Tutorial 4

SUPER STRUCTURE CONSTRUCTION

Que: 01 Write construction sequences for various projects and its design
consideration: Cooling towers, Silos, Chimney, Skyscrapers, Lattice Tower, and
Cable stayed bridge.

1. Cooling Towers

Construction Sequence:

1. Site Preparation: Clear the site and conduct soil tests.

2. Foundation Work: Excavate and lay foundations, typically reinforced concrete.

3. Structure Fabrication: Construct the tower shell using precast concrete or steel
sections.

4. Internal Components: Install fill media, drift eliminators, and distribution systems.

5. Mechanical Installations: Install fans, pumps, and motors.

6. Electrical Works: Complete wiring and control systems.

7. Testing and Commissioning: Test for performance and compliance with regulations.

Design Considerations:

- Thermal Performance: Optimize for heat exchange e iciency.

- Structural Integrity: Ensure stability against wind and seismic loads.

- Water Management: Design for water distribution and drainage.

- Noise Control: Incorporate sound dampening measures for fans and pumps.

2. Silos

Construction Sequence:

1. Site Survey and Preparation: Conduct site surveys and prepare the ground.

2. Foundation Installation: Lay a solid foundation with appropriate drainage.

3. Silo Fabrication: Construct the silo body, often using reinforced concrete or steel.

4. Roof Installation: Install the top roof structure to protect the contents.

5. Access Systems: Install ladders, platforms, and access doors.

6. Mechanical Systems: Install conveyors, aeration systems, and discharge

mechanisms.
7. Testing and Inspection: Conduct structural and operational tests.

Design Considerations:

- Material Properties: Choose materials based on stored contents (e.g., grain,

chemicals).

- Pressure and Load: Design for internal pressures and external loads.

- Ventilation: Ensure proper ventilation to prevent spoilage or combustion.

- Safety Measures: Incorporate explosion-proof designs and safety equipment.

3. Chimney

Construction Sequence:

1. Site Preparation: Clear the site and prepare for foundation work.

2. Foundation Construction: Lay a strong concrete foundation to support the chimney.

3. Chimney Structure: Erect the chimney using brick, masonry, or reinforced concrete.

4. Internal Lining: Install flue liners for durability and heat resistance.

5. Cap and Flashing: Install the chimney cap and flashing to prevent water ingress.

6. Access and Safety Features: Install ladders and access platforms for maintenance.

7. Final Inspections: Ensure structural integrity and compliance with emissions

standards.

Design Considerations:

- Height and Diameter: Design based on emissions dispersion requirements.

- Material Selection: Use materials resistant to high temperatures and corrosive gases.

- Structural Stability: Ensure resistance to wind loads and seismic forces.

- Maintenance Access: Provide easy access for inspection and cleaning.

4. Skyscrapers

Construction Sequence:

1. Site Preparation and Excavation: Clear site and excavate for foundations.

2. Foundation Work: Construct deep foundations, such as piles or caissons.

3. Core Construction: Build the central core for elevators and stairs.

4. Floor Slabs: Install floor slabs and framing for each level.

5. Facade Installation: Install curtain walls and exterior finishes.

6. Mechanical Systems: Integrate HVAC, plumbing, and electrical systems.

7. Finishing Work: Complete interior finishes and landscaping.

8. Commissioning: Conduct systems testing and final inspections.

Design Considerations:

- Wind Load Analysis: Use wind tunnel testing to design for lateral forces.

- Vertical Transportation: Plan for e icient elevator systems.

- Fire Safety: Incorporate fire-resistant materials and evacuation routes.

- Sustainability: Optimize energy usage and incorporate green technologies.

5. Lattice Tower

Construction Sequence:

1. Site Survey and Preparation: Assess site conditions and clear the area.

2. Foundation Installation: Construct a robust concrete foundation.

3. Tower Assembly: Fabricate and assemble lattice sections on-site.

4. Erection: Use cranes to erect the tower in segments.

5. Electrical Installations: Install necessary wiring and communication equipment.

6. Safety Systems: Implement safety measures and climbing apparatus.

7. Final Inspection: Ensure structural integrity and compliance with regulations.

Design Considerations:

- Load-Bearing Capacity: Design for wind and seismic loads.

