An Analysis of Formwork Failures

o rm w o rk failures can occur on a small wall or a

high-rise building. Failures in high-rise work usually result in the most injuries and deaths. This is true,
logically, because men are either on the deck or below
it and have neither the time to move nor a place to
which they can move.
We can assume that failures are caused either by poor
planning, poor design, inadequate inspection or the human element.
Almost all failures occur at the time when concrete
placement adds considerable weight and pressure on
the formwork. On normal wall forming, a breakout is a
common failure and it can occur on any height wall at
any time.
Some of the major causes of breakouts are:
1. Missing hardware
2. Improperly connected hardware
3. Tie ends not secured with hardware or forms
4. Placing at too fast a rate
5. Damaged ties left in place
6. Improper tying
7. Insufficient tying
8. Vibration
9. Inadequate waling and strongbacking
10. Inadequate bracing

Lets look at each of these points:

1. Missing HardwareWhen erecting forms, it is very
easy to overlook placement of hardware. Most systems
require hardware wherever a tie is used. Howe ve r, in order to speed up the job as forms are erected, only
enough hardware is connected to hold the forms in
place. The workmen plan to come back and place the
balance of the hardware later on. As they follow up, they
may overlook a location or two, or prior hardware may
loosen and weaken the total connection at a joint.
2. Im p ro p e rly Connected Ha rd w a re This relates
somewhat to the first problem, but is a major cause by itself. Each tie end should be checked to be sure it is secured in place by hardware. Although most systems are
fairly similar, some use attached hardware while others
do not. This can be a problem, for while it appears the
hardware and tie are connected, they may not be.
3. Tie Ends Not Secured in PlaceIn some systems, the
tie end or loop is between the forms and the connecting
hardware can miss the loop of the tie. This leaves the tie
loose and the formwork unsecured.
4. Placing Too FastAll ties are designed for a safe
working load and the manufacturers of ties will recommend the rate of placing under various conditions. This
information is usually printed on tie cartons, packaging
materials or in brochures.
5. Damaged Ties Left in PlaceTies damaged during

shipping or erection should be replaced. The common

snaptie has a breakback point for breaking back the tie
ends after stripping. Its at this point where trouble may
occur if the tie has been damaged or bent. Steel workers
and mechanical tradesmen should be cautioned regarding the care taken of ties. Taking chances with damaged
ties can mean expensive trouble and possible injury.
6. Improper TyingThe use of the wrong size tie or the
use of ties in a manner for which they were not intended can cause trouble. Manufactured ties are normally
marked for size and the type of use for which they are intended. A difference of a quarter- or half-inch in tie
length can cause offsetting of forms. Once placing starts,
additional load is placed on the shorter length ties and a
breakout may occur.
7. Insufficient TyingCareful planning and control
means that the correct number of ties will be used, both
vertically and horizontally. Overtying can add up, but a
failure due to lack of ties can be more expensive. The
number of ties and their spacing should be determined
by wall height, rate of placement, temperature of concrete and safe load capacity of the ties.
8. VibrationThe proper vibrator should be selected
for different types of work, to avoid ove rv i b ration or an
increase in temporary pressure on the forms and ties.
The careful insertion and removal of a vibrator from the
concrete is important to good vibration and the protection of ties. Vibrators in direct contact with ties can cause
a tie to snap or break under impact.
9. Inadequate Waling and StrongbackingDepending
upon the formwork system used, walers and strongbacks may be used for alignment, structural strength
and tying. They should be considered for size of lumber
used and location or spacing depending upon wall dimensions. Their function or design can have a direct
bearing on the performance of the formwork and its stability.
10. Inadequate BracingBracing usually begins with
the plumbing and aligning of the formwork. Proper
spacing should be determined for both vertical and horizontal use on different wall heights. For high walls,
braces can be spliced or cables and trusses used.
On high-rise buildings, as stated earlier, the problem
is increased and much harder to control. A shoring failure (and this appears to be the greatest cause of form
failures) can result in a job shutdown, an investigation as
to cause, a financial loss, and possible injuries or loss of
life to workers.
There are, generally speaking, three methods of
shoring in use today: (1) the use of contractor-designed
and built shoring, (2) the use of manufactured shores
and accessories, and (3) the use of a complete prefabricated shoring system.

When a contractor builds and erects his own shoring

materials, he alone is usually responsible for its performance. He must design his formwork considering proper loads, ease of stripping, reshoring, and the safety factor. The design of such work should only be undertaken
by an engineer or a person knowledgeable enough to
know the requirements. A failure in do-it-yourself equipment can be the hardest to determine or locate.
When the contractor rents or purchases shoring and
accessories, the manufacturer provides printed information on shore spacing and load specifications. Additional help is usually available from the manufacturer in
detailing and field assistance. A failure can be the contractors fault if he does not follow recommendations, or
the manufacturers responsibility if the equipment
should fail. It can be a combination of both if there is a
lack of communication between them. The same holds
true if the contractor uses a complete prefabricated system. If the equipment is misused, layouts are not followed, short cuts are taken, or there is inadequate supervision, a collapse is likely to occur.
In order to have an accurate shoring layout prepared
by any manufacturer, complete information and all
known job conditions should be furnished. If the layouts
are followed and changes in job design are incorporated,
no problems should arise.
Another failure factor may result from stripping forms
and shoring before the concrete has achieved adequate
strength. Reshoring, if necessary, should be properly located with relation to the forming of floors above.
Bracing cannot be emphasized enough. All lateral
movement must be eliminated. Bracing will add
strength to the shoring if it should be bumped accidentally, and it protects against a chain reaction if some area
should fail. There is no guarantee against failure, but
good cross bracing is good preventive practice.

There are always other factors which could contribute

to a failure. For example, reinforcing steel stockpiled in
the wrong location could trigger trouble or a crane boom
could fall across a deck. Other dangers are column failure, collapse of a lower floor due to improper practices,
and unexpected foundation settlement, due to unsound
bearing capacity.
Prior to concrete placement a final check should be
made, for overlooking even one item could be disastrous. The following are some major points that should
be checked, although each system will have its own design and will have different erection and inspection procedures:
1. Check for sound bearing or sill
2. Be sure all shoring is plumb
3. Be sure all shoring is resting on plate or sill, not
hanging loose from deck work
4. Check out bracing locations and see that all bracing
is connected
5. Check shoring against layouts for correct positioning
6. Check for proper grade adjustment
7. Check all locking devices
8. Be sure shoring is properly secured to deck work
above
9. Check layouts to see that correct sizes have been
used and that nothing is missing
10. Double check spans so that overloading will not
occur.
Regardless of the type equipment or materials used,
the same attention, careful planning, supervision and
inspection should prevail on each job. Forming failures
shouldnt occur, but they do. The point is to do everything possible to eliminate them, thereby reducing the
percentage of accidents, injuries and deaths.

PUBLICATION #C670161
Copyright 1967, The Aberdeen Group
All rights reserved