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Formwork and Scaffolding Collapses IMIA Working Group Paper WGP 80 (13) IMIA Conference New Delhi, 21st to 25th September 2013 Formwork and Scaffolding Collapses Working Group Members: Alon Eisenberg, Engineers, Surveyors & Loss Adjusters, Modiin, Israel Richard Gordon, Infrassure Ltd, Zurich, Switzerland Patricia Marzullo, Fairfax Brasil Seguros Corporativos S/A, São Paulo, Brasil Chairman: Martin Frey, Amlin Re Europe, Zurich, Switzerland Sponsor: Max Benz, XL Insurance, Zurich, Switzerland IMIA WGP 80 (13) Formwork and Scaffolding Collapses Page | 2 __________________________________________________________________________________________ TABLE OF CONTENTS Subject Page 1. Executive Summary: ........................................................................................ 3 2. Introduction and Motivation: ............................................................................. 3 3. Definition of Scaffolding and Formwork ........................................................... 4 3.1. The Evolution of Scaffolding and Formwork..................................................... 4 3.1.1. Scaffolding ...................................................................................................... 4 3.1.2. Shoring and Formwork .................................................................................... 5 3.2. Types of Scaffolding, Shoring & Formwork ...................................................... 6 3.3. Prices and Depreciation .................................................................................. 9 4. Insurance Aspects of Formwork and Scaffolding ........................................... 10 5. Examples of Formwork and Scaffolding Losses ............................................ 14 5.1. Predominant Loss Types ............................................................................... 14 5.2. Baileys Crossroads Building .......................................................................... 16 5.3. New York Coliseum, 1955 ............................................................................. 16 5.4. Bridge Falsework Collapse ............................................................................ 17 5.5. Motorway Viaduct Collapse ........................................................................... 19 5.6. A scaffolding Collapse – John Hancock Center in Chicago, 2002 .................. 20 5.7. A comment on Employers Liability ................................................................. 20 6. Best Practice Formwork and Scaffolding temporary Work Procedures. ......... 24 6.1. Legislation ..................................................................................................... 24 6.2. Temporary Works procedures ....................................................................... 25 6.3. Works and Management of the Key Risks Elements ..................................... 25 6.4. Consequences of the Risks involved in Formwork and Scaffolding ............... 25 6.5. Safe Implementation of Formwork and Scaffolding Schemes on Site ............ 26 6.6. Typical Organigram of Key Personnel for a “Temporary Works Team” .......... 26 6.7. Management of Temporary Works during the Construction Phase ................ 28 7. Conclusions: .................................................................................................. 31 IMIA WGP 80 (13) Formwork and Scaffolding Collapses Page | 3 __________________________________________________________________________________________ 1. Executive Summary: Collapses of formwork and scaffolding are occurring at a disturbing frequency. They are, however, only noted in the wider public when third party property is affected in a spectacular way or, tragically, when workers or pedestrians are injured or even killed. The main focus of this paper shall be on “Engineering Insurance” related aspects even though we are aware and respect that the Employers Liability dimension to the formwork and scaffolding industry has a much wider relevance in view of the immense cost and pain such accidents cause to workmen, third parties and their families. After a brief overview of the basic technologies used, we will discuss insurance aspects and explain the typical challenges in assessing construction projects. The special insurance features and issues encountered in the claims adjustment process of formwork and scaffolding losses are described and best practice recommendations are given. Several loss examples are illustrating and identifying typical loss scenarios and the devastating effects formwork and scaffolding failures may have on site – and how little it would take to avoid these. The paper concludes with a chapter on best practice and will propose “concrete” steps to install a state of the art risk management procedure on construction sites. 2. Introduction and Motivation: Not a single construction project can be executed without the use of scaffolding and formwork. Sometimes, as Engineers, we may admire the courage and the skills of workers climbing to breath taking heights on scaffolds. At times, we may note the beauty of scaffolding structures or be impressed by the sheer size and complexity of the arrangements. Most of the time, however, we may consider scaffolds a nuisance because they block our way or sight. As construction underwriters, we assess projects in great detail and depth. We check time schedules, bills of quantities, design criteria, new technologies, third party and Nat-Cat exposures to name just a few – but do we spend enough time on considering and managing the impact, scaffolding and formwork activities may have on the construction projects we insure? Just google “formwork collapse” or “scaffolding collapse” and you will be amazed (eventually shocked) about the incredible number of postings and pictures your search will yield. Quite clearly, formwork and scaffolding collapses do occur at a surprising frequency. Why is it that there seems to be little attention paid to this aspect in the field of engineering insurance? This paper tries to describe insurance related aspects of formwork and scaffolding techniques in a practical and “hands on” manner. Real lif e examples will be used to explain the typical loss scenarios. Building on these, we will discuss insurance aspects as well as risk management procedures and conclude with a set of recommendations. Our aim is to attract and raise our awareness as underwriters and risk managers to the many issues around formwork and scaffolding activities on construction sites. Our motivation is to help reduce injuries and losses. We hope your help enables us to succeed in this. IMIA WGP 80 (13) Formwork and Scaffolding Collapses Page | 4 __________________________________________________________________________________________ 3. Definition of Scaffolding and Formwork When we started our work on the topic, we soon realized that it is very easy to create Babylonian confusion by using dozens of different expressions for almost the same (e.g.: false work, shoring, propping, staging…). In order to reduce the level of confusion to the bare minimum (we hope), we have chosen to only use the term “Formwork and Scaffolding” (F&S) going forward (except here in this chapter 3 which describes some standard types of F&S). Therefore, for the purpose of this paper, the term F&S stands for a temporary means: 1. On which workers may stand in order to perform their work 2. Which will carry and support the weight of the structure until it can hold itself 3. Which will be used for the containment of the concrete until it is hardened. 3.1. The Evolution of Scaffolding and Formwork 3.1.1. Scaffolding The use of scaffoldings made of timber or wooden beams has a history dating back several thousand years. The picture below shows an example of a drawing found in the tomb of Rekhmire, a governor of Thebes who lived in the 14th century BC in Egypt. It illustrates the use of scaffolds consisting of tall vertical and horizontal poles lashed together with ropes and planks providing walk-ways for stonemasonry workers. Illustration of the use of scaffolds in the tomb of Rekhmire In many countries in Asia, bamboo scaffolding is still common practice. This ancient method of traditional bamboo scaffolding is very effective and efficient due to the low weight, the surprising strength and the low cost of bamboo. No machinery is needed to assemble the scaffold and it can be easily adjusted to any shape (provided you have the necessary skills, of course). Even for very modern and complex structures, bamboo scaffolds may be the right choice as illustrated on the next page. IMIA WGP 80 (13) Formwork and Scaffolding Collapses Page | 5 __________________________________________________________________________________________ Traditional bamboo scaffolding on complex structures Introduced in the mid-1950s, the basic lightweight tube scaffolding (with the three main components tubes, couplers and boards) became the standard and has revolutionized the scaffolding industry. The tubes are made either of steel or aluminum – and these scaffolds are used in countless projects all over the world. 3.1.2. Shoring and Formwork One of the first and finest examples of skilful use of formwork to create a concrete structure is most probably the spectacular Pantheon Dome in Rome with a diameter of 43 meters (below). Believed to be built at the beginning of the second century AD, it has been admired throughout the ages till today. IMIA WGP 80 (13) Formwork and Scaffolding Collapses Page | 6 __________________________________________________________________________________________
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