- Material Durability: Use corrosion-resistant materials.

- Accessibility: Ensure safe access for maintenance.

- Aesthetic Integration: Consider visual impact in urban settings.

6. Cable-Stayed Bridge

Construction Sequence:

1. Site Preparation: Clear the site and perform geological surveys.

2. Foundation Construction: Build deep foundations or piles for the bridge towers.

3. Tower Construction: Erect bridge towers using reinforced concrete or steel.

4. Cable Installation: Install stay cables from towers to the bridge deck.
5. Deck Construction: Pour the bridge deck and install road surfaces.

6. Expansion Joints and Barriers: Install necessary joints and safety barriers.

7. Final Inspection: Conduct load testing and inspections before opening.

Design Considerations:

- Load Distribution: Analyze load paths and stress distributions.

- Aesthetic Design: Integrate the bridge design with the surrounding landscape.

- Wind Resistance: Ensure stability against lateral forces from wind.

- Maintenance Access: Design for easy access to cables and structural components.

Que: 02 Write advantage of aluminum formwork over traditional formwork?

Aluminum formwork o ers several advantages over traditional formwork systems,

including:

1. Lightweight: Aluminum is significantly lighter than steel or wood, making it easier to

handle, transport, and assemble on-site.

2. Reusability: Aluminum formwork can be reused many times (typically over 200 uses),
reducing material costs and waste compared to traditional options.

3. Speed of Construction: The prefabricated nature of aluminum formwork allows for

quicker assembly and disassembly, accelerating the overall construction timeline.

4. Accuracy and Finish: Aluminum forms provide a smooth surface finish, leading to
higher-quality concrete surfaces and reducing the need for additional finishing work.

5. Durability: Aluminum is resistant to corrosion and degradation, making it suitable for

various weather conditions and extending the lifespan of the formwork.

6. Reduced Labor Costs: The ease of handling and quick assembly reduces the labor
required for formwork installation and removal, leading to cost savings.

7. Improved Safety: The lighter weight and modular design reduce the risk of injury during
handling and setup compared to heavier traditional materials.

8. Less Material Waste: The precision of aluminum formwork minimizes waste during the
pouring process, leading to a more e icient use of concrete.

9. Design Flexibility: Aluminum formwork can be customized for various shapes and
sizes, allowing for greater design versatility in complex structures.

10. Environmental Benefits: By reducing waste and promoting reuse, aluminum

formwork contributes to more sustainable construction practices compared to
traditional methods.
Que:03 Sketch typical slip form system. State functions of each component of slip
formwork system.

describe a typical slip form system and the functions of its components in detail.

Typical Slip Form System Components and Functions

1. Slipform Assembly:

- Function: The primary structure that holds the concrete while it is poured and supports
the vertical rise. It moves upwards as the concrete sets.

2. Form Panels:

- Function: These are the vertical walls of the slip form. They contain the poured
concrete and shape it into the desired form, such as walls or columns.

3. Jacks or Hydraulic Lifting System:

- Function: Used to raise the slip form assembly gradually as the concrete sets. This
ensures a continuous and smooth rise, allowing for uninterrupted pouring.

4. Concrete Hopper:

- Function: A funnel-like structure that receives and distributes concrete evenly into the
slipform system, ensuring consistent filling of the form panels.

5. Guides and Supports:

 - Function: Provide stability and alignment for the slip form system as it rises. They
ensure that the form remains vertical and properly positioned during the lifting process.

6. Access Platforms:

- Function: Allow workers to access di erent parts of the slipform system for pouring,
monitoring, and maintenance. These platforms are often adjustable to accommodate
the upward movement of the system.

7. Concrete Vibrators:

- Function: Used to eliminate air pockets and ensure proper compaction of the concrete
as it is poured into the slip form. This helps achieve the desired strength and finish.

8. Struts and Bracing:

- Function: Provide additional support and stability to the slip form system, especially
during the initial setting of the concrete.

