School of Professional and Continuing Education

The University of Hong Kong

Postgraduate Certificate in Building Engineering (Sept 2012 intake)

Module: Temporary Works Design

Assignment No. 1

Assignment No. 1 [Part A is to be done in Group (of around 5 members) and Part B
by individual]

Part A:- (Submission deadline: 7 November` 2012 )

Objectives - Formwork design for shaft wall construction

1. Project Introduction

This report is specially focused on the temporary work scheme, design and calculations for
a shaft wall construction. The design shall include the assumption/s adopted for design the
formwork. The codes and regulations which are related should be well referenced in this
report. A feasible and structure safe scheme of the temporary works for the shaft wall
should be suggested. Moreover, the stability of the proposed formwork during the
construction stage is vital to be assessed in the design. The imposed loadings associated the
formwork should be stated clearly and assessed.

2. Intended Learning Outcomes

 to design temporary support systems and prepare temporary works details.

Submission of Part A (in Group) is to be made to Dr. W.H. LAU [by email to
[email protected]]

3. Assignment Details:

3.1 Information provided

The wall dimension is 8.4m width x 5.5 m height

The wall shall be constructed in one pour of concrete

Rate of placing, slump and wall thickness shall be chosen from the table below

Density of concrete: 2500 kg/m3

All concrete pressure is taken by the struts or anchor bolt

Assignment 1
 Rate of Rate of placing Rate of placing Rate of placing
placing = 1.5m/hour = 2.0m/hour = 2.5m/hour
= 1.0m/hour
Slump = 50mm GP 1 GP 2 GP 3 GP 4
Wall thickness
0.25m
Slump = 50mm GP 5 GP 6 GP 7 GP 8
Wall thickness
0.5m
Slump = 100mm GP 9 GP 10 GP 11 GP 12
Wall thickness
0.25m

3.1 Assignment requirements:-.

The design should include the followings: -

 State the design assumptions, codes and regulations for reference

 Suggest a feasible and structural safe scheme of temporary works
 Typical Layout Plan and Sections showing the necessary details
 Suggest the dimensions adopted for each of the structural elements
 Detail design of the formwork calculations
 Sequence of erection of falsework
 Supporting design information sheet (e.g. catalogue of anchor bolts), if any
 All submissions (calculations and drawings) shall be in A4 size paper
 In case of doubt, make reasonable assumptions.

4. Assessment schemes:

The following is an example of formwork layout. You should propose your own layout plan
with suitable supporting system and spacing.

Assignment 1
Part B:- (5 minutes presentation in class )

Presentation on a topic (in not more than 5 minutes) :-

What measures you would suggest to improve the communication between a designer and
the client such that the requirement/ specifications can be met as far as possible.

Assignment 1
Assignment No.1 (Part A) Temporary Works Design

Assumption

In order to make the assignment more approximate to its existing construction site condition,
the following assumption points are made to tailor the temporary formworks design.

Location: Proposed site on the semi-country town of football playground, which nearby a
children playground and the proposed wall is constructed for a structure wall of
food stall. Therefore, more safety factor for calculation of the falseworks will be
allowed in this situation.

Location of Wall: The proposed wall will be located on the poured concrete slab of G/F which
are enough to support the pressure of propose wall loading of 8.4m width X
5.5 m Height with 250 mm Th wall.

Proposed Wall: The design wall formwork will be located on top of the 250mm Th concrete
structural slab and the concrete grade is 35D/20 with poured concrete more
than 28 days.

Pour Concrete : The proposed wall shall be poured in one go.

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Assignment No.1 (Part A) Temporary Works Design

Design of Formwork
For Wall

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Assignment No.1 (Part A) Temporary Works Design

Design Assumption Information

• The wall dimension is 8.40 width X 5.50 height

• The wall shall be poured in one pour

• Rate of placing shall be 1.5m/hr

• Slump shall be 100mm

• Thickness of wall shall be 250mm Th

• Density of concrete is 2500 kg/ m3

• All concrete pressure is taken by the anchor bolt

List of Design Code and Reference

• Falsework: B.S. 5975:1996-Code of Practice for Falsework

• Falsework:B.S. 5628-1991 Structure of Timber Part 2:

• B.S. 5950: 1990 Structural Use of Steel Work in Building

• Formwork- A Guide to Good Practice

• Code of Practice on Wind Effects in Hong Kong 2004 (BD HKSAR)

• CIRIA Report 108 “Concrete Pressure on Formwork

• HILTI HAS/Stud Anchor by Hilti Ltd

Related Statutory Ordinance, Regulation and Guidance

• Factories and Industrial Undertaking Ordinance, Chapter 59

• Factories and Industrial Undertaking (Woodworking Machinery) Regulations

• The Construction Site (Safety Regulation) 2003

• Building (Construction) Regulations 2001

• Guidance Notes: Safety at Work (Falsework – Prevention of Collapse) by Labour

Department

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Assignment No.1 (Part A) Temporary Works Design

