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MICROCOPY~ RE§OLUTION TEST
BUREAUOF STANDARDS1963-A
NATIONAL.
CONCRETE CONSTRUCTION USING SLIPFORM TECHNIQUES
BY
BRUCE R. CARTER
;-C.
pa
10
UNIVERSITY OF FLORIDA
NOVEMBER 1982
- 83 02 025 027
b'" .. . . .. ..
To my wife
Margaret
for her patience and support
I
ACKNOWLEDGEMENTS
Company of Spokane, WA.; and GOMACO Corp. of Ida Grove, Iowa for their
technical assistance.
I/
. UAvailaliMy
I I
Codes
':" ----- Nvali wWlsr
. "" , 'Dist Sipetl,
.
TABLE OF CONTENTS
PAGE
CHAPTER ONE - INTRODUCTION 1
1.1 Background 1
!:1.2 Definitions 2
1.3 Scope of Report 2
CHAPTER TWO -HISTORY 3
b.
-E CHAPTER 1
INTRODUCTION
1.1 BACKGROUND
the job done properly and on time. In fact, concrete formwork frequently
costs more than the concrete and reinforcing steel combined. Therefore,.
- "i - i"..
". ' "• "- " " ."... .". ' " " " " m, m,. ,i,,,,.,.'.--. ,, z. w, ~a ,m:-.,',,,,,b" " , ,,, ,I" , ,,,,,. .,1
I ........
1.2 DEFINITIONS
will examine the economic and productive aspects involved with slip-
forming. Chapter Six is a summary of conclusions and recommendations.
It is the purpose of this report to acquaint the reader with the
2
CHAPTER TWO
BRIEF HISTORY OF THE USE OF SLIPFORMING IN AMERICA
is generally accepted that the first use of this technique took place
lifting sectional forms were tried, but all had the same defect of
3
leaving numerous horizontal and vertical joints in the walls.
angle walers and yokes to maintain the spread and shape of the forms,
outside the form through the use of wooden jacking legs. Such a
3
~ WALERMOVING
~ - -P. CONCRETE
'~YOKE
.. AOL.~t~L
;.FORM
JACINGFigure
r~ 1 -Slipform Technique
~,*~Circa 1899
(Source: Linden-Alimak Inc.
$
~ ~ WAL~ '~W7Publication)
e j.
2..',SCCRW
. . .. . YKE
DEC.. 0 0,10 HOLLO
oo co
DECK c o rIJACK ROD
~') ... COMPLETED
Figure 2 Slipform Technique
Circa 1903
.WALL
- L
(Source: Linden Alimak Inc.
Publication)
* MOVING
CONCRETE- FR
WALL
Figure 3 SlipfoftTechnique
-
Circa 1910
4 (Source: Linden-Alimak' Publication)
-.. I-
This first true slipform system highlighted the problems associated
with concrete vibration, fallouts, honeycombing, and wall damage by
buckling climbing-tubes which had to be overcome in order to success-
fully employ the vertical slipform concept. Several additional
lifting systems were devised, and by 1910, the most commonly used
and the fresh high slump (5-6 inch) concrete at the top of the forms
was spaded. It was thought that mechanical vibration incr-ased the
pressure on the forms, and posed some danger to the concrete within
7
the forms that had already set.
However, rapid improvements in the vertical slipform technique
in the late 1950" 3nd earl 1960's soon led to average slide rates
i=...................
5
concrete was made possible through the use of immersion type vibrators,
concrete admixtures and air entrainment. At this time, peak slide
rates in excess of 18 inches per hour were being achieved.8
In the last 10 years, refinements in material, equipment, and
K
"management techniques have led to slide rates of over 40 inches per
hour, and application of the slip forming process to an increasing
* number of structural types, including tapered chimneys, communications
towers, cooling towers, offshore drilling platforms, ski jump towers,
nuclear shield walls, high-rise building cores, and the worlds largest
dry dock.
The first slipform paver was the Johnson Machine which consisted
of a simple skid-mounted box equipped with a vibrator and extrusion
6
trucks which supplied the concrete. The first production slipform
paver and Quad "ity machine, was placed on the market in 1955. The
In the late 1950's and early 1960's slipform paving was adapted
to the lining of canals. The R.A. Hanson Company which had developed
a self-leveling mechanism for wheat combines in the state of Washington,
was asked by construction firms in that state who were engaged in
canal work to adapt their leveling device to canal machinery. The R.A.
Hanson Co. canal trimmer and concrete placer proved to be very popular.
In 1964, the R.A. Hanson Co. successfully designed, manufactured and
during this time period also produced automatic machines for placing
7
I
CHAPTER 3
vertical molding of concrete walls through the use of a 4-6 feet form
fresh concrete and reinforcing steel are placed in the top of the open
material is stationary and the form moves upward. Normally the setting
time of concrete is 2-3 hours. Using this typical setting time and
with slipforms 4 feet deep, a possible form speed of 16-24 inches per
hour can be achieved. The actual median form speed however, depends
used, the grind of the cement, the water-cement ratio, the percent of
that is not within the confines of the inner and outer sheathing of
the moving forms. This means that beams, slabs, corbels, or other
8
Inserts that do not project outside the formed wall are used to
provide attachments for floor members and beam-and-girder frames.
Inserts can include keys, pockets, weld boxes, and electrical conduit
runs. Blockouts provide for such items as door frames and window
12
3.2.1 Yokes
Yokes provide two primary functions: to keep the forms from
spreading, and to transfer the load of the forms and working decks to
14
the jack.
The yokes are inverted U's consisting of two legs and a cross
beam. The legs are attached to the wales and carry the vertical
loads in tension, and the lateral loads as cantilever beams. The
cross arm of the yoke must be designed as a simple beam supported at
the center by the jack and subject to the moments from both the vertical
and lateral leg loads. Although yokes are normally of steel, they can
be constructed of wood or other material . They should al.o be
.4 designed with enough clearance above the forms to allow horizontal
reinforcement steel and embedded items (blockouts, insert material)
to be installed in a correct fashion prior to being submerged in the
concrete.
I9
• , ., ., ' *- , - : ......
...
.....
- .........:,9
ThinPipeYoke Assembly
Around Jock
-Working Deck
Bracing for
10
I. " ..... .-
Figure5 - ReinfTp
clng
i eel w ItJack Rod
scf lauppotes Le.t
DOec k
nstitute 1, p. 2
indicated
scaffld. s ,,.
