IDC Develops Radical New Safety Device for Concrete Construction Industry

IDC has developed an innovative new device that promises to transform the safety of falsework in the construction industry. Working for leading concrete construction contractor, Byrne Brothers, IDC was commissioned to develop a falsework release tool that would remove falsework with dramatically improved safety, minimal noise and frame damage; while also bringing financial benefits. This innovative new tool has just been shortlisted for the 2013 British Construction Industry Awards.

Modern buildings are often constructed from concrete by using a process called shuttering where falsework posts are positioned to hold liquid concrete in place until it sets. Once the concrete structure has hardened, the falsework posts are removed to allow the building to stand alone. Unfortunately, the process of dismantling the falsework can be hazardous and damaging as the metal nuts which hold the falsework together are literally struck until they are loosened; often breaking them in the process. The noise this creates is also a problem as in many cities there are restrictions on noise levels during certain hours; forcing delays as workers have to remove the falsework at inconvenient times.

Byrne Brothers was keen to come up with an easier solution for removing the falsework and IDC was challenged to develop a tool for this. IDC handled all design stages from concept, mechanism, product and electronic design, right through to power and stress analysis, materials and systems research, and finally prototype manufacture and field trials. IDC’s main obstacle was designing a device that would be light enough to be lifted into place manually by construction workers, but was powerful enough to release the nuts.

When designing the tool, IDC formulated a ‘Locate, Position and Lock’ solution. The final solution works by attaching a rotating mechanism to the falsework which forces the nut to release. The device uses a hydraulic motor which pumps oil at high pressure to initiate the rotation. A gear attaches to the collar adaptor which then engages with the nut once the rotation has been put into effect, which dismantles the falsework. Byrne Brothers has been granted a UK patent for IDC’s design of the tool and is also pending international patent approval.

Stephen Knowles, Managing Director of IDC commented on product feedback, “We are delighted to hear that the device has transformed falsework removal for Byrne Brothers. It is already being used in the city of London, where they have strict noise regulations and the client has seen immediate benefits with noise levels, enabling projects to continue around the clock. The process of removing falsework is also much quicker and the cost of replacing damaged nuts has been eliminated altogether.”

The new falsework removal device is being widely used across Byrne Brother projects, but the company would like to bring its benefits to the rest of the construction industry and is currently seeking partners to do this.

For further information about the tool or partnership opportunities, please

visit: http://www.byrne-bros.co.uk or

email: nicks@byrne-bros.co.uk.