Design Data

Design Loading:-
• Concrete lateral pressure based on the CIRIA Report 108

• Impact load approx 10KN/m2

• Design wind pressure = 1.82 KPa i.e. > than 5m

(Ref Table 1 of Wind Code in HK 2004)

Design of the Plywood & Timber is to be used:

• Canadian 20 mm Douglas Fir 7 ply standard plywood

• Canadian Fir larch GS timber grade to B.S. 5975: 1996. Timber Strength Class SC5

• 16 D mm MS tie rod with washer for fixing the twin wailing on both side of formwork.

• 16 D mm steel wire will be used for stability check to the falseworks which fixed to the
twin waling with inclined 45 degree to the existing concrete slab

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Assignment No.1 (Part A) Temporary Works Design
1. Method Statement to erect of Wall Formwork

• Before carrying out any erection works of wall formwork, detailed method statement and
risk assessment must be checked with approved by the Safety Officer, Design Engineer,
Site Agent, Quality Control Engineer and Project Manager with got no adverse comment
by the Representative(s) from the Consultant.

• All relevant participating workers must be accepted a brief talk held by the Safety Officer
and experience Site Works Ganger before proceeding of erection works.

• Assume roughen/scrape off on the surface in the middle of proposed wall to accept key
joint for concreting.

• Assume wall foot kickers 250 widthX 100 height were made at both end and in the
middle of wall to form as a guide for foot kicker board.

• Setting out line of wall with addition 300 mm reference line for checking verticality on
wall.

• Check the re-bars with adjust the vertically to accept the lap length of vertical steel bar.

• Fabrication of re-bars in accordance with the construction drawings.

• Vacate space on or vacate structural openings for E&M box, conduit or any other E & M
instrument which are required to cast into the wall (all aforesaid must be approved by the
Structural Engineer) and in accordance with the approved drawing.

• Provide sufficient circular plastic spacer to the vertical bar, stirrup for making them have
enough concrete cover to wall which approved by the Structural Engineer.

• Mark off finish height of wall with in practice of marked 300 mm height above pouring
concrete finishes level to prevent any over pour.

• Notification the Resident Engineer or their representative to take an inspection/checking

before erection of the formwork.

• Installation of toe board according to the setting out line on the bottom of the timber
formwork with cleaning inside of the wall.

• For the front side that installation of first side 20mm plywood timber formwork for walls
(on site practice are the 50X100 solider @ 275mm c/c fixed by the nails on the plywood
board with ready for fixing one by one. For safety purpose and prevent the collapse of
sole side formwork, temporary fixing i.e. temporary strut to fixed to the formworks is
required

• Construct three small boxes opening to the bottom of wall formwork (approx 100X100
for diverting debris before concreting) at both end and in the middle.

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Assignment No.1 (Part A) Temporary Works Design
• For the other side that installation of side 20mm plywood timber formwork for walls (on
site practice are the 50X100 solider @ 275mm c/c fixed by the nails on the plywood
board with ready for fixing one by one. For safety purpose and prevent the collapse of
sole side formwork, temporary fixing i.e. temporary strut to fixed to the formworks is
required

• Drill holes for inserting of 16 D MS via the PVC plastic tube tie rod with washer @ 550
mm c/c and through the plywood formworks

• Installation of twin waling 50X100 mm @ 550 mm c/c with start from the bottom of the
toe board to the top of formwork.

• Repeat the installation of twin waling 50X100 mm @ 550 mm c/c with start from the
bottom of the toe board to the top of formwork on anther side.

• Fasten up the 16 D tie rod one by one from the bottom to top level.

• Installation of raking shore in 2 nos of 16 mm D steel wire at both side of formwork at

1500 mm c/c which opposite and fixed to two rows of twin waling timber form at 45
incline degree @ 3000 mm height with welded on the 300X300 mm steel plate with fixed
by 4 nos of 16 mm D of Hilti anchor bolt to the concrete slab.

• Adjust the vertically of formwork with checked by plumb, by using the marked 300 mm
reference line apart from the edge of wall, however the tolerance in accordance with the
specification that not more than + - 10 mm at 6 meter height.

• Final cleaning inside the wall with final checked by the front line site supervisor.

• Closed the constructed three small boxes opening before concreting.

• Checking with fill the small gap between joint on plywood to prevent any grout leakages
during poker vibration.

• Installation of concreting working platform or scaffolding in accordance to the Safety

Regulation where required.

