A Non-stop Method for Building Concrete Structures

written by: Jayant R Row edited by: Lamar Stonecypher updated: 8/17/2011
The slipform technique of construction allows for the continuous pouring of concrete into walls
of a structure and only stops when the full required height of the structure has been reached.

Development of the Slipform Technique

Cement, and concrete by its association with it, has an initial setting time of just about thirty
minutes, after which the cement and the concrete have gained sufficient strength to remain in the
shape into which it has been poured. It is this property that led to the development of slipform
building that allows a non-stop method of construction.
It is this property of early setting that inspired engineers to develop means of moving the
formwork so that the concrete can be poured continuously. The height of the formwork is
designed in such a way that while the top of the formwork is being filled by concrete the lowest
layer of concrete poured earlier has already gained an initial set. When the formwork is moved
upwards the concrete that is then exposed remains firm.
Image Source : Wikimedia

Advantages of Slipform Building

A major cost of concrete structure construction comes in the form of the required formwork to
retain the concrete while it retains it necessary shape and gains the necessary strength till it can
be safely de-shuttered and be able to support itself and other imposed loads. It also requires the
formwork to be continually removed to newer locations and then re-erected. All this requires the
continuous use of manpower and lifting equipment like cranes. In the case of slipform building,
the formwork is erected only once and remains intact until the entire structure is completed.
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This greatly reduces the cost of the formwork as well as any time that may be required to erect
and move it for re-erection, which can result in huge savings in time as well as money.
The continuous operations also allow for an evening-out of the manpower requirements and also
a huge saving in the labor that may have to be periodically employed during otherwise
intermittent concreting operations.
The reduction in the movement of formwork and workers also leads to far more safe working
conditions that also make it a major advantage.

The Components of Vertical Slipform

A slipform assembly can only start after the foundations of the walls have been correctly laid and
a starter for the walls laid out in its correct alignment with all the necessary steel for the walls
already in position. The slipform shuttering is then firmly aligned to this starter with the means
of yokes on each side of the shuttering that help to keep the panels in position. The yokes are all
connected by horizontal crossbeams. Hydraulic jacks are then installed rigidly to the crossbeams
that can all act simultaneously so that the entire slipform shuttering moves upwards. The heights
of such slipform shuttering will normally be between 1. 1 meters to 1. 5 meters in height. The
yokes and horizontal crossbeams are also used to support a working platform that can afford
space for men and materials. The jacks climb using jacking rods that are installed within the
concrete and become a permanent part of the structure, or can be retrieved if so desired.
The design of the working deck and the yokes and horizontal crossbeams are a very vital part of
efficient slipform construction. It is very important that the entire structure be such that its
rigidity and shape is maintained at all times. It is quite normal for the two sides of the shuttering
to be inclined towards each other at the top with the correct wall dimension available at the
center. This allows the shuttering to move easily and eliminates any drag that concrete can cause
on the shutters to prevent its free upward movement. The rigidity of the supporting platform is
also essential so that all parts of the structure move simultaneously. If there is any lag from one
part to the other, this can cause the shuttering to drag and make it difficult to be pulled up. It is
also possible to reduce wall thicknesses as the construction gains height and arrangements have
to be made in the slipform structure that will enable such reduction at regular intervals.

Non-stop method of Construction

Once the slipform shutters along with the jacks and support deck are in position, concreting
operations can then commence. Sufficient working space has to be created on the deck to
accommodate reinforcement bar activity. The bars have to be continually lengthened and placed
in position as per the structural requirements for the wall. The concrete is poured in layers, and
by the time the concrete level has reached the top, the concrete at a level 300 mm above the
bottom of the panel should have gained the initial set. The rate of pouring of the concrete has to
be adjusted so that this is achieved. The slipform is then moved upwards in steps of 10 mm to 25
mm and both the concreting and placing of the reinforcement bars is done continuously till the
final height is reached. All jacks are fitted with brakes that act automatically by mechanical
means and do not allow the jacks to slip on the jack rods.
Slipform methods of construction can also be adapted to horizontal structures and are used for
paving, canals, and tunneling. The technique is more in use for structures that have continuous
walls like silos, chimneys, and piers for very tall bridges. It has also been successfully used for
construction of buildings, although this requires the manner of leaving inserts for openings like
doors and windows to be decided well in advance, as well as also any necessary inserts to
support floor slabs after the walls are constructed.