3.2.2 Wales
Wales serve the following purposes:
a. They support and hold the sheathing in position
0. They support the working platform
c. They support the suspended scaffolding
d. They transmit the lifting forces from the yokes to the
form system.1
Wood wales are usually built up of 2 or 3 plies of two inch
thick material. Two ply wales are always built of 2 inch thick
material. (for example a double layer of 2x6's) Three ply wales
may be a combination of 2 inch and 1 inch material. 9 For structures
with plane surfaces, such as buildings and piers, the wales may be 4x 6
inch or 4 x 8 inch lumber in solid pieces. However, for structures
having curved surfaces, such as silos, the wales usually are assemblies
of two or three 2 x 6 inch or 2 x 8 inch planks sawed to required
curvatures. 20 Steel wales are also used. The miniiwum depth of seci-
mented wales for curved walls should be 41i inches at the center after
cutting to the required shape. 21
12
323Sheathing
The sheathing makes up the sides or walls of the forms and is the
portion of the formwork which actually contains and shapes the concrete.
Since slip-forms are subjected to the hydrostatic pressure of the
plastic concrete, the sheathing must support this lateral pressure with
beam action between the wales, and as a cantilever at the bottom of the
form. At one time the wood most commnonly used for sheathing was 1
inch thick staves in 4 inch widths, tongue and groove or squared ended
depending upon the job. 22 The 1 inch thick staves were placed vertically
to reduce drag, and often presoaked to reduce swelling during the sliding
operation. 23 However, the use of staves as slip-form sheathing is
diminishing and according to some experts, should be avoided. 2 To
accommodate expansion due to moistisre pickup, the staves must be spaced
approximately 3/32 inch face to face (depending on the stave width
and initial moisture content). Consequently, stave sheathing cannot
provide a stiff partition, and a complex water system must be used to
prevent the sheathing from undergoing excessive distortion. An
additional, and more serious problem with staves is their tendency to
deflect between the walers under the hydrostatic pressure of the
concrete. This causes a negative batter, or pinching action to take
place just above the bottom waler, and produces a tendency for the
sheathing to pick up the concrete.2 Often this results in large
through-wall horizontal cracks and voids. Cracks 2 feet high and 10 feet
long have been observed. For straight walls, J.M. Henry of Linden-
Alimak Inc. recommnends that the minimum slip-form be constructed with
3/4 inch high strength plywood braced with 2x4 inch or 2x6 inch vertical
stiffeners, spaced approximately 12 inches on center. Depending on the
13
radius, 3/8 inch, 1/2 inch, 5/8 inhor multiple laeso /8 nho
plwoo (al wthvertical stiffeners) is recommended for
1/4inc
curved walls. If the vertical stiffeners are omitted from the plywood
forms, then they too will tend to pick up the concrete and cause
damage. 26
It should be noted that some firms still use 1 inch stave sheaths
for curved surfaces, and under proper circumstances of form control,
27
staves do have the advantage of requiring smaller wales than plywood.
All-steel forms with steel sheathing, though more expensive than
wood, are economical if sufficient reuse is anticipated. Steel forms
are more rugged, smoother, and easier to clean, but they do not lend
themselves to easy alteration or repair during the slip operation.
Steel sheathing is impermeable, but wood sheathing must be oiled or
given plastic treatment in order to prevent or minimize absorption
of the film of excess moisture on the inner sheath surfaces. The film
of excess moisture is desirable because of its ability to reduce form
drag.
The friction or drag force on the forms during the sliding action
is significant. This loading is highly variable, and depends not only
on the type and depth of sheathing used, but on the temperature, moisture
content, workability, and rate of set of the concrete. A drag load
of 100 lb. per lineal foot of sheathing is sometimes used in form
design. 28(The drag load is discussed in more detail in Section 3.2.4)
A slight batter of between 1/32 inch per foot and 1/16 inch per
foot of the sheathing, suich that the bottom of the forms are slightly
further apart than at the top helps to reduce the drag of the concrete
on the sheaths. In fact, the top of the forms may be slightly smaller
14
than the required wall thickness and the bottom of the forms slightly
*larger. (See Figure 4) In this way the concrete can take its final
shape about halfway down the form, and is completely free of the form
P =100 + 6000R
where:
and an assumed separation point between the form and the concrete
15
II
0
Top of the new concrete
-/
2 M
Tb e~3 Hydroststic
+D pressure
• ,," d istributio n
Timber 5
formwork
7 C,
:/
Concrete wall
r.'7
. ..
16
a distance of 600mm (23.6 in) below the top of the fresh
concrete. Figure 6 illustrates the slipform pressure
17
Top of the new concrete
N Reduced
hydrostatic
-~ . N pressure
INNN
Concrete wall P a
18
(c) Nennig's Method 33
The third European method used is Nennig's Method. Nennig assumes
a parabolic pressure distribution acting over the depth at which the
concrete is against the form. Figure 8 illustrates the
framework pressure distribution according to this method.
For slow speeds ("slow" is not defined in the reference,
h = 2a = 2 vbtv
where:
tv = setting time of concrete
:4
3 (Vbtv)
The lateral pressure for slip-form work is often lower than for
19
Top of the new concrete
7 - NHydrostatic
N pressure
p,max Ndistribution
T rN NN NI
foo
rmwo rk NN
Concrete wallI
20
i~i.
The depth of the sheathing is commonly 3 to 6 feet with 4 ft.
being the usual depth. 35 The depth of the form depends on the desired
VL. rate of slide, and the time required for initial set of the concrete. 36
The lesser form depths are used when a relatively rapid set of the
concrete is expected. The deeper forms have proven successful in
winter weather or when greater sliding speed was desired.37
21
and the degree of batter. Figure 9 illustrates these points. Batterham
Snoted that the nature of the formwork face, especially its permeability,
had a great effect on the friction and pressure factors. With timber
forms, if small gaps were left between the wood slats (usually to allow
S for expansion), a certain amount of grout would leak through, thus re-
ducing lateral pressure and increasing friction.
3.3.2 Test Setup
consisting of one timber slipform with expansion gaps between the wood
slats, and a second slipform made of plywood with a watertight form-
work face. Figure 10 shows the general formwork arrangement.
