CBLM Fabricating Formworks

COMPETENCY-BASED LEARNING MATERIAL

Sector:

CONSTRUCTION

Qualification Title:

CARPENTRY NC II

Unit of Competency:

FABRICATE FORMWORKS

Module Title:

FABRICATING FORMWORKS

Technical Education and Skills Development Authority Jacobo Z. Gonzales Memorial School of Arts and Trades San Antonio, Biñan City

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 1 of 33

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL Welcome to the module in fabricating form works. This module contains training materials and activities for you to complete. You are required to go through a series of learning activities in order to complete each learning outcome of the module. In each learning outcome are Information Sheets, Self-Checks, Operation Sheets and Job Sheets. Follow these activities on your own. If you have questions, don't hesitate to ask your facilitator for assistance. The goal of this course is the development of practical skills. To gain these skills, you must learn basic concepts and terminology. For the most part, you'll get this information from the Information Sheets and multimedia materials This module was prepared to help you achieve the required competency, in "Fabricating Form works". This will be the source of information for you to acquire knowledge and skills in this particular competency independently and at your own pace, with minimum supervision or help from your instructor. Remember to: Work through all the information and complete the activities in each section. Read information sheets and complete the self-check. Suggested references are included to supplement the materials provided in this module. Most probably your trainer will also be your supervisor or manager. He/she is there to support you and show you the correct way to do things. You will be given plenty of opportunity to ask questions and practice on the job. Make sure you practice your new skills during regular work shifts. This way you will improve both your speed and memory and also your confidence. Use the Self-checks, Operation Sheets or Job Sheets at the end of each section to test your own progress. When you feel confident that you have had sufficient practice, ask your Trainer to evaluate you. The results of your assessment will be recorded in your Progress Chart and Accomplishment Chart.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 2 of 33

UNIT OF COMPETENCY

:

FABRICATE FORMWORKS

MODULE TITLE

:

FABRICATING FORM WORKS

MODULE DESCRIPTOR

:

This module covers the knowledge, skills and attitude in selecting and preparing materials, tools and equipment for fabricating form works, layingout, cutting to dimensions of form sheating and stiffeners and assembling form panels.

NOMINAL DURATION

:

40 hrs.

CERTIFICATE LEVEL

:

NATIONAL CERTIFICATE LEVEL II

PREREQUISITE

:

SUMMARY OF LEARNING OUTCOMES: Upon completion of this module, the trainee/student must be able to: LO 1. Prepare materials, tools and equipment for fabricating form works according to job requirements LO 2. Lay-out and cut to dimension of form sheating and stiffeners LO 3. Assemble form panels

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 3 of 33

ASSESSMENT CRITERIA: 1.

Plans and details are correctly interpreted and identified according to job requirements

2.

Materials, tools and equipment are identified consistent with job requirements

3.

Materials and tools are properly stored and freed from defects.

4.

Appropriate PPE are selected according to job requirements.

5.

Form sheating and stiffeners are measured and marked according to job specifications

6.

Form sheating and stiffeners are laid out and cut with tolerances of ±3 mm for all measurements and squareness

7.

Appropriate PPE is used according to job requirements

8.

Form panels and stiffeners are laid-out for pre-assembly

9.

Form panels and stiffeners are pre-assembled

10.

Form panels and stiffeners are checked for squareness according to job requirements

11.

Form panels and stiffeners are assembled

12.

Appropriate PPE is used according to job requirements and safety regulations

13.

