SECTION 03100 CONCRETE FORMWORK

PART 1 - GENERAL 1.1 A. DESCRIPTION OF WORK The work of this section includes furnishing, fabricating, and placing of formwork for cast-in-place concrete as indicated on the drawings. Provide formwork and shoring for cast-in-place concrete and installation of items into formwork such as anchor bolts, setting plates, bearing plates, anchorages, inserts, frames, nosings, and other items to be embedded in concrete. Related Work: 1. 2. 3. 4. 1.2 A. Section 03200: Concrete Reinforcement Section 03210: Epoxy Coated Concrete Reinforcement Section 03300: Cast-In-Place Concrete Section 03740: Concrete Repairs

B.

C.

QUALITY ASSURANCE Codes and Standards: Comply with the provisions of the following codes specifications and standards, except as otherwise shown or specified. 1. 2. ACI 347 "Recommended Practice For Concrete Formwork." ANSI A199.1 "Construction and Industrial Plywood."

B.

Allowable Tolerances: 1. Construct formwork to provide complete cast-in-place concrete surfaces complying with the tolerance specified in ACI 347. Before concrete placement check the lines and levels of erected formwork. Make corrections and adjustments to ensure proper size and locations of concrete members and stability of forming systems. During concrete placement check formwork and related supports to ensure that forms are not displaced and that completed work will be within specified tolerances.

2.

3.

P.O. Number : 7200018725

1.3 A.

SUBMITTALS Manufacturer's Data: 1. Submit manufacturer's data and installation instructions for materials including form coatings, manufactured form systems, ties and accessories.

B.

Shop Drawings: 1. Submit shop drawings for fabrication and erection of formwork for finished concrete surfaces. Show the general construction of forms including jointing, special formed joints or reveals, placement of inserted items, location and pattern of form tie placement, and other items which affect the stable retention of the cast concrete and the exposed finish surface of cast concrete.

C.

Certificates: 1. Submit reports certified by a surveyor, verifying that the work is within specified tolerances.

PART 2 -PRODUCTS 2.1 A. MATERIALS Forms For Exposed Finish Concrete: 1. Unless otherwise shown or specified, construct formwork for exposed concrete surfaces with plywood, metal, metal-framed plywood-faced or other panel type materials acceptable to MARAFIQ, to provide continuous, straight, and smooth as-cast surfaces. Furnish in largest practicable sizes to minimize number of joints and to conform to joint system shown on drawings. Provide form material with sufficient thickness to withstand pressure to newly placed concrete without bow or deflection.

B.

Forms For Concrete Not Exposed: 1. Form concrete surfaces which will not be exposed in the finished structure with plywood, lumber, metal, or other acceptable material. Use lumber that is dressed on at least 2 edges and 1 side for tight fit. Undressed lumber may be used if approved by MARAFIQ.

C.

Forms For Textured Finish Concrete 1. Form textured finish concrete surfaces with units of face design, size, arrangement, and configuration as shown on the Drawings or as required to meet MARAFIQ's control sample. Provide solid backing and form supports to ensure stability of textured form liners.

P.O. Number : 7200018725

D.

Corrugated Steel Forms: 1. Fabricate of galvanized steel sheets complying with AISC "Specification for the Design of Light Gauge Cold Formed Steel Structures." Depth of ribs and metal gage as shown on drawings.

E.

Cylindrical Columns and Supports shall be formed by one of the following methods: 1. Form round-section members with paper or fibre tubes, constructed of laminated plies using water-resistant type adhesive with wax-impregnated exterior for weather and moisture protection. Use units with sufficient wall thickness to resist loads imposed by wet concrete without deformation. a. Provide manufacturer's seamless units to minimize spiral gaps or seams.

2.

Form round-section members with no less than 12 gage steel sheets. Butt sections together, with bolted or keyed and welded joints. Finish interior joints of forms smooth so there is no visible seam on finished concrete surfaces.

F.

Pan Forms: 1. Provide forms for concrete pan type construction complete with covers and end closures to form a true, clean, smooth concrete surface. Design units for easy removal without damaging placed concrete. Block adjoining pan units as required to avoid lateral deflection of formwork during concrete placement and compaction. Use standard or tapered end forms, as shown. Pan form units shall be factory fabricated using one of the following materials: a. Steel: 1.52 mm minimum, free of dents, irregularities, sag, and rust.

2.

G.