• Final checking for all the whole system timber falsework by the competent persons

• Final cleaning of formwork prior to notification to the Resident Engineer for inspection.

• Double checking by the contractor’s supervising team before pouring concrete into wall.

• Wet to the wall formwork before pouring concrete

• Trimie pipe or chute pipe to be used when concreting over 2.m in height.

• Do not allow any workers standing or working underneath the working platform during
concreting.

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Assignment No.1 (Part A) Temporary Works Design
• Pay attention to any change of weather with ready tarpaulin sheet for covering the top of
wall formwork

• Curing of walls by covering the plastic sheet on top of concrete wall.

• The Works Ganger and site front line supervisor shall pay attention to the change of
weather during the operation of works.

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Assignment No.1 (Part A) Temporary Works Design
2. Design of Formwork for Wall

2A.Design Assumptions:
Design of Formwork for Wall
Design Formwork Height = 5.5m
Wall thickness = 0.25m

Reference: Table 9, Code of Practice For Falsework BS5975 : 1996 by BSI

Permissible Stress for Timber Strength Class: SC5

Using (50mm x 100mm timber)

• Bending stress parallel to grain = 11.87 MPa
• Compressive stress perpendicular to grain = 3.35 MPa
• Shear stress perpendicular to grain = 1.97 MPa
• Modulus of Elasticity = 9200 MPa
• 16 Dmm ordinary bolts, R16 Thread mild steel = 250 N/mm2 Cop for Structure
Use Works at 2004
• 16 Dmm Twin Steel Wire = 150 N/mm2 Cop for Structure
Use of Works at 2004
Allowable deflection for plywood = 1/270
Reference: Clause 8.3.5 BS5975 1996

2B. Calculation of Concrete Loading

Reference: Formwork Loading Design Sheet (by CIRIA) (See Appendix 4a.)

Assumptions:
a. Concrete density ,Δ = 2500 Kg/m3
b. Concrete slump = 100mm
c. Rate of placing, R = 1.5 m/hour
d. Concrete temperature = 25o Celsius
e. Correction Factor, K = 0.90

I. Total height = Δ x H / 100 KN/m2

= 2500 x 5.50 / 100
= 138 KN/m2

II. Arching limit = (3R + d/10 + 15) KN/m2

= (3 x 1.5 + 250 /10 + 15) KN/m2
= 45 KN/m2
Where d does not exceed 500mm

III. Stiffening of concrete = (ΔR K / 100 + 5 ) KN/m2

= (2500x 1.5x 0.90/100+5)KN/m2
= 40 KN/m2
Thus, the maximum is the least of I, II and III ,

Pmax = 40 KN/m2 + 10 KN/m2 (impact load ) = 50 KN/m2

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Assignment No.1 (Part A) Temporary Works Design
2C. Timber Strut Checking
50mm x 100 mm timber, spacing = 275mm

w = 50 KN/m2 x 0.275m = 14 KN/m

Assume Continuous beam ,
M = wl2/10 = 14 KN/m x 0.55m x 0.55m /10 = 0.42 KN-m
For 50mm x 100mm timber strut,
I = 50 x 1003 / 12 = 4,167,000 mm4
Z = 50 x 1002 /6 = 83333 mm4
Stress = MY / I
= 420000 N-mm x 50 mm / 4167000 mm4
= 5.03 MPa < 11.87 MPa = Allowable bending stress OK (See Appendix 4b.)

Check Shear:
Shear by concrete loading
= (0.050 N/mm2 x 275mm x 550 mm) / (50mm x 100mm)
= 1.51 MPa < 1.97 MPa = Allowable shear stress O.K.

For conservative purpose, check deflection using formula for simply support
beam:
Max. Deflection = 5 w l 4 /384 EI (See Appendix 4c.)
= 5 x 0.050 N/mm2 x 550 mm x 5504 mm 4
/ 384 x 9200 N/mm2 x 4167000 mm4 (See Appendix 4b.)
=0.85 mm. < Span / 270 = 550/270 = 2.03mm , OK

2D. Check Timber Waling

a. Twin Timber 50 mm x 100mm, Spacing at 550mm

w = 50 KN/m2 x 0.55m = 28 KN/m
For Continuous beam,
M = wl2/10 = 28 KN/m x 0.55m x 0.55m /10 = 0.84 KN-m

For 50mm x 100mm timber strut,

I = 50 x 1003 / 12 = 4,167,000 mm4
Z = 50 x 1002 /6 = 83333 mm4
Stress = MY / I
= 840000 N-mm x 50 mm / (2 Nos. x 4167000 mm4)
= 5.03 MPa < 11.87 MPa = Allowable bending stress O.K. (See Appendix 4b.)