Unexpected situations are responded to in line with company rules and regulations

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 4 of 33

LEARNING OUTCOME NO. 1

Prepare materials, tools and equipment for fabricating formworks

CONTENTS: • Tools, materials and equipment for fabricating formworks • Materials estimates • Mechanical properties of lumber • Economic use of materials ASSESSMENT CRITERIA 1. Plans and details are correctly interpreted and identified according to job requirements 2. Materials, tools and equipment are identified consistent with job requirements 3. Materials and tools are properly stored and freed from defects. 4. Appropriate PPE are selected according to job requirements. CONDITIONS: You must be provided with the following: 1. WORKPLACE LOCATION 2. TOOLS AND EQUIPMENT • Claw Hammer • Pencil/Marking pen • Pull-Push Rule • Nylon String • Steel Square • Try-square • Hand Saw • Chalk Line 3. TRAINING MATERIALS Leaning Packages Bond paper Ball pens ASSESSMENT METHOD

• • • • • •

Personal Protective Equipment Portable Circular Saw Plan and working drawings Lumber Nails Plywood

Manuals Related References

Portfolio

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 5 of 33

Learning Experience PREPARE MATERIALS, TOOLS AND EQUIPMENT FOR FABRICATING FORM WORKS Learning Activities

Special Instructions

Read Information Sheet No. 2.1-1 on Tools , materials and equipment for fabricating formworks Compare your answer to the answer key

Answer Self-Check No. 2.1-1 Read Information Sheet No. 2.1-2 on Material for fabricating formworks

Compare your answer to the answer key

Answer Self-Check No. 2.1-2 Read Information Sheet No. 2.1-3 on Mechanical properties of lumber Read Information Sheet No. 2.1-4 on Economic use of materials Answer Self-Check No. 2.1-4

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Compare your answer to the answer key

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 6 of 33

INFORMATION SHEET NO. 2.1-1 TOOLS, MATERIALS AND EQUIPMENT FOR FABRICATING FORMWORKS Refer to module on Stake-out Building Lines, Information Sheet No. 1.1-4 on Tools, Materials and Equipment in Staking-out Building Lines

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 7 of 33

INFORMATION SHEET NO. 2.1-2 MATERIALS FOR FABRICATING FORMWORKS LEARNING OBJECTIVE: Upon completing this section, you should be able to KNOW the DIFFERENT MATERIALS for FABRICATING FORMWORKS and FORMWORK DETAILS. A. Materials used for Formwork Materials used for the construction of concrete formwork range from traditional materials such as wood, steel, aluminum, and plywood to nontraditional materials such as fiberglass. Wood products are the most widely used material for formwork. 1. Timber and Plywood Timber and plywood are the material used most for formwork because it is high in quantity whereby the material is easy to get. Besides that , timber and plywood can be handled better because it is easy to cut it and fix as a formwork. This includes the easy handling of it .

2. Metal Panel Metal formwork has a very high reuse potential. So it is more economical than timber where repetitive work is necessary.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 8 of 33

3. Plastic (FRP) Another material used here is the fiberglassreinforced plastic as a formwork. Its functions well because : • Moldability • Light weight • Strength • Toughness

B. Construction of Forms consist of: 1. Plywood - It is made in thicknesses of 1/4, 3/8, 1/2, 5/8, and 3/4 inch, and in widths up to 48 inches. The 8-foot lengths are most commonly used. The 6/8- and 3/4-inch thicknesses are most economical. 2. Supporters or studs - Vertical studs make the sheathing rigid. These studs are generally made from 2 x 4 lumber. Studs also require reinforcing when they extend more than 4 feet. 3. Braces - Braces give the forms stability. The most common brace uses a horizontal member and a diagonal member nailed to a stake and to the stud or wale. The diagonal member of the brace should make a 30° angle with the horizontal member. 4. Spacer - Spreaders must be placed near each tie wire. Spreaders are cut to the same length as the thickness of the wall and placed between the two sheathing surfaces of the forms. 5. Tie Wire - Tie wires hold the forms secure against the lateral pressures of unhardened concrete. Double strands are always used. Ties keep wall forms together as the concrete is positioned. The tie wire is made taut by twisting it with a smooth metal rod or a spike. 6. Assorted CWN - refers to the different size of nail ranging from 1”-4” (25 mm100 mm) in length. C. Formwork detail for different structural members In concrete construction formwork is commonly provided for the following structural members:

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 9 of 33

1. Formwork for sloping side column It consists of • Side Supports • Side Planks • Cleats

2. Wall foundations It consists of: • Plywood Sheeting • Struts

3. Formwork for Wall It consists of: • Timber sheeting • Vertical posts • Horizontal members • Rackers • Stakes • Wedges After completing one side of formwork reinforcement is provided at the place then the second side formwork is provided. 4. Formwork for Column It consists of the following: • Side & End Planks • Yoke • Nut & Bolts Two end & two side planks are joined by the yokes and bolts.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 10 of 33

5. Formwork for Slabs & beams It consists of: • Sole plates • Wedges • Props • Head tree • Planks • Batten • Ledgers - Beam formwork rests on head tree - Slab form work rests on battens and joists - If prop height are more than 8’ provide

horizontal braces 6. Formwork for Stairs It consists of: • Vertical & inclined posts • Inclined members • Wooden Planks or sheeting • Stringer • Riser Planks

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 11 of 33

SELF- CHECK NO. 2.1-2 Check your mastery in materials in fabricating forms by completing the tasks below. MULTIPLE CHOICE: Read the statement carefully. Choose the letter of the correct answer. Write the letter of your choice on the space provided. ________1. These materials are used for most formwork because it is high in quantity whereby the material is easy to get. a. Earth b. Metal Panel c. Timber and plywood d. Plastic ________2. These material is more economical than timber where repetitive work is necessary a. Earth b. Metal Panel c. Timber and plywood d. Plastic ________3. lumber. a. b. c. d.

These make the sheathing rigid and are generally made from 2 x 4 Braces Spacer Supporters Tie wire

________4. a. b. c. d.

It gives the forms stability. Braces Spacer Supporters Tie wire

________5. a. b. c. d.

Which of the following is not a member of formworks for column? Rackers Side & End Planks Yoke Nut & Bolts

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 12 of 33

ANSWER KEY 2.1-2 Check your answer with the answer key below. If you fail to get it right, refer back to corresponding resources until you make it perfect. 1. 2. 3. 4. 5.

JZGMSAT QA SYSTEM

C B C A A

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 13 of 33

INFORMATION SHEET NO. 2.1-3 MECHANICAL PROPERTIES OF LUMBER LEARNING OBJECTIVE: Upon completing this section, you should be able to KNOW the MECHANICAL PROPERTIES of LUMBER. Basic understanding of mechanical properties of lumber is necessary for concrete formwork design. Wood is different from any other structural material in that allowable stresses of wood are different according to the orientation of the wood. A. Bending Stresses The figure below shows a simply supported wood beam with a concentrated load applied at the midpoint. This process results in bending. The lumber is stressed internally to resist the external loads. Bending in a member causes tension forces in the extreme fibers along the face farthest from the load and causes compression in the fiber along the side closest to the applied load. The maximum stress induced in the fibers, which occurs at the edges, is referred to as the ‘‘extreme fiber stress in bending.’’ This stress is highly dependent on the parallel-to-grain strength of the wood in both tension and compression. B. Modulus of Elasticity (MOE) Modulus of elasticity is a measure of stiffness. This factor (MOE) is a relationship between the amount of deflection in the member and the value of load applied that causes the deflection. The amount of deflection depends on the size of the member, the span between the supports, the load, and the particular member specie of wood. The parallel-to-grain MOE (i.e., the stiffness when wood is pushed or pulled parallel to the wood grain) is about 30 times greater than the perpendicular-tograin MOE.

