Formwork for dummies

When it comes to buying formwork we can’t be too hasty. Construction Week has lined up industry professionals to give their advice on what to look for when purchasing these systems and the dangers buyers need to avoid.

Formwork - a term that describes the temporary or permanent moulds into which materials are poured to form structural elements of a building - sounds simple enough. Formwork makes up about 1.2% of the total costs of the entire structural work of a building; a minimal percentage, one might say. But, simple and insignificant as it may seem, formwork is not to be taken lightly.

Buy the right formwork system and the construction of a building could be a complete success. Buy the wrong formwork system and the building could literally tumble down. Devastating accidents have happened when forms were removed too soon before the building material was set.

Poor and under-designed formwork has also been known to bend or even break during the filling process because it had a minimal load capacity.

Just over a year ago, a bridge under construction on Dubai’s Sheikh Zayed Road collapsed, injuring five workers. In a statement, the RTA said that the accident was caused by the collapse of pillars and scaffolding supporting the bridge.

A similar accident occurred the previous year in Dubai Marina, killing seven workers.

The use of counterfeit products is one main reason why such accidents occur and therefore it is important to know the difference between a genuine product that will give your clients peace of mind and a faulty product, which could have
dangerous consequences.

According to Brand Owners Protection Group (BPG) chairman and regional intellectual property advisor for Nestlé Middle East Omar Shteiwi the Middle East is a target for counterfeiters due to the high number of importation and exportation that goes on in the region.

The BPG and the Intellectual Property Forum work towards protecting companies own brands and designs, which are often copied by counterfeiters, produced in China and brought to international parts of the world like the Middle East.

Last week, the BPG signed an agreement with China’s Quality Brands Protection Committee (QBPC) and the BPG and the International Intellectual Property Protection Forum (IIPPF) of Japan to fight for the protection of intellectual property rights.

“Both our companies are seeking full implementation of intellectual property protection laws and regulations in the region,” Shteiwi explained. QBPC was established nine years ago. We have only been in business since 2006, so we want to work together to share information with them.”

Shteiwi urged buyers and developers who come across a counterfeit product to complain straight away, and said that they need to be aware of the difference between counterfeit and non-counterfeit systems.

“There are lots of toll-free numbers within the law enforcement authorities out there; we have the Ministry of Economy, the Department of Economic Development; we have the police and customs who are all willing to help,” he said. “Using counterfeit products to construct a building would be a huge disaster.”

He explained that buyers need to look for difference in price: “If the product is more than 20% cheaper than other systems they [buyers] have looked, at they should question it,” he added. “They should buy from reputable companies and there will be no mistakes made.”

Whether a system is a counterfeit product or not it is always important to know how to spot the most reliable, safe, easy to use and a positive investment for the client. To guide buyers through this challenge, six formwork companies have given their advice on what to look for when buying and leasing formwork as well as some of the top products in the industry.

Doka
Doka has offered tailor-made services to its customers since its launch in 1958. The company identifies each customer’s and project’s needs to provide an appropriate solution. Major milestones in Doka’s history include work on the Burj Dubai, for which the company produced a self-climbing system, Xclimb 60, for the wing-walled structure core of the building.

Other projects include the Jaber Al Ahmed International Stadium in Kuwait and the company is currently working on the Capital Tower, dubbed the “leaning tower of Abu Dhabi.”

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Dokaflex floor system
Dokaflex is a hand-operated floor formwork system, which consists of few components making it easy and fast to set up. The props’ high load-bearing capacity is complemented by numbered holes for easier height adjustment plus special thread geometry, which makes it easier to release them even when under a high load. This reduces the user’s handling time.

Framax Xlife
Framax Xlife has been developed to meet the increasing demand for faster and cost-effective forming by including long-life plywood.  Due to the plastic coating of the Xlife sheet, the pre-designed Framax Xlife panels offer durability and a maximum number of re-use cycles. Applicable to different wall heights and cross-sections of columns, the panels can be erected quickly and can be re-used for new applications.

Regional presence
The Doka Group currently has 150 sales locations and logistics centres in more than 65 countries. In the Middle East, Doka’s subsidiaries are located in nine countries; the UAE (Dubai, Abu Dhabi, Sharjah, and Umm Al Quwain); Saudi Arabia (Jeddah, Riyadh and Dammam); Bahrain; Qatar; Kuwait; Oman; Jordan; Iran and Lebanon. Doka plans to upgrade its distribution network in 2009.

Last year’s growth
During 2008, the Doka Group’s revenues exceeded US $1 billion (AED3.6 billion).

Certification
ISO 9001 quality certificate.

Peri
Peri was founded in Germany in 1969 and is now one of the top 50 companies in the country. Peri formwork is available all over the world, either through regional offices or representatives that are based in the country. Peri Sales Engineers in the UAE cover all of the emirates.

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Peri GT24
Peri GT24 is a girder, which is used for slab and wall formwork solutions. The product can be used in systems such as Peri’s Multiflex, a slab formwork system used for any slab thickness, floor plan and height; and Vario GT24, a girder wall formwork system with adjustable element connections.

