Title: Comparison of Current Traditional System of Formwork in Fe Construction With Modern Formwork System Prepared By: Id - No

DIRE DAWA UNIVERSITY INSTITUTE OF TECHNOLOGY
SCHOOL OF CIVIL ENGINEERING AND ARCHITECTURE

CONSTRUCTION TECHNOLOGY AND MANAGEMENT CHAIR
INTERNSHIP FINAL PROJECT
TITLE: COMPARISON OF CURRENT TRADITIONAL SYSTEM OF

FORMWORK IN FE CONSTRUCTION
WITH MODERN FORMWORK SYSTEM
PREPARED BY: ID.NO
MARAKI MEAZA 1002518
ADVISOR: INS. ZEMICHAEL
FEBRUARY, 2022
DIRE DAWA, ETHIOPIA

INTERNSHIP FINAL PROJECT- MARAKI MEAZA - 2022
Contents
List of Figures................................................................................................................................iii
List of Tables..................................................................................................................................iii
Abstract...........................................................................................................................................iv
Abbreviations...................................................................................................................................v
CHAPTER ONE..............................................................................................................................1
1. INTRODUCTION...................................................................................................................1
1.1. Background of the study...................................................................................................1
1.2. Statement of problem........................................................................................................4
1.3. Objectives of the project...................................................................................................5
4.1.1. General Objective......................................................................................................5
4.1.2. Specific Objectives....................................................................................................5
1.4. Scope of the Study Area....................................................................................................6
1.5. Significance of the study...................................................................................................6
1.6. Limitation of the Study.....................................................................................................6
CHAPTER TWO.............................................................................................................................8
2. Literature Review....................................................................................................................8
2.1. Formwork Definitions.......................................................................................................8
2.2. Formwork Requirements...................................................................................................8
2.2.1. Economy....................................................................................................................8
2.2.2. Speed..........................................................................................................................9
2.2.3. Quality.......................................................................................................................9
2.2.4. Safety and Health.....................................................................................................10
2.3. Causes of formwork failures...........................................................................................10
2.4. Classification of formwork.............................................................................................11
2.4.1. Classification According to size..............................................................................11
2.4.2. Classification According to Location of Use...........................................................11
2.4.3. Classification According to Nature of Operation....................................................11
2.4.4. Classification According to Brand Name of the Product........................................11
2.4.5. Classification According to Materials of Formwork...............................................18
2.4.6. Selection of Formworks...........................................................................................21
ii
CHAPTER THREE.......................................................................................................................22
3. Methodology..........................................................................................................................22
3.1. Introduction.....................................................................................................................22
3.2. Study Design...................................................................................................................22
3.3. Study population.............................................................................................................22
3.4. Data collection methods..................................................................................................22
3.5. Data analysis...................................................................................................................23
CHAPTER FOUR.........................................................................................................................24
4. Result and Discussion............................................................................................................24
4.1. Introduction.....................................................................................................................24
4.2. Formwork materials and costs........................................................................................24
4.3. Quality analysis...............................................................................................................26
4.4. Speed analysis.................................................................................................................28
4.5. Safety and Environment Analysis...................................................................................29
4.5.1. Safety analysis.........................................................................................................29
4.5.2. Environmental Analysis...........................................................................................30
4.6. Result (Suitable Formwork for Ethiopian construction industry)...................................31
4.6.1. Suitable Wall Formwork System for Ethiopia.........................................................31
4.6.2. Suitable Slab Formwork System for Ethiopia.........................................................32
4.6.3. Suitable Column and Beam Formwork Systems for Ethiopia.................................34
4.6.4. Special Formworks for Ethiopia..............................................................................36