Bending stress

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 14 of 33

C. Tensile and Compressive Strengths Tensile strength is a measure of the ability of wood to resist pulling forces. On the other hand, compressive strength is a measure of the ability of wood to resist pushing forces. For clear wood (wood without defects), the tensile and compressive strengths for parallel-to-grain loads are approximately 10 times greater than for loads applied perpendicular to the wood grain.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 15 of 33

INFORMATION SHEET NO. 2.1-4 ECONOMIC USE OF MATERIALS LEARNING OBJECTIVE: Upon completing this section, you should be able to KNOW the ECONOMICS USE of MATERIALS Formwork is the largest cost component for a typical multistory reinforced concrete building. Formwork cost accounts for 40 to 60 percent of the cost of the concrete frame and for approximately 10 percent of the total building cost. Timber is an economical material of formworks construction but it has a short life span. As the reusability of timber formwork is low and it can only be reused 8-15 times, several sets of timber formworks are needed for a high-rise building or a large project. Hence, the cost of the formwork is high in long run. Steel formworks might have the high cost at the beginning of the construction but as steel formwork has a long lifespan and high reusability; it can save the cost in long run. This is because less replacement of old formwork is needed. It can save concrete volume needed because it can form a long span comparing to timber formwork. A. Tips for avoiding waste construction materials 1. Study carefully the plan and detailed drawing. 2. From the given detailed drawing, you can study its different parts, including sizes of these parts 3. Cutting lumbers, always refer to the schedule of cutting 4. Always determine the methods of measurement used in the plan for marking 5. Always remember the principles for cutting “measure twice and cut once” 6. In cutting lumber and plywoods, always use effective tools.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 16 of 33

SELF- CHECK NO. 2.1-4 Check your mastery in the economic use of materials by completing the tasks below. ENUMERATION: 1. Explain the differences of using timber formworks from steel formworks (7 points). 2. Enumerate at least three (3) in avoiding waste on construction materials used in fabricating formworks.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 17 of 33

ANSWER KEY 2.1-4 Check your answer with the answer key below. If you fail to get it right, refer back to corresponding resources until you make it perfect. 1. Timber is more economical material in formwork construction but it has a shorter life span and it can be reused 8-15 times only while steel formworks might have the high cost at the beginning of the construction but as steel formwork has a long lifespan and high reusability in long run because less replacement of old formwork is needed. It can save concrete volume needed because it can form a long span comparing to timber formwork. 2. Answers are any of the following • Study carefully the plan and detailed drawing • From the given detailed drawing, you can study its different parts, including sizes of these parts • Cutting lumbers, always refer to the schedule of cutting • Always determine the methods of measurement used in the plan for marking • Always remember the principles for cutting “measure twice and cut once” • In cutting lumber and plywoods, always use effective tools.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 18 of 33

LEARNING OUTCOME NO. 2

Lay-out and cut to dimension of form sheating and stiffeners

CONTENTS: • Form design • Prefabrication of formwork panels ASSESSMENT CRITERIA 1. Form sheating and stiffeners are measured and marked according to job specifications 2. Form sheating and stiffeners are laid out and cut with tolerances of + 3 mm for all measurements and squareness 3. Appropriate PPE is used according to job requirements CONDITIONS: You must be provided with the following: 1. WORKPLACE LOCATION 2. TOOLS AND EQUIPMENT • Claw Hammer • Pencil/Marking pen • Pull-Push Rule • Nylon String • Steel Square • Try-square • Hand Saw • Chalk Line 3. TRAINING MATERIALS Leaning Packages Bond paper Ball pens

• • • • • •

Personal Protective Equipment Portable Circular Saw Plan and working drawings Lumber Nails Plywood

Manuals Related References

ASSESSMENT METHOD Portfolio Demonstration

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 19 of 33

Learning Experience LAY-OUT AND CUT TO DIMENSION OF FORM SHEATING AND STIFFENERS Learning Activities

Special Instructions

Read Information Sheet No. 2.2-1 on Form design Compare your answer to the answer key

Answer Self-Check No. 2.2-1 Read Information Sheet No. 2.2-2 on Prefabrication of formwork panels Perform Operation Sheet No. 2.2-2 on Prefabricate Form Panels and Stiffeners

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Evaluate your own work using the Performance Criteria Checklist Present your work to your trainer for evaluation Keep a copy of your work for the next activities

