Formwork System and Methods

Basic Form work system and methods

New trends in system formworks
Special Information
Form work for in situ concrete may be described as a mould where
the wet concrete can be poured and compacted so that it will flow
and finally set to the inner profile of the mould.
If chamfered edges are required triangle fillets must be inserted
into the form work.
Functions of Formwork system
It should be strong enough to support the load of wet concrete.
( 2400 kg/m3)
It must not be deflected under load which includes the loading of the
wet concrete, self wt and any superimposed loads such as
operatives and machines etc.
It must have grout tight joints. (Grout leaks can cause honeycombing or produce fins. Defective concrete means time /
cost) Grout leaks can be prevented by using sheet material
to seal the joints. Eg. flexible Poly urethane strips or self
adhesive tapes.
It must be accurately setout. (correct shape, size, position etc.)
Form size should be designed so that they are the maximum size
which can be handled by hand or by a mechanical means.
Material should be light, tough, easily fitted, cost effective, easy to
remove and give a good surface finish.
The design should be such that they can easily assembled and
dismantled without any member being trapped.
Materials for formwork
Rubber or class III timber (comparatively Soft wood) ~
Low quality works
Plywood
Chipboard
Steel
Al alloys
Mould oils and Emulsions
There are 2 particular defects
Blow holes small holes in the concrete surface due to
trapped air between formwork and concrete.
Uneven colours due to irregular absorption of water
from the wet concrete by the formwork material. A
mixture of old and new materials very often accentuates
this particular defect.

Mould oils will alleviate these defects. Mould oils are designed to
overcome these problem specially using steel forms by encouraging
the trapped air to slide up the surface of the formwork.
Care to be taken since some oils cause some retardation of the
setting time of the cement causing the defect Dusting.
Emulsions are easy to apply but may promote rusting in steel forms.
Oils and emulsions are release agents and it is essential they are
only applied to the form work and not to the reinforcement since
this may cause a reduction of bond.
Spacing of ties and clamps are depend on the actual concrete
pressure at the location. Pressure will vary according to
Rate of placing
Type of mix richer will be the grater
Method of placing if vibrators are used pressures can
be increased up to 50% over hand placing.
Air temperature lower temperature the slower is the
hydration and consequently higher pressures.
1. Preliminary preparations/Pre planning
Reference of latest drawing
Shop drawing to be prepared
Surrounding area to be cleaned
Level and lines to be obtained
Idea about the sizes of columns, beams, slab thickness and wall
thickness and heights also their locations and elevations etc.
Organize required materials plywood, nails, nut and bolts, form oil,
timber, frames, How many?
Required accessories - props, pipes, tie rods, soldiers, P- cones,
threaded bars, wing nuts, rapid clamps
Priority areas to be identified
Identify the sizes and locations of openings, drops, ducts etc.
Kickers to be checked with the setting out
Co-ordination with R/F, Concrete, M&E parties etc.
Check whether there any built-in parts in the concrete.
2. Pre-Concrete works
Verticality to be checked (Columns, walls, beams sides)
Levels to be checked.( Columns, walls, slabs, beams etc)
Method of concrete to be pre determined (to plan the scaffolding
etc)
Props to be checked
Joints, holes and connections to be checked properly.
Cleanliness in the formworks Column heads, beam bottoms
specially.
Keep cleaning provisions in the form work specially in the columns.
3. Post concrete inspections
Verticality to be checked

Spilled concrete on formwork and props etc. to be cleaned

Clean the concrete on R/F
Cover the area if there going to be rain
Protect it from trespassers while green
Avoid walking on the projected R/F starters
4. Dismantling/ striking of form work
Extra care to be taken not to damage the shutters and finish product
Shutters to be removed using appropriate methods and tools and
should be stacked properly after cleaning
Collect accessories
Remove all ties utilized
Remove P- cones
Clean the area
Striking time of the form work
5. Problems noticed in this area
Buldging
Verticality
Finish defects
Sagging
Twisted columns
Leaving form pieces unattended with the concrete
Tie failures
Brace failures and Collapse
Grout leaks/ debris collection pits

System Formwork
Systematic / Methodical / Easy to erect
Quality finish
Virtually zero fabrication
No fabrication debris
Speedy construction
Less indirect works for construction gangs
Easy / Clear planning
Easy to monitor and control

(-) ves
High initial capital cost / High maintenance cost
Make up panels for missing and lost ones
Zero sharing
Strict material planning and management required
Accessories are costly and liable to get lost
Well trained technical support
High welding and fab. Cost
Zero changes/ alterations
Noise during errection
Consistent labour gangs / Labour disputes
Work specialization
Theft

Climbing Shutters