The reinforcement in each case was made up of 10mm diameter mild
thickness, and setting time was used. The concrete used in each case
was of a plastic consistency (no slump test results given) with a
22
25 mm climbing tubes
Top of
the new concrete
I *
Timber formwork . .
ilkC.
..
4.
** Hardened concrete
- . .
occur until depth h2. Note the slight difference
in wall thickness wfiich results.
(Source: Batterham, Slipform Concrete, Longman Publishers,
S1981, p. 41)
23
Jacks
Yoke plates
Vertical members of
the lifting frame
r
1200
LA
Board formwork Watetgtfrn
2100 2100
30
Climbing gear
Strain gauge
- Cimbing tube
Section A-A
Jointing timber
Strain gauge
Section B-B
24
2
nominal 28 day strength of 375 kg/cm (5334 psi). The aggregate was
proportioned as follows:
% Retained Material Particle Size (mmn)
18 crushed stone 15-30
22 gravel 7-15
17 sand 3-7
35 fine sand 0.2-3
8 fines 0-0.2
To begin the test, the forms were filled with concrete, and allowed
to set for 3 hours before sliding operations began. Strain measurements
were taken beginning with the first movement of the form, and there-
after at 200 mm (7.9 in)intervals of upward vertical form movement.
After the slipform operations had begun the concrete was placed in
200 mm (7.9 in)lifts, and vibrated by internal vibration. The actual
horizontal and vertical forces acting on the forms were measured con-
currently with three major activities: after concrete placement, after
vibration, and during formwork lifting. (The lift increment was not
* given, but is assumed to be on the order of 70mm (2.8 in)based on
typical British practice.)
25
I.
Test 1 2 3
Sliding speed (cm/h) 10 40 40
Wall thickness (mm) 150 150 400
Setting time (min) 45 15 20
Final set (h/min) 3:50 2:55 5:5
Laboratory temperature ( 0 C) 19 20 14
0after
0
placing
p max - - 270 143 374 364
o concrete mean - - 210 120 330 298
0 after max - - 320 133 440 480
- vibration mean - - 268 119 400 352
o 0
E during max 128 92 320 140 - -
lifting mean 64 39 273 125 - -
WT = watertight timber
BT = board formwork
26
a b c
0
U.
Horizontal: /
lower waling ____________ F
D
DatumI
1 2 5 7 10-
t (S)
27
K- in motion, the vertical force continues to decrease until the hydraulic
force in the upper waling decreases during the slide. The initial dip
in horizontal force on the upper waling is caused by the inward batter
of the form which resulted from the concrete pulling on the formwork.
The force on the lower waling is relatively constant, reflecting the
fact that the concrete has already begun initial set by the time it
reaches this lower portion of the slipform. Batterham noted that the
horizontal forces increased on both wales whenever vibration of the
concrete was taking place.
The extent of increase was greater with greater depth of vibration.
28
American Experimental
Bohm Drechscl Nennig Regulation results
(kg/ni) (kg/rn) (kg/m) (kg/m) (kg/m)
Formwork 280 458 375 1100 748
pressure WT
Forruwork 45 - 75 - 600
friction BT
WT = watertight formwork
BT = board forinwork
29
of the form sheathing, and the depth of concrete vibrations. All of
these factors except concrete vibration can be controlled. If the
concrete is lightly vibrated, the concrete will achieve initial set
and detach itself from the form at a higher elevation. However, well
vibrated concrete is desired in many cases for the increased density
and strength which is produced. Excessive vibration will have a
detrimental effect on the deeper concrete which has already begun
initial set. It should be noted that a watertight form tends to
•. increase effective depth via the trapped water pressure, while
this is actually the sum of moments about point A (in meter - kg)
divided by the sum of the horizontal forces on the wales (in kg.), for
*I a 1 meter longitudinal length of slipform.
* 30
Top of formwork
10A
CC.
Bottm
o forwo '
Pulser,18, p.h
51) T
B, E2 C31
Again using Figure 12, Batterham defines three limiting values
as follows:
(a) At point A which corresponds to the top of the freshly
placed concrete, which also corresponds to j(z) = 0, and
z =0
(b) Hydrostatic pressure for the density of the concrete just
placed is represented by j(z) = pz
(c) Point B is the point where the concrete and form separate.
- . Using these assumptions, Batterham determines what he calls the first
approximation of lateral pressure distribution with formwork depth.
Here the lateral pressure is equivalent to a hydrostatic pressure
distribution corresponding to triangle AC1 B1 and with the resultant
horizontal or lateral pressure equaling P1. P1 is assumed to equal
P0. Using the given assumptions and limitations, Batterham states
that:
2P0
Z1 = 2.25p
The derivation is not given, but the following method may have been
used. Triangle AC1 B1 represents the hydrostatic pressure distribution
for concrete which weighs approximately 140 lb/ft3 or 2.25 times that
of water. P equals the hydrostatic pressure due to water.
:4
al 32
r
-- Thus:
z
Force = -2-(2.25p)(Z 1 ) = P0
(Z )2
2= 2P0
Z1 2.25p
i l= 2
2p
2.25p
points B and C are connected by a dotted curve such that the sum of
forces F3 , F4 and F5 equals zero, and F4 + F5 = F3.
Each approximation is successively more realistic, with
33
representation given in Figure 13 and the figures given in Table 3.
The final approximation curve shows that the concrete and slipform
indicating that the slide speed could have been increased. At the
with point B.
at point B (at the bottom of the slipform for optimal slide rate) be
used as the design load. This can be easily done because the trape-
deep, and with concrete lifts of 200 mm (7.9 in) the bottom of the force
hydrostatic pressure of a point 800 mm (31.5 in) below the top of the
can be determined by the formwork base, the top of the fresh concrete,
and a lateral force equal to one half the maximum hydrostatic pressure
taken at a depth equal to 2/3 the form depth. This maximum force
trapezoid represents a maximum slide rate. For less than maximum slide
rates, the lateral pressure would correspond to one half the hydrostatic
34
Top of formwork
Top of new concrete
134
13rssr2o eria
Sl
pfrm
Batterham Model
(Source: Batterhai, Slipform Concrete, Longman
Publihers
198, p.52)
Z'P, P, (Z)
(min) (kg) (kg/rn)
.4Plywood 450 544 47
forniwork
4 35
In concluding his analysis of these tests, Batterham states that
formwork friction depends on three main factors, which in turn are all
between the concrete and the form facing, which provides a lubricating
Roughness of the formwork increases with use, and this is more pro-
the tests. The test results gave unexpectedly high values for friction,
indicating that the minimum wall size should be much la-ger. (how much
larger, Batterham didn't state). Thus, the frictional forces can very
likely be greater than the weight of the barely set concrete resulting
36
These cracks also tended to be sealed by the layer of grout between
the concrete and the form face when watertight forms were used.