CHAPTER FIVE...........................................................................................................................37
5. CONCLUSION AND RECOMMENDATIONS..................................................................37
5.1. Conclusion......................................................................................................................37
5.2. Recommendations...........................................................................................................38
References......................................................................................................................................39
List of Figures
Figure 4.1 1 Unsafe column formwork construction.....................................................................29
Figure 4.2 1 Concrete surface casted using TRIO panel, Darmstadt 32
iii
Figure 4.3 1 Concrete surface casted using traditional timber formwork, Dire Dawa 32
Figure 4.4 1 Concrete column formwork casted using PERI formwork, Darmstadt 35
Figure 4.5 1 Concrete column formwork casted using Timber formwork, Dire Dawa 35
Figure 4.6 1 Self Climbing Systems at Tower 185, Frankfurt 36
List of Tables
Table 4.1 1 Productivity of Formwork Construction in Ethiopia..................................................28
Table 4.2 1 Material Costs of PERI products 34
iv
Abstract
The quality of resulting concrete can be dictated by the quality of formwork materials and
workmanship. Many concrete related problems such as discoloration, stains, and dusting are
attributed to concrete formwork. Formwork operations are also risky and workers are exposed
to unsafe working conditions. Moreover traditional formwork construction has negative
impact on the environment. The objective of this research was to compare the current practices
of formwork construction in FE construction with the modern formwork system and identify
problems related to speed, quality, and labor and environmental safety. Recommendations of
modern
formwork systems which alleviate such problems are also the objective of this thesis.
The study was conducted by taking formwork systems of the famous formwork producing and
renting company, PERI Germany, as the case study. Almost all the products of the company
were studied through desk study. The study mainly used the data found from secondary sources.
The results of the research show that alternative formwork materials are not well known and
used in Ethiopian construction industry. Steel panels and timber are the prominent formwork
materials. In comparisons made based on the parameters listed above the study found that
modern formwork is far better than traditional formwork system in all parameters. Formwork
construction practice in FE is not safe and environmentally friendly. Finally, modern formworks
such as MULTIFLEX, TRIO, QUATTRO and UZ are assessed and recommended for major
construction projects in Ethiopia.
v
Abbreviations
OPC – Ordinary Portland Cement
PPC - Portland Pozzolana Cement
vi
i
CHAPTER ONE
1. INTRODUCTION
1.1. Background of the study
Formwork is a term given to temporary or permanent matrix or a mold comprising of all
supporting members, the whole and sole function of which is to give appearance and assist
concrete till sufficient strength to carry its own weight is achieved. It should be able to bear all
imposed and live loads apart from its own self-weight. From past 3 decades the use of formwork
systems for concrete construction has been developed appreciably. The upheaval till now
concentrated on on-site production, health and safety, environmental issues which helped the
concrete industry towards improved efficiency and better quality of construction. Different range
of formwork systems offers wide solutions to concrete construction which aids to suit the
requirements of a particular development. Traditional formwork techniques for formwork
construction offer tailor made solutions requiring skilled labors. This formwork technique offers
indigent safety features and slow rate of site construction and waste generation is also on large
scale.[14.]
Advanced Techniques in Formwork
As time progressed, the use of advanced techniques of formwork for construction of structures
has gained wide acceptance. In the present competitive market, speed and efficiency are of
prime importance; thus by use of advanced technology, the duration of project is reduced by
using latest materials, equipment’s and techniques which are effective, durable and intensify
the pace of construction. Some of the advanced construction formwork techniques used now
days are …
 H-Beam
 Plastic formwork
 Fiber-reinforced polymer formwork system
 Aluminum panel system formwork
 Jump form or Slip form system
1
As the use of the techniques gained prime importance in the market, many organizations like
MIVAN, Doka, Plastech, and RMD etc., started producing such techniques under their own
brand, which is widely used in the Indian Construction Industry now-a-days. [19.]
The increase in population and the limitation of space has leaded the way to multi-storey or
high-rise buildings. In order to make these structures sound, we need to focus on factors that
impart strength to concrete and this is where formwork plays an integral role. Formwork is a
temporary structure like a die or mould, used to contain poured concrete, to give concrete the
desired shape and support it until it attains sufficient strength to carry its own weight.
Formwork should be capable of carrying all imposed dead and live loads apart from its own
weight. Pantheon, a former Roman temple and now a church in Rome, is the earliest example
of use of mould for concreting. Formwork should be properly designed, fabricated, and
erected to achieve high quality concrete finish. If this is not done properly the desired shape
and strength of concrete is not achieved.
Formwork planning process is divided in 3 stages
First stage: The necessary information and limiting conditions must be collected and defined.
When projects of similar nature are executed, a checklist can be of immense help in obtaining
information required to prepare a complete scheme.
Second stage: The formwork system to be used can be selected. In addition to cost of the
materials, the choice of the system will be influenced by the experience of the planner and of
the team, which has to set up the formwork on the site, and by the project archive. A
database / project archive that captures the experience gathered over the years can aid in cost
effective system selection.
Third stage: This involves all engineering design tasks. This part of the process is most time
consuming. It is important to be able to allow for changes arising at later phases of the
project. The emphasis should be on maximum reuse of materials available and procuring
minimum materials Just-In- Time.
Plastic form work System
(i) Easy Handling: Light weight so very easy to handle by single labor as well
(ii) Superior Finish: Gives a good surface finish of the wall, columns, beams & slabs etc.
2
(iii) Reusable: It can be used 80 to 100 repetitions.

