Formwork

By Aabhinav Kumar

Formwork

Definition
A structure, usually temporary (but sometimes
wholly or partly permanent), used to contain
poured concrete to mould it to required
DIMENSIONS, FINISHES and SUPPORT it
until it is able to support itself.
Formwork consists of contact face material and
the bearers which support the face material.
2

Common Types of Formwork

Wall Form

Common Types of Formwork

Wall
Form

Combined formwork and

falsework

Formwork and falsework can be combined into a single

handleable unit
Time could be saved in erection and stripping and the
labor content of the operation thus significantly reduced
Large repetition is a must for this method to be effective.

Formwork
Three general principles govern
formwork design and
construction:
QUALITY
SAFETY
ECONOMY
6

Quality of Formwork
Relating to the formed faces of the
permanent concrete structure and
refers to the following two aspects:
Accuracy of Concrete Shape
Quality of Concrete Surface

Quality of Formwork
Accuracy is controlled by the
deviations permitted (Tolerances)
in the :
Formwork deflection
Materials
Components
Workmanship
8

Quality of Formwork
To minimise deviations, all formwork
must have adequate means of:
Alignment and adjustment both at
construction joints and throughout the
formwork
e.g. Simple wedges, screw adjustments
on supports, camber adjustments
9

Quality of Formwork

Failures in achieving surface quality are

often caused by:
Lack of formwork stiffness to resist the
movement coming from concrete vibrators
during concrete placement and the
subsequent grout loss at the joints (honeycombing, harder stripping)
Concrete shape, disposition of steel bars
Efficiency of conc. placement, forms
stripping
10

Quality of Formwork
Different concrete structures buried
underground or exposed to naked eyes
require different class finishes specified by
the contract document
The formwork design requires appropriate
method of construction/treatment, different
surface irregularities requirements and
types of contact face sheeting materials

11

Safety of Formwork
Two major aspects must be
covered:
Personal Safety of both
formworkers and the public
Safety of the formwork
structure
12

Safety of Formwork
I.

Construction phase
As a general practice, the erected formwork
shall be :
Structurally safe
Having secured and effective guard rails,
toeboards, access ladders and stairs around its
periphery
Formworkers equipped with safety helmets and
boots
For high work, safety harnesses and security
screen are to be installed
13

Safety of Formwork
II. Design phase
a) Evaluation of possible Loading
Combinations occurred in the following
stages:
Stage 1: before conc. Placement
Stage 2: during conc. Placement
Stage 3: after conc. Placement
14

Safety of Formwork
b) Structural requirements
Three important aspects to be met:
STRENGTH (material strength and force
equilibrium)
STABILITY (Sliding, overturning, uplift and
sidesway)
STIFFNESS (accuracy and permissible
tolerances)
15

Economy of Formwork
Where formwork is highly repetitive
activity, a small reduction in
fabrication/stripping could result a
significant overall cost saving.
Cost involves formwork materials and
labor, erection (including hoisting),
stripping, repairing and cleaning of
formwork after concrete pour.

16

Economy of Formwork

Increase in no. of reuses lower the unit cost

of the formwork
More sophisticated design could be
economically justifiable esp. when less
maintenance will be required.
Good formwork, apart from meeting the
technical specifications requirements,
means it is easy to fabricate, erect, adjust,
dismantle, and within the available
crane/man handling.
17

Care of Formwork
For maximum formwork life, efficient
stripping; care in formwork handling,
storage, and maintenance are essential
After stripping, the formwork units for
reuse should be moved away from the
work area (workers of other trades may
damage it as an item of obstruction left
there).

18

Care of Formwork
They should be stored and protected
from weather to avoid surface damage
Large formwork panels should be
stacked in racks, facing away from direct
sunlight
Hardened slurry, dirt left from previous
pour should be removed from plywood
sheeting surfaces before they are getting
harder

19

Care of Formwork

Mechanisms, locking devices and fixings

should be cleaned and oiled.
Face sheeting to be given a coat of release
agent
Care to be taken not to damage the presealed
surface of the plywood sheeting (Use a soft
brush in dust removal and a softwood wedge
to remove larger concrete particles)
20

Backpropping

The speed of construction

vertically will dictate a number
of slab levels acting together to
support the total construction
loads imposed from the topmost
concrete slab casting operation
21

Backpropping

To avoid excessive loads building

cumulatively in the backprops,
backprops are loosened after
striking a slab formwork and then
repositioned and retightened. The
cast floor is thus allowed to take its
deflected shape hence the load
imposed from the floor(s) above
22

Formwork Materials
Face Contact Materials (features left*)
Sawn board formwork (sawmarks*)
Plywood (fine & smooth surface*)
Steel form (variable color*)
Aluminium form (react with cement*)
Glass fibre reinforced plactics (highest quality
for sculptured profiles*)
* features/drawback

23