During the tests, a prolonged stoppage on the order of 45 minutes
* produced wide horizontal cracks once the formw'ork was restarted,
37
3.4 WORKING DECK
The working deck (See Figures 14 and 15) provides space for
Figure 16)
The floor and joists of the work deck are usually designed for a
can give dangerously high lateral loadings to the slipform, and should
be used only when truly required. Working deck beams and trusses,
Often the working deck is used as the roof slab form at the end of
the slide. In such cases the working deck has to be designed to hold
(See Figure 15) The top deck is the work platform, the middle deck
44
becomes the forming deck, and the third level is the finishing deck.
items from falling from the working deck into the forms, the decks
* must be scraped and swept daily. In order to insure safety for the
a 38
M.
~a.
II - aa0.4--
a
-~ __Z4~ )
'.VA Al;~
a m
a 4-)
---- LL.
39/
7-1 ~-q-- vat
40
Figure 16 -View Inside Typical Slipform Working Deck
(Source: Camellerie, Vertical Slipforming as a Construction
Tool, Concrete Construction Magazine, May 1978, p. 268)
1 41
4
workers below the forms, it is recommended that special cleanout chutes
and openings be provided.45
fold hung about 7 feet below the forms. (See Figures 15 and 17)
Equipment for application of curing compound is also carried by this
jacks.4 7
42
I
43
therefore requiring fewer jacks, creating more work space, and adding
to project efficiency.
In any slipform system, the jacks should be placed so that they
each carry nearly equal vertical loads that do not exceed the jack
capacity. The steel rods on which the jacks climb should be especially
placing a thin pipe sleeve about 3 or 4 feet long around the jacking
with the forms. Since the pipe is carried upward, the jackrods are
system employing 22 ton jacks, has typically required a jack for approx-
imately every 175 sq. ft. of core plan area on succEssful highrise
52
construction projects involving slipformed cores.
44
-- - -
Formed
Ope ning-
. Bottom of
Slop Form
RodseBarracedSid
I~~Jc
Concrete
SOpenings, Beam Pockets,
Figure 18 -Typical Forming Details to Allow for
S45
Reserve jacking and placing equipment and standby service equipmeit,
lubrication. 53
The higher concrete slump desired for slipforming results from
the fact that the vibration is confined to each thin layer plus a
couple of inches into the preceding layer, and a higher slump assures
good bonding to the steel without heavy vibration. The higher slump
also aids lubrication of the moving forms. 54
6G 46
The aggregate sizes are determined by the reinforcement steel
design and the wall width Ellison indicates a limiting size of 1
inches while Pruitt56 sets 3/4 inch as the maximum size. The propor-
tion of sand should be as high as possible to produce a high degree
of workability in the mix.
In addition to workability, the concrete set time, moisture
content, and temperature are also key elements of proper slipform
concrete control. Retarding mixtures may be required to accommodate
blockouts, heavy reinforcing steel placement, inserts or other
factors which might cause a reduction in the slide rate.
47
As stated earlier, the concrete is normally placed in
layers of 6 to 10 inches keeping the forms as nearly full as possible
used which prevent uneven loading and rotation of the formwork system.
Shrinkage cracks in slipform concrete tend not to be a problem
because the concrete is in the form for only 3 or 4 hours, the batter
of the forms allows excess water to escape, and both sides of the wall
61
are exposed to the air simultaneously.
The hanging scaffold or finishers' scaffold attached to the
Mr. Henry stated 64 that detection ;.f the construction joinsts required
close inspection with a straightedge.
48
In general, when finishing the concrete surface it is desirable
climate.
Curing of the concrete is usually done by using membrane curing
compounds applied by workers on the finishing scaffold. Water curing
using water lines hung from the forms can be used but is subject
to several problems including discoloration and erosion of the concrete.
67
If water curing is used, it is best to use fog type nozzles.
49
-- -". . - -.
50
vertical steel bars are usually limited to 10-15 feet, depending on
diameter, to avoid the whipping action which could occur on windy days
if the rebar extended too far above the templdtes. 69 However, some
contractors use as a rule of thumb, limiting the length of vertical
rebar; to 1 floor plus lap length.
The vertical rebar splices should be staggered, not only for
structural considerations, but to spread the workload for the iron
workers.
With respect to the placement of horizontal reinforcement steel,
some contractors prefer to weave the horizontal rebar among the vertical
steel and jack rods, while other contractors using recently developed
high capacity, high clearance yokes are able to efficiently tie the
horizontal steel to the verticals thus maintaining better quality
control.
The vertical spacing of the horizontal steel should be designed
for maximum placement efficiency in the field. Camallerie 7 recommends
sizing the steel for 10-12 inch spacings, except where such a design
leads to bar diameters in excess of 1 inch. The lengths of the rebar
are usually limited to 20 feet, since steel bars any longer than that
amount would be difficult for the workers to handle. 71Pruitt 7
recommends that the horizontal steel be placed on the outside of the
vertical steel when the rebar is tied together. This would increase
51
in place of sandard hooks, since these hooks can be placed from the
side and rotated into position. Open ties must be used. Of course,
special care must be taken that the design and placement of reinforce-
ment steel does not interfere with weld plates, embedment and anchor
steel, and blockouts. Pruitt73 recommends the following general
guidelines with respect to reinforcement and embedment steel placement
during the slipforming of highrise building cores:
(a) Dowels out of the footing to be of staggered lengths
(b) Minimum dowel length of 4 feet plus lap length
(c) Rebar spacing should be consistent if possible. Rebar size
could be graduated.
(d) Minimum coverage of 1 inch for walls, 2 inches for columns
and pilasters
(e) Vertical splices should not be made on more than 1/3 of the
vertical steel at any one elevation
(f) Detail reinforcing required at weld plate locations
(g) Consider use of weld plates in place of pockets or blockouts
for beam connections. Oversize plates 3 inches and set to a
plumb tolerance of 1 inch per foot
(h) Break out dowels and slab dowels should be 40 KSI steel, and
inserts should be used in place of break out dowels when
feasible
(i) Weld plate thickness should be checked against rebar clearance.