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 20 of 33

INFORMATION SHEET NO. 2.2-1 FORM DESIGN LEARNING OBJECTIVE: Upon completing this section, you should be able to KNOW the IMPORTANCE OF FORMWORKS, FACTORS INFLUENCING FORM DESIGN and FORM CHARACTERISTICS. Form is a temporary boarding, sheating or pan used to produce the desired shape and size of concrete. The structural members of a building are built-up into its desired shape and dimension through the use of forms which serve as mold for the mixed concrete. Concrete mixture is generally semi-fluid that reproduces the shape of anything into which it is poured. Concrete form should be water tight, strong enough and rigid to sustain the weight of the concrete. It should be simple and economically designed in such manner that they are easily removed and reassembled without damaged to themselves or to the concrete. A. Form Design 1. Importance of Formwork • Protects the concrete • Aids in the curing of the concrete • Supports any reinforcing bars or conduit embedded within it • Represents up to one-third of a concrete structure's total cost 2. Factors influencing form design • Nature of the structure • Availability of equipment and form materials • Anticipated reuse of the forms • Familiarity with construction methods that influence the formwork design • Strength of the forming materials and the loads they must support • Concrete's final shape, dimensions, and surface finish B. Form Characteristics 1. Ensure that the forms are tight, rigid, and strong. Loose forms permit loss of cement which can result in-• Honeycombing. Honeycombing is when the concrete is not satisfactorily consolidated or vibrated air pockets form within the concrete and present a pocked appearance. JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 21 of 33

• 2. 3. 4. 5.

Sand streaking. Sand streaking occurs when concrete loses too much water due to loose forms; the water carries sand with it through the gaps in the formwork and causes streaking. Ensure that the forms are braced enough to align them and strong enough to hold the concrete. Take special care in bracing and tying down forms used for configurations, such as retaining walls. Ensure that the forms are wide at the bottom and taper toward the top. Ensure that wall forms are braced properly. The concrete in wall forms, such as the first pour, tends to lift the form above its proper elevation. Reuse forms by constructing them in a manner that allows easy removal and replacement with minimal damage.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 22 of 33

SELF- CHECK NO. 2.2-1 Check your mastery in form designs by completing the tasks below. ENUMERATION: 1. What are the importance of formworks? Give at least 2 a. ___________________________ b. ___________________________ 2. What are the factors influencing form designs? Enumerate at least 3 a. ___________________________ b. ___________________________ c. ___________________________ 3. What are the 2 results of loose forms? a. ___________________________ b. ___________________________

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 23 of 33

ANSWER KEY 2.2-1 Check your answer with the answer key below. If you fail to get it right, refer back to corresponding resources until you make it perfect. 1. Importance of formworks are (any of the following answers): a. Protects the concrete b. Aids in the curing of the concrete c. Supports any reinforcing bars or conduit embedded within it d. Represents up to one-third of a concrete structure's total cost 2. Factors influencing form design are (any of the following answers): a. Nature of the structure b. Availability of equipment and form materials c. Anticipated reuse of the forms d. Familiarity with construction methods e. Strength of the forming materials and the loads they must support f. Concrete's final shape, dimensions, and surface finish 3. Loose forms results in: a. honey combing b. sand streaking

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 24 of 33

INFORMATION SHEET NO. 2.2-2 PREFABRICATION OF FORMWORK PANELS LEARNING OBJECTIVE: Upon completing this section, you should be able to KNOW the DIFFERENT HAND TOOLS and MACHINE USED and the PROCEDURES in PREFABRICATING FORMWORK PANELS. Prefabricated formwork panels are indispensable for beam and column formworks. Prefabricated formwork panels, however, are also recommended for series production of foundation and ceiling formworks. In that case the construction of the panels differs from that of panels for beam and column formworks but the technology of prefabrication is the same. A. Hand tools and machines • Circular saw • hand saw • hammer • wrecking bar

