Handbook on Formwork Systems for DLF Capital Greens

Handbook On Methodology for Formwork System
For DLF, Capital Greens
Prepared by: - Formwork Dept., RB&F, DLCL
L&T Construction
Doc Ref:-SOP/DLF Capital Greens/R0
SOP DLF Capital Greens

Released by :- Formwork Dept., RB&F, DLCL
L&T Construction
INDEX
SL.
Topic
1)
General Information / Formwork strategy
2)
Methodology for formwork systems proposed

HY-RIB Stopper use for construction joints
Column formwork
Wall formwork
Flex Formwork system
Cup lock system
Access Scaffold system
CB 150 A
3)
L&T Stair tower system
4)
Form release agent & Plywood
5)
Roles & Responsibilities of site Engg. / Foreman and charge hand
6)
Standard allowable deviation as per IS 456:2000
7)
Formwork: hand tools
8)
Dos & Donts in formwork & stacking
9)
Stacking (Housekeeping)
10)
Water jet for efficient cleaning of Shutter panels
11)
Shuttering oil sprayer machine
12)
Formwork safety
13)
Accident Prevention
14)
Slab & Beam striking time as per the IS 456
15)
Formwork Check List

L&T Construction
Formwork Strategy
Structure
System proposed
Total scope
(Sqm)
Catering area
(Sqm)
Isolated footings
Wall / Column FW
4838
227
Column square/ rectangle
Wall / Column FW
443544
7819
Retaining Wall
Wall / Column FW
5155
254
Beam & slab Conventional
Cup lock system
400697
10595
Peripheral/ Heavy beams
Flex System
447817
11841
Staircase
Flex System
23524
871
1325575
31608
Total FW Scope
CLUSTER BSCC IN-CHARGE
SITE PLANNING IN-CHARGE
As per the formwork ACE

L&T Construction
METHODOLOGY FOR FORMWORK SYSTEMS PROPOSED

HY-RIB Stoppers for construction joints:
Hy-rib stoppers shall be used in the foundation where mass construction of concrete
has to be done with-out any construction joints or heavy dense reinforcement is used
where it is difficult to erect vertical formwork shutter.
Hy-rib permanent formwork comprises of Zinc-coated steel which are
formed into a ribbed expanded mesh.
It is a lost type formwork item to form construction joints in concrete &
Stopper ends for retaining walls, columns & beams. It can also be used to
support horizontal slab flooring.
It will produce a surface which will bond directly with the next pour.

L&T Construction
COLUMN FORMWORK SYSTEM

SYSTEM DESCRIPTION:
Column Formwork is a complete Column

Formwork system, mainly consists of plywood
sheathing backing by timber H-Beams and Steel
Waler which can be erected manually & also can be
handled by crane.
Besides giving smooth concrete finish this
System comes with inbuilt safety and working accessories platform.
Work
Platform
Lifting Bracket
Steel
Waler
H-Beam
Alignment
System
Ply

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Method Statement for Column Formwork:
Formwork Erection:
Making of shutter panels
1) Drill holes in H-beams for fixing beam clamp, lifting
bracket & Working platform bracket.
2) Make shutter panels (without/with fixing of walers
and accessories) of required size including cutting
plywood for stitching with H-beams.
3) Fix of wooden planks (40mm) at top & bottom sides
of shutters. Minimum size of column that can be
done is 300mm x 300mm.
4) The shutter panels can be combined as an L
shaped panel using angle plate& lifted to next location.
5) Fix starter suitable to column size.
6) Remove the forms for starter after concreting is
over.
7) After concreting clean the shutters with water jet for any excess / over concreting.
Assembly of formwork:
1) Fix both shutter panels in position.
2) Fix tie rod, anchor plates and wing nuts at the corner of shutters in each waler level.
3) Fix Alignment props/supporting brackets with Head adaptor assembly and
foot adaptor assembly on the adjacent sides of the shutters.
4) Plumb the shutter panels as required and checking the column size as per requirement.
5) Fix the stop anchor, anchor cone with PVC sleeve to facilitate for fixing of climbing
bracket for next lift.
Deshuttering of column formwork:
1) Remove side panels in after removing the alignment props, tie rods/accessories only.
2) Clean, apply oil and shift.
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WALL FORMWORK
SYSTEM DESCRIPTION:
Wall Formwork is a complete