(iv) Water Resistant: Can be used in fresh and salt water.
(v) Environment Friendly: Green product (even carbon credits can be earned if applied).
(vi) Flexibility: Sizes can be changed very easily as it is modular allowing low inventory.
(vii) Safety: Plastic and light weight allows for safer working conditions avoiding fall hazard
during both setup and dismantling.
(viii) Fast Setup: The simple mechanics of speeds up the assembling at removal operations
saving a lot of time.
(ix) Simplified Logistics: The need for amount of material is reduced at site as the same
panels can be used for wall, slabs, shear wall, columns, foundations, pile caps, rafts etc.
(x) Leakage Proof: No leakage between joints due to its good locking.
(xi) Easy Cleaning: No need of using shuttering oil if cleaned with water after each
repetition.
(xii) Storage: No special storage space is required can be stored even in water areas and in
open as well.
(xiii) Plaster Cost Saving: There is no need to plaster as the finish is good.
(xiv) Labour Cost Saving: No need of skilled carpenter’s normal unskilled people can do
the job in supervision and it takes less time labour is saved.
(xv) Light Weight: The average weight is around 15 kg per sq.mtr.[14.]
New Applications: Monolithic applications for high rise buildings using drop head system for
faster cycles, can be used in cellular low weight concrete cast in situ walls having density of
1000 to 1200 with installing electrical piping plumbing fitting, door frames, window frames, air
conditioner piping etc done in one go saving a lot of labour and time making the project low
cost and deliverable on time.
Conventional Formwork
(i) Conventional formwork has normal quality

(ii) Speed of construction is slow because of step by step completion of building element
like Column, Beam, Slab so that lines on surface is visible may be due to plastering
must be required.
(iii) In conventional formwork wood so it is not eco- friendly.
(iv) Various type of conventional formwork such as steel formwork, wooden formwork. It is
3
not easily carried because of heavy in weight.[12.]
1.2. Statement of problem

