Optimization of the technology for forming monolithic vertical elements using moving belt formwork systems

Abstract

This article develops a comprehensive methodological framework for the structural and operational optimization of technologies used to form monolithic vertical building elements through the application of vertically movable belt-type formwork systems. The proposed approach is based on a detailed decomposition of the construction process into nine standardized microelement matrices that represent the full operational cycle: installation of guide frames, placement of reinforcement, suspension of modular units, multilayer concrete placing, regulated curing, vertical lifting of modules, adjustment operations, and subsequent dismantling procedures. Such decomposition makes it possible to quantify labor intensity, assess the technological sequence, and determine the dominant factors influencing productivity.

A key feature of the investigated system is the flexible forming strip, tensioned on drive and bypass rollers, which ensures tangential detachment from the concrete surface during lifting. This mechanism substantially decreases adhesion forces, reduces mechanical resistance, and minimizes risk to the integrity of the freshly formed concrete layer. Compared with conventional panel formwork, belt-type systems demonstrate significantly lower energy demands, reduced labor consumption, and improved turnover rates. The study presents analytical dependencies for evaluating cycle duration, conformity coefficients, turnover ratios, and required operational resources.

The research substantiates the advantages of using mechanized group configurations of belt modules, which enable synchronized lifting, stable geometric accuracy, and continuity of concreting cycles within accelerated construction schedules. Moreover, the methodological framework provides a foundation for digital integration, supporting the application of BIM-based planning tools, SCADA monitoring solutions, and predictive analytics for process optimization.

The results confirm that vertically movable belt formwork systems represent a technologically and economically efficient alternative to traditional formwork approaches. Their implementation leads to measurable improvements in labor productivity, material utilization, cycle stability, and the quality of concrete surfaces. The proposed methodology also creates opportunities for future development of digital twins, automated control algorithms, and advanced rationalization models for modern monolithic construction..