• • •

folding rule try square measuring rods

B. Procedure 1. Prepare the work. Make available the tools and materials. A work table is to be manufactured 2. Enter all sizes required from the working drawing. Derive the sizes from the dimensions of the column for which the formwork is to be made. Prepare the size distribution of the stiffeners in particular. 3. Cut up the boards. Locate the sizes of the forms to the plywood at both ends then using your chalk line, mark the boundaries to be cut.. Do not place the rough edge of the board to the inside of the formwork. Always consider the economy use of materials. Note: If you use circular saw for cutting plywood ask the Permission of your teacher 4. Cut the stiffeners straps to length. Use 2”X 2” lumber for the stiffener. Butt joint is commonly used in this construction. Adopt the schedule for cutting. 5. After cutting, arrange and classify cut members ready for assembling.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 25 of 33

OPERATION SHEET NO. 2.2-2 Title:

Prefabricate Form Panels and Stiffeners

Performance Objective:

Given the necessary materials, you should be able to pre-fabricate form panels and stiffeners

Supplies and Materials:

Working Drawing/ Plan Lumber, plywood, fasteners

Tools and Equipment:

• • • •

circular saw hand saw hammer wrecking bar

• • •

folding rule try square measuring rods

Steps/Procedure: 1. 2. 3. 4.

Prepare the work. Enter all sizes required from the working drawing shown below. Cut up the boards. Cut the stiffeners straps to length. Use 2”X 2” lumber for the stiffener. Butt joint is commonly used in this construction. Adopt the schedule for cutting. Note: If you use circular saw for cutting plywood ask the permission of your teacher 5. After cutting, arrange and classify cut members ready for assembling.

Assessment Method: Portfolio Demonstration

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 26 of 33

PERFORMANCE CRITERIA CHECKLIST OPERATION SHEET NO. 2.2-2 Name of Trainee:______________________________ Date: __________________

CRITERIA

YES

NO

1. Did I measure and mark form sheating/board according to plan? 2. Did I measure and mark form stiffeners according to plan? 3. Did I use appropriate personal protective equipment in cutting formwork materials?

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 27 of 33

LEARNING OUTCOME NO. 3

Assemble form panels

CONTENTS: • Assembling form panels and stiffeners ASSESSMENT CRITERIA 1. Form panels and stiffeners are laid-out for pre-assembly 2. Form panels and stiffeners are pre-assembled 3. Form panels and stiffeners are checked for squareness according to job requirements 4. Form panels and stiffeners are assembled 5. Appropriate PPE is used according to job requirements and safety regulations 6. Unexpected situations are responded to in line with company rules and regulations CONDITIONS: You must be provided with the following: 1. WORKPLACE LOCATION 2. TOOLS AND EQUIPMENT • Claw Hammer • Pencil/Marking pen • Pull-Push Rule • Nylon String • Steel Square • Try-square • Hand Saw • Chalk Line 3. TRAINING MATERIALS Leaning Packages Bond paper Ball pens ASSESSMENT METHOD

• • • • • •

Personal Protective Equipment Portable Circular Saw Plan and working drawings Lumber Nails Plywood

Manuals Related References

Portfolio

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 28 of 33

Learning Experience ASSEMBLE FORM PANELS Learning Activities

Special Instructions

Read Information Sheet No. 2.3-1 on Assembling form panels and stiffeners

Perform Operation Sheet No. 2.3-1 on Assembling form panels and stiffeners

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Evaluate your own work using the Performance Criteria Present your work to your trainer for evaluation Keep a copy of your work for the next activities