Formwork system, which mainly consists of plywood sheathing backed by H-Beams and
Steel walers (ISMC 100 B/B
channels). The support is given
by double nut alignment props
which can be used to
align the shutters to the required angle and position.
These shutters can be erected
manually &also can be handled
by crane.
Besides giving smooth concrete
finish this system comes with
inbuilt safety and working
accessories.
Method statement for Wall Formwork:
Formwork Erection:
Making of shutter panels
1) Lay waler @ distance (or) predetermined location over the leveled surface. (Either a
timber platform or with lean concrete to accommodate the size of the shutter panel)
2) Drill holes in H-beams for fixing beam clamp, Lifting bracket & working platform bracket
at predetermined locations using suitable power drill.
3) Drill holes in H-beams with Drilling plate & safe guard for fixing M 6 x 70 bolts with
waler.
4) Place the H-beams above the waler and connect the same with beam clamp / M6 bolts.
5) Place the Plywood (the grains should be perpendicular to the timber beams) and ensure
proper butting of plywood with the Assembly.
6) Use only screws (1.5 long) for fixing plywood with H-beams. (approx. 8 nos for 8 x 4
plywood size )
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7) Fix wooden planks (40mm thk. x 160 mm) at top & bottom sides of shutters. Provide slot
in the top plank of lifting bracket location.
8) All the above should be done with an accuracy of ( + or -) 2mm
9) Any lengths of panel to suit the required dimension of walls can be formed using the
available lengths of waler, splice plate & connecting pins, if the system is to be crane
handled.
Erection of wall formwork:
1) The wall panels should be placed on the outside first and all the gaps to be filled
appropriately using fillers/sponge etc. for maintaining the form finish, then reinforcement can be tied and inner shutters be placed.
2) The wall panels should be placed alongside each other & aligned properly; edges
checked using plumb bob and line threads.
3) The joints of the wall panels should be filled with sponge or appropriate filler material
so that the slurry leakage is arrested.
4) The tie rod hole locations shall be made prior to erection of shutters so that the
alignment &pattern of hole locations is to be maintained uniformly. No other holes
should be allowed to drill later.
5) The grout check has to be fixed to the shutters at the top so that the concrete level can
be maintained in a straight line for the pour and it also acts as a starter for the second
pour above.
6) Fix timber spacers to maintain the wall thickness at top.
7) High strength tie system bears large concrete pressures and avoids load-bearing struts.
8) Panels can be made in large units for handling by crane and in smaller ones to facilitate
manual handling.
9) Panels can be used along with Climbing Formwork system for the more height.
De-shuttering of wall formwork:
1) First remove Wing nut, Anchor plates, Tie rods, Head adaptor assembly, Alignment
struts, Supporting Brackets, Foot adaptor assembly.
2) Remove shutters (each separately) with the help of crane or manually.
3) In case of subsequent lifts remove climbing brackets, Suspended platforms handrail post,
accessories.
4) In case of shutter being used for subsequent lifts the Alignment struts head adaptor
assy., Foot adaptor assy., Supporting Brackets need not be removed.
5) Stacking of wall shutters shall be done vertically with fabricated steel racks (Ref. fig vertical stacking of formwork).

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FLEX SYSTEM
SYSTEM DESCRIPTION:
The forms shall be made with plywood backed by H-beam & supported by using props. Props
take the load and shall be erect in position using tripods for lateral stability. The spacing between the timber beams shall be in accordance with design criteria & should be properly
screwed to the plywood and safely placed over the props to avoid toppling.
The props are designed to take care of the vertical loads which are tested under maximum
loading conditions. The spacing of CT prop will be decided based on the thickness of the slab
i.e. load coming from the slab & the prop height required. More the height, the lesser will be
the capacity so it should be ensured that use of props in the fully extended condition should
be avoided.
Method statement for FLEX FORMWORK:
Formwork Erection:
Erection of FLEX SYSTEM:
1) Mark Props location.
2) Place main Props I step, Tripods, - II step, Four way heads III step.
3) Use four way heads over props at the lapping joints of primary H-beams.
4) Place primary & secondary layers of H-beams.
5) Place plywoods and screw with H- beams.
6) No need to place tripod at all the prop Location but should provide at ends and joints
of primary H-Beam
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7) Maintain the required level of slabs by adjusting the props.

