DESIGN METHODOLOGY
The Design calculation of „Formwork / Shuttering scheme for Beam & Slab“
is
done by manually as per the differents relevents codal standard.
For Beam:
The formwork is consist with 12mm thick wooden ply as shuttering plate
over
3“ x 2“ wooden horizontal batten at a specific spacing to withstand the
shuttering
plyboard against bending & deflection criteria. These beam bottom batten are
supported
on main joist wooden batten of 3“ x 4“, are passes through the vertical
supporting system
of Prop-Jack / Cup-Lock system at a specifiv grid spacing to carry the total
loading
system and transfer to the under bed. The all components are checked in bending
&
deflection .
For Slab:
The formwork is consist with 12mm thick wooden ply as shuttering plate
laid over
3“ x 2“ wooden horizontal batten at a specific spacing to withstand the
shuttering
plyboard against bending & deflection criteria. These slab bottom batten are
supported
on main joist structural steel batten of ISMC 75, are passes through the
vertical
supporting system of Prop-Jack / Cup-Lock system at a specifiv grid spacing to
carry the
total loading system and transfer to the under bed. The all components are
checked in
bending & deflection .
Codal Provision:
The following design standard has bben used for design of the formwork ,
i) ACI_347_04_Guide_to_Formwork_for_Concret
ii) IS_303.1989_Ply Wood For General Purpose
iii) IS-4990.2011-Concrete-Shuttering-Ply
iv) IS-14687.1999-Concrete-Falsework
v) IS 1161
Basic Design Concept:-
The design concept are made in two differents option
Option I – Prop-Jack system is considered as the vertical loading
supporting
frame.
Option II – Cup-Lock system is considered as the vertical loading
supporting
frame.
Critical Design Section:-
There have differents size of beam & slab section & the following critical
section
are chosses for the design of formwork/shuttering arrangement scheme,
Beam – 500mm x 600mm
Slab- 225mm Thick
Conceptual Attangement Scheme:-
Formwork Design For 500 x 650 mm2 Beam
OPTION - I WITH PROP-JACK SYSTEM
Design Parameter & Used Material Spec.
Beam Size = 500 mm X 650 mm
Ply Thickness = 12 mm [ As Sheeting Plate]
Batten used = 50 X 75 [Timber Wooden 3" x 2", Below
Ply]
Batten Spacing = 225 mm [Considered 3 Nos at Beam Bottom]
Batten length (Span) = 0.65 m
Main Joist Beam = 75 X 100 [Timber Wooden 3" x 4"]
Beam Length (Span)= 1.2 m
Prop-Jack Spacing = 1.2 x 0.65 m2 [As Vertical
Support]
Prop-Jack section = 60NB & 40 NB (M)
Max. Unrestrained Length = 1.5 m [Vertically Both Direction]
Material Specification:-
Unit wt. of Ply-Wood = 0.65 Ton/m3
Elastic Modulus, Ep = 2000 Mpa
Allowable Bending Stress, σb (all) = 15 Mpa
Unit wt. of Timber-Wood = 0.9 Ton/m3 Mpa
Elastic Modulus, Et = 10000 Mpa
Allowable Bending Stress, σb (all) = 12 Mpa
Loading:-
Dead Load from Slab = 1.625 T/Sq.m
Live Load(LL) on Staging = 0.125 T/Sq.m
Total Impose Load = 1.75 T/Sq.m
A Design of 12mm Thick Ply as Shuttering Plate:-
Check Against Bending
2
Load on Ply = 1.7578 t/m [Including Self Wt. Ply]
Span = 0.225 m
Max. BM = 0.0111 t-m / m width
3
Z (for Ply) = 24000 mm / m width
Bending Stress developed, σbc (cal) = 4.63 Mpa <15 Mpa
Hence o.k.
Check Against Deflection
δcal = 5/384x(wl^4/EI) = 0.46 mm
δper = (L/270) = 0.84 mm Hence o.k.