9. Monitoring Equipment:

- Function: Includes sensors and gauges to monitor the consistency of the concrete and
the proper functioning of the slip form system, ensuring quality control throughout the
process.

The slip form system allows for continuous vertical pouring of concrete structures, such
as tall buildings and bridges. Each component plays a crucial role in ensuring that the
concrete is poured e iciently, remains properly shaped, and achieves the required
structural integrity. The system is particularly e ective for projects that require rapid
construction and high-quality finishes.

Que: 04 Enlist and explain various formwork failures?

Formwork failures can significantly impact construction projects, leading to delays,

increased costs, and safety hazards. Here are several common types of formwork failures
along with explanations:

1. Structural Failure

- Description: This occurs when the formwork cannot support the weight of the concrete,
leading to collapse.

- Causes: Insu icient design strength, inadequate bracing, or overloading with concrete
or equipment.

- Impact: Total loss of the formwork system, potential injuries, and damage to the poured
concrete.
2. Deflection or Deformation

- Description: Excessive bending or deformation of formwork panels during concrete

pouring.

- Causes: Inadequate support, incorrect spacing of formwork components, or heavy

loads exceeding design specifications.

- Impact: Can result in misalignment of the finished concrete surface, leading to quality
issues and necessitating costly repairs.

3. Leakage

- Description: Occurs when concrete seeps through gaps or joints in the formwork.

- Causes: Poorly sealed joints, wear and tear on formwork, or improper installation.

- Impact: Leads to loss of concrete, resulting in structural weakness and surface

imperfections.

4. Instability

- Description: The formwork system becomes unstable during installation or concrete

pouring.

- Causes: Poorly designed or constructed supports, inadequate anchoring, or adverse

weather conditions.

- Impact: May cause the formwork to topple, risking injury to workers and damaging the
structure.

5. Inadequate Compaction

- Description: Insu icient compaction of the concrete within the formwork.

- Causes: Lack of vibration during pouring, incorrect formwork design that hinders
access, or improper concrete mix.

- Impact: Results in air pockets and weak concrete, compromising structural integrity.

6. Material Failure

- Description: The formwork material itself (e.g., plywood, steel, or aluminum) fails under
stress.

- Causes: Using substandard materials, wear and tear over time, or exposure to moisture
or chemicals.

- Impact: Can lead to sudden failures or degradation of the formwork, resulting in poor-
quality concrete surfaces.
7. Misalignment

- Description: The formwork does not maintain its intended position or alignment during
the concrete pour.

- Causes: Inadequate support, poor installation practices, or vibrations from nearby

activities.

- Impact: Results in structural issues, necessitating rework or modifications to the final

product.

8. Improper Removal

- Description: Failure occurs during the removal of formwork after concrete has set.

- Causes: Removing formwork too early or without adequate support can cause the
concrete to crack or break.

- Impact: Leads to damage to the finished concrete, requiring repairs or replacement.

9. Environmental E ects

- Description: External factors such as rain, wind, or extreme temperatures a ect the
formwork.

- Causes: Poor weather conditions or lack of protective measures.

- Impact: Can cause warping, weakening of the formwork, or improper curing of the
concrete.

10. Overloading

- Description: Excessive weight is applied to the formwork beyond its design capacity.

- Causes: Misjudgment of the weight of the concrete, equipment, or workers.

- Impact: Can lead to premature failure of the formwork structure, risking both safety and
project integrity.

Que: 05 Discuss essential requirements for good formwork.

Good formwork is critical for the successful construction of concrete structures. Here
are the essential requirements for e ective and reliable formwork:

1. Strength and Stability

- Requirement: Formwork must be structurally strong to support the weight of wet

concrete, as well as any construction loads (workers, equipment).

- Consideration: It should be designed to withstand vertical and lateral pressures without

deformation or failure.
2. Leakproof Design

- Requirement: The formwork should be designed to prevent concrete leakage.

- Consideration: Joints and seams must be sealed properly to avoid loss of material and
ensure a uniform finish.

3. Accuracy and Precision

- Requirement: Formwork must be constructed to precise dimensions to ensure the

finished concrete meets design specifications.