52
Since the rebars are being continually engulfed by the rising
the workers to place one complete set of steel as shown on the detail
drawings. The inspector can then more easily check to insure that no
steel is missing.
There are several ways to check the vertical spacing of the
be permitted until the forms have passed by. Packets with anchors and
the use of inserts and blockouts. Blockouts are also necessary in order
53
~~~~~~~. .'
, ..... " " . - -" " " - " ."- ... . . . . . . - "-' - "
Concrete -wail Concrete wall
After sliding
formwork has
passedl, block
Prefabricated unit fixed to is removed and
steel reinforcement of walls steel reinforcement
Prefabricated uslit bent out to suit
isfixed into wall4
before sliding; m s Steel starters
reinforcing bars are
fixed to main bars
within the actual
concrete wall
~ I_____
l
-
54
WI
(b) It is more economical to have repetition of the same blockout
+ 1 inches.
+ I inch.
(e) Designers must note the minimum yoke spacing when considering
away from wall corners. This will also keep the blockout
away from the jack and yoke situated at the corner point.
blockout shape.
55
probably because most slipforming is performed by contractors on a
obtained from the ACI Committee Report on, Bins Wall Design and
feet of height.
can cause the formwork to loose its proper shape. In order to counter
shape by the horizontal members and bracing of the interior working decks.
The forms must be rigid, and strong, and should be checked for
level before lifting of the form begins. The level of each jack should
be monitored and whenever any jack gets to be more than 3/4 inch out of
the proper elevation, the jack should be adjusted.7 9 This can be done
to skip one lift increment. Marks may be cut into vertical rebar at
between the forms and ground level, with the tape measure being unwound
56
Several systems have been devised to check overall formwork level.
These include water leveling systems, vertical plumbs, and optical
plumb systems. With water leveling systems, there is usually a control
reservoir with plastic tubing leading to various jacking points.
Operators of water leveling systmes must, however, be careful not to
let air bubbles develop in the system, for these bubbles will cause
57
Using good techniques and proper formwt~ork control, tolerances
U within 12 inch in 400 ft. have been consistently achieved on building
cores.~8
However, to set such achievements as a standard is unrealistic.
Pruitt84 reccomends the following tolerance goals:
(a) Wall thickness tolerance, -1to +2 inch.
(b) Plan alignment along entire length, + 1 inch.
(c) Variation from plumb, + 2 inch in any story and + 1 inch
over the entire height.
()Variation in location and placement of embedded plates, +
2 inches (both in horizontal and vertical directions).
(e) Variation in alignment of embedded plates + . inch in 1
foot.
Mf Variation in size and location of sleeve, + 2 inches.
With regard to nuclear shield wall construction, the engineer is
faced with a different set of tolerance limits, and additional complicating
factors influencing the structural design and construction.
Because these walls are typically 2.5 -3 feet thick, they are
included in the category of mass concrete under some codes. However,
as leading engineers such as J.C. Ellison of Fegles-Power Corp. have
pointed out, even slipforming a wall 3 feet in diameter, really involves
placing 6-10 inch layers of concrete that will be exposed to the air
within 4 hours. Thus the concrete temperature standards for mass
concrete are really too low to apply to typical slipformed shield
walls.
* Shield walls involve high reinforcing steel concentrations involving
550 lb. or more of steel per cubic yard of concrete, and greater forces
o 58
acting on the formwork than in typical slipform wall construction.84
The need for wall placement precision is less stringent. Ellison 85
59
* * - , ,*
support. It should also be noted that with the increasing use of 22
ton jacks vice the traditional 3 ton setups, the typical jack spacing
is increasing from the former 7 feet to approximately 21 feet. This
460
Although the maximum slide rate can be designed and planned for before
aconstruction operations begin, a change in concrete temperature, or the
necessity to install blockouts or complicated rebar arrangements can
require a change in the slide rate. For these reasons, a supervisor
experienced in slipform operations must be present at all times to
ensure that the most rapid.slide rate feasible is being maintained.
- If the slide is too fast, the concrete will be too soft at the
feasible.
:I6
ia 61
1219 Assumptions made:-
1 Placing of concrete 15 mins after mixing
1118 2 Test cube A shows consistency at 3 hours
Test cube B shows consistency at 4 hours
1000 203 mm of freshly Test cube C shows consistency at 5 hours
E 914 Placed concrete 3 Formwork height 1066 mm
813
0 Formwork face
3:711
EC 71 A__ _ Concrete must not stiffen above this level
0 610
5086
4007
Level of
305 Istiffening at "
203 203 average speeds _ "
100..
0.00
25 51 76 102 127 152 178, 203 229- 254 280 305 356
330
- p.ed (mm/h)
62
With forms 4 ft. deep, the rate of slide will normally be 16 to 24
inches/hour.9 3 The average slip-forming rate for silo work is 10 to 15
inches per hour, and the average slip-forming rate for buildings is 15
to 20 inches per hour. Of course, on projects with numerous delays
* due to placing blockouts, inserts and rebar placement, the overall
63
V At the working deck level, distribution of the concrete can be
accomplished with wheelbarrows, monorail systems, crane, conveyors,
pump, buggies, or combinations of these methods.
Some contractors have placed concrete at two or more points on the
cranes. 98 It must be noted that when using concrete pumps, the pumping
rate must be high enough to prevent plugging, thus the use of a single
pump with a line split, can succeed where two separate pump lines may
not.
In the case cited above, the contractor credited the improved
concrete delivery system, as one of the reasons he was able to underbid
the competition by a huge margin, leaving 1 million dollars on the bidding
table on a 10.5 million dollar job.
In any event, the relative costs of delivery systems of the concrete
to the slipforms is a significant aspect of the overall economy of the
4construction operation.
64
40°F. Camallerie 99 recommends that the following special provisions
be considered when undertaking vertical slipform operations in cold
weather:
(a) Use of Type III cement with air entrainment.
curing period the forms will have moved 36 feet, thus necessitating
a protective enclosure 36 feet high to shield the green concrete and
maintain the required temperatures.
