Made-to-measure formwork for complex projects

06.11.2017 | Press
Doka offers special services, from the Ready-to-Use Service to On-site Pre-assembly

Round, angular, abstract, two- or three-dimensional – architects' drafts can be highly extravagant, so the need for custom formwork solutions and additional services increases all the time. The Doka Ready-to-Use Service manufactures the complex and individual formwork shapes that produce superior-quality concrete surfaces and ensure efficiency on the build. And specially trained Doka personnel assemble load-bearing towers and formwork units directly on site.

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The sharply rising proportion of modern architectural designs generates demand for custom formwork able to meet special requirements for engineering and the concrete finish. On particularly challenging builds, geometric complexity renders standard formwork systems only conditionally viable. Made-to-measure formwork, custom formwork in other words, built to specification for a given project, gives shape to any design idea. These ideas or architectures with unconventional geometries are becoming increasingly common in the context of construction projects in general and builds for public spaces in particular. Meeting high architectural requirements necessitates a whole chain of prior steps; professional project management is essential.

As an international formwork expert, Doka considers the construction process in its entirety and accompanies its clients through all the phases of a construction project – from planning through implementation to completion. So Doka supplies a precision-built formwork solution perfectly matched to the construction project. Formwork from simple through to complex designs is pre-assembled to specification in the Doka Ready-to-Use Service centres. Each project-specific creation is unique in size and shape. Consequently, every single unit poses new challenges for the planners and builders. Wood and wood-based materials are the most used. With the Formwork Pre-assembly service, Doka ensures the pre-assembly and disassembly of the formwork units by specially trained personnel, reducing working time on the jobsite.

The wide range of the Doka Ready-to-Use Service
For out-of-the-ordinary builds, the Doka Ready-to-Use Service supplies the jobsite with made-to-measure, pre-assembled formwork units. Every year, Doka Amstetten produces about 25,000 m² of custom formwork, and more than 45,000 hours of work go into assembly and disassembly. The assembly plans for the custom elements are drawn up by Doka technicians to meet the project's specific set of requirements. Standard components, special parts, client-supplied items and materials from timber suppliers and others are utilised in production of the formwork units. In addition to straight-line elements, circular formwork and conical elements are also produced. In this way, Doka can build even highly unusual custom solutions. Precision-built custom formwork enhances the surface quality of the finished concrete structures, saves space on the site and streamlines the construction workflow. Disassembly and professional disposal of non-reusable materials are also services available on request. And the customer has access to cutting-edge technologies and machinery and can put the know-how of the Doka specialists to good use.

Unique formwork moulds created with 3D planning
Right now, everyone is talking about digitisation, building information modelling (BIM), collaboration and Industry 4.0. The construction industry, with its complex planning and process flows, anticipates a significant increase in productivity from digitisation and Construction 4.0. The 3D planning of structures and structural members is an important contributor in this respect. Animations and photo-realistic images make complicated structures easier to understand and make project progress forecasts more transparent. 3D models have moved on from visualisation purposes alone. Already they form the basis for energy predictions and in future they will be used to calculate total cost of ownership of buildings and structures.

Some structures are so complex that formwork planning in 2D is no longer viable. This is when 3D formwork design comes into play. The basis of planning is a 3D model, generally made available by the customer. When this does not apply, the Doka engineers generate the 3D model from 2D plans of the structure. Depending on the necessities and the complexity of the structure, 3D formwork planning can extend to the tiniest detail of the entire formwork. On less complex builds only certain sections or views of the 3D model are visualised and then transposed to 2D for further elaboration of the plans. Even before planning gets under way, everything has to be arranged with the Ready-to-Use Service so that issues such as the alignment of the shaped timbers, the make-up of the form facing and the options for assembly can be finalised.

Formwork pre-assembly for efficiency on the jobsite
Working closely with the construction company, trained Doka specialists assemble special units and custom formwork directly on site. The work is meticulous, precise and on time. This is the Formwork Pre-assembly and Disassembly Service. The formwork is assembled and erected properly, and is ready for use on the agreed date. Doka offers an entire portfolio of formwork pre-assembly – set-up, modification and disassembly of load-bearing towers, supporting construction frames, climbing formwork and windshields, even composite forming carriages and cantilever forming travellers – plus reconditioning of custom formwork. When complicated formwork units are assembled and disassembled by skilled Doka specialists, this ensures high quality and optimises progress. A broad basis of empirical values from numerous formwork pre-assembly projects permits realistic assessments and avoids uncertainties and problems.

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