8) Apply shutter release agent over plywood surface & fix masking tape in joints of
plywood to avoid slurry leakage.
De-shuttering of flex formwork:

1) Lower the props height by collapsing.
2) Remove secondary beams and parallel remove plywood.
3) Remove primary beams.
4) Remove four way heads and Intermediate props.
5) Remove main props, four way heads, Tripods.
6) Clean and stack the plywoods and H-beams for next portion.
7) Shift the materials to next location.
8) Use Stacking pallets for the shifting.
CUPLOCK SYSTEM
SYSTEM DESCRIPTION:
Sequence for Assembling:

1.
2.
3.
4.
10
Level the ground and compacted the earth.

Mark the Scaffolding location on the ground/floor.
place the concrete sill or wooden sleeper above ground ( 300 x 300 x 150 mm )
Provide gap 300 mm between the scaffolding and permanent structure.
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5. Erect Scaffold Screw jack.

6. Erect Vertical leg over screw jack and connect with horizontal bracing both directions at
every cup location.
7. Rotate the cup by hammering gently to tight the bracing.
8. Level the Scaffold after fixing the first level of the leg with water level.
9. Fix the working platform over the horizontal bracing ( 50 mm thick Timber planks )
10. Fix the next level of scaffold leg.
11. Brace the scaffolding with permanent structure and between towers
at every 4.0 m height intervals.
12. For fixing of bracing with permanent structure to scaffolding, use 150 x 150x 6 mm thick
insert plate welded with NB 40 mm pipe.
13. Use Anchor fastener 12 mm at 4 corners.
14. Use scaffold up to a maximum height 40 meters.
15. If Cup lock is used as staging, then place adjustable screw jack with U-head followed by
other formwork components above it.
STEP-1
11
STEP-2

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STEP-3
STEP-5
STEP-4
STEP-6
Sequence for dismantling :

1. If used as staging remove the above formwork arrangement by lowering the adjustable
screw jack with U-head.
2. Route the cup by hammering.
3. Remove horizontal bracing (above the working level).
4. Remove the Vertical legs simultaneously at same level as mentioned above.
5. Remove the working platforms (scaffold board the level above the working level).
6. Remove the Bracing between towers / with permanent structure when dismantling work
reaches level below.
7. Remove Screw jack.
8. Shift the materials to next position.
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Electrical safety guidelines:

Scaffolds shall not be erected, used, dismantled, altered, or moved such that they or any
conductive material handled on them might come closer to exposed and energized power
lines than as indicated in the chart that follows:
Insulated lines voltage

Less than 300 volts
300-15 kv
More than 50 kv
Un Insulated lines voltage

Less than 50 kv
More than 50 kv
13
Minimum distance
3 feet (0.9)
10 feet ( 3.1m)
10 feet (3.1m) plus 4
inches
10 cm for each 1 kv
over 50 kv
Alternatives
2 times the length of
the line insulator
but never less than
Minimum distance
Alternatives
10 feet (3.1m)
10 feet (3.1m) plus 4
inches
10 cm for each 1 kv over
50 kv
2 times the length of

the line insulator
but never less than 10
feet (3.1m)
10 feet (3.1M )

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GENERAL ACCESS SCAFFOLD SYSTEM DETAIL
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CB150A & CB150F FORMWORK SYSTEM for the Highrise vertical