Conventional formwork also having disadvantages including requires extensive manpower, such
as skill dependant and semi-skilled workers dependent would result in problems of cost, time,
waste, poor finishes, leakages, and corrosion of structures. In term of cost and time, the
formwork contributes approximately up to 20% of concrete cost and 60% of the concrete time as
described in various studies. The conventional timber formwork system is economical but highly
environmentally undesirable. In terms of cost the traditional formwork seems cheaper but there
subsequent cost related to man power, cutting and drilling of the plywood by size, and also its
not reusable so, indirect costs are associated with this formwork type and these costs are
unsatisfactory for construction companies.
The other defective aspect of this type of formwork is quality output it delivers in constructing
column, slab, beam and wall as it is difficult to deliver smooth surface using such formwork
types.
The traditional formwork is known for its consumption of manpower in construction process.
The most concerning impact associated with this type of formwork is the impact it has on the
environment. As almost all of traditional formworks are prepared from wood and this wood
which will be used as formwork construction is a main cause for deforestation. Nowadays the
world is in great treat due to changes on the environment and such types of formworks needs to
be modernized and their impact on the atmosphere should be altered.
Finally, such formwork type is not favorable in its negative feature of time consumption. Such
formwork types consume too much time starting from early stage of drilling and cutting in all
sizes, to their removal from their contribution in formation of column, slab, beam and wall.
4
Figure 1.1 1 Traditional formwork construction on FE construction site

Generally speaking traditional formwork has a lot of unpleasant attributes which needs to be
dealt with. This formwork type has a great deal of impact on the productivity of construction
projects. In this regard the main purpose of this paper is to introduce a modern formwork method
that can contribute a lot to the overall efficiency of the construction project.
1.3. Objectives of the project
4.1.1. General Objective

The main objective of this project is to compare the advancement of the modern formwork in
terms of quality, safety, and economic aspects relative to the traditional formwork in
construction building projects.
4.1.2. Specific Objectives

 To Examining Modern Formwork System and Conventional Formwork.
 To present comparative study of Modern formwork and conventional formwork to
eliminate the reasons which act as barrier for the local construction industries in terms
of cost, quality, speed and safety.
 To Recommend best formwork techniques that ensure the productivity of construction
projects.
5
1.4. Scope of the Study Area

The study mainly focuses on the formwork systems for building projects. Formworks for precast
concrete elements will not be part of this project. Only cast in situ concrete formworks are
investigated. Comparison of the traditional and modern formwork techniques is done based on
the parameters which are believed to be basic in productivity of construction projects.
The scope of this project is limited to the structural elements of building projects such as
column, beam, slab, shear wall retaining wall and stair that are casted in the construction site.
Additionally, this study focuses on introducing modern formwork for concrete elements. The
purpose is not to prove that one product is superior to another, but rather to determine which
systems are superior.
1.5. Significance of the study

This study is expected to put significant positive impact from different possible perspectives. The
impacts of this study are illustrated as following.
 The study gives a direction to whomsoever engaged in construction building sector in

implementation and become beneficiary of the major advancements.
 The stakeholders will be noticed on the negative impacts of implementing traditional
formwork techniques.
 The whole society involved in the construction building would be available with
awareness of how this traditional formwork techniques indirectly harming the
environment and would be helpful in taking appropriate measure like the one that this
study has proposed.
 Most of all this study can be used as a reference for concerned body in designing and
proposing further studies and solutions in revolutionizing the implementation of
formwork techniques.
1.6. Limitation of the Study

It is obvious that every study preparation goes through challenges and obstacles that hinder its
effective implementation. Likewise this study has been some major challenges and they are listed
below as follows;
6
 Practical application of modern formwork techniques in Ethiopia is rare and it has been
difficult to find actual experience our country’s construction industry to derive the best
possible specific solutions to the existing problem.
 Difficulty in attempt to compare the modern formwork technique with traditional
formwork in terms of cost analysis as there is no actual recorded and organized data
associated with the area understudy.
 Time is one of those problems associated with every study and still being the case on this
study hindering the possibility of addressing wider view of the area understudy.
 Most of the data used in this study is found from previous studies made abroad and it has
been difficult to have access to direct data about the area understudy.
 It has been difficult to find clearly organized resources on the area understudy and it was
time consuming.
7
CHAPTER TWO
2. Literature Review
2.1. Formwork Definitions
The type of formwork systems used is among the key factors determining the success of a
construction project in terms of speed, quality, cost and safety of works. Therefore, selecting the
formwork system, that is, making structural frames faster, simpler, and less costly to build, must
begin in the earliest phase of the design efforts. [14.] Generally there are two board category of
formwork system as horizontal and vertical formwork system.
2.2. Formwork Requirements

