Coordinating formwork plans

with overall project planning

o much emphasis has been

S placed on formwork as a
major part of the cost of a
concrete structure that at
times we may put too much effort
into planning and constructing the
f o rm w o rk systems without ade-
quately considering the best inter-
ests of the overall project. The con-
crete forming plan and selection of
form handling equipment can have
serious consequences for other
trades and operations, including
both subcontractors and the gener-
al contractor.
Fo rm w o rk planning typically Time and sequence of the work of subcontractors must be phased into the
concentrates on speed of erection formwork schedule. The conduits, inserts, blockouts, and rebar cannot be put
and removal which reduces cost down until the deck form is in place.
through form reuse and minimiza-
tion of manpower re q u i re m e n t s.
Fast formwork erection and recy- construction contract. In deciding newly cast floors, their presence can
cling tends to accelerate completion how much time is to be allocated to p re vent interior work from follow-
of the structure, thus allowing more the structural frame we must con- ing too closely.
time for follow-up operations such sider the electrical, mechanical, ar-
as mechanical and electrical instal- chitectural, and other miscella- Formwork system selection
lations and architectural finishes. neous disciplines and a multitude of Factors influencing the selection
Of course reducing formwork cost project details. Allowance must be of a formwork system can be sum-
is highly desirable, but not if it caus- made for variables such as start-up m a ri zed as follows:
es too large an increase in the cost of operations or life safety testing,
other operations. Therefore all fea- which can take an inordinate 1. Cost of materials used to build
tures of a proposed formwork sys- amount of time. the forms
tem and their effect on other as- Also we must consider how close-
pects of the work must be carefully ly these operations can follow com- 2. Labor or manufacturing costs
analyzed, and cost comparisons pletion of various parts of concrete to build the forms
must be made of the various op- placement. If the building will be
tions. In the discussion that follows 3. Design for simplicity of erec
closed in with precast concrete pan-
a typical high-rise building serves as tion and stripping
els or materials other than concrete,
an example, although many of the we must decide whether to do this 4. Effect on architectural finish or
points apply equally well to other closely following concrete opera- detail
concrete structures. tions floor by floor or wait for avail-
ability of cranes or other hoisting 5. Access for concrete placing and
Sequence of operations equipment after the building is for cleanout before placing
A project plan begins with deter- topped out. If the forming system
mination of the overall duration of calls for several floors of forms and 6. Safe access for workers includ-
work, usually established by the shores to remain in place below the ing scaffolds, railings, etc.
 7. Necessary camber and deflec-
tion control

