ON CONTINUOUS INNOVATION

Scaffoldings and formworks are temporary structure made for construction of the different structures like building, bridge, culvert etc. Scaffolding is a type of temporary construction that is used for access around the building when the height of the building exceeds about 1.5 m. Formwork is a temporary construction which is used as a mould for different structures like column, beam, slab, stairs and so on, in which concrete is placed and hardened and matured.

Scaffolding market scenario

According to a Market Research Future (MRFR) report, the global scaffolding market to grow at a CAGR of approximately 6.3% from 2020 to 2027 (forecast period). Increasing FDI in construction in the Asia Pacific region and supportive government regulations and policies are driving the scaffolding market. The scaffolding market is constrained by factors such as fluctuating raw material prices and slower economic growth, which impede market growth, the report says.

The global scaffolding industry has been segmented into type, material, and application. Based on type, the global scaffolding industry has been segmented into supported scaffolding, suspended scaffolding and rolling scaffolding. Based on material, the scaffolding market has been segmented into steel, aluminium, wood, and others. Based on the application, the global scaffolding market has been segmented into the construction industry, electrical maintenance, temporary stage, and others.

Formworks market

As per the market research analysts at Research Cosmos, construction companies are growing at a rapid rate where overall formwork market size is estimated to reach US$6.12 billion by 2024 from US$5.21 billion in 2017 registering a healthy CAGR during the forecast period. This growth is taking place because construction companies are paying high attention to labour and severe time-saving methodologies.

The determining factor in the growth of the formwork market is the strong demand of the construction sector. The industry is growing at a rapid pace and it is estimated that the current cement production will become double in the near future. In recent years, concrete technology has grown by leaps and bounds. Advances in concrete technology have led to many innovations and emerging trends as a result of construction speed and durability.

Scaffoldings and formworks in iconic projects

Scaffolding and formwork technologies have evolved over the years to become an integral part of the construction of unique structures. The Statue of Unity is a monument dedicated to Indian independence movement leader Sardar Vallabhbhai Patel located in Gujarat. With 182 m (597 ft) in height, it is world's tallest statue. In this project, there are two cores in elliptic shape with a size of 11.0 m x 8.50 m each. The core walls starts from the feet of the statue structure reaching to the shoulder of the structure. PERI provided RCS for core wall and tower crane area along with ACS for lifting of boom placer hydraulically. PERI supplied 24 nos. RCS rail climbing units and one ACS self-climbing unit for faster and crane independent construction of elliptical core. PERI provided complete solution for the project. With its engineering and site supervision support, the project was completed well within the timeline.

BSL Scaffolding Ltd associated with Godrej Properties Ltd (GPL) for the execution of their prestigious Godrej Infinity project at Pune in mid-2016. BSL designed and supplied 15,000 sq m of formwork area for this luxury housing prime project. The project was planned by GPL for 43 acres of residential development of land bank located on the river bank of Mula-Mutha River at Pune. The project has premium homes with 1, 2 & 3 BHK type flats with balconies and many amenities. In the first phase of construction 06 high rise towers where planned to be constructed using aluminum formwork, apartments where ranging from 400 sq ft to 1,100 sq ft.

BSL followed the following methodology to execute this project:

• Conceptual meetings with project team to address specific customer needs
• Study of all possible available technical drawings through serious of meetings with GPLs project, structural, architectural, MEP teams & their respective consultants etc.
• Freezing shell plans with clients decision makers to define our scope on client's drawings.
• In-house design of internal flat-wise panels & other connecting material members
• Manufacturing & quality testing at our unit
• Clients witness of a dry mock up of the system at BSL's manufacturing base to check up design, confirmation to quality parameters etc
• BSL's onsite support team consisting of supervisors and formwork experts at client's disposal at the project site to monitor erection, best practices, improvisation and time management.

The BSL site support team worked in coordination with the client, BSL design team and factory to ensure continuous improvement and to minimise deviation from all required parameters. Doing the above BSL ensured they get a slab cycle of 07 days to meet with client's demands and expectations.