Check Shear:
Shear by concrete loading
= (0.050 N/mm2 x 550mm x 550 mm) / (2 nos. x 50mm x 100mm)
= 1.51 MPa < 1.97 MPa = Allowable shear stress O.K.

For conservative purpose, check deflection using formula for simply support
beam:
Max. Deflection = 5 w l 4 /384 EI (See Appendix 4c.)
= 5 x 28KN/m x 550 4 mm 4
/ 384 x 9200 N/mm2 x 2 x 4167000 mm4 (See Appendix 4b.)
= 0.43 mm. < Span / 270= 550/270= 2.03mm, OK

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Assignment No.1 (Part A) Temporary Works Design
2E. Check 20mm Timber

20mm Timber Grade SC5, spacing = 275mm x 550mm (See Appendix 4b.)

w = 50 KN/m2 x 0.275m x 0.55m= 7.5KN/ 0.550m = 13.6KN/m

Assume Continuous beam ,

M = wl2/10 = 13.6KN/m x 0.55m x 0.55m /10 = 0.4 KN-m

I = 550 x 203 / 12 = 366666mm4

Z = 550 x 202 /6 = 36666 mm4
Stress = MY / I
= 400000 N-mm x 20 mm/2 / 366666 mm4
= 10.90 MPa < 11.87 MPa = Allowable bending stress OK (See Appendix 4b.)

Check Shear:
Shear by 50mm x 100mm timber
= (0.050 N/mm2 x 275mm x 550 mm) / (50mm x 100mm)
= 1.51 MPa < 1.97 MPa = Allowable shear stress O.K.

For conservative purpose, check deflection using formula for simply support
beam:
Max. Deflection = 5 w l 4 /384 EI
= 5 x 0.050 N/mm2 x 550 mm x 5504 mm 4
/ 384 x 9200 N/mm2 x 4167000 mm4 (See Appendix 4b.)
=0.85 mm. < Span / 270 = 550/270 = 2.03mm , OK

2F. Check Bolt Stress: 16mm bolts--- 550mm center

Stress = P / A
= 0.050 N/mm2 x 550mm x 550mm / (3.1416/4 x 16mm x 16mm)
= 75.2 MPa < Allowable stress of steel = 250 N/mm2 OK

2G. Raking Shore for Stability

If columns or walls exceeded 2 meter in height, then raking shore will be installed
accordingly.

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Assignment No.1 (Part A) Temporary Works Design
2H. Check Bolts

For 5.5 m high column

Assume horizontal force to be wind load = 2.01KN/m2

Ref: Code of Practice For Wind Effects in Hong Kong 2004, Table 1.
(See Appendix 4d.)

For temporary works

wind load = 1.4 x 0.7 (temporary works) x 2.01KN/m2 = 1.97KN/m2

Total horizontal load

= 1.97 KN/m2 x 5.5m high x 1.5m wide
= 16 KN

Using 2 Nos. of 16 mm diameter steel wire

Stress on each steel wire

= 16000 N /Cos 45 / (2 Nos. of wires x 3.1416/ 4 x 16mm x 16mm )
= 57 MPa < Allowable steel stress of wire= 150 MPa OK

Use 4 Nos of Hilti HSA M16 , 1 M16 = 12.9 KN in tension

4 M16 = 4 x 18.3 = 73.2 KN > 16 KN OK (See Appendix 4e.)

End of Calculation

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Assignment No.1 (Part A) Temporary Works Design

3. Construction Drawing

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Assignment No.1 (Part A) Temporary Works Design

3 a Detailed Drawing
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Assignment No.1 (Part A) Temporary Works Design

3b. 3D Drawing (Section)

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Assignment No.1 (Part A) Temporary Works Design

3c. 3D Drawing (Elevation)

End of Assignment 1

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Assignment No.1 (Part A) Temporary Works Design

4. Appendix

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Assignment No.1 (Part A) Temporary Works Design

4a. Concrete Pressure

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Assignment No.1 (Part A) Temporary Works Design

4 a. Concrete Pressure

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Assignment No.1 (Part A) Temporary Works Design

4 a. Concrete Pressure

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Assignment No.1 (Part A) Temporary Works Design

4a. Formwork Loading Design Sheet

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Assignment No.1 (Part A) Temporary Works Design

4b. Permissible Stresses and Moduli of Elasticity for Timber

in General Falsework Application
Reference : Code of Practice For Falsework: BS5975 : 1996

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Assignment No.1 (Part A) Temporary Works Design

4c. Loading Table

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Assignment No.1 (Part A) Temporary Works Design

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Assignment No.1 (Part A) Temporary Works Design

4d. Wind Code at Hong Kong 2004

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Assignment No.1 (Part A) Temporary Works Design

4e. Hilti Information