An enclosure 36 feet high attached to the forms, would complicate
efforts to keep the forms plumb, and could even jeopardize the sliding
operation. However, an enclosure 12 feet high would be manageable,
reasonably safe and far more economical. A 12 feet high enclosure
equates to a protection period of 24 hours, at the assumed slide rate
of 6 inches/hour. And, as alluded to earlier, a 24 hour protection
period is most feasible with high early strength concrete.
Canvas tarpaulins and polyethylene sheets, are probably the most
common materials associated with protective enclosures, although
Camallerie 100 prefers enclosures constructed of rigid panels of plywood,
masonite, or insulation board. Rigid panels hold the air in better
65
II .
since they don't flap in the wind. Hanging the enclosure in a series
Steam heat is preferred since a dry heat would tend to dry out the
within the forms. For these reasons, a slower slide rate and deeper
void space will be left over after the cement has hydrated. When the
water to cement ratio gets to 0.70 the voids start connecting. The
whereas the freezing point of the mixture in large pore spaces approaches
concrete feasible for use in the slip forms will be required in cold
66
I
emerges from the forms, and Type IlIA cement is used. The strength of
rate of hydration, the concrete would reach 300 psi at 7.2 hours. For
psi strength for the emerging concrete may be very conservative, since
the compressive stress at the base of the 555 ft. high Washington
Monument is only 300 psi. 109 The fact remains that slower slip rates
and additional heating costs are necessities of cold weather vertical
sl ipforming.
Once the forms have reached the top of the structure and the
jacking is complete, the weight of the forms is usually transferred
from the jacking rods to the finished wall. This is generally done by
sliding bolts through carefully placed holes in the walls just below
the wales. Once the weight is off the jacks, and jackrods, the formwork,
"! 67
The removal of the inside forms can be facilitated by leaving holes
jin planned positions in the roof slab to enable the hanging of a stripping
scaffold. 1i 1 The removal of the outside forms does not need to involve
-_ any special procedures.
The form stripping operations must be properly organized and
controlled in order to save labor costs, and ensure reuse of formwork
materials.
Although safety is of paramount importance throughout the
construction sequence, there is a greater opportunity for accidents
during formstripping operations, with relatively large amounts of
Both single wall and double wall vertical shaft linings can be
slipformed. In 1979, an Indiana contractor constructed the first under-
68
thick. The annular space was filled with a bituminous mixture. The
outer 1 foot thick wall was built with 10' jump forms descending the
shaft, while the bituminous mixture and the 2.3 feet thick inner wall
were slipformed from the bottom up. Figure 22 illustrates the formwork
Sand working platform setup. The concrete slump was 4-4.5 inches and
slide rates in excess of 24 inches/hour were attained.
I-.,
113
3.15.2 Dry Dock
The worlds largest dry 'dock (able to accommodate 1 million ton
114
3.15.3 Providing a Facing for Mass Concrete
A Japanese contractor used a single face slipforming system in
* •69
r
bearing system. The concrete was pumped alternately to 2 main distribution
hoppers on the slipform frame. Each hopper in turn distributed the
concrete to a pair of sub-hoppers, which in turn fed (again alternatively)
ten 8 inch diameter discharge hoses, in order to balance the distribution
of the concrete. The slipform rose in 1.6 inch increments at an
overall average rate of approximately 2 inches/hour.
4 70
KNYOAUUC JA§JE
CELLAR 2
FR'EEZE I
ELEMENTS
DoblWl ShaftE
Lining
BEARING
COL MN L#04 SIFOMFRM
ROLLER
*,g~ ~ ~a . .CONCRETE FR
Figure
~ ~ ~ ~ "--FRS
23CSpcalyCosrutdETEfrn
o
(Source:2 pal
ConstructineMtod Eguipent
d Juef 177o.r6
71
include lifting equipment, various accessories, and are usually con-
116
structed of steel.
72
CHAPTER FOUR
canal linings.
alone. 117 Slipform pavers are not to be confused with the side-form
side forms which contained the concrete and set the finished grade
for the pavement. In slipform paving, the forms move with the paving
Trailing forms attached to the paver give the concrete its final
shape with smooth vertical sides, and a smooth top surface. Figures
73
ii
~ a
74
slipform paver must be carefully controlled with a uniform consistency.
The slump employed is between 1 inch and 4 inches, with a 1-2 inch
75
a,--.-
With lesser project lengths, the full economic potential of
the paver is not realized, while longer projects start to incur
problems with concrete transportation cost and control.
However, the key ingredient to success in rmst slipform paving
projects is speed. Contractors have been able to lay over 15,900 feet
of 24 feet wide pavement in 20 hours. To maintain that pace
the availability and coordination of aggregate, batching capacity,
materials stockpiling, and materials delivery is critical. In
another record-setting project, over 16,390 cubic yards were placed
in 16 hours. (6,013 ft. of 17 to 21 inch thick pavement, 50 feet
wide) That is a rate of over 1024 cubic yards per hour. On such
large volume projects, a sufficiently large fleet of trucks is re-
quired to reduce the risk of halting the paver for lack of concrete.
Queuing theory equations can be used to help decide the appropriate
number of material haulers.
Aggregate stock piles and cement supplies need to be replenished
constantly, and aggregate moisture content and gradation need to be
monitored continually.
Even with proper planning and operational control, the contractor must
take all feasible steps to ensure the paver will not break down during
operations. Some contractors have on the job site a mechanical
engineer or other machinery repair expert in order to minimize downtime.
Operator carelessness can lead to costly errors, since there is
practically no room for profile error, and the expense of grinding
27
down bad sections can be prohibitive. 1
76
The slipform paver is usually followed by two gantry type pieces
curing compound. The finishers work the surface with large bullfloats.
the steel dowels used at the construction joints are usually pre-
assembled into dowel baskets and nailed to the earth base at pre-
determined joint locations. The slipform paver places and shapes the
concrete over the dowels. Between 6 and 30 hrs. after the paver has
concrete. 128
The spreader will receive the concrete from the trucks and spread the
spreader will pass over the dowels.) After the spreader has passed
concrete. The slipform paver, which follows about 50 feet behind the
spreader will then bring the concrete to final shape and grade. 12 9
When dowel ties are needed to tie the pavement slab to a subsequent,
inserted by hand into gang-drilled holes, a few hours after the paver
has passed.
