SCOPE

This procedure applies to the installation of formwork and the controls required during
assembly, erection and final positioning of formwork used in Structural concrete operations.

REFERENCE OF DOCUMENTS:
1. IS: 4990:2011- PLYWOOD FOR CONCRETE SHUTTERING WORKS —
SPECIFICATION
2. Technical Specification of Contract

PROCEDURE

.1 All formwork activities will be carried out in accordance with the specification.

.2 After studying the structural drawings, the Project Engineer will plan for sizes, numbers
and type of formwork to be used in consultation with the Structural Engineer, if required.
Depending upon the programme, the number of repetitions will be decided.

.3 Availability of formwork will be checked with the Procurement Manager and decision
will be taken to buy, hire or reuse formwork material.

.4 During fabrication of formwork shutters, all dimensions shall be cross-checked with a

view to avoiding corrective action during erection.

.5 Paint reference numbers on all panels to ensure their use in correct positions.

.6 Ensure that the props, shores, waling, bearers, clamps and tie rods are the right size
and at the correct spacing. The Formwork designer shall check the false work system with
respect to load imposed on it and design parameters as laid down in the specification.

.7 Check that the false work is securely braced and is on a firm foundation.

.8 Forms fastened to previously cast concrete must be tightly fixed to prevent grout loss.
Cellular foam plastic strips can be used to make a seal.

.9 Check quality of shutter lining, tightness of bolts and wedges, built-in items, inserts and
other embedment.

.10 Tie – rod holes to be made in the formwork shall be neat so that they can be patched
or plugged later on.

.12 Particular attention will be paid to the rigidity and line of stop ends and joint formers.

.13 Remove all tie-wire clippings and nails, which may stain both the formwork and the
concrete.

.14 Ensure that adequate access and working platforms are in place for the concreting
gang and that toe boards and guardrails are provided.

.15 A spreader or lifting beam shall be used to prevent distortion when placing formwork.

.16 Adjustable steel props shall be erected in plumb and verticality of props checked using
a spirit level.

.17 A prop should not be used if it is bent, creased or, rusted or has a bent head or base
plate, damaged pin etc.

.18 Proper release of agent shall be used so that it can be removed without damaging the
surface finish of the concrete.
.19 New timber and plywood forms shall be given first coat of the appropriate release
agent 36 hours in advance, then a second coat just before they are used. Avoid excessive
use of release agent as this can cause staining or retardation of the concrete.

.20 A close watch should be kept on all wedges and fastenings. Make sure that they do
not work loose. Grout loss is an indication that some movement has occurred.

.21 When unsleeved tie bars are being used, ease them slightly before the concrete sets,
and remove them as soon as it is safe.

22 Striking the Formwork:

i) Always obtain approval before striking the formwork in the form of Appendix
CONC/04/A.

ii) Ensure adequate safety measures while striking formwork.

iii) Cleaning the face of forms shall start as soon as they have been struck.

iv) Good storage is essential to ensure that formwork can be used again.

v) Paint code numbers on them so that they can be readily identified when next needed.

.23 Safety During Formwork Operations:

i) The weights of large prefabricated sections of formwork should be marked on them so

that the lifting capacity of the crane at the working radius is not exceeded. Lifting points are
usually provided.

ii) If necessary, a spreader or lifting beam shall be used to prevent distortion.

iii) Where lifting is done by the vertical soldiers, check that they are adequately connected
to the walings.

iv) Fire extinguishers in working order shall be in close proximity to the stored formwork.

Safety During Formwork Operations:

i) The weights of large prefabricated sections of formwork should be marked on

them so that the lifting capacity of the crane at the working radius is not
exceeded. Lifting points are usually provided.

ii) If necessary, a spreader or lifting beam shall be used to prevent distortion.

iii) Where lifting is done by the vertical soldiers, check that they are adequately
connected to the waling.

iv) Fire extinguishers in working order shall be in close proximity to the stored
formwork.

Formwork Design:

Both types of formwork shall be designed to meet the following requirements:

 The structure dimensions indicated in the construction drawings.

 Stability of the formwork (both vertically and laterally) in the initial position during
or after concreting.
 The surface finish shall be as per the required type.
 The formwork shall allow proper concrete placement and vibration.
 The formwork shall be well tight to prevent mortar loss.
 The formwork shall withstand the pressure of the fresh concrete and, dead and
live loads as well as reshoring loads in multi stories structures.
  The form shall support solidly and in accurate positions, all the embedded items
placed as per construction drawings.

Coating:

 Prior to concreting, the form shall be cleaned and any foreign material shall be
removed. If necessary, openings shall be provided in the formwork for the
removal of the foreign materials.
Before placing the formwork, it will be coated with the approved release agent.
The properties and coating procedure shall conform to project specifications.

Removal of Forms and Shoring:

Formwork for columns, sides of beams, walls (except for tank foundations) and other
formworks not supporting the concrete weight shall be removed.

Shoring and Propping:

All shoring and propping requirements shall be submitted to client for approval.

Chamfers:

All exterior exposed corners shall be chamfered as indicated in the construction drawings.
An outline of the configuration of the system of form work proposed to be used is given here
under.

 It is proposed to use timber formwork for all the works. The main panel of the
form will be made with 18mm laminated ply board. Lesser thickness may be used
 in the case of minor items. In any case, the forms will be made to withstand the
pressure of concrete and also such that it is water tight.
 In panels mostly vertical will be stiffened using aluminium and/or timber beams
fixed along the length and width of the planks.
 Steel soldiers may be used to hold the panels together, where the height of the
form is more than 1.5M.
 External corners of the structures above ground level will be formed with 25mm
chamfer.
 For vertical elements like walls etc. openings will be provided to
facilitate pouring in and compacting, if required.
 Cover blocks made of same concrete mix of parent material will be
used for supporting of reinforcement rebar with correct cover.
 Stripping of forms will be done very carefully so that no damage is
caused to the concrete.
 Forms for columns, walls, sides of beams and other vertical forms not
supporting the weight of concrete will be stripped after 48 hours after
placing of concrete.
 Forms for beam soffits, slabs, and other parts requiring support will be
removed as per specified standards.
 The quality assurance for formwork will be followed as per approved
inspection and test plan.

WORKMANSHIP AND FINISH:

 The plywood for concrete shuttering work shall be smooth and the
faces and back shall be free from harmful discoloration, pleats,
overlaps and loose knots. The edges shall be of smooth uniform finish.
 Gaps and open joints shall be permitted as follows: a) In face — The
gap or opening shall not exceed a width of 0.4 mm. If it exceeds 0.4
mm, this may be rectified by well-fitted veneer inserts of suitable width
provided the grain of the veneer insert does not deviate by more than
 10 percent from the grain direction of the surrounding veneer. b) In
core (cross-band) — The width of the opening shall not exceed 1 mm
in the case of 3-ply and 5-ply, and 2 mm in the case of plywood of
more than 5-ply, provided such openings are not less than 300 mm
apart in any veneer and staggered not less than 150 mm between any
veneer and the next one with the same grain direction.
 The faces of plywood for concrete shuttering work with plastic coating,
or with suitable overlay, shall be dense, smooth and without blisters
and patch marks. It shall be of uniform color.