ACS climbing bracket
ACS is a bracket, which climbs smoothly and evenly on climbing rails using hydraulic pumps. It has a lifting power of 100 kilonewtons and raises the unit to the next pour without the need of an intermediate anchor.

Regional presence
In 1997, Peri was formed to expand its services of the representative office, which was established in Dubai in 1994. In 2006 a new branch was established in Abu Dhabi.

Last year’s growth
Peri made over US $1.39 billion (AED5.1 billion) in turnover.

Certification
Quality system ISO 9001:2000

Meva
Founded in 1970, Meva designs, manufactures and supplies formwork systems, as well as providing consultancy services to clients. Over the years, Meva has developed a formwork system that incorporates an all-plastic facing, which lasts as long as the frame, never needs to be replaced and survives an unlimited number of re-uses, where plywood could disintegrate.

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Mammut 350
Mammut 350 is a wall formwork system, which has been in the market since 1982.  It is ideal for civil engineering projects, as well as for industrial and engineering construction. The system can take 100KN per m² of concrete.

Regional presence
In 2006, Meva Formwork Systems and KHK  Scaffolding Systems formed a joint venture to establish offices in Dubai, UAE. Meva Formwork Systems is based in Haiterbach, Germany and has 40 other locations across Europe and North America.

MEP shoring system
The MEP shoring system can support slab formwork at all heights from underground carparks to high structures and is integrated with a safety latch and two prop options for normal and heavy duty loads in one system.

Last year’s growth
The MEVA Group recorded sales of just over US $181.9 milion (AED667.8 million) last year.

Certifications
Quality standard DIN EN ISO 9001.

German Formwork Technology
German Formwork Technology (GFT) was established just last year but is already a leader in supplying formwork and scaffolding systems. GFT provides customers with technical consultancy, operational support solutions and repair and maintenance solutions.

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H20 Wall and Column Formwork
With this system, wall and column elements are pre-assembled on site and are used for all types of shear, core and single sided walls.

GFT 20 Support Tower
This system incorporates galvanised steel frames. It is mainly used for high and heavy slabs, beams and bridges.

Regional presence
The head office for GFT is located in Dubai and the company also has a branch office in Abu Dhabi. GFT’s products are also available in Saudi Arabia and Qatar.

Last year’s growth
The company brought in US $4.5 million (AED16.5 million) in revenue last year and $300,000 in profit.

Certification
Several contactors have confirmed that they have successfully used German Formwork Technology systems on various job sites.

Ulma
Ulma is one of the top three developers, manufacturers and providers of formwork, shoring and scaffolding systems in the world. Founded in 1961, the company is headquarted in Spain and belongs to one of the biggest Spanish industrial groups – Mondragón Corporación Cooperativa.

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CC-4
CC-4 is a modular aluminium drop-head panel system used for large areas of flat deck slabs. It is a portable and light slab system that requires no crane. Early striking can be achieved with this product. Its main elements are made of aluminium, and it can be erected quickly as its stand-alone grid structure allows one team to set up the grid, while another teams puts the panels in place.

LGR
Launched in January 2008, LGR system is an engineer-profiled steel lightweight panel system especially designed for columns and extensively used in villa projects. LGR allows for an easy and fast erection because it is portable and its accessories are fixed to the panel, so there are no lost parts.

Its formwork surface includes long-lasting plastic (no plywood) and it can withstand pouring pressures of up to 80KN per m².

Regional presence
Ulma Formworks UAE has been in business since 2005 and from there it has served other countries like Jordan, Bahrain and Saudi Arabia. The company established an office in Abu Dhabi in 2008, and from this year Ulma is represented in Saudi Arabia through a joint venture with Attieh Steel. Ulma is also expanding its presence in Qatar through a well established contractor.

Certification
Ulma is ISO 9001 certified since 1994 and its entire factory welding processes are certified by SLV Mannheim Institute
in Germany.

Last year’s growth
Ulma's turnover in 2008 was over US $601.9 million (AED2.2 billion).

Ischebeck Titan
Founded in Germany in 1881, Ischebeck Titan has become a leading provider of formwork, and offer safety and ground engineering products. Ischebeck systems can be bought all over the world and are supported by local representatives who can provide advice on how each product can be suited to a particular project.

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Propping
Titan’s range of legs and props offers fast, effective support for formwork during in-situ and precast casting operations as well as for back-propping of recently cast slabs. Buyers can choose from Titan aluminium legs, push-pull props, steel props and aluminium props.

Noetop
Neotop is a large, high strength formwork system used for efficient casting of walls in a wide variety of situations. Thus, the system sustains concrete pressures up to 88 kilonewtons.

Regional presence
Ischebeck Titan currently operates from Ajman, UAE. However, the company is actively seeking partnership opportunities in other GCC locations.
 
Certification
The Ischebeck Titan system is Llyod’s registered and has been certified with the DIN EN ISO 9001:2000 quality management standard.

Last year’s growth
Ischebeck operates a financial year from July to June is in its final month of the year’s trading. It anticipates a growth of at least 30% on last year’s turnover.