Slipform paving machines are also used to pave ramps, curb, gutter,
77
techniques. If ramps are designed originally, so that the slipform
payers can be used, the owners can realize a significant economic
savings. The recommended ramp design features include:'3
(a) Uniform pavement width
(b) Minimize length of tapered section
(c) Construction of a sufficiently wide subbase to support
a 24 feet wide slipform paver, regardless of pavement width
(d) The elimination of reinforcing steel from ramp pavement
(e) Construction of a stabilized subbase that concrete delivery
trucks can use
(f) Greater range of tolerances than those required of mainline
pavements
(g) For ramps with curbs, a provision for attaching the curb
to the pavement at a later date, as an alternative method
to integral pavement and curb construction.
In addition to the numerous slipform payers that can produce curb
and gutter sections simultaneously with the main pavement surface,
there are at least six different slipform machine models available
in America that specialized in curb, gutter, and barrier wall
placement.13 1 These machines have operating speeds which vary from
25 to 60 feet/minute, and some can extrude barrier walls up to 65
inches high. 132 The general minimum radius that these curb and barrier
33
slipflormer payers will negotiate is approximately 7-15 feet.'1
Figures 26 and 27 illustrate typical slipform machines used for
constructing curbs and barriers. Since these machine involve
relatively small daily volumes of concrete, they are used in conjunction
78
~.611__ __ __IA.
~RED
42 L
.6 79
fiL
swell wave in the concrete just emerging from the trailing edge. 136
* Figure 28 illustrates the operation of a slipform screed.
Numerous sophisticated slipform pavers are available to line
canals and channels at a single pass. These full section canal lining
machines are used on canals with up to about 50 feet of total lining
width. Larger canals are lined in half sections, or the slopes and
bottom deck are constructed separately.
.-.
a80
- - -- -• -
Unvibroted Concrete
Steel Plate
For Weight-.
Vibrated
81
After the concrete passes through the trough, it is consolidated by a
vibrating tube parallel to and just a few inches in front of the
slipform. The trailing edge of the slipform is set at a position
lower than the leading edge which tends to further improve concrete
consolidation. 139 The concrete consistency must be even more carefully
monitored than that for conventional road pavement, with low slump
concrete being used. Another key consideration, is whether or not the
slipforms have enough weight to resist hydrostatic uplift.
82
The collapsible forms are left in place for 4-6 hours after the concrete
placement.
This machine has produced 120 inch diameter pipe with walls 12
inches thick at the rate of 30 feet/hour.
The R.A. Hansen Company has another type of cast-in-place machine
to slipform large diameter concrete pipe in place. This machine works
essentially the same as that described in the previous section, with
the concrete being produced between the upper slipform, the circular
inner form, and the trench walls. However this machine includes a
forward trench scraper, and a mobile truck ramp system for unloading
large bottom-dump trucks. A 16 meter long rubber-tired form transporter
recovers the inner forms for reuse several hours after the slipform
machine has passed. This system has been used to case nearly 700 feet
of 14.3 feet diameter pipe with an 8 inch wall thickness in only 8 hours.
That placement required the use of 700 feet of collapsible inner forms.
83
K. slipform which has a length equal to or greater than the width of the
invert.
84
H .
CHAPTER FIVE
the owner and contractor. However, slipforming is not always the most
general, the higher the building, the lower the unit form cost;
Normally a set of 4 foot high forms will last for 400 feet of slipforming,
85
example of the success afforded by slipforming is the $125 million
Executive Center Project in Honolulu, Hawaii. Project manager, Albert
but there are other times when a tight schedule must be met despite
the premium of overtime costs.
86
Tables 4 and 5 show the relative costs associated with different
u concrete casting systems. The tables show that with respect to the
as having a lesser cost factor, than any of the other 4 systems shown
with the single exception of precasting. Note, however, the significant
savings in construction time that slipforming gives when compared to
the other systems being analyzed. With todays interest rates, the
87
A erage Ihgh.Risc: lhlulding AIedium-Rife Bulding
Comparative
C'ost A Ic'rug" Ihgh Low A Itra'ge Ihg/h Low
borming Svysiem Factors Labor Ciost Labur Cost Labor Cost labor Cost Labor Cost Labor Cost
-'(oi nmIon ul
Slip and Gang Form .98 .94 1.12 .75 1.02 1.21 .82
Cunstruction
:='- Tolerance
Conlparative ConstructionT
Cost Concrete liime Plwnb. Wall
Placing Svsten Pactors Finish Joints Factor j .
SaJc tV t x i, 'k Spccial Features
1. \V lroteiot
:,at
Grade.
2 In,pection at
[retjja ' .94 A+ h1oriiUntal .50 A 12" -14", +12" Gliade.
SIgmnh ratedias J nto$' fv
IJrinish wilulj tie uule.; -+
Utiprir,, Jtvi wah tie hlw''s
as jollw$,
*,',vy rati'd WoI A Pnostil
i a ,rneandl por pltatforn
.t'o/id
.l'OlA lo.$
fy 11scaljuldting, - II
88
savings over the once conventional paving methods. 153 As stated earlier,
the optimal horizontal slipforming job would be a straight stretch of
multi-lane highway 1-10 miles in length. Some contractors, however,
set a minimum total cubic yardage before they will consider undertaking
a slipform paving project. Some contractors set a minimum volume as
high as 300,000 cubic yards while others will take jobs as small as
1500 cubic yards total volume or mile in length. 154
1 89
bq I
CHAPTER SIX
CONCLUS IONS/RECOMMENDATIONS
systems includes:1 58
(a) Accuracy
(g) Speed
structures
r
'90
i~b '90
(c) May require round-the-clock operations to maximize profit
(d) Employees must become trained in use of the equipment and
methods
problems
and supervised
(1) Workers needed on the job before and after the daily
slide operations
sl i pformi ng
tend to be costly.
in saving time, can save the owner and contractor significant sums
4 91
D-R124 923 CONCRETE CONSTRUCTION USING SLIPFORN TECNNIOUES(U) 2/2
FLORIDA UNIV GAINESVILLE B R CARTER NOV 92
UNCLASSIFIED F/G 13/3 N
IND
1111
UEUOFSADRS1
PtTOA
MIRCP R§LTO TS HR
7- -. .7
Since the forms are usually only 4 feet deep most slipforms can be
economically constructed and still achieve a relatively high factor
*Q 92
o _ . . . .- : - - . . . . . . . . . . -
. . - . • - , , - - - '- . . "
The larger slipforming machines can place more concrete than the
contractor can supply. It appears that the weak link in horizontal
slipforming is the delivery system design and control.
