SUMMARY

-Definition of
FORMWORK
.4

-Categories of
FORMWORK
5

-Materials
used
6

- Timber
formwork
..7
- Plywood
.7
- Steel
formwork
.8
- Aluminium
formwork
..9
- Plastic
formwork
.9

-Process of formwork
construction...10

- Formworks for
wall
.11
- Formworks for
column
.12
- Formworks for circular and octagonal
columns.14
- Formworks for
beam
..15
- Formworks for
staircase.
.15
- Formworks for suspended slab..
......16

1
 - Formworks for sole
plate.1
7

-
Curing
.18

-
Deshuttering
..18

-Formwork
techniques
..20

- Slip form
technology
.20
- Tunnel formwork
system
24
- Column system
formwork
.29
- Prefabricated
formworks
32

-Time of removal of
formworks
36

-Safety
precaution
..37

-Striking, maintenance, storage of

formwork.37

2
3
FORMWORK
Formwork is an ancillary construction, used as a mould for a structure. Into
this mould, fresh concrete is placed only to harden subsequently.

The construction of formwork takes time and involves expenditure up to

20 to 25% of the cost of the structure or even more.

The operation of removing the formwork is known as stripping. Stripped formwork

can be reused. Reusable forms are known as panel forms and non-usable
are called stationary forms.

A good formwork should satisfy the following requirements:

- Strong enough to withstand all types of dead and live loads

- Rigidly constructed and efficiently propped and braced both

horizontally and vertically, so as to retain its shape

- The joints in the formwork should be tight against leakage

of cement grout

- Construction of formwork should permit removal of various parts in

desired sequences without damage to the concrete

- Material of the formwork should be cheap, easily available and should

be suitable for reuse

- The formwork should be set accurately to the desired line and levels
should have plane surface.

- As light as possible

- Material of the formwork should not warp or get distorted when

exposed to the elements

- Should rest on firm base

4
 The following points are to be kept in view to effect economy in the
cost of formwork:

The plan of the building should imply minimum number of variations in the
size of rooms, floor area etc. so as to permit reuse of the formwork
repeatedly.

Design should be perfect to use slender sections only in a most economical

way.

Minimum sawing and cutting of wooden pieces should be made to enable

reuse of the material a number of times. The quantity of surface finish
depends on the quality of the formwork.

CATEGORIES OF FORMWORK
Conventional: The formwork is built on site out
of timber and plywood or moisture-resistant particleboard. It is easy
to produce but time-consuming for larger structures, and the
plywood facing has a relatively short lifespan. It is still used
extensively where the labour costs are lower than the costs for
procuring reusable formwork. It is also the most flexible type of
formwork, so even where other systems are in use, complicated
sections may use it.

Modern-Day Formworks: This formwork systems are mostly

modular, which are designed for speed and efficiency. They are
designed to provide increased accuracy and minimize waste in
construction and most have enhanced health and safety features
built-in. The main types of formwork systems in use now are:

1. Table form/flying form

2. System column formwork

3. Horizontal panel

4. Slip form

5. Tunnel form

Engineered/Pre-fabricated Formworks: This formwork is built

out of prefabricated modules with a metal frame (usually steel
or aluminium) and covered on the application (concrete) side with
material having the wanted surface structure (steel, aluminium,
timber, etc.). The two major advantages of formwork systems,

5
 compared to traditional timber formwork, are speed of construction
and lower life-cycle costs (barring major force, the frame is almost
indestructible, while the covering if made of wood; may have to be
replaced after a few or a few dozen uses, but if the covering is
made with steel or aluminium the form can achieve up to two
thousand uses depending on care and the applications).

MATERIALS USED
Formwork are mainly of two types

- Steel formwork

- Wooden formwork

Steel formwork is made of

- Steel sheets

- Angle Iron

- Tee Iron

Wooden formwork consists of

- Props

- Planks battens

- Ledgers

- Sheeting

6
 Timber formwork:

- Most common material used for bracing the member, hence called
as the traditional formwork.

- can easily be cut to size on site. Joist are replaced with engineered
wood beams and supports are replaced with metal props. This
makes this method more systematic and reusable.

- Various sizes of members of timber

Sheeting for slabs, 25 mm to 40mm

beam, column side thick
and beam bottom

Joints, ledges 50 x 70 mm to 50 x
150 mm

Posts 75 x 100mm to 100

x 100 mm

Plywood

- This is by far the most common material used for the facing panel. It
is easily cut to shape on site, and if handled and stored carefully, it
can be used many times.

- A standard plywood thickness on site is 18mm. This is usually

sufficient for most pours.

7
 - However, if the formwork is curved, a thinner plywood is used to
facilitate bending.

- Thicker plywood may be used when the weight of concrete causes a

standard thickness plywood to bow out, distorting the concrete face.

Steel formwork:

- Steel forms are stronger, durable and have longer life than timber
formwork and their reuses are more in number

- Steel forms can be installed and dismantled with greater ease and speed.

- The quality of exposed concrete surface by using steel forms is good and
such surfaces need no further treatment.

- Steel formwork does not absorb moisture from concrete.

- Steel formwork does not shrink or warp

8
Aluminium formwork

- Often used in pre-fabricated formwork, that is put together on site.

- Aluminium is strong and light, and consequently fewer supports and ties
are required.

- The lighter sections will deflect more, but this can be avoided by simply
following the manufacturers recommendations.

Plastic formwork

- Glass reinforced plastics (GRP) and vacuum formed plastics are used when
complicated concrete shapes are required (e.g. waffle floors).

- Although vacuum formed plastics will always need support, GRP can be
fabricated with integral bearers making it self supporting.

- Like steel, plastic formwork can be re-used many times, as long as care is
taken not to scour the surface whilst vibrating the concrete.

9
 PROCESS OF FORMWORK
CONSTRUCTION
Construction of formwork:

This normally involves the following operations:

1. Propping and centering

2. Shuttering

3. Provision of camber

4. Cleaning and surface treatment

10
FORMWORKS FOR WALL

It consists of

Timber sheeting

Vertical posts

Horizontal members

Rackers

Stakes

Wedges

After completing one side of formwork reinforcement is provided at the place

then the second side formwork is provided.

Wall Formworks and its components :

FORMWORK FOR COLUMN:

11
Erection sequence for a column

Prior to positioning column formwork check that steel for the column has been ins
pected and cleared for casting.

- Position formwork for the column from predetermined grids.

- Plumb formwork both ways and securely support using adjustable steel pro
ps.

- The propping angle should be 45 to the floor.

- Ensure the steel props are safely secured to the column formwork and the

floor, and that adjustment for pushing and pulling is operational.

- Set out the positions of column clamps from a storey rod.

- Transfer the column clamp positions from the storey rod onto column form
work.

- Use nails to support the arms of column clamps while wedging.

- Position and wedge the bottom, middle and top clamps sets.

- Check the formwork at the top for square.

- Position and wedge the remainder of the column clamps.

- Using a plumb bob suspended from a gauge block plumb the comlum

12
 When all the column formwork is securely propped a final check must be made f
or plumb and column alignment before and immediately after the concrete
has been poured and vibrated.

CIRCULAR AND OCTAGONAL COLUMNS

Circular column formwork

13
Fabricated steel, usually two piece, and often with a hinge.

Fibre cement pipes which are left in place as permanent formwork.

Timber sheathing tied with standard column clamps. Corners need to have infill pi
eces. Alternatively, metal strap can be used without the need for corner infills.

COLUMN BRACING FORMWORK

Column formwork bracing performs two functions:

It must maintain the accuracy of the column form position and plumb so that it i
s within tolerance.

Withstand results of forces acting on either the column formwork or the bracing.
The forces may be wind or
impact. These impact forces can occur from the collision of
concrete buckets or cranes hoisting materials

14
FORMWORK FOR BEAM

Beam soffit must be thickened timber or strengthened plywood.

Beam sides 18mm plywood or 25mm boards, with studs (cleats) at 500 to
600mm centres.

Deep beams (over 600mm) should have walkers and ties.

Use angle fillets in the beam side to soffit joint where possible.

Allowance must be made for height adjustment of the props or falsework.

Erection sequence for constructing beam formwork includes

Position of sole plates;

Marking out and setting heights for falseworks;

Assemble and position props, adjustable head jacks,

falseworks , bearers and Spreaders;

Construct and erect side walls and beam soffit.

Position of sole plates

FORMWORK FOR STAIRCASE

Points to consider when designing stair form work :

15
Stair formwork must support the weight of concrete.

The weight of the throat of the stair and the steps will

have to be supported.

Because of the slope of the stair, some of the force is

transmitted sideways. All formwork must be well tied

together to prevent sideway movement.

Consider the finish of the stair treads and type of nosing.

Space may have to be left for purpose made nosing.

SUSPENDED SLABS

Suspended floor slabs can be constructed using cast in situ, precast units or a co
mbination of both.

Whichever method is
used, it is important to support the proposed method ofconstruction using a comb
ination of timber or steel bearers and adjustable shoring.

The spacing and type of support system required is

determined by the load imposed during the

construction process.

Manufacturers provide tables to assist in the selection

and spacing of adjustable shoring

systems. The erection sequence for con

structing a

suspended floor slab includes:

Determining the bearer spacin
g;

Erecting bearers and joists;

Fixing the sheeting;

SOLE PLATE

The purpose of a sole plate is to transfer vertical load from

16
one vertical support member to the foundation

The vertical support requires a base plate fitted to help

distribute the load to the sole plate, which is usually a

sleeper.

If the sole plate is positioned on natural ground, it is

important the ground is graded and consolidated to a

level surface.

The objective is to achieve maximum bearing beneath

sole plate. Once sole plates are positioned and firmly

bedded they should be checked for level.

CURING
Curing is the process in which the concrete is protected from loss of
moisture and kept within a reasonable temperature range. The result of
this process is increased strength and decreased permeability. Curing is

17
 also a key player in mitigating cracks in the concrete, which severely
impacts durability

The length of adequate curing time is dependent on the following factors:

Mixture proportions

Specified strength

Size and shape of concrete member

Ambient weather conditions

Future exposure conditions

Deshuttering is a process after curing

DUSHUTTERING
DESHUTTERING in simple means, the process of removing the
shuttering (Formwork for Concrete).

Order and method of removing formwork:

Shuttering forming vertical faces of walls, beams & column sides should
be removed first. Shuttering forming sofit to slab should be removed next.

Shuttering forming soffit to beams, girders or other heavily loaded

members should be removed in the end.

Factors considerd :

Concreting is done under normal circumstances

Cement used is Ordinary Portland Cement

Adequate curing is done

Ambient temperature is not fall below 15 degree

DESHUTTERING AGENTS

There are chances of concrte sticking to the formwork

18
 Hence deshuttering agents are used to ease the process

Dosage / Coverage:

Dilution

TRADITIONAL FORMWORK

Timber form work was used traditionally later it got replaced with modern
materials due to its limitations and cost factors

Formwork is built on site with timber and ply or moisture resistant particle
board.

It is easier to produce but the time taken is more

Extensively used where the labor cost s are low

It is the most flexible type of formwork

-Usually timber in the form of plywood, planking,batten and joist are used as the
basic material.

-Human workers need to enter into every corner to perform

the formwork installation works.

EXPLORING FORMWORK
TECHNIQUES
19
SLIPFORM TECHNOLOGY
INTRODUCTION:

Method of vertically extruding a reinforced concrete section and is

suitable for construction of core wallsin high-rise structures lift shafts,
stair shafts,towers.

The formwork rises continuously, at a rate of about 300 mm per hour,

supporting itself on the core and not relying on support or access from
other parts of the building or permanent works.

Allows for the continuous pouring of concrete into walls of a

structure and only stops when the full required height of the
structure has been reached.

The height of the formwork is designed in such a way that while the top of
the formwork is being filled by concrete the lowest layer of
concrete poured earlier has already gained an initial set. When the
formwork is moved upwards the concrete that is then exposed remains
firm.

PROCEDURE :

Assembly can only start once the foundations are in place and the wall
starter is in correct alignment.

Slipform shuttering is aligned with the help of yokes.

Horizontal crossbeams connect these yokes.

20
 Hydraulic jacks are attached to these crossbeams for simultaneous
upward movement.

Height of the slipform ranges from 1.1 to 1.5 metres.

Yokes and crossbeams also used to support the working platform

Structure should be rigid and shape maintained at all times.

Make sure there is no lag or else it prevents the structure from free
upward movement

It is also possible to reduce wall thicknesses

as the construction gains height and arrangements

have to be made in the slipform structure that will

enable such reduction at regular intervals.

21
HORIZONTAL FORMWORK :

Slipform methods of construction can also be adapted to horizontal

structures and are used for paving, canals, and tunneling.

The technique is more in use for structures that have continuous walls
like silos , chimneys, and piers for very tall bridges.

It has also been successfully used for construction of buildings, although

this requires the manner of leaving inserts for openings like doors and
windows to be decided well in advance, as well as also any necessary
inserts to support floor slabs after the walls are constructed.

ADVANTAGES:

A major cost of concrete structure construction is the required

formwork to retain the concrete till it can be safely de-shuttered and be
able to support itself and other imposed loads.

The formwork needs to be continually removed to newer locations and

then re-erected.

Continuous use of manpower and lifting equipment like cranes.

22
 In the case of slipform building, the formwork is erected only once and
remains intact until the entire structure is completed.

Great reduction in the cost of formwork as

well as time saving for re-erection.

Cost effective

Saving onto the labour cost otherwise

used for intermittent concreting operations.

The reduction in the movement of formwork and workers also leads to far
more safe working conditions that also make it a major advantage.

PRECAUTIONS

Concrete is continuously protected against loss of moisture and

rapid temperature changes for 7 days

Unhardened concrete is protected from rain and flowing water

Prevent plastic shrinkage

Plastic cracks are filled by injection of epoxy resin.

23
TUNNEL FORMWORK SYSTEM
Tunnel formwork system allows the contractor to cast walls and slabs in
one operation in a daily cycle.

It combines the speed, quality and accuracy of factory/off-site

production with the flexibility and economy of in-situ construction

Recognized as a modern method of construction (MMC).

The result is a cellular reinforced structure, the surfaces of which are

sufficiently high quality to require only minimal finishing for direct decoration,
while the end walls and facades are easily completed with thermally insulated
units that can be clad as required.

The system creates an efficient load-bearing structure for use in a wide

variety of applications.

It is particularly effective in projects suited to repetitive cellular construction

such as residential blocks, hotels, student accommodation, barracks and
prisons.

24
ADVANTAGES:

Cost

cost-effective, high quality construction,

generating significant savings in time

and costs over alternative methods

without compromising on design

Building

The repetitive nature of the system and the use of prefabricated forms
and reinforcing mats/cages simplifies the whole construction process,
producing a smooth and fast operation

Quality

Quality is enhanced despite the speed of construction. The precise, even steel
face of the formwork creates a smooth, high quality finish capable of receiving
direct decoration with the minimum of preparation (a skim coat may be
required). This reduces the requirement for following trades, thus
providing additional cost savings and speeding the entire process.

Design

The large bays constructed provide exceptional flexibility in the design and
layout of the building and allow a high degree of freedom in the final
appearance.

Safety

Integral working platforms and edge protection systems. The repetitive,

predictable nature of the tasks involved encourages familiarity with operations.
The minimal requirement for tools and equipment further reduces the
risk of accidents on site.

25
Sustainability

The in-situ casting of units on site and the local availability of ready-mixed
concrete supplies reduce transportation impacts.

Just-in-time deliveries and near zero wastage produce an overall tidier site
with associated cost savings and safety benefits.

Concretes thermal mass coupled with correct insulation and boiler design
minimises heating costs and can even reduce air-conditioning
requirements.

GENERAL FACTS :

Tunnel formwork come in half units and in the form of an inverted L which
are bolted together at the top to form each tunnel. The inbuilt wheels and the
jacks help the formwork move in and out of the position and adjusted to the final
height.

The factory-made steel formwork can be re-used up to 600 times and it can
suit a variety of module sizes. This makes the method of construction very
versatile and extremely economical.

Tunnel-form work allows a 24-hour construction cycle to be achieved and thus

the buildability of in-situ concrete is improved by choosing this type of formwork.

The Casting Process of Tunnel Formwork:

1) Stage One: Prefabricated Wall reinforcement is placed by crane along the

entire wing prior to casting the kickers (used to position wall formwork).

26
2) Stage Two: Two and a half tunnel is craned into place, bolted together and
ties are added.

3) Stage Three: The wall concrete is poured.

4) Stage Four: The slab reinforcements are fixed

5) Stage 5: The slab concrete is placed. The formwork system provides for a
pour to be wrapped in tarpaulins and for the use of butane heaters to maintain a
sufficiently high temperature for the concrete to reach its striking strength
overnight.

27
6) Stage 6: The tunnel-forms are removed next day.

7) Stage 7: The process is repeated for the next two bays.

Tunnel form can produce strong and durable in-situ cellular structures. This
method of construction can achieve time savings up to 25% with cost savings of
15%.

Since the concrete finish is very good, the requirement for post construction
trades such as plasterers and electricians are greatly reduced.

28
 COMPONENTS OF TUNNEL FORMWORK

COLUMN SYSTEM FORMWORK

The column formwork systems now available are normally modular in nature
and allow quick assembly and erection on-site while minimizing labor and
crane time. They are available in steel, aluminium and even cardboard (not
reusable but recycled) and have a variety of internal face surfaces depending
on the concrete finish required. Innovations have led to adjustable, reusable
column forms which can be clamped on-site to give different column sizes.

29
Benefits

Increased speed and efficiency in construction

The requirement of skilled labor is reduced due to the

simplicity of assembly and disassembly.

Metal column forms can be assembled and erected more easily than
traditional formwork.

Disposable forms come ready assembled to site.

High quality surface finishes are possible.

The highly engineered nature of the metal formwork system enables precision
adjustment to the formwork

Safety

30
 Metal formwork systems can have integral ready-to-use concreting
platforms with guard rails and access equipment including ladders. This
reduces the need for independent access.

For systems with disposable formwork, working platforms for concreting

have to be erected separately to allow safe access to the top of the column
forms.

Formwork systems are available which need to be worked only from one
side. This could be an important safety consideration for columns situated
at building edges and corners.

Metal systems typically provide robust assemblies.

Assembly process is simple allowing site operatives to become familiar

with health and safety aspects.

Normally these formwork systems require minimal use of power tools.

Other considerations

Column forms are designed for specific maximum concrete pressures. The
concrete placement rates have to be adjusted to keep the concrete pressure
within the specified limits.

The assembled formwork has to be restrained at the base properly to avoid

displacement, and grout loss during concreting.

31
PREFABRICATED FORMWORK

ADVANTAGES OF PRE- FABRICATED FORMWORK

Very little on-site skilled labor needed.

The ability to reuse forms either as a large section or as individual units.

All prefabricated systems are designed for light as well as heavy

construction.

32
 Contractors can bid almost any type of work; straight, battered, curved or
cut-up.

Prefab forms may be set in any combination, horizontally and vertically, to

any wall height.

On high walls, one side of forms can be erected and ties placed; then the
close-out side can be erected during placement, minimizing concrete drop
and assuring effective vibration.

In a prefab system the contractor can remove and replace forms at any
point. This simplifies erection and stripping, which can be started at any
location.

To allow for a casting pocket, a panel is simply removed and replaced

maintenance of forms can be a tiresome task, but well-maintained forms
mean more reuses.

A big advance in prefab forming has been the development of gang

forming, which is simply defined as the grouping together and moving of a
number of forms as a single unit.

The success of gang forming is due to the development of easy-to-use

hard w a re and ties, made especially for this forming technique.

Since pre forms are pre - engineered and precision made, they offer the
best materials available and work equally well on all jobs, resulting in lower
cost per use. Although prefabricated forms work well on any size job, the
small job is a good way to introduce the system to the workmen

DRAWBACKS

33
 High cost factor

Greater transportation cost, due to the large pieces, where as the regular
formwork can be transported easily .

Too many pieces involved in the pre fabricated formwork

Pre fabricated formwork, leave poor finishes at the joints of the forming
members.

Pre- fab formwork deflect during placement.

The first cause of deflection is the rate of placing, which is usually too fast.

If recommended placing rates are followed and there is good supervision of

placement and vibrating, the problem of deflection can be controlled.

With many prefab systems, panels can be re m oved at different locations

and used as casting pockets.

This procedure avoids dropping the concrete a great distance and helps to
maintain a more constant rate of placement.

POINTS OF CONVENTIONAL MODERN DAY PREFABRICATED

DIFFERENTI METHOD METHOD METHOD

34
 ATION

MATERIAL TIMBER( Plywood STEEL AND Frame of

USED Or moisture- ALUMINIUM. ALUMINIUM
resistant covered with
Particleboard). ALUMINIUM OR
TIMBER

TIME VERY TIME DESIGNED FOR Work happens

CONSUMPTI CONSUMING. SPEED AND simultaneously
ON (For large EFFICIENCY. with construction
structures.) (mostly modular) hence saves time

LIFE SPAN The plywood LONGER LIFE SPAN The frame is very
facing has a durable
relatively (If made of metal
SHORT LIFE SPAN. n aluminium can
be used for 2000
times)

USED IN The labour costs The labour costs The labour costs
are LOWER than are HIGHER than are HIGHER than
the costs for the costs for the costs for
procuring reusable procuring reusable procuring reusable
formwork. formwork. formwork.

FLEXIBILITY MOST FLEXIBLE LESS FLEXIBLE. There is NO

FLEXIBILITY after
making the
formwork

Time of Removal of
formwork
Sr. No Structural Member CPJ

1 Beam sides, walls 7 Days

& Columns

2 Slab (Vertical 7 Days

Supports remains
intact)

35
3 Slab (Complete 10 Days
Formwork
removal)

4 Beams (Removal 12 Days

of Sheeting, Props
remains intact)

5 Beams & Arches 18 days

(Complete
formwork
removal) (up to 6
m span)

6 Beams & Arches 23 days

(Complete
formwork
removal) (more
than 6 m span)

36
 FAILURE OF FORMWORK
Formwork failures are the cause of many accidents and failures that occur
during concrete construction which usually happen when fresh concrete is
placed

Generally some unexpected event causes one member to fail, then others
become overloaded or misaligned and the entire formwork structure
collapses

Improper stripping and shore removal

Inadequate bracing

Vibration

Unstable soil under mudsills, shoring not plumb

Inadequate control of concrete placement

Lack of attention to formwork details

Inadequate cross bracing and horizontal bracing of shores

Forms sometime collapse when their shores/ jack are displaced by the
vibration caused by:

passing traffic

movement of workers & equipment on the formwork

the effect of vibrating concrete to consolidate it

37
 SAFETY PRECAUTION
Material used for the construction of formwork must fulfill the specification.

Formwork is fixed firmly & properly

Construction area must be protected to prevent vandalism of formwork.

Warning sign must be put up at the area where the formwork is fixed to
prevent entrance of people that may damage the formwork.

The formwork must be inspected before the concrete is poured.

STRIKING, MAINTENANCE, STORAGE OF FOR

MWORK
Striking :

As column and beam side formwork will be removed before beam and slab
soffit formwork, provision must be made for easy removal and in the correct
order.
If beam and slab soffit formwork is to be removed before the concrete has achiev
ed working strength, permanent propping or shoring is required.

38
Take care to avoid damage to formwork which is to be re used. Eight or more use
s may be obtained from timber formwork.

Maintenance Clean forms with stiff brush and clean cold water.
Use scrapers only as a last resort.
Keep forms well oiled to prevent delamination of
plywood or rusting of steel and always oil the edges.

Storage of forms
Any formwork with steel components should be stored in the dry. Avoid direct
sunlight on timber forms.

Store clear of the ground without twist or bend, and keep free of dirt.

39