Form Ties: 1. Use factory-fabricated, adjustable-length; removable or snap off metal form ties, designed to prevent form deflection, and to prevent spalling concrete surfaces upon removal. Unless otherwise shown, use ties so that portion remaining within concrete after removal of exterior parts is at least 38 mm from the outer concrete surface. Unless otherwise shown, use form ties which will not leave a hole larger than 25 mm diameter in the concrete surface.

2.

P.O. Number : 7200018725

H.

Form Coatings: 1. Use commercial formulation form-coating compounds that will not bond with, stain, nor adversely affect concrete surfaces, and will not impair subsequent treatment of concrete surfaces requiring bond or adhesion, nor impede the wetting of surfaces to be cured with water or curing compounds.

I.

Metal Inserts: 1. Use metal inserts for anchorage of materials or equipment to concrete construction as required for the work. Use adjustable wedge inserts of malleable cast iron, complete with bolts, nuts and washers; 20 mm bolt size unless otherwise shown. Use threaded inserts of malleable cast iron, furnished complete with fulldepth bolts; 20 mm bolt size, unless otherwise shown. Use sheet metal reglets formed of the same type and gage as the flashing metal to be built into the reglet, unless otherwise shown. Where resilient or elastomeric sheet flashing or bituminous membranes are terminated in reglets, provide reglets of not less than 0.45 mm galvanized sheet steel. Size, shape, and install reglets as detailed. Fill reglet or cover face opening to prevent intrusion of concrete or debris.

2.

3.

4.

2.2 A.

DESIGN OF FORMWORK Design, erect, support, brace, and maintain formwork so that it will safely support vertical and lateral loads that might be applied, until such loads can be supported by the concrete structure. Carry vertical and lateral loads to ground by formwork system and in-place construction that has attained adequate strength for the purpose. Construct formwork so that concrete members and structures are of correct size, shape, alignment, elevation and position. Use shores and struts with positive means of adjustment capable of taking up formwork settlement during concrete placing operations, using wedges or jacks or a combination thereof. Use trussed supports when adequate foundations or shores and struts cannot be secured. Support form facing materials by structural members spaced sufficiently close to prevent deflection. Fit forms placed in successive units for continuous surfaces to accurate alignment, free from irregularities and within allowable tolerances. Provide camber in formwork as required for anticipated deflections due to weight and pressure of fresh concrete and construction loads to long span members without intermediate supports. Provide temporary openings in wall forms, column forms and at other locations necessary to permit inspection and clean-out.

B.

C.

D.

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E.

Design formwork to be readily removable without impact, shock or damage to cast-in-place concrete surfaces and adjacent materials. Construct formwork sufficiently tight to prevent leakage of cement paste during concrete placement. Solidly butt joints and provide backup material at joints as required to prevent leakage and fins.

F.

PART 3 - EXECUTION 3.1 A. INSPECTION Examine the condition under which concrete formwork is to be erected. Do not proceed with the work until unsatisfactory conditions have been corrected. FORM CONSTRUCTION Construct forms to the exact sizes, shapes, lines and dimensions shown, and as required to obtain accurate alignment, location, grades, levels and plumb work in finish structures. Provide for openings, offsets, sinkages, keyways, recesses, mouldings, rustications, reglets, chamfers, blocking, screeds, bulkheads, anchorages and inserts, and other features required. Use selected materials to obtain required finishes. Fabricate forms for easy removal without hammering or prying against concrete surfaces. Use crush plates or wrecking plates where stripping may damage cast concrete surfaces. Use top forms for inclined surfaces where the slope is too steep to place on concrete with bottom forms only. Kerf wood inserts for forming keyways, reglets, recesses, and the like, to prevent swelling and assure ease of removal. Provide temporary openings where interior area of form-work is inaccessible for cleanout, for inspection before concrete placement, and for placement of concrete. Brace temporary closures and set tightly to forms to prevent loss of concrete mortar. Locate temporary openings on forms in as inconspicuous location as possible, consistent with project requirements. 1. 2. All exposed corners shall be chamfered. Provide openings in forms to accommodate other work, including mechanical and electrical work. Accurately place and securely support items required to be built into the forms.

3.2 A.

B.

C.

D.

Place steel forms with ribs perpendicular to supports and secure with plug welds to each support using curved welding washers. Falsework: 1. Erect falsework and support, brace and maintain it to safely support vertical, lateral and asymmetrical loads applied until such loads can be supported by

E.

