FORMWORK

A STUDY OF ITS VARIOUS TYPES, MATERIALS

AND
CONSTRUCTION TECHNIQUES
INTRODUCTION TO FORMWORK
What is Formwork?
Formwork in construction is the use of support structures and moulds to
create structures out of concrete which is poured into the moulds.
Formwork can be made using moulds out of
steel, wood, aluminium and/or prefabricated forms.

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.

Formwork is designed according to The ACI document SP-4.

 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
 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, 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 Wooden formwork
- Tee Iron

Wooden formwork consists of

- Props
- Planks battens
- Ledgers
- Sheeting

Steel Formwork
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.

- 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
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.
PROCESS OF FORMWORK
CONSTRUCTION
FORMWORK FOR VARIOUS STRUCTURAL
MEMBERS
Construction of formwork:
This normally involves the following operations:
1. Propping and centering
2. Shuttering
3. Provision of camber
4. Cleaning and surface
treatment
FORMWORK 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

• It consists of the following

– Side & End Planks
– Yoke
– Nut & Bolts
• Two end & two side planks are
joined by the yokes and bolts.
Erection sequence for a column

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

- Position formwork for the column from predetermined grids.

- Plumb formwork both ways and securely support using adjustable steel props.
- 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 colu
mn formwork.
- 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
column.

Column clamps are created to give extra external

support to the formwork from avoiding
When all the column formwork is securely propped a final check must be made for circularing of the column
plumb and column alignment before and immediately after the concrete has been
poured and vibrated.
CIRCULAR AND OCTAGONAL COLUMNS
 Circular column formwork
 Fabricated steel, usually two piece, and often with a hinge.
 Fibre cement pipes which are left in place as perm anent
formwork.
 Timber sheathing tied with standard column clamp
s. Corners need to have infill pieces. Alternatively, metal
strap can be used without the need for corn er 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 is
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 coll ision of concrete buckets or
cranes hoisting materials
 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, bearers and falseworks ,
Spreaders;
• Construct and erect side walls and beam soffit.
• Position of sole plates
FORMWORK FOR
STAIRCASE
• Points to consider when designing stair form work :

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 combination of both.

Whichever method is used, it is important to support the proposed

method ofconstruction using a combination o f timber or steel
bearers and adjustable shoring.

The spacing and type of support system required is

determined by the load imposed during the construction The erection sequence for constructing a
process.
suspended floor slab includes:
Manufacturers provide tables to assist in the selection and • Determining the bearer spacing;
spacing of adjustable shoring
• Erecting bearers and joists;
systems.
• Fixing the sheeting;
• Preparation for concrete.
 SOLE
PLATE

 The purpose of a sole plate is to transfer vertical load from 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 be dded they should be
checked for level.
 DESHUTTERIN

G
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 concrète sticking to the formwork
 Hence deshuttering agents are used to ease the process

 Dosage / Coverage:

 Dilution ratio: KEM MRA 2: water at 1:10. Coverage: 1600 sq. ft. depending
on conditions of formwork

 KEM MRA 1 - 25 / 30 m� / liter depending upon the porosity and usage
condition of the substrate
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
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.
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 syst to
the formwork.
em enables precision adjustment
Safety
•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.
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.
• 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.
G
A • 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
N forms as a single unit.
• The success of gang forming is due to the
G
F development of easy-to-use hard w a re and ties, made
O especially for this forming technique.
R • 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.
M Although prefabricated forms work well on any size job,
I the small job is a good way to introduce the system to
N the workmen.

G
 DRAWBACK
•
S
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 CONVENTIONA MODERN PREFABRICATED
DIFFERENTIATI L METHOD DAY METHOD
ON METHOD

 MATERIAL TIMBER( Plywood Or STEEL AND Frame of ALUMINIUM

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

 TIME
VERY TIME DESIGNED FOR Work happens simultaneously
CONSUMPTIO CONSUMING. SPEED AND with construction hence saves
N (For large EFFICIENCY. time
structures.) (mostly modular)

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

 USED The labour costs are The labour costs are The labour costs are HIGHER
IN LOWER than the costs HIGHER than the costs than the costs for procuring
for procuring reusable for procuring reusable reusable formwork.
formwork. formwork.
 FLEXIBIL
ITY MOST LESS There is NO FLEXIBILITY
FLEXIBLE FLEXIBLE. after making the formwork
Time of Removal of formwork
Sr. OPC Rapid Hardening
Structural Member (Ordinary Portland Cement) Cement
No

1 Beam sides, walls & Columns 2-3 Days 2 Days

2 Slab (Vertical Supports remains intact) 4 Days 3 Days

3 Slab (Complete Formwork removal) 10 Days 5 Days

4 Beams (Removal of Sheeting, Props 8 Days 5 Days

remains intact)

5 Beams & Arches (Complete formwork 14 Days 5-8 Days

removal) (up to 6 m span)

6 Beams & Arches (Complete formwork 21 Days 8-10 Days

removal) (more than 6 m span)
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
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
FORMWORK

 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 achieved working strength, permanent
propping or shoring is required.
Take care to avoid damage to formwork which is to be re used. Eight or more uses 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.