Key products and solutions

Modern infrastructure development demands technologies that are faster, safe and innovative. PERI has developed ground breaking formwork and scaffolding technologies, which continues to set standards in the industry. Recently, PERI introduced three new systems in India, i.e. PERI UP MI, PERI ALPHADECK and HANDSET Alpha.

PERI UP MI is a cutting-edge shoring and scaffolding technology in India. PERI UP MI is an innovative solution among the steel shoring and scaffolding systems and stands for quick and simple assembly. PERI UP MI has unique gravity lock technology. Ledger of this system has a connection in the form of a wedge, which is hooked into the rosette opening, thereby, the gravity lock drops into the rosette opening due to its own weight and locks self-actuating. This feature makes simple and safe assembly of the system and offer huge savings in time and cost.

PERI ALPHADECK is the modular aluminium slab formwork system with economic and faster cycle times. It allows fast as well as safe forming operations with a systematic assembly sequence. The system provides efficient solutions for standard applications. The unique design of the system offers safe and confident erection from level below. It also ensures easier de-shuttering of panels, while the props remain undisturbed. PERI ALPHADECK slab formwork system is designed for slab thickness of 350 mm for the panel size of 2,400 mm x 1,200 mm and 550 mm for panel size of 1,800 mm x 1,200 mm.

PERI HANDSET Alpha is a modular panel formwork system suited for various walls and column applications. It is designed in such a way that all panels are multi-purpose panels that can be used in any direction. With two sizes in height and three sizes in width, it offers all possible configurations to meet different pour height requirements with less unutilized formwork area. Hence, it is an efficient and economic system for construction.

HANDSET Alpha provides the highest flexibility in the construction of walls and different sizes of columns with optimal material utilization and easy handling by only two people. The system meets all requirements with infills up to 30 cm, 90º internal and external corners, T-junctions and stop-ends.

HANDSET Alpha panel formwork system is designed for concrete pressure up to 60kN/m² for walls, 75 kN/m² for columns (up to 600mm x 600mm) and 60 kN/m² for columns (from 650mm x 650mm to 900mm x 900mm) according to DIN EN18218 (Evenness: line 6 in accordance with DIN EN18202). The panel is made of high-grade steel frames and 12mm ply with phenolic resin, which makes the system very robust and offers smooth concrete finish.

Industry speaks

Infrastructure development is need of the hour for Indian economy: be it road, railway including metro rail, affordable housing or airports. Raj Lakhani, Managing Director, PERI (India), says, “We see many opportunities in this sector for formwork and scaffolding industry. PERI India has been growing its footprints in real estate and infrastructure sector in India. With landmark infrastructure projects such as Mahatma Mandir, Statue of Unity, Agra-Lucknow Expressway, Hyderabad Metro, Mumbai Metro, Bengaluru Metro, Mumbai Trans Harbour Link (MTHL), Lucknow Metro, Trichy Airport, Pune Airport using our state-of-art formwork and scaffolding system, we have proved our mettle in delivering customised solutions for every complex need in a cost effective manner.”

Uday K. Patil, Managing Director, Uday Structurals & Engineers Pvt Ltd, explains, “We mostly cater to the specialised scaffolding and formwork requirements from heavy infrastructure or special building projects like nuclear reactors, radiation buildings, heavy or high-roof structures, metro rail projects, bridges, underground tunnels, heavy industrial buildings, aqua ducts, etc. These structures require special design and innovative approach and UDAY with its vast experience in projects is well equipped to deliver in the most optimum cost with the highest safety standards.”

Hari Om, Director, BSL Scaffolding Ltd, adds, “We have always been at the forefront in the scaffolding space, having the first mover advantage in India gave us a lot of success stories, but we would like to share our success story in the aluminium formwork space as we didn't have first mover advantage but marched well ahead to be a distinguished solution provider.”

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