- Consideration: Accurate alignment and leveling are essential for maintaining correct
shapes and dimensions.

4. Ease of Assembly and Disassembly

- Requirement: The formwork system should be easy to assemble, adjust, and dismantle.

- Consideration: This enhances e iciency on site and minimizes labor costs. Modular
systems can aid in this flexibility.

5. Durability and Reusability

- Requirement: Formwork should be made from durable materials that can withstand
multiple uses.

- Consideration: Aluminum, steel, and high-quality plywood are common choices that
provide longevity and can be reused many times.

6. Surface Finish

- Requirement: The inner surfaces of the formwork should provide a smooth finish to the
concrete.

- Consideration: This reduces the need for additional finishing work, contributing to
overall quality.

7. Adequate Support and Bracing

- Requirement: Proper bracing and support systems are essential to maintain stability
during the curing process.

- Consideration: This prevents movement or collapse under the weight of the concrete.

8. Cost-E ectiveness

- Requirement: The formwork system should be economical while meeting the necessary
performance criteria.
- Consideration: Evaluate life cycle costs, including the initial investment, maintenance,
and reusability.

9. Safety Features

- Requirement: Formwork must include safety features to protect workers during

assembly and concrete pouring.

- Consideration: Guardrails, access platforms, and proper lifting equipment are

important for maintaining safety on the job site.

10. Compatibility with Concrete Curing

- Requirement: The formwork should accommodate the curing process of the concrete.

- Consideration: It should allow for adequate moisture retention and temperature

control, especially in extreme weather conditions.

11. Adaptability

- Requirement: Formwork should be adaptable to various shapes, sizes, and

configurations.

- Consideration: Customizable or modular systems allow for flexibility in design and can
handle complex structures.

Que: 06 Enlist types of sca olding. Explain any one in detail?

Here are several common types of sca olding:

1. Single Sca olding (Bricklayer's Sca olding)

2. Double Sca olding (Independent Sca olding)

3. Cantilever Sca olding

4. Suspended Sca olding

5. Rolling Sca olding (Mobile Sca olding)

6. Trestle Sca olding

7. Steel Sca olding

8. Aluminum Sca olding

9. Pump Jack Sca olding

10. Shoring Sca olding

 1. Double Sca olding (Independent Sca olding)

Overview

Double sca olding, also known as independent sca olding, consists of two rows of
sca olding that are placed parallel to the wall or structure being worked on. This design
provides additional stability and support, making it ideal for work on brick or stone
structures where wall anchorage may not be feasible.

Components

1. Standards: Vertical tubes that bear the load and support the entire sca olding system.

2. Ledgers: Horizontal tubes that connect the standards at regular intervals, providing
lateral stability.

3. Braces: Diagonal tubes that stabilize the structure and prevent lateral movement.

4. Planks: Wooden or metal boards laid across the ledgers to create a working platform.

5. Base Plates and Sole Plates: Plates placed at the bottom of the standards to distribute
weight and prevent sinking into the ground.

Construction Process

1. Site Preparation: Ensure the ground is level and stable for erecting sca olding.

2. Base Installation: Place base plates on firm ground; use sole plates if necessary for
extra stability.

3. Erecting Standards: Position the vertical standards in place, ensuring they are plumb
and secure.

4. Installing Ledgers: Attach horizontal ledgers between the standards at specified

heights, creating a grid for the working platforms.

5. Adding Bracing: Install diagonal braces to enhance the stability of the sca olding
structure.

6. Laying Planks: Position planks on the ledgers to create safe working platforms for
workers.

7. Access Points: Install ladders or stairways to provide safe access to the platforms.

Advantages

- Stability: The two-row design provides enhanced stability and support for heavy loads.

- Versatility: Suitable for various construction and maintenance tasks, especially on

masonry buildings.
- Safety: The independent structure allows for safer working conditions, minimizing the
risk of collapse.

Disadvantages

- Space Requirements: Takes up more space than single sca olding due to the two-row
configuration.