Column / Wall
CLIMBING BRACKET 150A
SYSTEM DESCRIPTION:
The L&T-Formwork Climbing System are used for tall structures like cooling towers,
etc. where very uneconomical & unsafe to provide staging or scaffolding for supporting
the external or internal wall formwork.
In this system bracket is hanged on anchors called lost stop anchors provided in the already casted wall and supports/alignments are taken from these brackets. The brackets
are suitably braced to prevent any sway and are provided with walkways/working platforms / handrails etc. for safety and ease of working.
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CLIMBING BRACKET -150A
--
SEQUENCE
Assembly of Simple Climbing Formwork
After dismantling the shutters from the 1st pour of concrete, remove anchor cone using DK spanner
and fix climbing cone in the stop anchor.
Assemble Climbing bracket 150 A 2 no's (max distance should be 2.0 to 2.40 m) and brace with NB
40 pipes and couplers to form as a unit.
Provide working platforms with 4X 4 (or) timber as supporting member and 2 thick planks.
Brace the primary member and climbing bracket with brace stirrup.
Fix Handrail post on each bracket and hand railing at 2 levels should be done with NB 40 pipes &
couplers.
Lift the entire assembly of climbing bracket 150 A with the help of crane and place over the climbing
cone correctly and lock the pin.
Follow the procedures described in the assembly of wall formwork; however the alignment props to be
fixed in the climbing bracket platform.
Suspended platform 80 A should be fixed in the predetermined holes provided in the climbing bracket
and brace the suspended platforms with NB 40 pipes and couplers. Provide 2 thick planks as working platform.
Cover the open face of suspended platform with safety net.
Check the verticality of the shutter using plumb bob.
Dismantling
17
Remove the wall panel assembly and keep it on the ground.

Remove Climbing bracket set and lift to the next location and place over Climbing cone already fixed
in position.

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L&T STAIR TOWER SYSTEM

Assembly of stair Tower:
1. Mark the Heavy-Duty tower location on the
ground/floor (1525X2250
systems)
2. Erect H.D. Tower spindle
with Foot plate and spring
lock pin 16 dia.
3. Erect Basic frames 1.20 m
height with 1525mm X
2250 mm Configuration
over spindles and connect
the frames with Diagonal
and Horizontal bracing.
4. Level the basic frames after fixing the first level.
5. Fix Connection angle with
frames and connect it with
spring lock pins and click
and pawl.
6. Fix the stair brackets (left
& right) over horizontal
member of the frames and
clamp them.
7. Fix the Grid Irons over
Stair brackets using bolts
& nuts.
8. Fix Inner hand railing, Intermediate railing.
9. Fix Diagonal bracing 12225 with connection angle
in each tier.
10.
Fix Horizontal Bracing H-152 with connection angle in landing location.
11. Brace stair towers at every 6-m heights with the permanent structures.
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Dismantling of stair Tower:

1. Remove intermediate railing and inner hand railing from Top.
2. Remove Grid irons.
3. Remove the stair brackets (both left & right)
4. Remove Diagonal bracing, Horizontal Bracing
5. Remove connection angle.
6. Remove Bracing and frames.
7. Remove the Bracing between towers / with permanent structure when dismantling Work reaches that level.
8. Remove Tower spindles with Foot plates at bottom.
9. Stack the small components in the stacking pallet
STAIRTOWER WITH NET

Description:
Stair towers outer frame has been modified to accommodate mesh so as to prevent both men
and material from falling.
COMPONENTS
STFR 152 (Replacement of

basic frame 1.2)
STFR 225 (Replacement of
all bracings)
STFR 225 OP (Half open
for entry)
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Stair tower assembly
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FORM RELEASE AGENT AND PLYWOOD

APPROVED FORM RELEASE AGENT
FOSROC MAKE - REEBOL ( 20 60 SQM/LT)
BASF MAKE RHEOFINISH 202 ( 30 70 SQM/LT)
DON MAKE SET RELEASE RTU ( 22 30 SQM./LT)
CICO MAKE CICO LEASE ( 20 60 SQM/LT)
PLYWOOD IS CODES
PLYWOOD FOR CONCRETE SHUTTERING WORKS IS 4990:1993
RESIN TREATED COMPRESSED WOOD LAMINATES (
Sl.no
Description
Moisture content
3
4
5
Dimensional
Tolerances
Thickness of
face veneer
layer
Timber
Mass
Adhesives
7
No. of ply in
a board
Tensile
Strength
Water Resistant Test
10
Test Report
Specifications
Reference / Remarks
Moisture content not<5% & not>15%
For testing procedure refer