B Checking for Wooden Batten 50 x 75 @ 225 mm c/c
i) Check Against Bending
Loads from Ply = 1.7578 t/m2
UDL on each Batten with S/W = 0.3989 t/m [Including Self
Wt.of Batten]
Length (Span)= 0.65 m
Max. BM in the Batten = 0.0169 t-m [As Continious
Beam Action]
Zxx ( of Batten ) = 46875 mm3
σbc cal = 4 Mpa < σbc all = 12 Mpa
Hence o.k.
Formwork Design For 500 x 650 mm2 Beam
ii) Check Against Deflection
δcal = 5/384x(wl^4/EI) = 0.53 mm
δper = (Lx/325) = 2.00 mm >
Hence o.k.
C Checking for Main Joist, Wooden 3" x 4" @ 650 mm
c/c
Check Against Bending
Load from upper Batten = 0.5185 Ton
S/W of Joist = 0.0068 t/m
Length (Span)= 1.2 m
Max. developed Moment, = 0.1568 t-m
Zxx = 125000 mm3
Ixx = 6E+06
σbc cal = 11.92 Mpa < σbc all = 12 Mpa
Hence o.k.
Check Against Deflection
δcal = ( M.L2) / (10EI) = 3.61 mm
δper = (Lx/325) = 3.69 mm > 3.61 mm
Hence o.k.
D Checking of Vertical Prop Jack System
Influence area of one vertical = 0.78 Sq.m
rcr for Pipe (NB40-M) = 16 mm [Ref. Code -
IS1161]
Critical l / r = 93.75
Coresponding Allowable fc = 86 Mpa
Max. load on a single vertical = 0.263 Ton
2
Area for 40nb. Pipe = 453 mm
So, Calculated Comp. stress = 6 Mpa < 86 Mpa
Hence o.k.
The floor slab stagging is safe against the following consideration.
1) Use Verticals Prop Jack System of 60NB + & 40 NB (Medium) - 1.2 x 0.65
m c/c with unrestrained length @ 1.5 m c/c.
2) Use Main Joist Section 3" x 4" Wooden Battem - 1.2 m unsupported length @
0.65 m c/c.
3) Use Beam Bottom-3 Nos. 2" x 3" Wooden Battem - 0.65 m unsupported length @
225 mm c/c.
4) Use Shuttering Plate -12 mm Thick Ply board.
Formwork Design For 500 x 650 mm2 Beam
OPTION - II WITH CUP LOCK SYSTEM
Design Parameter & Used Material Spec.
Beam Size = 500 mm X 650 mm
Ply Thickness = 12 mm [ As Sheeting Plate]
Batten used = 50 X 75 [Timber Wooden 3" x 2", Below
Ply]
Batten Spacing = 225 mm [Considered 3 Nos at Beam Bottom]
Batten length (Span) = 0.65 m
Main Joist Beam = 75 X 100 [Timber Wooden 3" x 4"]
Beam Length (Span)= 1.2 m
Cup - Lock Spacing = 1.2 x 0.65 m2 [As Vertical
Support]
Cup - Lock Section = 40 NB (M)
Max. Unrestrained Length = 1.5 m [Vertically Both Direction]
Material Specification:-
Unit wt. of Ply-Wood = 0.65 Ton/m3
Elastic Modulus, Ep = 2000 Mpa
Allowable Bending Stress, σb (all) = 15 Mpa
Unit wt. of Timber-Wood = 0.9 Ton/m3 Mpa
Elastic Modulus, Et = 10000 Mpa
Allowable Bending Stress, σb (all) = 12 Mpa
Loading:-
Dead Load from Slab = 1.625 T/Sq.m
Live Load(LL) on Staging = 0.125 T/Sq.m
Total Impose Load = 1.75 T/Sq.m
A Design of 12mm Thick Ply as Shuttering Plate:-
Check Against Bending
2
Load on Ply = 1.7578 t/m [Including Self Wt. Ply]
Span = 0.225 m
Max. BM = 0.0111 t-m / m width
3
Z (for Ply) = 24000 mm / m width
Bending Stress developed, σbc (cal) = 4.63 Mpa <15 Mpa
Hence o.k.