- Complex Assembly: Requires more materials and labor for assembly compared to
simpler sca olding types.

Que: 07 Advantage and Disadvantage of sca oldings.

Advantages of Sca olding

1. Safety:

- Provides a safe working platform for workers at height, reducing the risk of falls and
injuries.

2. Access:

- Allows workers to reach elevated areas easily, facilitating construction, maintenance,

and repair tasks.

3. Stability:

- O ers a stable structure for workers and materials, ensuring that tools and supplies
can be safely stored and accessed.

4. Versatility:

- Can be used in various construction scenarios, including residential, commercial, and

industrial projects, and can be adapted to di erent shapes and sizes.

5. E iciency:

- Increases productivity by providing easy access to high or hard-to-reach areas,

enabling workers to complete tasks more quickly.

6. Customization:

- Can be customized to fit specific project requirements, including height, weight

capacity, and configuration.

7. Temporary Structure:

- As a temporary installation, sca olding can be erected and dismantled as needed,

reducing long-term impact on the site.
Disadvantages of Sca olding

1. Cost:

- Initial setup and rental costs can be high, especially for complex sca olding systems.

2. Labor Intensive:

- Requires skilled labor for assembly and disassembly, increasing labor costs and time.

3. Space Requirements:

- Takes up significant space on construction sites, which may be a constraint in limited

areas.

4. Weather Dependency:

- Sca olding can be a ected by adverse weather conditions, such as wind and rain,
which may hinder work progress and safety.

5. Risk of Collapse:

- If not properly erected or maintained, sca olding can collapse, posing safety hazards
to workers and bystanders.

6. Maintenance Needs:

- Requires regular inspection and maintenance to ensure safety and stability, adding to
the operational burden.

7. Inconvenience:

- Can obstruct pathways and access to certain areas of the site, causing potential
delays in construction activities.

Que: 08 Discuss the factor a ecting sca olding?

Several factors can a ect the e ectiveness, safety, and overall performance of
sca olding in construction projects. Here are some key factors to consider:

1. Design and Engineering

- Importance: Proper design ensures that the sca olding can support the intended loads,
withstand environmental conditions, and maintain stability.

- Consideration: Compliance with local building codes and regulations is essential for
safe design.

2. Material Quality

- Importance: The type and quality of materials used (e.g., steel, aluminum, wood)
directly impact the durability and safety of the sca olding.
- Consideration: High-quality, certified materials are necessary to prevent failures.

3. Load Capacity

- Importance: Sca olding must be designed to handle the weight of workers, materials,
and equipment.

- Consideration: Overloading can lead to structural failure, so load limits must be clearly
defined and adhered to.

4. Site Conditions

- Importance: The physical characteristics of the construction site (e.g., soil stability,
slopes, nearby structures) can a ect sca old installation and stability.

- Consideration: Proper site assessment is crucial for determining the right type and
configuration of sca olding.

5. Weather Conditions

- Importance: Wind, rain, snow, and extreme temperatures can impact the safety and
stability of sca olding.

- Consideration: Work should be halted in adverse weather, and protective measures (like
tarps) may be needed during rain or snow.

6. Installation Practices

- Importance: Proper assembly and alignment are critical for the stability and safety of
the sca olding.

- Consideration: Workers should be trained and experienced in sca old erection and
dismantling.

7. Maintenance and Inspection

- Importance: Regular inspections and maintenance are essential to identify and address
wear, damage, or structural issues.

- Consideration: A maintenance schedule should be established, and inspections should

be conducted before and during use.

8. Worker Training and Competence

- Importance: Proper training for workers on sca old use, safety protocols, and
emergency procedures is vital.

- Consideration: Competent personnel should be assigned to erect, inspect, and use

sca olding.
9. Regulatory Compliance

- Importance: Adherence to local, national, and international safety standards and

regulations is crucial.

- Consideration: Compliance helps prevent accidents and legal issues, ensuring a safe
working environment.

10. Accessibility

- Importance: The design should allow easy access to the sca olding for workers while
minimizing risk.

- Consideration: Proper ladders, stairways, and safety rails should be integrated into the
design.