IS 1734 (Part 1) :1983
Length=+6mm,-0mm,
Width= +3mm, -0mm,
Thk. tol.=for > 6mm = +/-5% & for < 6mm = +/10%
Edge straightness & squareness 2mm per 1000mm
i.e 0.2%,
Refer IS 12049 : 1987 for

tolerance limits and
thickness tolerance shall
be as per
IS 303 : 1989
not < 1.2 mm

Any Plantation timber shall be used as raw material
for 6mm - 3.90 kg/Sqm.
for 9mm - 5.85 kg/Sqm
Shall be of the hot press synthetic resin (phenol
formaldehyde)
The accuracy of the mass

specified can be taken only
within a tolerance of +/10%
Shall conform to IS 848 :
1974
7-ply / 9-ply
not < 32.5 N/mm2 parallel to grain direction of the
face veneers
not < 22.5 N/mm2 right angles to grain direction of
the face veneers
sum of the tensile strength in both directions shall
be not < 60.0 N/mm2
Shall conform to IS 1734
(Part 4) :1983
Each consignment shall be supplied along with
Test Report on the above parameters
PLYWOOD FOR GENERAL PURPOSES (THIRD REVISION) IS 303-1989
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ROLES & RESPONSIBILITY OF FORMWORK ENGINEERS AT SITE

1. Preparation of formwork strategy based on the overall construction programme
& GFC drawing.
2. Finalization and coordination of shuttering scheme and should execute as per
the FW scheme drawings and design.
3. Ensuring effective and proper utilization of shuttering and staging material
4. Planning and allocation of materials/labour/plant & machinery for formwork activities in coordination with concerned persons at site.
5. Educating sub-contractor on system formwork.
6. Making mock-up of various system formwork.
7. Periodical reconciliation of formwork materials
8. Preparing FW schedule (requirement/release) within the ACE provision and
sending the same to cluster office.
9. Preparing stock statement of formwork materials both in units and in nos. with
area of shuttering done category wise/Plywood/Timber procured during the
quarter/till date and productivity report.
10.Maintain close interaction with stores and site people for proper accounting of
materials.
11.Dispatch and receipt notes to be sent to cluster office in the regular basis.
12.Making of purchase requisition for plywood and timber after thoroughly analyzing the number of repetitions.
13.Receipt of plywood/formwork materials to be acknowledged after quality
checks to cluster office on monthly basis.
14.100% materials reconciliation at the end of the job.
15.Looking after pre-dispatch maintenance.
16.Ensuring that dispatched materials are in usable condition.
17.Sending monthly reports to cluster office.
ROLES & RESPONSIBITY OF SITE FOREMAN/CHARGEHANDS

1. Material accountability right from the materials receipts at site to dispatch to
other site after completion of the job.
2. Small items have to be issued to the subcontractors form the stores and make
them responsible for those items. For their sake, tool-box can be issued. These
items have to reconcile after completion of the job.
3. Ensure the Proper utilization of the formwork materials and avoid the misuse &
wastage of particularly H-Beam and Bracing.
4. Ensure proper housekeeping at site as well as the maintenance (greasing/oiling
after De shuttering etc.) of the formwork materials.
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5. De-shuttering in right time to achieve maximum number of repetitions of formwork materials.

6. Optimum use of screws & Accessories of formwork.
7. Quality in works carried out at site so that the tolerance should be within the
tolerance limit.
8. Formwork labour productivity should be monitored closely to achieve the management goal.
9. Training of labour and sub-contractor workmen at site either by mockup or
classroom programme by drawing sketches.
10.Adoption of safety standards while working by fully equipped with PPE and using the complete system at site (do not miss any bracing/connecting pin/locking
pin etc.).
11.Use of stacking pallets
STANDARD ALLOWABLE DEVIATION AS PER IS 456:2000
The tolerances on the shapes, lines and dimensions shown in the drawing shall be within the
limits given below as per IS 456:2000
a) Deviation from dimensions
of footings
+ 12 mm
- 6mm
1) Dimensions in plan
+ 5omm
- 12 mm
0.02 times the
width of the footing
in the direction
of deviation
but not more than
50mm
+ 0.05 times the
specified thickness
2) Eccentricity
3) Thickness
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L&T FORMWORK HAND TOOLS
WORK
BENCH
MEASURING
TAPE
CLAW
HAMMER
CHISEL
PLUMB
BOB
TUBE LEVEL
AUGUR
24
SCREW BAR
ADJUSTABLE
SCREW
SPANNER
TRY
SQUARE
LINE
THREAD
DOUBLE END
SPANNER
HAND
SAW
SPIRIT
LEVEL
RING
SPANNER
HAND
PLANNER
TWO WAY
RATCHET
PLYWOOD
TRY SQUARE
( BIG)

