APRESENTATIONBY

SIMPLEXLAFARGESONADIHTEAM

ON

SLIPFORMWORKSBY
CONCRETEPUMP

Introduction:
Conciete pump may be useu in constiuction of silo wall by slip foim As the conciete pump has
acceleiateu the iate of concieting so much fastei piogiess we can expect By this piocess of
concieting we can ieuuce the manpowei engagement Concieting by conciete pump in slip foim woik
give us the bettei quality of conciete by ieuucing the hanuling of conciete in uiffeient stage As the
pouiing time incase of using conciete pump is less so we can poui a complete unifoim layei well
befoie the initial setting time of conciete Anu this piactice gives us smooth suiface of wall Conciete
ouiing in unifoim layei well befoie the initial setting time of conciete has helps in unifoim lifting of
SLIP FORM WORKS BY CONCRETE PUMP
p
the slip foim so we can able get bettei ieauing with the plumbs
By the above uiscussion it is cleai that concieting by conciete pump in slip foim woik gives us lot
moie contiol in quality of conciete accuiate plump of the stiuctuie anu bettei suiface of conciete
all Not only that this is much economical piocess to get exact technical specification iequiieu in the
ctual opeiation of the stiuctuies as the engagement of laboui is less the piogiess of woik is fastei
w
a
ExampleforConcretingbyPumpinSlipformWork:
Some examples fiom the Simplex Lafaige Sonauih site may inspiie to uo the slip foim concieting by
onciete pump In this pioject we have thiee nos silo woik anu eveiy silo have the uiffeient c
specification by the natuie of theii opeiation
Foi the fiist time in Inuia simplex Sonauih team hau maue the expeiiment with the above stiuctuies
by convincing Ns Lafaige Inuia with theii woik pioceuuie of concieting by conciete pump in slip
foim anu ultimately get the iesult foi which simplex Sonauih team was awaiting to call the
xpeiiment successful Anu now it is a new way woiking foi slip foim to achieve fastei piogiess
ithout hampeiing the iequiieu quality of woik
e
w
ACCESS
TOWER
TOWER
FOR
CONCRETE
PUMP PIPE
LINE
CONCRETE
PUMP USED IN
SLIP FORM
WORK OF
BLENDING SILO
The above photograph showing arrangement required for concreting in slip form work. This was taken at
Simplex Lafarge Sonadih site during construction of Blending Silo wall by Slip form.
SLIP FORM WORKS BY CONCRETE PUMP
CLINKER
SILO
This is the photograph of Blending Silo after
the completion of slip form work. Blending has
the 15m diameter & 52m tall structure. Here
concrete pump had used for concreting of the
wall. We can see here the surface & alignment
of wall is almost accurate. The average rate of
lifting achieved in this construction 2.5m per
day.
So, the experiment of concreting by concrete
pump in slip form work is successful. This
experience has shown us a new way of
working in slip form to achieve better quality
of construction.
It was constructed in phases. 1
st
up to +15m
(wall thickness 800mm) has taken 8 days and
2
nd
from +15m to +52m has taken only 22days.
BLENDING
SILO
By the successful experiment of Blending Silo slip
form work, we have construct the clinker silo by the
same process of concreting and made it second time
successful.
Clinker Silo is the biggest silo in our Lafarge Sonadih
Project. It has 45m diameter & 26m tall. We have used
here 3 nos. of concrete pump for feed the concrete
during slip form works. Total wall length had divided
in to 3 parts and to feed the each area a concrete pump
has engaged.
We have also successful here by adopting this process
of concreting in slip form.
Duration taken in construction of clinker silo only 19
days.
SLIP FORM WORKS BY CONCRETE PUMP
CONCRETE
PUMP
In clinker silo we have used three nos. of
concrete pump to feed the concrete into the wall
during slip form work. Photographs are showing
the concrete pump used during slip form work.
Concrete pump showing in the photograph feed
one-third portion of the silo wall.
BOOM
PLACER
Boom placer also being used to feed the concrete
to feed another one-third portion of the silo wall.
This photographs has been taken during slip for
work of clinker silo.
By the above process concrete feeding has done
for concreting work at clinker silo.
HOSE PIPE HAS USED
TO POUR CONCRETE
DIRECTLY TO THE
SLIP FORM SHUTTER
This photograph has taken during concreting
was done at Clinker Silo.
Here we can see the concrete has poured to
slip form shutter through the hose pipe of
concrete pump pipeline and this hose pipe
has connected to main pipeline of concrete
pump.
SLIP FORM WORKS BY CONCRETE PUMP
CONCRETE
PUMP
TOWER
ACCESS
TOWER
REJECT
SILO
After successful completion of Blending & Reject
Silo in this process of concreting, we have
applying same process of construction another one
no. of silo (Reject Silo).
Reject Silo have 12.5m diameter & 35m tall. We
have completed this silo wall by slip form only by
13 days with maintaining better quality of work &
safety.
CONCRETE
PUMP

