Investing in a high quality automatic climbing system can vastly improve construction processes and save cost, workforce and construction time says Keshab Chopra, Managing Director- India and SAARC countries, Doka.

Considering more and more buildings in India are destined to be sky rises, how can automatic climbing formwork (ACF) aid in faster construction of the high-rises?
The use of the appropriate climbing system such as climbing formwork or automatic climbing formwork has a huge impact on high-rise construction, including towers and skyscrapers. Investing in a high quality automatic climbing system can vastly improve construction processes and save cost, workforce and construction time — particularly in India where high-rises and other tall structures are increasingly dotting the skyline.

ACF is a combination of wall formwork and lifting machanism (or working platform) that can rise by itself from one pouring section to the next. It is an advanced framing system that utilises built-in hydraulics and simultaneously repositions spacious, high capacity working or climbing platforms without exposure to fall hazards or the elements such as high wind speeds, thereby eliminating the need for cranes.

Automatic climbing formwork speeds up highrise construction where there is a constant need for elevation. The crane-independent system provides a quick and efficient solution for every type of vertical concrete structure and at every step of the work flow. Some ACF systems have a highlifting capacity suitable for additional working platforms or live loads with a lifting capacity of 10 metric tonnes per climbing unit. The guided climbing formwork is connected to the structure at all times, even when it is being repositioned and climbing.

ACF units can aid faster construction of highrises for several other reasons. These include higher payloads during the elevation of platforms, easyto-operate hydraulic system and repositioning process, less physical effort and high safety in every phase of the work, and versatility and multifunctional features across building components.

Doka has been using climbing formwork on high-rise projects since 1977, a little over 40 years now, and ACF has been available since 1989. Whatever the requirements, Doka’s modular and hydraulic-drivenX climb 60, SKE50 plus SKE100 plus and Lubeca ACF range is ideal for different types of construction such as forming high-rise cores, industrial structures, bridge piers and pylons, and building facades. The all-round enclosure makes it safe for labourers to work at imposing heights. Multiple automatic climbers can be raised from one casting section to the next by a single hydraulic unit.

The efficiency and versatility of Doka automatic climbing formwork has been demonstrated at projects worldwide, including during the construction of the tallest tower, the Burj Khalifa in Dubai and in India for several reputed projects in high-rise and bridges like : Orchid Crown, Omkar Worli, Lodha World One, Lodha The Park, India Bulls Sky Forest, India Bulls Blu in Mumbai,  Supertech’s Spira Tower in Noida and Basoli Bridge and Bandra Worli Sea link respectively.

Especially for big projects, how can BIM aid in drafting of better scaffolding and formwork structures?
Building Information Modelling (BIM) is not new to the Indian construction industry. BIM models are powerful software tools used for automated formwork planning during construction. The technology boosts efficiency, speeds up the workflow and saves cost across the construction process, including scaffolding and formwork. BIM also plays a significant role in digitally optimising on site productivity as well as designing and mapping innovative solutions for every type of structure, no matter how high they rise into the sky.

Efficient formwork systems have a significant influence on the success of large construction projects. This requires correct and reliable formwork planning and optimal cycle planning. BIM software can be used to simulate situations and determine the optimal construction sequence even before the project begins. BIM provides detailed information during planning, visualisation and simulation of both scaffolding and formwork solutions.

The intelligent 3D model-based system makes large and complex projects easier to understand and at the same time, provides a more transparent progress report of the project. Depending on the complexity of the structure, BIM is used to generate the tiniest detail of the entire scaffolding and formwork. Errors and problems are spotted and removed before they can disrupt construction work.

Doka has its own BIM competence centre to ensure successful BIM implementation. The centre employs approximately 20 staff and 50 BIM designers worldwide, who are working in the fields of planning, visualisation and simulation of formwork solutions. Doka CAD for Revit represents the overall formwork planning process in BIM. It is an Autodesk Revit plug-in that allows native, automated formwork planning in BIM software. Doka CAD for Revit can be used to establish cycles that optimise safety, time and costs, as well as assembly and deployment plans for the formwork elements and including the bill of materials. Thus, BIM is adapted to first digitally model the structure, including scaffolding and formwork, from beginning to end before the actual start of construction.

What kind of assistance in assembly and operation do you offer to your clients?
Doka provides comprehensive support from the beginning of the construction process and all the way until the end of the high-rise project. We start with site mobilisation plan as well as formwork planning and training for the site engineers and labourers. We optimise the construction progress by offering professional consultancy services across products and processes. For example, we help our clients reduce their costs by designing innovative solutions. Doka’s global experts and technicians advise clients from very early on so that the projects are executed seamlessly and with high levels of efficiency.

Right from the project development stage, Doka offers the right formwork solutions with high-performing service packages tailored to suit each construction project, thus ensuring its success. We also provide a single-source supply — from products, services, and planning through to project management and logistics.

Our specially trained and experienced formwork Instructor plays a crucial role on project sites by providing supervision and training for our materials and supports construction moves ahead efficiently and safely. This includes the safe use of formwork systems as well as managing the various elements — cycle time, construction method, type of reinforcement, site equipment and concrete placement — that help develop ideal formwork solutions for projects. Doka also instructs site crews on the proper use of all its products and processes.

What is the scope of a rental model in the backdrop of the current economy?
At a time when the Indian economy and the construction industry are on a slow down, Doka’s rental service is a big help for clients who are looking to reduce capital expenditure and focus on completing their projects on time.

We offer several flexible commercial frameworks that help clients deal with the uncertain business environment. We help our clients manage the assets on site and elsewhere, thus ensuring flexibility and increasing efficiency; and we optimise the use of our formwork equipment during the construction process.

Doka’s international network of sales and logistics facilities, including high-capacity rental yards, ensures steady supply times. Our high quality standards lead to cost-effective construction work flows through qualitydriven formwork equipment. We strive to accommodate last-minute contract awards and abbreviated planning cycles. Our formwork units are tailor-made for extended life spans, safety, and time and cost saving.