Check Against Deflection
δcal = 5/384x(wl^4/EI) = 0.46 mm
δper = (L/270) = 0.84 mm Hence o.k.
B Checking for Wooden Batten 50 x 75 @ 225 mm c/c
i) Check Against Bending
Loads from Ply = 1.7578 t/m2
UDL on each Batten with S/W = 0.3989 t/m [Including Self
Wt.of Batten]
Length (Span)= 0.65 m
Max. BM in the Batten = 0.0169 t-m [As Continious
Beam Action]
Zxx ( of Batten ) = 46875 mm3
σbc cal = 4 Mpa < σbc all = 12 Mpa
Hence o.k.
Formwork Design For 500 x 650 mm2 Beam
ii) Check Against Deflection
δcal = 5/384x(wl^4/EI) = 0.53 mm
δper = (Lx/325) = 2.00 mm >
Hence o.k.
C Checking for Main Joist, Wooden 3" x 4" @ 650 mm
c/c
Check Against Bending
Load from upper Batten = 0.5185 Ton
S/W of Joist = 0.0068 t/m
Length (Span)= 1.2 m
Max. developed Moment, = 0.1568 t-m
Zxx = 125000 mm3
Ixx = 6E+06
σbc cal = 11.92 Mpa < σbc all = 12 Mpa
Hence o.k.
Check Against Deflection
δcal = ( M.L2) / (10EI) = 3.61 mm
δper = (Lx/325) = 3.69 mm > 3.61 mm
Hence o.k.
D Checking of Vertical Prop Jack System
Influence area of one vertical = 0.78 Sq.m
rcr for Pipe (NB40-M) = 16 mm [Ref. Code -
IS1161]
Critical l / r = 93.75
Coresponding Allowable fc = 86 Mpa
Max. load on a single vertical = 0.263 Ton
2
Area for 40nb. Pipe = 453 mm
So, Calculated Comp. stress = 6 Mpa < 86 Mpa
Hence o.k.
The floor slab stagging is safe against the following consideration.
1) Use Verticals Cup - Lock System of 40 NB (Medium) - 1.2 x 0.65
m x m c/c with unrestrained length @ 1.5 m c/c.
2) Use Main Joist Section 3" x 4" Wooden Battem - 1.2 m unsupported length @
0.65 m c/c.
3) Use Beam Bottom-3 Nos. 2" x 3" Wooden Battem - 0.65 m unsupported length @
225 mm c/c.
4) Use Shuttering Plate -12 mm Thick Ply board.
Formwork Design For 225mm Thick Floor Slab
OPTION - I WITH PROP-JACK SYSTEM
Design Parameter & Used Material Spec.
Max. Slab Thicness = 225 mm
Ply Thickness = 12 mm [ As Sheeting Plate]
Batten used = 75 X 50 [Timber Wooden 3" x 2", Below
Ply]
Batten Spacing = 275 mm [Along The main Joist Beam]
Batten length (Span) = 1.2 m
Main Joist Beam = ISMC 75
Beam Length (Span)= 1.5 m
Prop-Jack Spacing = 1.2 x 1.5 m2 [As Vertical
Support]
Prop-Jack section = NB60 & NB 40 (M)
Max. Unrestrained Length = 1.5 m [Vertically Both Direction]
Material Specification:-
Unit wt. of Ply-Wood = 0.65 Ton/m3
Elastic Modulus, Ep = 2000 Mpa
Allowable Bending Stress, σb (all) = 15 Mpa
Unit wt. of Timber-Wood = 0.9 Ton/m3 Mpa
Elastic Modulus, Et = 10000 Mpa
Allowable Bending Stress, σb (all) = 12 Mpa
Loading:-
Dead Load from Slab = 0.5625 T/Sq.m
Live Load(LL) on Staging = 0.125 T/Sq.m
Total Impose Load = 0.6875 T/Sq.m
A Design of 12mm Thick Ply as Shuttering Plate:-
Check Against Bending
2
Load on Ply = 0.6953 t/m [Including Self Wt. Ply]
Span = 0.275 m
Max. BM = 0.0053 t-m / m run [As Continious Beam Action]
3
Z (for Ply) = 24000 mm / m run
Bending Stress developed, σbc (cal) = 2.19 Mpa <15 Mpa
Hence o.k.