8. Form handling and hoisting

9. Shoring off subgrade or con

Architectural finishes
The first four factors listed should
have little effect on operations other
than the architectural finish. Sys-
tems based on multiple use of forms
require better-quality materials to
assure that the forms hold up over
their full term of use. This becomes
particularly important where the ex-
posed concrete surface quality is
critical. Painted or textured ceilings
depend heavily on the quality of the
form surface and its ability to with-
stand many uses. Architectural fin- Preassembled rebar cages for columns and beams speed site operations.
ish of walls, columns, and beam However, they must be planned for in selection and scheduling of hoisting
sides may require careful fabrica- equipment.
tion of form surfaces, sealing of
joints and tie holes to prevent grout in developing the forming system. or trades must be considered in de-
loss, and other measures to assure signing forms for critical areas such
unblemished surfaces and accuracy Deflection control as elevator shafts, slab edges, and
of detail. Where appearance of exposed beams where prefabricated work or
Before final selection of a forming surfaces is critical, forms are de- special architectural finishes are to
system the job must be studied in signed to limit deflection as well as be installed. Normal tolerances for
detail to determine whether or not to carry loads safely. This is particu- concrete work may sometimes be
there are form penetrations needed larly important for walls and unacceptable for the other trades.
which could affect the use of expen- columns where the rate of place- In post-tensioned work, al-
sive material for contact surfaces ment of concrete is apt to be rapid. lowance may have to be made for
and limit form stripping options. Suspended slabs, although not af- the shortening of the slab during
Look for such penetrations as ma- fected by the rate of placing con- stressing. This can present prob-
sonry anchors, plumbing fixtures, c re t e, have their own deflection lems for positioning exterior panels
piping, conduit, or embedded items problems. Sometimes the structural or for layout of interior work. Where
requiring depressions in a floor slab. designer specifies camber to com- a closure strip is required to join two
If a form is likely to be butchered to pensate for normal dead load de- post-tensioned slabs, special
accommodate these needed items, flection that occurs when the slab shoring of the cantilevered slabs is
it may make more sense to use starts to carry its own weight. In ad- needed to control their deflection.
cheaper material and replace or dition to this the form designer lo-
resurface it from time to time. cates and spaces shores and Hoisting equipment
stringers to limit deflection during Selection of form handling equip-
Access and safety construction; if the design is not ment (Item 8 above) interfaces with
Items 5 and 6 relate to costs nec- carefully thought out, it may be dif- the process of selecting hoisting
essary to assure ease and safety for ficult if not impossible to incorpo- equipment for the project. We must
workers cleaning out forms and rate the camber specified by the consider other trades and opera-
placing concrete. These expenses s t ru c t u ral designer. Flying forms, tions at the same time we review the
pay for themselves in the which have a long span between hoisting equipment needed for the
economies they bring about in supports must be designed stiff proposed forming system.
those operations. Access require- enough to eliminate deflection Early in the planning process all
ments of other trades—such as re- since they are not readily cambered operations requiring hoisting
bar placers and post-tensioning by adjusting shores. equipment must be listed and
crews—also should be considered Requirements of other disciplines quantified in terms of hoisting time.
The size and frequency of lifts must move them must have capacity and en full consideration. This process
be studied to decide what type, ca- reach to handle their size and should begin in the early discus-
pacity, reach, and number of units weight and must be positioned so sions at the time of pricing or bid-
may be needed. Measures which that it does not obstruct their re- ding the work, and certainly before
can be taken to reduce hoisting re- moval from the building. agreeing on subcontract items.
quirements include the following: When placing booms or even These are some of the subcon-
tower cranes are positioned within t ra c t o r s’ concerns that may affect
■ Flying forms in large ganged pan- the building, they must be located selection of the formwork system:
els. This can reduce the number carefully to minimize the effect on
of picks required for form materi- the structure of temporary openings ■ Definition of responsibility for
als, but large wall panels may in the slab as well as their potential basic line and grade layout
need placing pockets to minimize for delaying other operations fol-
dropping concrete or avoid heavy lowing concrete work. ■ Access to the forms for installa-
rebar congestion. Putting material or personnel tion or performance of their work
hoists next to the building delays in-
■ Self-raising wall and column stallation of exterior facing of the ■ Space required for storage of ma-
forms building in these areas. Expediting terials being installed
operations that lead to early con-
■ Use of form material which can struction use of permanent eleva- ■ Needs for penetrations through
be handled by hand or transport- tors help in obtaining earlier re- forms
ed vertically with hoisting towers moval of the hoists and completing
or light-duty equipment the closing in of the building. ■ Time needed for installation of
work in specific pours
■ Preassembly of rebar cages for Shoring off subgrade or slab?
columns or beams; sometimes al- Item 9 highlights the need for an ■ Construction joint location; po-
so feasible for walls and slabs early decision before starting to tential conflict with the subcon-
form the first suspended floor slab. tractor’s work
■ Use of concrete pumps and plac- Shoring from a slab on grade costs
ing booms instead of placing by less in both material and labor than ■ Hoisting: type, capacity, reach,
crane and bucket placing shoring on mudsills, and it duration, and frequency or num-
is easier to maintain a precise grade ber of picks
■ Having a second shift to perform under load.
part of the critical hoisting To get off to an early start on ■ Means for removing debris
forming and shoring, careful review
Timing of hoisting needs also of the plans, particularly electrical ■ Architectural concrete surface re-
must be considered. If we plan to and mechanical, should be made to quirements that might limit the
use the same crane for placing con- determine how much underground type of fasteners the subcontrac-
crete and erecting exterior building work must be done before placing tor uses in attaching work to the
panels, the latter would have to the slab on grade. If it cannot be forms
await completion of the concrete done quickly, then starting the sus-
f ra m e, even though closing in the pended slab construction on A thorough and detailed review
building as it goes up would be shoring supported on mudsills may with the subcontractors of all as-
preferable. be necessary. If this occurs, we also pects of a project plan and schedule,
The need to install structural steel must decide how to meet the pro- including details and sequence of
or mechanical equipment on top of ject’s need for temporary power and formwork operations, is essential to
the building after the frame is com- water where distribution lines for completion of a project and mini-
pleted may influence equipment se- these must be located under the mization of conflicts with subcon-
lection. Debris removal also may be first or basement floor slabs. tractors or owners.
a factor. Material or personnel For a successful plan with a mini-
hoisting towers may be used, but in Relationship with mum of conflicts, no one operation
many cases debris handling chutes subcontractors can be planned without considera-
reduce the demands for hoisting Although the general contractor is tion of its effect on all other project
time. responsible for successful comple- features.
Hoisting equipment location— tion of a project, in most construc-
Where we put cranes and hoists is tion he or she accomplishes much
just as important as which ones we of the work through subcontractors. PUBLICATION#C890927
choose. Where flying forms are In any well-thought-out plan their Copyright © 1989, The Aberdeen Group
to be used, the crane selected to needs and obligations must be giv- All rights reserved