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Technical Education and Skills Development Authority Jacobo Z. Gonzales Memorial School of Arts and Trades San Antonio, Bian City
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FABRICATE FORMWORKS FABRICATING FORM WORKS This module covers the knowledge, skills and attitude in selecting and preparing materials, tools and equipment for fabricating form works, layingout, cutting to dimensions of form sheating and stiffeners and assembling form panels. 40 hrs. NATIONAL CERTIFICATE LEVEL II
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SUMMARY OF LEARNING OUTCOMES: Upon completion of this module, the trainee/student must be able to: LO 1. Prepare materials, tools and equipment for fabricating form works according to job requirements LO 2. Lay-out and cut to dimension of form sheating and stiffeners LO 3. Assemble form panels
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ASSESSMENT CRITERIA:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Plans and details are correctly interpreted and identified according to job requirements Materials, tools and equipment are identified consistent with job requirements Materials and tools are properly stored and freed from defects. Appropriate PPE are selected according to job requirements. Form sheating and stiffeners are measured and marked according to job specifications Form sheating and stiffeners are laid out and cut with tolerances of 3 mm for all measurements and squareness Appropriate PPE is used according to job requirements Form panels and stiffeners are laid-out for pre-assembly Form panels and stiffeners are pre-assembled Form panels and stiffeners are checked for squareness according to job requirements Form panels and stiffeners are assembled Appropriate PPE is used according to job requirements and safety regulations Unexpected situations are responded to in line with company rules and regulations
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CONTENTS: Tools, materials and equipment for fabricating formworks Materials estimates Mechanical properties of lumber Economic use of materials ASSESSMENT CRITERIA 1. Plans and details are correctly interpreted and identified according to job requirements 2. Materials, tools and equipment are identified consistent with job requirements 3. Materials and tools are properly stored and freed from defects. 4. Appropriate PPE are selected according to job requirements. CONDITIONS: You must be provided with the following: 1. WORKPLACE LOCATION 2. TOOLS AND EQUIPMENT Claw Hammer Pencil/Marking pen Pull-Push Rule Nylon String Steel Square Try-square Hand Saw Chalk Line 3. TRAINING MATERIALS Leaning Packages Bond paper Ball pens ASSESSMENT METHOD Portfolio
Personal Protective Equipment Portable Circular Saw Plan and working drawings Lumber Nails Plywood
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Learning Experience
PREPARE MATERIALS, TOOLS AND EQUIPMENT FOR FABRICATING FORM WORKS Learning Activities Read Information Sheet No. 2.1-1 on Tools , materials and equipment for fabricating formworks Answer Self-Check No. 2.1-1 Read Information Sheet No. 2.1-2 on Material for fabricating formworks Answer Self-Check No. 2.1-2 Read Information Sheet No. 2.1-3 on Mechanical properties of lumber Read Information Sheet No. 2.1-4 on Economic use of materials Answer Self-Check No. 2.1-4 Compare your answer to the answer key Compare your answer to the answer key Compare your answer to the answer key Special Instructions
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INFORMATION SHEET NO. 2.1-1 TOOLS, MATERIALS AND EQUIPMENT FOR FABRICATING FORMWORKS
Refer to module on Stake-out Building Lines, Information Sheet No. 1.1-4 on Tools, Materials and Equipment in Staking-out Building Lines
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2. Metal Panel Metal formwork has a very high reuse potential. So it is more economical than timber where repetitive work is necessary.