Check Against Deflection
δcal = 5/384x(wl^4/EI) = 0.5 mm
δper = (L/270) = 1.02 mm Hence o.k.
B Checking for Wooden Batten 75 x 50 @ 275 mm c/c
i) Check Against Bending
Loads from Ply = 0.6953 t/m2
UDL on each Batten with S/W = 0.1946 t/m [Including Self
Wt.of Batten]
Length (Span)= 1.2 m
Max. BM in the Batten = 0.035 t-m
Zxx ( of Batten ) = 31250 mm3
σbc cal = 11 Mpa < σbc all = 12 Mpa
Hence o.k.
Formwork Design For 225mm Thick Floor Slab
ii) Check Against Deflection
δcal = 5/384x(wl^4/EI) = 2.69 mm
δper = (Lx/325) = 3.69 mm >
Hence o.k.
C Checking for Main Joist, ISMC 75 @ 1200 mm c/c
Check Against Bending
Reaction force from each Batten = 0.1167 Ton
No of batten support on single span = 4.3636 Nos
S/W of Joist = 0.007 t/m
Length (Span)= 1.5 m
Support Reaction at Main Joist end = 0.2589 Ton
Max. developed Moment, = 0.0481 t-m
Zxx = 20.30 cm3 rxx = 2.96 cm ryy = 1.21
cm
λxx = 51 λyy = 23
σbc cal = 24 Mpa < σbc all = 158 Mpa
Hence o.k.
Check Against Deflection
δcal = ( M.L2) / (10EI) = 0.68 mm
δper = (Lx/325) = 4.62 mm > 0.68 mm
Hence o.k.
D Checking of Vertical Prop Jack System
Influence area of one vertical = 1.8 Sq.m
rcr for Pipe (NB40-M) = 16 mm [Ref. Code - IS1161]
Critical l / r = 93.75
Coresponding Allowable fc = 86 Mpa
Max. load on a single vertical = 1.252 Ton
2
Area for 40nb. Pipe = 453 mm
So, Calculated Comp. stress = 28 Mpa < 86 Mpa
Hence o.k.
The floor slab stagging is safe against the following consideration.
1) Use Verticals Prop Jack System of 60NB + & 40 NB (Medium) - 1.2 x 1.5 m c/c
with unrestrained length @ 1.5 m c/c.
2) Use Main Joist Section ISMC 75 - 1.5 m unsupported length @ 1.2 m c/c.
3) Use Beam Bottom-3" x 2" Wooden Battem - 1.2 m unsupported length @ 275 mm
c/c.
4) Use Shuttering Plate -12 mm Thick Ply board.
Formwork Design For 225mm Thick Floor Slab
OPTION - II WITH CUP LOCK SYSTEM
Design Parameter & Used Material Spec.