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in-place concrete structures. Construct falsework so that adjustments can be made for take-up and settlement. 2. Use wedges, jacks or camber strips to facilitate vertical adjustments. Carefully inspect falsework and formwork during and after concrete placement operations to determine abnormal deflection or signs of failure; make necessary adjustments to produce work or required dimensions.

F.

Forms for Exposed Concrete: 1. Drill forms to suit ties and to prevent leakage of concrete mortar around tie holes. Do not splinter forms by driving ties through improperly prepared holes. Do not use metal cover plates for patching holes or defects in forms. Chamfer all exposed corners. At intersecting planes, provide back joints with extra studs or grits to maintain true, intersections. Use extra studs, walers and bracing to prevent bowing of forms between studs and to avoid bowed appearance in concrete. Do not use narrow strips of form material which will produce bow. Assemble forms so they may be readily removed without damage to exposed concrete surfaces. Form moulding shapes, recesses and projections with smooth-finish materials, and install in forms with sealed joints to prevent displacement.

2. 3. 4. 5.

6. 7.

G.

Corner Treatment: 1. Form exposed corners of beams and columns to produce square, smooth, solid, unbroken lines, except as otherwise shown. Form chamfers with 20 mm x 20 mm strips, unless otherwise indicated, accurately formed and surfaced to produce uniformly straight lines and tight edge joints. Extend terminal edges to required limit and miter chamfer strips at changes in direction. Unexposed corners may be formed either square or chamfered.

2.

3. H. Joints: 1.

Refer to Section 03300 for treatment of control and construction joints, including wood screeds, metal keyways, and sawcuts. Submit drawings showing locations.

I.

Provision for Other Trades: 1. Provide opening in concrete formwork to accommodate work of other trades. Accurately place and securely support items to be built into forms.

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J.

Cleaning and Tightening: 1. Thoroughly clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt or other debris just before concrete is to be placed. Retighten forms immediately after concrete placement as required to eliminate mortar leaks.

3.3 A.

FORM COATINGS Coat form contact surfaces with form-coating compound before reinforcement is placed. Do not allow excess form coating material to accumulate in the forms or to come into contact with surfaces which will be bonded to fresh concrete. Apply in compliance with manufacturer's instructions. Coat steel forms with a non-staining, rust-preventative form oil or otherwise protect against rusting. Rust-stained steel formwork is not acceptable. INSTALLATION OF EMBEDDED ITEMS General: Set and build into the work anchorage devices and other embedded items required for other work that are attached to, or supported by, cast-in-place concrete. Use setting drawings, diagrams, instructions and directions provided by suppliers of the items to be attached thereto. Edge Forms and Screed Strips for Slabs: 1. Set edge forms or bulkheads and intermediate screed strips for slabs to obtain required elevations and contours in the finished slab surface. Provide and secure units to support types of screeds required.

B.

3.4 A.

B.

3.5 A.

SHORES AND SUPPORTS Comply with ACI 347 for shoring and reshoring in multi-storey construction, and as herein specified. Remove shores and reshore in a planned sequence to avoid damage to partially cured concrete. Locate and provide adequate reshoring to safely support the work without excessive stress or deflection. REMOVAL OF FORMS Formwork not supporting concrete, such as sides of beams, walls, columns, and similar parts of the work, may be removed after cumulatively curing at not less than 10 degrees centigrade for 24 hours after placing concrete, provided concrete is sufficiently hard to not be damaged by form removal operation, and provided that curing and protection operations are maintained.

B.

3.6 A.

P.O. Number : 7200018725

B.

C.

Formwork supporting weight of concrete, such as beam soffits, joists, slabs, and other structural elements may not be removed until concrete has attained its design 28 day compressive strength. Determine potential compressive strength of in-place concrete by testing fieldcured specimens representative of the concrete location or members, as specified in Section 03300. Form facing material may be removed 4 days after placement, only if shores and other vertical supports have been arranged to permit removal of form facing material without loosening or disturbing shores and supports. RE-USE OF FORMS Clean and repair surfaces of forms to be re-used in the work. Split, frayed, delaminated, or otherwise damaged form facing material will not be acceptable. Apply new form coating compound material to concrete contact surfaces as specified for new formwork. When forms are extended for successive concrete placement, thoroughly clean surfaces, remove fins and laitance, and tighten forms to close all joints. Align and secure joints to avoid offsets. Do not use patched forms for exposed concrete surfaces, except as acceptable to the MARAFIQ. + + END OF SECTION 03100 + +

D.

3.7 A.

B.

P.O. Number : 7200018725