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 29 of 33

INFORMATION SHEET NO. 2.3-1 ASSEMBLING FORM PANELS AND STIFFENERS LEARNING OBJECTIVE: Upon completing this section, you should be able to PERFORM the PROCEDURES in ASSEMBLING FORM PANELS AND STIFFENERS. A. Procedure in Assembling Form Panels and Stiffener using Plywood and Lumber 1. Prepare all the materials and tools needed. 2. Position materials such as form sheating and stiffener correctly. The stiffener should be consistent with standard spacing for studs or nailer with tolerance of + 10 mm. O.C. 3. Assemble form panels. Check for squareness, levelness and alignment to specified tolerance. Make sure that the smooth side of the board is placed outside the frame 4. Nail the form sheating to the stiffener using as many nails as necessary to make the panel stable in itself. Fasten first the two sides of the form sheating with the stiffeners making sure it is flushed to its edges. Then fasten the ribs for strength at 50 cm. apart. Drive 3” CWN to fasten it. Note: Always check for squareness. 5. Clinch the nail tips. Turn over the panel and clinch the penetrated nail tips. 6. Check form panels in compliance with job requirement. 7. Label the finished form accordingly as specified in the working drawing.

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 30 of 33

B. Procedure in Assembling Form Panels using Forming Boards 1. Prepare the work. Make available the tools and materials. A work table is to be manufactured 2. Enter all sizes required into the working drawing. Derive the sizes from the dimensions of the beam for which the formwork is to be made. Prepare the size distribution of the cover straps in particular. 3. Cut up the boards. The board width should not exceeded 140 mm. Do not place the rough edge of the board to the inside of the formwork 4. Cut the stiffening cover straps to length. Cover straps to have a width of approx. 55 mm with 25 mm projection for comer joints! 5. Put the cover straps on the arranged boards according to the size distribution made. Use measuring rod, if necessary! 6. Nail the cover straps on the board−panel. It is provisional nailing with short nails (40 mm). Use as many nails as necessary to make the panel stable in itself. 7. Nail the cover straps on the boards from the opposite side. Turn over the provisionally nailed board−panel and nail it with 70 mm long nails. Two nails per board are to be diagonally arranged at the cover strap joint! 8. Clinch the nail tips. Turn over the panel again and clinch the penetrated nail tips!

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 31 of 33

OPERATION SHEET NO. 2.3-1 Title:

Assemble Form Panels and Stiffeners

Performance Objective:

Given the necessary materials, you should be able to assemble form panels and stiffeners

Supplies and Materials:

Working Drawing/ Plan Lumber, plywood, fasteners

Tools and Equipment:

• • •

Hammer Marking Tools Measuring Tools

• • •

Steel Square Try-square PPE

Steps/Procedure: 1. Prepare all the materials and tools needed. 2. Position materials such as form sheating and stiffener correctly. The stiffener should be consistent with standard spacing for studs or nailer with tolerance of + 10 mm. O.C. 3. Assemble form panels. Check for squareness and alignment to specified tolerance. Make sure that the smooth side of the board is placed outside the frame. 4. Nail the form sheating to the stiffener using as many nails as necessary to make the panel stable in itself. Fasten first the two sides of the form sheating with the stiffeners making sure it is flushed to its edges. Then fasten the ribs for strength at 50 cm. apart. Drive 3” CWN to fasten it. Note: Always check for squareness. 5. Clinch the nail tips. Turn over the panel and clinch the penetrated nail tips. 6. Check form panels in compliance with job requirement. 7. Label the finished form accordingly as specified in the working drawing. Assessment Method: Portfolio Demonstration

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 32 of 33

PERFORMANCE CRITERIA CHECKLIST OPERATION SHEET NO. 2.3-1 Name of Trainee:______________________________ Date: __________________

CRITERIA

YES

NO

1. Did I lay-out the panels and stiffeners properly before pre-assembly? 2. Did I check the measurements of the members of the form panels prior to assembly? 3. Are the form panels and stiffeners assembled according plans? •

squareness of forms?

•

smooth side of the board is placed outside the frame?

•

stiffeners are flushed to the edges of panels?

•

ribs are spaced at 50 cm on center?

4. Did I responded to unexpected situations accordingly? 5. Did I label the form panels according to plans?

JZGMSAT QA SYSTEM

Carpentry NC II Fabricating Formworks

Date Developed: Aug. 1, 2011 Developed by: Glenn F. Salandanan

Document No. Issued by: Revision # ____

Page 33 of 33