L&T Construction
L&T FORMWORK MACHINERY & POWER TOOLS
TABLE PLANNER CIRCULAR SAW CUTTING MACHINE
ELECTRIC SCREW DRIVER & BITS
HAND SAW CUTTING

MACHINE
DRILLING MACHINE UPTO 13.5

MM
JIG SAW
DOUBLE END
SPANNER
HEAVYDUTY DRILLING
MACHINE
RING
SPANNER
( HSS ) DRILL
BIT
WOODEN
FLAT DRILL
BITS
CONCERETE
DRILL BITS
HAND PLANNER
(ELECTRIC)
25
HEAVY-DUTY HSS
DRILL BITS
COUNTER SUNK
DRILL BITS

L&T Construction
DOS & DONTS

Flex system:
Use tripods only where the H-beams are lapping and at the ends.
All the legs of the tripods to rest on firm ground.
Props to rest on the ground firmly and should be compacted.
Ensure sufficient lap of H-beam in primary & as well as in secondary.
Ensure the Correct spacing of H-beam & Props. According to FW design (FW Scheme
drawing).
Cup Lock system:

Ensure
Ground should be fully compacted and uniform.
All the horizontal bracings should be in position.
Bracings between towers / tower and permanent structure, required at four times the
minimum width of scaffold in height.
Adjustable screw jack with base plates and adjustable screw jack with U-head are provided at the bottom and
top of vertical leg respectively.
Cup lock should be
straight/vertical
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40mm thick
Timber plank as
compression
strut
Angle should
not be less
than 60
Normal Lifting Position
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STACKING (Housekeeping)
Stack the materials properly when not in use & protect them.
It helps
In easy reconciliation
Faster retrieval of material & reconciliation.
Better space management
Improves work culture
Avoids wasteful expenditure
Safety- prevention & loss of material
Protection to materials- improves life of materials
Enables easy maintenance
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Water jet for efficient cleaning of shutter panels:

Application Area
Removal of rust, markings and concrete from plywood & steel surfaces.
Remove lime scale deposits and marine growth.
Deck cleaning.
Dust free sand blasting.
USEFUL
Easy and fast removal of dust particles, rust and plastic papers.
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Shuttering oil sprayer machine :
Shuttering oil sprayer machine can be used for easy application of shuttering oil on both horizontal and vertical shuttering panels. It sprays oil when compression pressure is maintained by
pumping. It is easy handling for workers; they can hold it in hand or hang on their back.
Benefits:
32
Better productivity (saving cost and time)

Less wastage
No separate rollers/brushes, containers required.
Protect shuttering plywood from damage as in case of conventional application method.

L&T Construction
FORMWORK SAFETY:
Inbuilt safety features in L&T System Formwork
Flex System
Clear passage for workmen & inspection, self-standing with tripods.
Beam Forming Support
Safe and easy fixing removal mechanism, no loose components.
Column Wall /Formwork system
Walkway Passage for tying of reinforcement, concreting & vibrating. Lifting hooks for
mechanical handling, double nut props for alignment in both directions.
Cup Lock System
Simple connections- no loose components, easy vertical alignment on uneven ground
also, self-locking pins.
Stair Tower System
Access to heights up to 100 m with adequate tying to structure at 6.0 m. Handrail at
all locations, Regular and comfortable risers, Uniform Head room, Proper arrangement of landing at regular intervals, Multiple entry possible on sides of buildings .
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SCAFFOLD Tag system
This should be installed by the Safety persons after inspected by the

