SLIPFORM CONSTRUCTION

Mt Piper Power StationNSW

INTRODUCTION
Structural Systems has been a leading provider of slipform technology and value engineered solutions for the past 50 years in Australia with a wealth of engineering and contracting experience obtained through the successful completion of hundreds of structures. Founded in Victoria, Australia in 1961, the Company commenced trading as BBR Australia Pty Ltd. The first project the Company undertook was the supply and installation of rock anchors for the Snowy Mountains Scheme. Listed on the Australian Stock Exchange as Structural Systems Limited in 1987 and now almost fifty years on from the first project, the organisation has grown into a diverse international contractor with a wide range of services which it delivers to its clients with the highest levels of value, quality and timeliness. The Company's head office is located in South Melbourne, Victoria, and manages its operations within Australia from offices in Melbourne, Sydney, Brisbane, Perth, Kalgoorlie and Townsville. Internationally the Company has offices in Dubai, Qatar, Bahrain and has recently opened an office in Johannesburg, South Africa. Structural Systems provides a complete slipform service and maintains experienced teams of personnel available to assist in all aspects of construction including design, planning, programming and construction techniques relating to the slipforming and formwork methods. It is essential that our experienced slipforming personnel are included at the early planning stage to ensure maximum benefit of the slipforming process. Structural Systems can provide a variety of service packages to match the requirements of the client. This can range from design, fabrication and supply of all specialised formwork items, hydraulic jacking equipment and technical assistance to ensure correct erection and operation of the slipform system, to a full package including labour for erection, installation of blockouts and placement of concrete and reinforcement.

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ECONOMICAL SOLUTION
The slipform technique is a rapid and economical construction method that can achieve considerable cost savings when compared with the cost of conventional formwork. The slipform construction system becomes viable on regular shaped structures generally four storeys or greater in height, although multiple uses on shorter structures has been achieved economically in the past.

ADVANTAGES
The advantages of the slipform system include: Off site assembly Greater speed and earlier completion of construction projects Early completion of lift motor rooms and early installation of lifts, plumbing and electrical services Reduced craneage as forms are lifted by hydraulic jacks Reduced scaffolding and temporary work platforms as the slipform system contains its own platforms for working. This also results in a cleaner and less congested constructed site A uniformity of wall sections and layouts can be achieved with the slipform method this is not achievable with conventional formwork systems Reduced labour costs, as the system provides an intensive work environment

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SLIPFORMING PROCESS
The slipform system is a hydraulically operated formwork system. 3 tonne hydraulic jacks are mounted on strategically located steel yoking frames to lift the formwork as the concrete is poured into the forms. The formwork system uses 1066mm high steel panels held rigidly by a framework built up from steel waler frames, trusses and bracing. The framework provides rigidity to the slipform as well as support for timber decking to form a working platform for placement of concrete, reinforcement steel and blockouts for doors and windows. Concrete is poured into the forms in layers of approximately 200mm. The setting rates of concrete are constantly monitored to ensure that it is matched with the speed at which the forms are raised. The jacks lift the form approximately 25mm per stroke generally producing a slipforming rate of 300mm per hour. Slipforming can be performed on either a continuous basis (i.e. 24 hours per day), or a discontinuous basis (i.e. pouring to a predetermined height usually within one working day). As the formwork is raised, reinforcement is held in the correct position using guides fixed to the top of the yokes. Horizontal reinforcement is threaded under the yokes and tied to the vertical reinforcement. Blockouts for doors and windows can be formed with either timber or steel. These are installed as the slipform proceeds and can be stripped from the trailing decks. Similarly with rebates that are used to provide connections between beams, slabs and the slipform walls. When the formed concrete is exposed from the bottom of the steel form panels it can be sponged or treated if required.
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Structural Systems experienced engineering and operational personnel ensure the smooth operation of the slipforming process and control of verticality. Structural Systems technical staff are always available to advise on all aspects of slipforming including coordination of various trades to optimise resources. Typical section through slipform system for vertical structures

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TAPERED SLIPFORMING
Structural Systems is also heavily involved in the construction of conical chimneys, cooling towers, piers and other tall concrete structures involving constant or changing thicknesses in walls, diameters and/or shapes. Structural Systems has been involved in the construction of tapered towers and chimneys from 50m to 275m high with diameters and wall thicknesses changing from 25m to 6m and 700mm to 250mm respectively. While the slipforming process is similar to that used on the standard slipform equipment the logistics and planning require greater attention the heights which often make the use of cranes impractical. Structural Systems experience and expertise ensures the success of such projects. Typical section through slipform system for tapered structures

1. Upper distribution and working deck 2. Working deck 3. Hanging scaffold 4. Radius screw 5. Screw for adjusting wall thickness 6. Screw for adjusting inclination 7. Horizontal turnbuckles 8. Spider beam 9. Lifting yoke 10. 3 tonne hydraulic climbing jack 11. Jack rod 12. 6 tonne hydraulic climbing jack 13. Hydraulic jack pump 14. Hydraulic turnbuckle pump 15. 6 tonne climbing rod extractor 16. 3 tonne climbing rod extractor 17. High pressure hose 3/8 18. High pressure hose 1 19. Distribution pipe

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CONCLUSION
Structural Systems innovative engineering and strict quality control ensures the increasing demands within the building industry to come up with solutions for difficult construction problems are met at the highest level, ensuring an efficient cost effective solution. Structural Systems is committed to maintaining the highest level of service at all times and to meet the changing demands of the building and construction industry.

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Structural Systems (Civil) Pty Ltd

ABN 31 083 214 439 20 Hilly Street Mortlake, NSW Australia 2137 Tel: Fax: Web:
VICTORIA

+61 2 87676200 +61 2 87676299 www.structuralsystems.com.au

112 Munro Street, South Melbourne VIC 3205 Australia Tel: +61 3 9296 8100 Fax: +61 3 9646 7133 24 Hines Road, OConnor WA 6163 Australia Tel: +61 8 9267 5400 Fax: +61 8 9331 4511 Unit 2, 16 Maiella St, Stapylton QLD 4207 Australia Tel: +61 7 3442 3500 Fax: +61 7 3442 3555 Office 603, Business Avenue, Deira PO Box 28987, Dubai, United Arab Emirates Tel: +971 4 2948 974 Fax: +971 4 2948 984 Block B, 60 Civin Drive, Pellmeadow Office Park Bedfordview, Johannesburg 2008, South Africa Tel: +27 11 409 6700 Fax: +27 11 409 6789

WESTERN AUSTRALIA

QUEENSLAND

MIDDLE EAST

AFRICA