fixed as follows: a. On the inside with a batten of panel placed vertically all the way up the angle. This batten shall be bounded around the stiffening sections of Formwork panels of the angle. b. On the outside right angle accessories are used as braces fixed on the angle panels . they are either screwed or tied.

Once done, the The verticality of all the pnels fixed shall be checked using a plumb line or level.

Page No:7 ARN - 303- Building Construction - IV Date: 24-09-2021 All sketches in this page are hand- drawn.

9.

STAY IN PLACE : COFFER SYSTEM 6.

FINISHING THE WALL On the outside, traditional hydraulic or sprayed façade coating shall be used. On the inside, normal plaster, panels of wood, tile, marble etc. shall be used.The ideal number of coats is two, namely the undercoat followed by a finishing coat. The total thickness of two coat plaster shall not normally exceed 20mm where - Back coat, both for internal and external shall be 10 to 12 mm thick and Finishing coat shall be 3 to 8 mm thick.

CLOSING THE RIMS OF DOORS AND WINDOWS

The opening for windows shall be done using a rotary saw. Rims of doors and windows shall be closed preferably with wooden boards/rib lath/preframes the width of which shall be equal to thickness of the panel. Then the openings of edges are closed with panels.

JOINERY DETAILING

.

7. ELECTRIC AND PLUMBING DUCTS The electric and plumbing ducts etc. shall be placed inside the ducts. For connectors, small openings shall be made.

Slab & outer wall connection

8.

Slab & Inner wall connection

POURING THE CONCRETE The pouring should be done with plastic concrete and can be poured using plump ,bucket or chauvel loader. The pouring shall be monitored at the jointing points, reveals and zones containing reinforcement bars.

In coffer system , it is possible to pour at the walls and slab at the same time.

This will ensure a monolithic structure of excellent quality.

Single coffor panels are used for slabs.

Reinforcement of slabs is placed on the coffor panels.

NAME: Muskan Aanand (19110016) .

Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

Roof Slab & outer wall connection Roof Slab & Inner wall connection

Wall “L” junction

STAY IN PLACE FORMWORK

Wall “T” junction

Wall Edge junction

Page No:8 ARN - 303- Building Construction - IV Date: 23-09-2021 Sketches are hand - Drawn.

STAY IN PLACE : COFFER SYSTEM

TEST PERFORMED AND TEST RESULTS

TESTING/ VERIFICATION PROCESS Test 1: Lateral capacity of the panels with concrete Details of Test:  Size of panels: 2.2 m x 3.0 m, thickness : 160 mm and no. of panels used = 2  Grade of concrete: M20 Test result;  Breaking load: 8.512 MT  Maximum deflection: 6.2 mm.

SOME IMP CODES AND STANDARDS USED IN ASSESSMENT

Test 2: Axial and Buckling capacity of the panels with concrete Details of Test:  Size of panels: 0.5 m x 3.0 m, thickness : 160 mm and no. of panels used = 2  Concrete grade : M20 Test Result:  Maximum load per cylinder given: 26.3 MT  Total load applied per cylinder: 105.2 MT  Maximum deflection observed: 1.87 mm Test 1: Compressive Strength on Hardened Concrete Cubes Details of Test:  Material description: Concrete cube (150 x 150 x 150mm)  Concrete grade: M20 for 28 days strength  Concrete grade: M25 for 7 days & 28 days strength  Concrete grade: M30 for 28 days strength Test 2: Compressive strength of Concrete cubes & Concrete panel (after 7 days & 28 days), Flexural strength of Concrete beam & concrete panel (after 7 days & 28 days), Shear strength of panel (after 28 days), Deflection of panel (after 28 days), Water absorption (after 28 days) and Modulus of Elasticity of Cylinder (after 28 days)

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

STAY IN PLACE FORMWORK

Page No: 9 ARN - 303- Building Construction - IV Date: 24-09-2021 Images From BTMPC manuals and videos

CASE STUDIES AND APPLICATIONS OF THE TECHNOLOGY

PVC STAY IN PLACE CONSTRUCTION SYSTEM Already in use in Canada & Australia, the plant manufactured rigid poly-vinyl chloride (PVC) based polymer components serve as a permanent stay-in-place finished form-work for concrete walls. The formwork System being used acts as pre-finished walls requiring no plaster and can be constructed instantly.

COFFOR CONSTRUCTION SYSTEM

This System is suitable for residential and commercial buildings of any height from low rise to high rise. In order to achieve speedier construction, strength and resource efficiency, the composite structure with PreEngineered Steel Structural System as structural members is being used in the present project.

LIGHT HOUSE PROJECTS - LUCKNOW, UTTAR PRADESH TECHNOLOGY : PVC Stay In Place Formwork System

Construction of demonstration housing project g+1 structure,tripura

construction of circular water purification tank,gujarat

construction of underground tank, vadodara, gujarat "The Light House Projects (LHPs) showcase the best of new-age alternate global technologies, materials and processes in the construction sector for the first time in the country at such a large scale. They are being constructed under GHTC-India which envisages to provide an ecosystem for adoption of innovative technologies in the housing construction sector in a holistic manner.

construction of police barak,west bengal

NAME: Muskan Aanand (19110016) Katta Sheetal (19110011) Amasa Pranay (19110002) Shreyes Gupta (19110025)

construction of government mass housing,in cameroon

STAY IN PLACE FORMWORK

Page No: 10 ARN - 303- Building Construction - IV Date: 24-09-2021 Images From BTMPC manuals and videos