Innovative formwork systems form the core of many projects for Pilosio´s technical team.
Bold and elaborate projects often require a detailed study of innovative construction methods besides minute planning of the provisional equipment necessary for their construction. An interesting example of this is the solution designed by the Pilosio technical team for the construction of the hollow circular pillars for a hospital in Caserta, where over 45,000 sq ft of interior space has been created to house 500 beds.
The Hospital of St. Anna and St. Sebastian has 13 large pillars, known as the ´Centuriatio´, which are four storeys high and support the floors of the hospital wings. The cavity inside these pillars allows wiring to be passed through it.
The hollow pillars have a total height of 18 m with an outer diameter of 2 m and an internal diameter of 1.40 m. Since the casting process was scheduled for summer, when the internal temperature of the steel pipe could have reached a temperature of 50¦ C. To prevent this, construction company required an adhoc solution for the safety of the workers. The Pilosio solution was designed to disable routine work during the operations of arming, disarming and handling.
The external formwork is made from two half-shells, while the internal structure is a single mold, with six conical semi-circular elements connected to each other through a conical sledge system that allows the automatic removal of the entire formwork with a construction crane.
Once the necessary time has passed, the removal of the internal formwork is simple and safe: Lifting the internal formwork with a hook, the six components slide over each other thus reducing the circumference and allowing complete removal of the formwork, without any of the workforce having to enclose themselves within the pillar.
Safe and reusable
If for any reason, an access to the interior is required; an integrated ladder system has been embedded and welded onto the formwork alongwith a safe working platform at the base for protection from falling objects.
This system alongwith climbing platforms enables the casting process in five successive stages and the formwork to be reused for around 52 times.
This solution offers a double advantage. It enables rapid execution due to quick disarming and rearming besides offering high safety due to the work being executed externally. Dario Roustayan, CEO, Pilosio states, ´For us, making the difference means anticipating market demand providing high level construction technology at competitive prices, well trained staff and 360¦ assistance. Not only a highly qualified commercial and technical assistance, but above all, a great flexibility to give a made-to-measure solution to meet any need. Our new R&D high professional team is capable of guaranteeing the best solutions, delivering a high quality service from budget estimates to feasibility studies, technical reports, calculation checks and site planning.´
Besides this special system, Pilosio also provided the following equipment.
Types of formwork
Besides enabling concrete slabs with 100 cm thickness, slabform system also increases on-site productivity by reducing need for equipment. The system is also simple to assemble, which guarantees rapidity and safety. Additionally, the reduced weight of each component and its modularity allows a single operator to manually reinforce the floor with high speed and ease. For instance, three operators can assemble up to 500 sq m a day of slabform formwork with a floor intrados of 3 m.
The assembly phases optimise the material and its rotation frequency. The system anticipates dismantling of the horizontal formwork permitting its reuse in the following phases. The main props remain in place, guaranteeing the support needed for the slab consolidation process.
Additionally, slabform is highly flexible and can create flooring of any geometry since the Slabprop aluminium supports, furnished with high mechanical specifications, allow the reinforcement of any floor thanks to openings from 2 to 5.20 m that can be increased with extensions, reaching capacities up to 7.5 kN.
The T28 is a support structure for the reinforcement of slabs, beams or any other horizontal structure cast at a height.These towers are manufactured with a limited number of components and can reach any height. They are placed on adjustable bases and are equipped with forks on which the beams that collect the loads to be borne, are placed. The beams can consist of wooden PL20 or metal profiles.
It is the ideal solution for the execution of underpasses,
box-conduits, viaducts and slabs of high thickness in general.
These structures are simple to install. The base components of the system are few and easy to handle; the weight of each item does not exceed 10 kg making assembly and disassembly easier.
The modularity of the elements and the screw adjustment of bases and forks allow reinforcing at any height with great accuracy.
Heavy Duty MP Towers
Pilosio´s MP system enables the construction of both scaffolding and shoring structures for the most varied requirements, as work platforms, support structures for concrete castings, reinforcement of slabs or any heavy-duty tower.
MP system is made up of simple components and a full range of accessories for any need. The availability of these components allows creation of structures of any size. The wedge and washer hooking system makes assembly and disassembly extremely easy allowing modularity, extreme adaptability and high capacity.
MP Shoring Structures
The modularity and versatility of this system enables the individual or combined towers and platforms to be obtained with suitable plant dimensions and elevations. The capacity of these structures varies depending on their height and the shoring system installed (braces and ledgers). It can be increased by reducing the distance between the standards and increasing the number of ledgers and/or façade braces.
The tower with 0.83 x 0.83 m or 1.15 x 1.15 sq m base allows capacities up to 50 kN for each vertical standards for a total of 200 kN for each tower. This capacity can be increased by reducing the distance between the standards and increasing the number of ledgers and/or façade braces or by doubling the standards.
The modularity allows solving of any problem on site, both of capacity and of geometry. It is possible to develop structures with curvilinear bases, triangular base or any other shape, to climb obstacles and also create supports for structures with negative or positive slope.
By using bases and adjustable forks, the towers can also be used as a temporary contrast for works to stabilise structures under construction. The structure can be combined with service stairs for an easy access at high altitude.
Heavy Duty Towers
All standard components of the MP scaffolding system are used, combined with lower and upper frames and adjusting screws, for the creation of support structures with high capacity. Each vertical element is constituted by four standards spaced 17 x 17 cm and can be combined to create towers or walls of various sizes depending on specific needs.
The capacity of base module is: 200kN for each vertical column, equal to 800 kN for the whole tower.
Many heavy duty towers can be combined together. The great flexibility of design and the MP multidirectional scaffolding hold, combined with various accessories allows the creation of structures of any kind both for supporting horizontal surfaces and formworks for castings at a height.
The towers can be moved with a handling trolley and combined with service stairs for easy access at high altitude
Adjustable Spindle Support
This system allows a simple and easy dismantling of the heavy duty MP towers, in order to minimise the effort of workers and additional tools during the installation operations. Attachment to other steel parts can be made with beam clamps and bolts. The system offers high flexibility due to its possibility of adjustment with great accuracy. The screw support can be unloaded manually by striking the ring nut arms.
Svelt formwork for circular walls
Svelt system is a modular formwork with variable radius for curved structures cast on site. The curvature radius of panels can be easily adjusted by using screw adjusters. The versatility of this formwork allows walls with oval or ´S´ shaped base and even linear walls. Maximum resistance to the pressure of fresh concrete: 60 kN or sq m.
The Svelt system consists primarily of vertical frames in shaped sheet metal, with reinforcing ribs equipped with screw-adjusters for curvature and plywood counter casting surface. It is a modular system that can reach 6 m in height. The formwork has been designed to be handled complete of super-elevation structures and accessories for subsequent uses without deformations. Svelt system can be used in combination with climbing support brackets for cold shut casting.
The application of Svelt formworks are mainly large sewage and water treatment plants, creating circular silos or piers and also semi-circular combined structures in residential construction.