PrecautiontobetakenincaseofConcretingbyPumpinSlipformWorks:
There is chance to disturb plumb of slip form during concreting concrete pump due to vibration produce by
concrete pump during each stroke.
To avoid this vibration we have to be use spring pad. During concreting work spring pad is to be placed
under the concrete pump line near to the slip platform where the pipeline get bend. This can minimized the
vibration produced by concrete pump.

Concrete Pump
Pipeline Tower
Concrete
Pump Pipeline
Spring pad
arrangement is
required here
SILO
WALL

METHODOLOGY USED
IN CONSTRUCTION OF
CLINKER SILO
AT
LAFARGE SONADIH PROJECT

MethodologyhasusedforClinkerSiloslipformwork:

Work Procedure:
1. Objective
Objective of this procedure is to provide a guideline for sequence of operations pertaining to
Slip form Works for Silo Construction, so as to ensure that the works are carried out in a
systematic manner and to ensure that the works conform to the Owners specification and
drawings.
2. Scope
This procedure is applicable for Construction of Clinker Silo at Lafarge Sonadih Cement Plant.
3. Reference
This Procedure is based on the requirements of the Owners Technical Specification for
Civil/Structural works for Silo package works and Simplex Experience in Construction of Silo by
Slipform.
4. Resource Deployment
The Contractor shall deploy any or all of the following resources as dictated by the volume and
nature of work.
a) Tools & tackles
x Spade.
x Shovel
x Basket
x Wheel Barrow
x Steel Wire Rope
b) Plant & Machinery
x Batching Plant.
x Transit Mixer.
x Concrete Pump with pipeline.
x Builder Hoist Winch.
x Vibrator with nozzle.
x High lift curing pump.
x Boom Placer.

In addition to the above, the Contractor shall deploy a specialist agency for slip forming having
experience for carrying out such work.

5. Slipform Technique:
We propose that we shall erect the slipform shuttering right from -2.0 m E.L. of R.C.C.
Shell of Outer Wall. The shuttering plates and other various components of Interform
type slipform equipment shall be erected as per line and level required for Clinker Silo.
The jack rod for 6.5 T Hydraulic Jacks shall rest on steel shoe placed at the top of
already cast shell. Some of the salient features of the various components to be used for
the slipform technique as shown in SKETCH NO.: 012 / DD / LAFARGE S / SILO / SDS /
002 Rev 0 are explained below.






5.1 Yokes:
A set of yoke leg placed at required alignment and connected by means of yoke
beams at the top wherein climbing jack mounted, provides key members for fixing
the Form Panel for inner and outer faces. Requirements of total number of yoke
sets depend on the sizes of the structure and the capacity of hydraulic jack.
Spacing of the jack would be around 2.0 m. for this Clinker Silo.
5.2 Slipform Hydraulic Jacks:
We shall be using 75 nos. 6.5 T capacities Interform type hydraulic jacks which
climbs on bright steel rod of 32 mm dia and operates with two sets of ball grip.
Jacks can only move upward direction when hydraulic pressure is applied. The
upper movement of the slipform will be as per set criteria provided by the
manufacturers of the Jacks or minimum of 100 mm / 150 mm per hour.
5.3 Consoles:
Consoles shall be provided on to the yokes meant for support of the working
platform both inside and outside. This working platform shall be used for
concreting, reinforcement binding and operation of the hydraulic pumps. Consoles
will be fabricated members in combination with structural angles and tubular pipes
/ reinforcement rod.
5.4 Hanging Scaffolding:
These members are suspended from consoles both inside and outside for the
purpose of inspection and finishing work of the exposed concrete after slipping.
These hanging scaffolds will be of rigid frame structural members.
5.5 Waler:
These member spans within the two yokes and provide support for the Form Panel
against Lateral Force due to green concrete.
6. Support For Reinforcement Steel:
Arrangements made from the top of yoke beams with reinforcement guide, supports
reinforcement to maintain its aligned position.
7. Guard Railings:
For the safety arrangement guard railings with post placed at the working platform both
inside and outside and reinforcement type rails also provided for the hanging scaffolds.
8. High Pressure Hydraulic Pumps Pipelines & Fittings:
Circuit oil lines of high-pressure rubber hoses inter-connect all vertical jacks and plug in
unit with one or more centrally positioned electrically powered high-pressure pump.
Connections to the jacks and pump are carried out through valves and male and female
fittings as required.