Max. Slab Thicness = 225 mm
Ply Thickness = 12 mm [ As Sheeting Plate]
Batten used = 75 X 50 [Timber Wooden 3" x 2", Below
Ply]
Batten Spacing = 275 mm [Along The main Joist Beam]
Batten length (Span) = 1.2 m
Main Joist Beam = ISMC 75
Beam Length (Span)= 1.5 m
Cup - Lock Spacing = 1.2 x 1.5 m2 [As Vertical
Support]
Cup - Lock Section = NB 40 (M)
Max. Unrestrained Length = 1.5 m [Vertically Both Direction]
Material Specification:-
Unit wt. of Ply-Wood = 0.65 Ton/m3
Elastic Modulus, Ep = 2000 Mpa
Allowable Bending Stress, σb (all) = 15 Mpa
Unit wt. of Timber-Wood = 0.9 Ton/m3 Mpa
Elastic Modulus, Et = 10000 Mpa
Allowable Bending Stress, σb (all) = 12 Mpa
Loading:-
Dead Load from Slab = 0.5625 T/Sq.m
Live Load(LL) on Staging = 0.125 T/Sq.m
Total Impose Load = 0.6875 T/Sq.m
A Design of 12mm Thick Ply as Shuttering Plate:-
Check Against Bending
2
Load on Ply = 0.6953 t/m [Including Self Wt. Ply]
Span = 0.275 m
Max. BM = 0.0053 t-m / m run [As Continious Beam Action]
3
Z (for Ply) = 24000 mm / m run
Bending Stress developed, σbc (cal) = 2.19 Mpa <15 Mpa
Hence o.k.
Check Against Deflection
δcal = 5/384x(wl^4/EI) = 0.5 mm
δper = (L/270) = 1.02 mm Hence o.k.
B Checking for Wooden Batten 75 x 50 @ 275 mm c/c
i) Check Against Bending
Loads from Ply = 0.6953 t/m2
UDL on each Batten with S/W = 0.1946 t/m [Including Self
Wt.of Batten]
Length (Span)= 1.2 m
Max. BM in the Batten = 0.035 t-m
Zxx ( of Batten ) = 31250 mm3
σbc cal = 11 Mpa < σbc all = 12 Mpa
Hence o.k.
Formwork Design For 225mm Thick Floor Slab
ii) Check Against Deflection
δcal = 5/384x(wl^4/EI) = 2.69 mm
δper = (Lx/325) = 3.69 mm >
Hence o.k.
C Checking for Main Joist, ISMC 75 @ 1200 mm c/c
Check Against Bending
Reaction force from each Batten = 0.1167 Ton
No of batten support on single span = 4.3636 Nos
S/W of Joist = 0.007 t/m
Length (Span)= 1.5 m
Support Reaction at Main Joist end = 0.2589 Ton
Max. developed Moment, = 0.0481 t-m
Zxx = 20.30 cm3 rxx = 2.96 cm ryy = 1.21
cm
λxx = 51 λyy = 23
σbc cal = 24 Mpa < σbc all = 158 Mpa
Hence o.k.
Check Against Deflection
δcal = ( M.L2) / (10EI) = 0.68 mm
δper = (Lx/325) = 4.62 mm > 0.68 mm
Hence o.k.
D Checking of Vertical Prop Jack System
Influence area of one vertical = 1.8 Sq.m
rcr for Pipe (NB40-M) = 16 mm [Ref. Code - IS1161]
Critical l / r = 93.75
Coresponding Allowable fc = 86 Mpa
Max. load on a single vertical = 1.252 Ton
2
Area for 40nb. Pipe = 453 mm
So, Calculated Comp. stress = 28 Mpa < 86 Mpa
Hence o.k.
The floor slab stagging is safe against the following consideration.
1) Use Verticals Cup - Lock System of 40 NB (Medium) - 1.2 x 1.5 m c/c
with unrestrained length @ 1.5 m c/c.
2) Use Main Joist Section ISMC 75 - 1.5 m unsupported length @ 1.2 m c/c.
3) Use Beam Bottom-3" x 2" Wooden Battem - 1.2 m unsupported length @ 275 mm
c/c.
4) Use Shuttering Plate -12 mm Thick Ply board.