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3. Plastic (FRP) Another material used here is the fiberglassreinforced plastic as a formwork. Its functions well because : Moldability Light weight Strength Toughness
B. Construction of Forms consist of: 1. Plywood - It is made in thicknesses of 1/4, 3/8, 1/2, 5/8, and 3/4 inch, and in widths up to 48 inches. The 8-foot lengths are most commonly used. The 6/8- and 3/4-inch thicknesses are most economical. 2. Supporters or studs - Vertical studs make the sheathing rigid. These studs are generally made from 2 x 4 lumber. Studs also require reinforcing when they extend more than 4 feet. 3. Braces - Braces give the forms stability. The most common brace uses a horizontal member and a diagonal member nailed to a stake and to the stud or wale. The diagonal member of the brace should make a 30 angle with the horizontal member. 4. Spacer - Spreaders must be placed near each tie wire. Spreaders are cut to the same length as the thickness of the wall and placed between the two sheathing surfaces of the forms. 5. Tie Wire - Tie wires hold the forms secure against the lateral pressures of unhardened concrete. Double strands are always used. Ties keep wall forms together as the concrete is positioned. The tie wire is made taut by twisting it with a smooth metal rod or a spike. 6. Assorted CWN - refers to the different size of nail ranging from 1-4 (25 mm100 mm) in length. C. Formwork detail for different structural members In concrete construction formwork is commonly provided for the following structural members:
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1. Formwork for sloping side column It consists of Side Supports Side Planks Cleats
3. Formwork for Wall It consists of: Timber sheeting Vertical posts Horizontal members Rackers Stakes Wedges After completing one side of formwork reinforcement is provided at the place then the second side formwork is provided. 4. Formwork for Column It consists of the following: Side & End Planks Yoke Nut & Bolts Two end & two side planks are joined by the yokes and bolts.
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5. Formwork for Slabs & beams It consists of: Sole plates Wedges Props Head tree Planks Batten Ledgers
- Beam formwork rests on head tree - Slab form work rests on battens and joists - If prop height are more than 8 provide
horizontal braces 6. Formwork for Stairs It consists of: Vertical & inclined posts Inclined members Wooden Planks or sheeting Stringer Riser Planks
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Bending stress
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C. Tensile and Compressive Strengths Tensile strength is a measure of the ability of wood to resist pulling forces. On the other hand, compressive strength is a measure of the ability of wood to resist pushing forces. For clear wood (wood without defects), the tensile and compressive strengths for parallel-to-grain loads are approximately 10 times greater than for loads applied perpendicular to the wood grain.
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ASSESSMENT CRITERIA 1. Form sheating and stiffeners are measured and marked according to job specifications 2. Form sheating and stiffeners are laid out and cut with tolerances of + 3 mm for all measurements and squareness 3. Appropriate PPE is used according to job requirements CONDITIONS: You must be provided with the following: 1. WORKPLACE LOCATION 2. TOOLS AND EQUIPMENT Claw Hammer Pencil/Marking pen Pull-Push Rule Nylon String Steel Square Try-square Hand Saw Chalk Line 3. TRAINING MATERIALS Leaning Packages Bond paper Ball pens ASSESSMENT METHOD Portfolio Demonstration
Personal Protective Equipment Portable Circular Saw Plan and working drawings Lumber Nails Plywood
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Learning Experience
LAY-OUT AND CUT TO DIMENSION OF FORM SHEATING AND STIFFENERS Learning Activities Read Information Sheet No. 2.2-1 on Form design Answer Self-Check No. 2.2-1 Read Information Sheet No. 2.2-2 on Prefabrication of formwork panels Perform Operation Sheet No. 2.2-2 on Prefabricate Form Panels and Stiffeners Evaluate your own work using the Performance Criteria Checklist Present your work to your trainer for evaluation Keep a copy of your work for the next activities Compare your answer to the answer key Special Instructions
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2. 3. 4. 5.
Sand streaking. Sand streaking occurs when concrete loses too much water due to loose forms; the water carries sand with it through the gaps in the formwork and causes streaking. Ensure that the forms are braced enough to align them and strong enough to hold the concrete. Take special care in bracing and tying down forms used for configurations, such as retaining walls. Ensure that the forms are wide at the bottom and taper toward the top. Ensure that wall forms are braced properly. The concrete in wall forms, such as the first pour, tends to lift the form above its proper elevation. Reuse forms by constructing them in a manner that allows easy removal and replacement with minimal damage.
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B. Procedure 1. Prepare the work. Make available the tools and materials. A work table is to be manufactured 2. Enter all sizes required from the working drawing. Derive the sizes from the dimensions of the column for which the formwork is to be made. Prepare the size distribution of the stiffeners in particular. 3. Cut up the boards. Locate the sizes of the forms to the plywood at both ends then using your chalk line, mark the boundaries to be cut.. Do not place the rough edge of the board to the inside of the formwork. Always consider the economy use of materials. Note: If you use circular saw for cutting plywood ask the Permission of your teacher 4. Cut the stiffeners straps to length. Use 2X 2 lumber for the stiffener. Butt joint is commonly used in this construction. Adopt the schedule for cutting. 5. After cutting, arrange and classify cut members ready for assembling.