9. Illumination:
Illumination is essentially required as the work normally carried out 24 hours a day non-
stop. Accordingly both on working platform, at the hanging scaffolds, stairways and
working areas are illuminated properly.
10. Operation:
For smooth operation of slipform, jack readings and plumb readings are to be monitored
once in every two hours.

11. Access Tower:
Tubular access tower is to be installed for concrete lifting and climbing of personnel
through temporary stairs, made of reinforcement rod and fixed with tower.
12. Special Arrangements:
1. Minimum 10% extra jacks are required as standby. Adequate jack rods should also be
available at site.
2. 75 nos jack of 6.5T capacity each to be put on the job i.e. with a spacing of around 2m
c/c.
3. Slow and uniform concrete pouring is to be maintained. Empty height of shutters
should be maintained 150-200mm from top/ deck level. Lifting of the shutters should
be limited to 10mm 15mm per lift i.e. in 10minutes interval, (60-90 mm per hour) to
avoid bulging of concrete surfaces, rate of slippages will also depend on the concrete
quality (i.e. on setting time)
4. To maintain verticality of shell wall, 12 nos plumb bobs (minimum) are to be hanged at
equal intervals at outer side of shell wall from deck through the gap between shutter
and masons platform (hanging platform), however the plumb points should be avoided
in front of openings. Verticality shall be checked at least 2 times in every shift
jointly. On the entire jack rod horizontal level is to be marked at 300mm height from
top of the jack by means of water level tube and Jack rod rings are to be put at this
level on the entire jack rod. During lifting when the entire jack touches the ring then
horizontality of the system will be ensured. At this time dia & plumb checking will be
done and readings are to be noted in a register. If any discrepancy is found that is to
be brought to the knowledge of the Owners Site In-charge immediately for necessary
remedial measures. Same procedure will continue till successful completion of slip
form concreting of shell wall.
5. All axis to be marked on the deck slab by means of triangular shaped GI sheet /Ply.
6. One standby hydraulic pump of same capacity in OK condition must the there on the
deck slab.





SketchdiagramforSlipformWorksatClinkerSilo:
































CONCRETING OF
THIS PORTION
HAS DONE BY
BOOMPLACER
CONCRETE
PUMP 2
CONCRETE
PUMP 1
BOOM
PLACER
TOWER FOR
CONCRETE
PUMP PIPELINE
CONCRETING OF
THIS PORTION HAS
DONE BY
CONCRETE PUMP 2
CONCRETING OF
THIS PORTION HAS
DONE BY
CONCRETE PUMP 1
TOWER FOR
CONCRETE
PUMP PIPELINE













7. Curvature of the walers should be proper to get accurate inner & outer diameter of
the shell wall when shutters are fixed in position. Curvature of all walers must be
checked before fixing.
8. It should be ensure that the quality of concrete as is required for slip forming work
and the desired speed as recommended for slip form work is achieved. The quality of
construction of the silo is ensured and the silo is executed within permissible
tolerances.
9. Concreting & other related job shall be continued round the clock till completion of
slip form.
10. Continuous /intermittent curing shall be done by means of high lift pumps and
perforated Circular water pipe line fixed 500mm above masons platform both inner
and outer side of silo wall.
11. Simultaneous finishing of concrete surfaces shall be done by masons working at
masons platform.

12. For the jack rods, in opening portions, dummy concrete columns are to be made, which
are to be dismantled later on after completion of the job.
13. Spokes will be placed at the middle portion of two consecutive yokes alternatively.
14. Proper illumination should be there at top of deck as well as at masons platform. Area
lighting inside/outside also should be proper as during nighttime also plumb readings
to be checked.
15. After completion of slip form activity the Jack rods are to be recovered and the
holes are to be grouted as per mix specified in contract/ as decided by Engineer In-
charge.

PhotographsRelatedSafePracticeUsedatSlipformWork: