FORMWORK OF BUILDINGS

Presentation By: Ar. Nandja Chopra

WHAT ?
_Formwork is a mold or open box, like container into which fresh concrete is poured and
compacted. _When the concrete is set, the formwork is removed and a solid mass is
produced in the shape of the inner face of the formwork. _The top of the formwork is
normally left open. _Falsework is the necessary support system that holds the formwork

in the correct position. ​General qualities

1. Strong enough to resist the pressure or the weight of the fresh
concrete plus any constructional live loads. 2. Rigid enough to retain the shape without
undue deformation. 3. Economical in terms of the total cost of the forms and the
concrete
surface finishing when required. 4. Sufficiently watertight to avoid leakage at the joints.

Where
•​Concrete formwork construction
•​Scaffolding
•​false work/shoring
•​Cofferdams
•​Underpinning
•​Diaphragm/slurry walls
•​Earth-retaining structures
•​Construction dewatering
Scaffolding
Falsework ​consists of temporary structures used in construction to support spanning or arched
... to give workers access to the structure being constructed, and ​shoring ​which is temporary
structural reinforcement used during repairs.
Shoring / Falsework
Diaphragm / Slurry Walls

Objectives of Formwork
Building
Quality ​- In terms of strength, rigidity, position, and dimensions of
the forms.
Safety ​- for both the workers and the concrete structure.
Economy ​is a major concern since formwork costs constitutes up
to 60% of the total cost of concrete work in a project. In designing
and building formwork, the aim should be for maximum economy
without sacrificing quality or safety.

Economy
In order to reduce the cost of formwork for concrete structures the following are to be
10. It should be strong enough to ​considered:
withstand all types of dead and live loads. 11. It should be rigidly constructed and ​1.
Design the formwork to provide adequate
efficiently propped and braced both ​but not excessive strength and rigidity.
horizontally and vertically, so as to retain ​2. Fabricate the forms into modular sizes to
its shape. ​provide more reuses without refabricating when practical.
12. The joints in the formwork should be tight ​3. Prepare working drawings prior to
against leakage of cement grout. ​fabricating the forms. 4. Prefabricate form sections on
the ground
13. Construction of formwork should permit ​rather than on scaffolding.
removal of various parts in desired ​5. Use the most economical formwork
sequences without damage to the

Materia ​ material considering the initial cost and

concrete. ​reuses.
Timber ​6. Use no more nails than are needed to join
14. The material of the formwork should be ​the forms together safely.
cheap, easily available and should be suitable for reuse.
Steel
7. Remove the formwork as soon as it is
15. The formwork should be set accurately ​permissible.
to the desired line and levels should have
Plastic ​8. Clean and oil forms by using releasing
plane surface. ​agent after each use.
16. It should be as light as possible.
Resin Bonded Plywood ​9. When it is permissible install construction
17. The material of the formwork should not ​joins to reduce the total quantity of form
warp or get distorted when exposed to ​material required and permit the
the elements.
Aluminum
carpenters to work more continuously.
18. It should rest on firm base.
Fabric
Magnesium
Advantages
• ​Timber can be cut into any required size easily.
• ​Timber is light in weight and it can be handled easily.
• ​Timber has good thermal resistance which prevents the damage of concrete in colder
regions.
• ​It is easy to understand the construction method of timber formwork hence, skilled
workers are not necessary.
• ​It is easy to replace the damaged parts of timber forms.
• ​Timber formwork can be easily dismantled.
Disadvantages
• ​Dry timber may absorb water from wet concrete which result in the reduction of
strength in concrete structure.
• ​Wet timber having high moisture content compress the wet concrete and forms
cracks in the structure and grout may leaked through joints when shrinking occurs.
• ​Timber forms have limited usage. So, they cannot be useful for more times.

Timber Formwork
Timber is the most commonly used material for formwork. Timber logs, lumber etc. are used as
bracing members from ancient times. So, the Timber formwork is also called as traditional
formwork. It is most economical material used for formwork. This is used in sites as formwork
material for number of years so, the method of constructing timber framework is well known to
the workers
Basic Steps Of Cons.
1. Propping and centering 2. Shuttering ( Plan issued by the architect ) 3. Provision of
camber 4. Cleaning and surface treatment
Figure 1(a): Details of timber formwork for RCC beam and
slab floor
Figure 1(b): Details at section (A) shown in above figure
Figure 2(b): Details of timber formwork for circular RCC column
Figure 2(a): Elevation
Figure 2(c): Details of timber formwork for Square/ Rectangular RCC
column
Figure 2(d): View
Timber formwork for RCC wall
Order and Method of Removing Formwork: The sequence of orders and method of
removal of formwork are as follows:
_ Shuttering forming the vertical faces of walls, beams and column sides should be
removed first as they bear no load but only retain the concrete.
_Shuttering forming soffit of slabs should be removed next.
_Shuttering forming soffit of beams, girders or other heavily loaded shuttering should be
removed in the end.
Imp* Rapid hardening cement, warm weather and light loading conditions allow early
removal of formwork. The formwork should under no circumstances be allowed to be
removed until all the concrete reaches strength of at least twice the stresses to which
the concrete may be subjected at the time of removal of formwork. All formworks should
be eased gradually and carefully in order to prevent the load being suddenly transferred
to concrete.

Plywood Formwork
Plywood which is a manufactured product of timber is also used for
formworks. It consists number of veneer sheets or plies in layers. Now a
days, the use of plywood formwork increases especially for facing panels.
The reason behind it is that the plywood formwork provides smooth finish
when compared to normal timber formwork. Hence, finishing cost may
reduce by the use of plywood
For formwork, special type of plywood called exterior plywood is used. The
veneer sheets of exterior plywood are bonded with strong adhesive to
make it watertight. The plywood boards are available in thicknesses from
7mm to 32mm. In general, plywood of size 1220 x 2440 and 18mm thick
boards are sufficient for most of the works. For curved structures, special
types of plywood with sufficient thickness are also available.
Advantages
•​Plywood can also be cut into required size easily.
•​Plywood Strong, durable and light in weight.
•​Provides smooth finish on the surface.
•​Very Large size plywood sheets are available which makes the
construction of formwork quicker and easier.
•​Curved formworks can also be prepared using plywood.
•​When compared to timber, it gives more number of reuses.
Disadvantages
•​When compared to timber it is costly.
•​Thin plywood sheets cannot sustain the weight of concrete they may bow
out if proper thickness is not provided.
Sheathing

-​W​ales

-​Studs

Footing
Plate
Figure ​5 ​- ​Typical ​wall ​form ​with ​components ​identified​.
Plywood ​sheathing
is ​more ​common ​than b
​ oard ​sheathing ​material

Plywood ​at ​the ​bottom ​- face grain parallel to span - is used the strong
w​ay​. In F
​ igure 11, with face grain perpendicular to the span
direction, the specimen at the top ​is used the weak way.
-
17

Plywood lupported by studs

STUO
STUD

WALE

Plywood Used The Weak Wa​y

stud span ​Le​qual​s distan​ce
between welen
WALE
Wales provide points of stud support

Plywood Used The Strong Way

Figure 6 - Parts of a typical wall form

Figure 11 - Plywood used in weak and strong way

Steel Formwork
Steel can also be used as formwork material. It is very costly but it can be used for more
number of times than others. They provides excellent finish to the concrete surfaces.
For mass strictures like dams, bridges, etc. steel from work is so strong and safe.
Advantages
•​Steel forms are durable and stronger.
•​Provides uniform and smooth surface finish to the structure.
•​Great reusability.
•​Easy to fix the formwork and also easy to dismantle.
Disadvantages
•​Cost is very much higher.
•​It is heavy in weight and requires lifting equipment for large structure formworks.
•​Corrosion will occur when there is a frequent contact with water.
•​The size and shapes of forms available are limited.
Steel forms compared with timber formwork: 1.Steel forms are stronger, durable and
have longer life than timber formwork and their reuses are more in number. 2.Steel
forms can be installed and dismantled with greater ease and speed. 3.The quality of
exposed concrete surface by using steel forms is good and such surfaces need no
further treatment. 4.Steel formwork does not absorb moisture from concrete. 5.Steel
formwork does not shrink or warp.

AluminumFormwork
Aluminum formwork is used often for pre-fabricated formworks. It is getting more
popular because of its light weight and good strength. It requires fewer supports and
ties. Advantages
•​Easy to fix and easy to dismantle.
•​It can be handled easily because of its light weight.
•​It can be re-used for many times.
•​The walls and slabs of structures can be casted simultaneously.
•​Monolithic crack free structures can be built using aluminum formwork. Disadvantages
•​When the load reaches its maximum limit, the lighter sections may deflect.
•​Architectural modifications are not possible when aluminum formwork is used.

Plastic Formwork
Plastic is another type of formwork material which is used for small concrete structures
or for complex portions of the structure. It is light in weight and durable for long periods.
For complicated concrete structures, Glass reinforced plastics (GRP) and vacuum
formed plastics are used. Advantages
•​Plastic is light in weight and can be easily handled.
•​Formwork for complex shaped structures can be prepared easily.
•​Good resistant against water.
•​The damaged plastic sheets can be recycled and useful to make new sheets.
•​Good quality plastic has great re-usability. Disadvantages
•​Plastic is weak against heat.
•​It is costly material.
•​It does not take much load when compared with others.
Plastic Formwork
Magnesium Formwork ​ Magnesium is

another metal element which is used for formwork. Magnesium is not directly used for
formwork and is used with the combination of oxygen atoms which forms magnesium
oxide, usually called magnesia or MgO. Magnesium oxide boards or MgO boards are
famous in some countries because of their multiple applications. MgO boards are
available in required sizes and grades. Advantages
•​Mgo boards are light in weight and easy to handle.
•​They are fire proof and waterproof.
•​Bio friendly boards cause no harm to the environment.
•​They are strong to resist heavy loads. Disadvantages
•​When Mgo boards meet wet concrete, the magnesium chloride present in MgO boards
may dissolve and cause corrosion to the reinforcement.
•​Skilled supervision is required for installation.
•​MgO boards cannot sustain in humid conditions. They absorb moisture easily from
atmosphere so, they are called as crying boards.

Fabric Formwork
Fabric formwork is the modern technology in construction sector. Fabric can be mold
into any required shapes which makes it more famous formwork for architectural
purposes. Advantages
•​It weighs very less when compared to any other formwork material.
•​It is economical.
•​Any complex shape can be constructed using fabric formwork.
•​It is waterproof.
•​Doesn’t affect the concrete properties.
•​Easy to removal after the hardening of concrete. Disadvantages
•​For installation skilled workers are required to form perfect and required complex
shapes.

Causes of form-work failure

The main causes of formwork failure are:
• ​Improper stripping and shore removal
• ​Inadequate bracing
• ​Vibration
• ​Unstable soil under mudsills (​Mudsill: A plank, frame, or small footing on
the ground used as a base for a for a shore or post in formwork.) ​shoring and not
upright
• ​Inadequate control of concrete placement
• ​Lack of attention to formwork details.
Too early shore removal at Bailey's Crossroads in Virginia (1972):
26-stories + apartment building Forms were supported by floors 7-days
old or older Failure occurred on the 24th floor, where it was shored to
the 5-day-old 23rd floor. The overloaded 23rd floor failed in shear
around one or more columns, triggering a collapse that carried through
the entire height of the building.

5-A Wake up in case you

have slept
Which building ? Who is the architect ?

U​N​I
VO
​
VAI​V>
PARAXANL ​SANA​T ​YIYIM
The construction of the Barajas Airport terminal was undertaken in three constructional
layers: firstly, the basement which drops to as much as 20 metres (66 feet) below
ground in some places; secondly, the three-storey concrete frame above ground; and
thirdly, the steel-framed roof. The concrete work was cast in-situ, and special attention
was focused on areas where the concrete would be visible, such as the edge strips to
the canyons in which steel shuttering has been used. In a bid to limit the height of the
building, post-tensioned concrete beams restrict the depth of the beams to only 90
centimetres (3 feet). The beams were cast in lengths of 72 metres (236 feet), with
concrete planks used to span between them to create the 18-by-9- metre
(60-by-30-foot) grid. Above the concrete frame, the concrete tree trunks on the top floor
provide fixed base points for setting out the roof steelwork. The structural system for the
roof works outwards from the tree trunks where four inclined branches prop a pair of
double-S modules. In this way, each pair of tubes, plus the roof steel, stabilise the roof
structure in both directions. The roof then passes over the cladding line at the edges of
the building, emphasising the canopy rather than the façade. To further reduce the
visual impact of the façade and enhance passengers connection to the activity of the
airfield outside, shading is not introduced at the cladding line but is hung from the roof
overhang which is propped with elegant Y-shaped props at the ends of each module.
The façade structure is in the form of cable ‘kipper’ trusses at 9- metre (30-feet) centres.
A pair of cables begin at a common point at ground level, one arcing in and one out,
held apart by compression struts that also support the horizontal glazing mullions. As
the cables approach the roof they come back together, held by a V- bracket, making a
fish outline, hence the name kipper truss. A jacking system was used between the roof
and terminal floor during erection, which when released ensures that adequate
permanent tension was introduced in the cable trusses.