formwork Engineers & safety authority together.
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Columnstaging arrangement
Proper access
Guard rails
Intermediate Landing
Workmen equipped
with all required
Personal Protective
equipment.
Safety Net
provided
to protect
from fall of
workman
& Material
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Workers working with their safety belts

connected to horizontal life line. They are
protected from fall even while moving from
place to place.
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Approach walkway
Flex System
All the main props should be fitted with folding tripod
Do not use tor steel in place of locking pin in CT Prop.
In ground level work, proper earth compacted and

necessary bearing below the prop should be done.
Do not use
Reinforcement
instead of locking pin
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Working Platform
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Working Platform
39
Every work-platform shall be provided with guardrails as shown.

Height of the guardrail shall be from 900mm to
1200mm.
Intermediate guardrail and toe-board are provided.
Height of toe-board is minimum 100mm.
Scaffold boards should be well secured without any
play.
Work-platform shall be provided with proper access,
like a ladder secured to the scaffold.

L&T Construction
Floor Openings
Cover the openings
Provide guard rails
Safety net with fishing net
to trap falling materials
Provide toe-guard to prevent materials falling
through openings
Guarded Edge
Unprotected sides and edges must have guardrails or equivalent

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Access to Work Platform

LADDER
1. Ladder shall be of sound

quality usable in construction having rungs equally
placed.
2. Ladder shall be secured to
the scaffold as shown.
3. Ladder shall be extended
at least 1m above the
work-platform.
4. Horizontal distance between the base of the ladder and the work-platform
shall be of the height of
the work-platform.
5. Length of ladder should not
be more than 10m
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Safe Access for the Concreting of wall / Column with the help of
brackets & NB pipe
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Dismantling of Scaffold
1. Cordon off the area and deploy
only experienced men. Provide
Red Tag
2. Start dismantling from top.
3. Each tier shall be completely
dismantled and the material lowered to the ground before beginning to dismantle the next tier.
4. Use Derrick and Pulley for lowering materials if at heights.
5. While removing jammed or rusted scaffold components, anchoring safety belt is essential.
6. At the end of the day, if a scaffold is going to be left halfdismantled, it is essential to lower all the loose scaffold materials
down and ensure that the scaffold is braced adequately to the
building.
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Improperly covered Floor Openings
Cover completely
and
securely
If no cover,
should
guard with a
guardrail
This opening could be made safe by using a guardrail, or strong cover

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Accident Prevention
1.
2.
3.
4.
Elimination of unsafe acts and conditions

Inclusion of Safety Aspects in the design itself
Integrating Safety into Systems & Work Methods
Should Confirm the Scheme drawing before doing any formwork
Activity in site.
Proper Slinging and Rigging Practices should be followed while
lifting the formwork assembly.
Strength and Location of lifting hooks should be checked.
No loose materials should be kept on the formwork panels or top
platforms.
Panels should be pre-checked before lifting
Safe Design
Adequate Factor of Safety for Formwork System and individual Components

Components can be inspected easily to check design adequacy and
acceptance criteria
Consideration of concrete pressure and rate of pouring in formwork
design
Formwork System is self-aligning and self-standing
Easy to fasten accessories
System integrated aligning and bracings
45
Work-platform with handrails for the works at heights

Integrated climbing arrangements
Study components which are light in weight for easier handling
System-integrated handles / lifting hooks for easier handling

L&T Construction
Slab & Beam striking time as per the IS 456

Re-propping has to do if early striking of formwork. For re-propping has to
follow the scheme drawing & design criteria.
46

L&T Construction
CHECK LIST FOR L & T FORMWORK SYSTEM

Tolerances : Dimensions = ( + or - ) - 1 mm , Plumb = ( + or - )-1 mm & Level = ( + or - ) - 5mm.
SL .
NO
Allowable
Tolerance
DESCIRIPITION
OK
NOT OK
REMARKS
Wall / Column Formwork System