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Steps/Procedure: 1. 2. 3. 4. Prepare the work. Enter all sizes required from the working drawing shown below. Cut up the boards. Cut the stiffeners straps to length. Use 2X 2 lumber for the stiffener. Butt joint is commonly used in this construction. Adopt the schedule for cutting. Note: If you use circular saw for cutting plywood ask the permission of your teacher 5. After cutting, arrange and classify cut members ready for assembling.
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CRITERIA 1. Did I measure and mark form sheating/board according to plan? 2. Did I measure and mark form stiffeners according to plan? 3. Did I use appropriate personal protective equipment in cutting formwork materials?
YES
NO
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CONTENTS: Assembling form panels and stiffeners ASSESSMENT CRITERIA 1. Form panels and stiffeners are laid-out for pre-assembly 2. Form panels and stiffeners are pre-assembled 3. Form panels and stiffeners are checked for squareness according to job requirements 4. Form panels and stiffeners are assembled 5. Appropriate PPE is used according to job requirements and safety regulations 6. Unexpected situations are responded to in line with company rules and regulations CONDITIONS: You must be provided with the following: 1. WORKPLACE LOCATION 2. TOOLS AND EQUIPMENT Claw Hammer Pencil/Marking pen Pull-Push Rule Nylon String Steel Square Try-square Hand Saw Chalk Line 3. TRAINING MATERIALS Leaning Packages Bond paper Ball pens ASSESSMENT METHOD Portfolio
Personal Protective Equipment Portable Circular Saw Plan and working drawings Lumber Nails Plywood
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Learning Experience
ASSEMBLE FORM PANELS Learning Activities Special Instructions
Read Information Sheet No. 2.3-1 on Assembling form panels and stiffeners
Perform Operation Sheet No. 2.3-1 on Assembling form panels and stiffeners
Evaluate your own work using the Performance Criteria Present your work to your trainer for evaluation Keep a copy of your work for the next activities
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B. Procedure in Assembling Form Panels using Forming Boards 1. Prepare the work. Make available the tools and materials. A work table is to be manufactured 2. Enter all sizes required into the working drawing. Derive the sizes from the dimensions of the beam for which the formwork is to be made. Prepare the size distribution of the cover straps in particular. 3. Cut up the boards. The board width should not exceeded 140 mm. Do not place the rough edge of the board to the inside of the formwork 4. Cut the stiffening cover straps to length. Cover straps to have a width of approx. 55 mm with 25 mm projection for comer joints! 5. Put the cover straps on the arranged boards according to the size distribution made. Use measuring rod, if necessary! 6. Nail the cover straps on the boardpanel. It is provisional nailing with short nails (40 mm). Use as many nails as necessary to make the panel stable in itself. 7. Nail the cover straps on the boards from the opposite side. Turn over the provisionally nailed boardpanel and nail it with 70 mm long nails. Two nails per board are to be diagonally arranged at the cover strap joint! 8. Clinch the nail tips. Turn over the panel again and clinch the penetrated nail tips!
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Steps/Procedure: 1. Prepare all the materials and tools needed. 2. Position materials such as form sheating and stiffener correctly. The stiffener should be consistent with standard spacing for studs or nailer with tolerance of + 10 mm. O.C. 3. Assemble form panels. Check for squareness and alignment to specified tolerance. Make sure that the smooth side of the board is placed outside the frame. 4. Nail the form sheating to the stiffener using as many nails as necessary to make the panel stable in itself. Fasten first the two sides of the form sheating with the stiffeners making sure it is flushed to its edges. Then fasten the ribs for strength at 50 cm. apart. Drive 3 CWN to fasten it. Note: Always check for squareness. 5. Clinch the nail tips. Turn over the panel and clinch the penetrated nail tips. 6. Check form panels in compliance with job requirement. 7. Label the finished form accordingly as specified in the working drawing. Assessment Method: Portfolio Demonstration
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CRITERIA 1. Did I lay-out the panels and stiffeners properly before pre-assembly? 2. Did I check the measurements of the members of the form panels prior to assembly? 3. Are the form panels and stiffeners assembled according plans? squareness of forms? smooth side of the board is placed outside the frame? stiffeners are flushed to the edges of panels? ribs are spaced at 50 cm on center?
YES
NO
4. Did I responded to unexpected situations accordingly? 5. Did I label the form panels according to plans?
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