Slipforming requires the best of our resource management skills
m and equipment management techniques.
. I .o
* 93
REFERENCES
3. Ibid., p. 2.
4. Ibid., p. 3.
5. Batterham, op.cit., p. 9.
94
'. .
19. Camellerie, "Vertical Slipforming as a Construction Tool,"
p. 267.
20. Peurify, Op.cit., p. 282.
21. Hurd, Op.cit., p. 285.
22. Carnellerie, "Vertical Slipforming as a Construction Tool,"
p. 267.
23. Hurd, Op.cit., p. 285.
24. Henry, J.M., "Coments on Vertical Slipforming as a Construction
Tool," Concrete Construction, August, 1978 (Reprinted by Linden-
Alimak Inc., Bridgeport, Conn.), p. 1.
25. Ibid., p. 1.
7 26. Ibid., p. 1.
,-. K 95
I
96
67. Camellerie, "Slip-Form, Details and Techniques," p. 1138.
68. Camellerie, "Vertical Slipforning as a Construction Tool," p. 269.
69. Ibid., p. 269.
70. Ibid., p. 269.
71. Pruitt, Op.cit., p. 9.
72. Ibid., p. 9.
73. Ibid., p. 9.
74. Camallerie, "Vertical Slipforming as a Construction Tool," p. 270.
97
,
_,_____ .. " * i ,, "." *" .. ., , " "- , •- . J ' j......L.....J a: . -L- - - a'
91. Camellerie, "Vertical Slipforming as a Construction Tool," p. 269.
92. Ibid., p. 269.
93. Ibid., p. 263.
94. Henry, Op.cit., p. 1.
p 95. Ibid., p. 17.
96. Stein, J., and Donaldson, P.K., "Techniques and Formwork for
Continuous Vertical Construction," Concrete, January, 1967, p. 32.
97. Ibid., p. 32.
98. "Improved Techniques Aid Record Slipforming Pace on Nuclear
Containment," Engineering News Record, September 13, 1979, p. 29.
99. Camellerie, "Slipform Details and Techniques," p. 1138.
100. Ibid., p. 1139.
101. Ibid., p. 1139.
102. Ibid., p. 1139.
103. Philleo, Robert "Crom Lecture Series, University of Florida - 1982."
104. Ibid.
105. "Design and Control of Concrete Mixtures," Eleventh Ed., Portland
Cement Association, 1968, p. 78.
106. Ibid., p. 78.
107. Ibid., p. 65.
108. Ibid., p. 78.
109. Urguhart, L.C., "Civil Engineering Handbook," McGraw-Hill, New
York, 1962, p. 7-2.
110. Hurd, Op.ctt., p. 289.
111. Ibid., p. 289.
112. "Double Wall Shaft Linings Slipformed in Salt Dome," Engineering
News Record, 11 October, 1979, p. 29-30.
113. "Largest Dry Dock Rises in Persian Gulf," Engineering News Record,
*9 June, 1979, p. 18-19.
98
114. "Slipforming with a Straight Face Proves no Laughing Matter,"
Construction Methods and Equipment, June 1917, p. 46-47.
115. Hurd, Op.cit., p. 287.
116. Ibid., p. 286.
1(7; "Specs, Concrete Slipform Pavers," Construction Contracting,
January/February, 1982, p. 118.
118. Oglesby, C.H., and Hewes, L I "Highway Engineering," John Wiley
& Sons, New York, 1966, p. 681.
119. "Specs, Concrete Slipform Pavers," p. 118.
,... 99
I
4
1
10
100
I
APPENDIX A
DATA REFERENCE
p..
r.
'.4
.4
.4
1,.
....................................
1 Specs Concrete slipform pavers
Standard Engine Dimensions
700
.% %..,
o 'k° * 4
MI SF-2 C8 0 10-6
SF-5w C 24-0 20 Yes No 60 180 115,000 M Cal D-3406 375 29-3 40-1 10-2
Suburban C z110 18 yes No 60 180 12,000 H Cat 0331106 200 40 206 so
S.... 2020 C O 1 00 to0 Y. Y. 2t, 00 29.1,00 H C., 0-3208 142 2W-I 202 6
Glu40JI11 C 40 04 0 . 46 60 1110
ow16 1. G2D63 1.4 2.4 Its 62
I...
671410 c Y. 40 40 3f-IOU
2 1O 100 240 120
E
Customer 1|1
Choice
Customer 1
Cualuor
Cholie
I
1I80
260
"
56-
2-
2-
13-6
10-0
10-0
13-0
I
W ..,l - L 4u k;.V 21 N. 30 100 W4UU EI. Deer 4319 52 1.11 13 V
M,9°0 C 210 00 120 Y. V,. 12 70 30W EA4 Deere 6414 11 o 26-0 9-4
At1/60 C 10 6 69 v., V.. C3O 70 24.UUU L Deere 6414 113 s0 111 00
:- ,-.f. w t30
W130
8100 C b-0 6 59 Yes Yes P112 70 35,600 F/* Duere 6414 113 8 17-10 6-9
1.11.. 02 C IOU 0-6 10 Yn vS. 45 80 Mow film Lh, 4239 lb 166 1-I
Ii1 C 22
It Io 0 N. , I LI 1 . 0330 Ito
BIBLIOGRAPHY
-I
BIBLIOGRAPHY
102
-----------
"First Slipformed Ski-jump Towers Built," Highway & Heavy Construction,
.-, September 1978.
"In Slipforming, Less can be More," Engineering News Record, June 12,
1980.
Johnson, M.R., "Slipform Lining of the San Luis Canal," American Concrete
Institute Journal, October 1965, pp. 1313-1326.
"Largest Dry Dock Rises in Persian Gulf," Engineering News Record, June
9, 1979.
"Multi-Stage Form, Slips Massive Core for Dallas Tower," Engineering News
Record, February 11, 1982, pp. 26-27.
Oglesby, C.H., and Hewes, L.I., Highway Engineering, John Wiley & Sons,
New York, 1966.
103
. . * -
Philleo, R., "Crom Lecture Series,-University of Florida, 1982."
104
Urguhart, L.C., Civil Engineering Handbook, McGraw-Hill, New York,
1962.
105
. .o . . . . . . . .
/I p