1
Verticality ( plumb )
Tightening of tie rods
Tie rod Tube inner dia. 22 mm

Thickness of tube - 2.5 mm
Tie rod tube both end using of tie rod cone
maintain of wall thickness timber spacer to be fixed at top level
Wall Thickness checked
Compression strut in Shutter panel top
protective Timber planks @ Shutter panel bottom
Connection of H-beam With steel waler
Every Joint
with
2" thk planks
Using of
m6 bolts
SLAB ( Flex system )
All the main props should be fitted with folding tripod

( H - Beam lapping location )
All intermediate prop should be fitted with four way head
( or ) supporting bracket
Locking pin For Props ( No Alternative to be use )
Verticality of props
1
2
47

L&T Construction
SLAB ( Cup Lock System )

1
Using screw jack with base plate below vertical leg.
Height of screw jack adjusted, so that bottom level of all verticals is same.
Screw jack with base plate to be fixed in rigid surface
Coupler with 2 nos of connecting pins at each joints of vertical
leg.
3
4
5
Bracings to be in position and to be secured with cup arrangement
Cup lock should be braced using NB 40 ledger pipes and swivel

couplers with permanent structure, at 4 times the minimum
base width of cup lock.
Common for all systems

1
2
Application of form release Agent @ should be uniform

Dimension as per drawing & Scheme
a) Length
b) width
c) Thickness
11
11
d) Diagonal
e) Radius
Spacing of CT prop., HDT, Steel waler / Timber H- beam and Tie

plate / Tie rod as per the scheme drg. Design.
Ground level should be uniform
FW line as per the GFC Drg.
Concrete pipe line should connect with the permanent structure

not with the stair tower or staging.
48

L&T Construction

Handbook on Formwork Systems for DLF Capital Greens

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Handbook on Formwork Systems for DLF Capital Greens

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Handbook On Methodology for Formwork System

For DLF, Capital Greens

Prepared by: - Formwork Dept., RB&F, DLCL

Doc Ref:-SOP/DLF Capital Greens/R0

SOP DLF Capital Greens

General Information / Formwork strategy

Methodology for formwork systems proposed

L&T Stair tower system

Form release agent & Plywood

Roles & Responsibilities of site Engg. / Foreman and charge hand

Standard allowable deviation as per IS 456:2000

Formwork: hand tools

Dos & Donts in formwork & stacking

Water jet for efficient cleaning of Shutter panels

Shuttering oil sprayer machine

Slab & Beam striking time as per the IS 456

Formwork Check List

SOP DLF Capital Greens

Column square/ rectangle

Beam & slab Conventional

Cup lock system

Peripheral/ Heavy beams

CLUSTER BSCC IN-CHARGE

SITE PLANNING IN-CHARGE

As per the formwork ACE

SOP DLF Capital Greens

METHODOLOGY FOR FORMWORK SYSTEMS PROPOSED

SOP DLF Capital Greens

COLUMN FORMWORK SYSTEM

Column Formwork is a complete Column

SOP DLF Capital Greens

Method Statement for Column Formwork:

SOP DLF Capital Greens

Wall Formwork is a complete

Method statement for Wall Formwork:

SOP DLF Capital Greens

SOP DLF Capital Greens

Method statement for FLEX FORMWORK:

SOP DLF Capital Greens

7) Maintain the required level of slabs by adjusting the props.

De-shuttering of flex formwork:

Sequence for Assembling:

Level the ground and compacted the earth.

5. Erect Scaffold Screw jack.

SOP DLF Capital Greens

Sequence for dismantling :

SOP DLF Capital Greens

Electrical safety guidelines:

Insulated lines voltage

Un Insulated lines voltage

2 times the length of

SOP DLF Capital Greens

GENERAL ACCESS SCAFFOLD SYSTEM DETAIL

SOP DLF Capital Greens

CB150A & CB150F FORMWORK SYSTEM for the Highrise vertical

SOP DLF Capital Greens

SOP DLF Capital Greens

CLIMBING BRACKET -150A

Assembly of Simple Climbing Formwork

Remove the wall panel assembly and keep it on the ground.

SOP DLF Capital Greens

L&T STAIR TOWER SYSTEM

SOP DLF Capital Greens