Design and Manufacture of Purpose Made Steel Formwork

Hydraulic Travelling Sea Wall Formwork

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KierBAM are working on a contract to build a very large Sea wall . They needed a set of formwork that can be quickly stripped and moved to the next pouring position between tides without the use of a crane.

Special Formwork developed the concept of casting the wall as a series of individual ‘buttresses’ with longer Infill pours.

Utilizing a travelling formwork system it virtually eliminated the use of cranes for setting moving and striking the forms – an important consideration for a very exposed coastal site.

Casting a series of ‘buttress’ blocks, with longer ‘Infill’ pours eliminated the need for any ‘single sided’ formwork to stop ends – which would have been time consuming and require a large number of anchors, tie rods and very expensive craneage given the large number of pours to be completed.

Special Heavy Duty anchors were built in to the kicker pours which virtually eliminated the need for long conventional through ties between landward and seaward faces – most of which would have been lost in the pour due to difficulty in extracting such long ties.

Shorter recoverable tie rods are used to connect the stop ends to each other.  The relatively small number of anchors per pour result in significantly less manpower being needed to strike and reset the forms – particularly during the tidal ‘window’.

The Formwork and traveller were manufactured and trial assembled and fully tested at our works saving valuable time on site. The formwork was shipped in large pre-assembled pieces in a series of wide loads again saving time on site and crane waiting time.

The Formwork and access is suspended from a traveller which is propelled using hydraulic motors and is mounted on wheels which travel on railway track. The formwork comprises of Four panels which can be opened hydraulically and raised so the whole assembly can travel to its next position without the need for disassembly.

The structure can quickly be adjusted by wireless remote control enabling operation from a safe position using hydraulic rams.  The legs can be raised and lowered independently, as pairs or all together. The Stop ends can individually lifted and the whole formwork can be moved crossways for alignment.

The main contractors are KierBAM JV.