Economy, safety, speed and quality are some of the requirements to be fulfilled by formworks.
These requirements will be described in the following sub sections.
2.2.1. Economy
Formwork is the largest cost component for a typical multistory reinforced concrete building. A
large proportion of the cost of conventional formwork is related to formwork labor costs in
developed country. Significant cost saving could be achieved by reducing labor costs. [23.]
Formwork economy is achieved by considering four important factors:
i. Cost of form materials

ii. Ease of form fabrication
iii. Efficient use of forms — erecting and stripping
iv. Planning for maximum reuse to lower per use cost. [7.]
Formworks which are easy to erect and strip will reduce the overall completion of the project
which leads to early collection of revenues to be generated from the building or other structure.
Such economic benefits are obtained if the formworks are modern and efficient. Maximum
reuse is obtained if the formworks materials are durable and handled well. The traditional
formworks which need many blows of hammer to strike will not be durable as the material is
threatened. Hence innovative formworks which can be easily striped, more durable and reusable
should be used to ensure formwork economy. Many scenarios should be considered in achieving
cost effective formworks. These include:
8
 Cost and feasibility of adapting materials on hand versus cost of buying or renting new
materials
 Cost of a higher grade of material versus cost of lower grade of material plus labor to
improve for required quality and use
 Selection of more expensive materials that provide greater durability and
capability for reuse vs. less expensive materials that have a shorter use life.
 Building on-site versus building in a central shop and shipping to site (this depends on
the site itself and space available, the size of project, the distance of shipping, etc.). [39]
2.2.2. Speed
Speed of construction is defined as the rate in which concrete building is raised and can be
expressed in terms of number of floors erected per week or months. Speed of construction can be
also measured in terms of inches or millimeters of concrete poured per hour. Formwork
operations can control the pace of construction projects. There are several levels of shores and
reshores that carry the loads until the concrete gains enough strength to support its own weight
and all other externally applied loads. Shores are vertical members that support recently built
concrete that have not developed full design strength. On the other hand, reshoring occurs when
the original shoring is removed and replaced in such a manner as to avoid deflection of the cured
concrete. Several floors may be blocked, preventing the progress of any other construction
activities, if the formwork system is not efficient. Faster formwork cycle from erection to
stripping would allow for faster removal of shoring and reshoring and faster overall project
progress. [40]
2.2.3. Quality
Many concrete-related problems such as discoloration, stains, and dusting are attributed to
concrete formwork. Also, some deformed concrete surfaces are due to deformed formwork
systems caused by repetitive reuse and inadequate support of formwork. If the surface of the
concrete is good, the cost of finishing to be applied on the surface will also be less. On the other
hand if concrete surfaces are of less quality, which results from poor quality of formworks, cost
of grinding and plastering will be higher. [23.]
9
2.2.4. Safety and Health

Formwork operations are risky, and workers are typically exposed to unsafe working conditions.
Partial or total failure of concrete formwork is a major contributor to deaths, injuries, and
property damages within the construction industry. Structural collapses and failures involving
concrete structures account for 25 percent of all construction failures. More than 50 percent of
concrete structure failure during construction is attributed to formwork failure. [16.]
2.3. Causes of formwork failures

Formwork failures are the cause of many accidents and building failures that occur during
concrete construction, usually when fresh concrete is being placed. Generally some unexpected
event causes one member to fail, then others become overloaded or misaligned and the entire
formwork structure collapses.
The main causes of formwork failure are:
 Faulty formwork structural design

 Improper stripping and shore removal:
 Premature stripping of forms, premature removal of shores, and careless practices in
reshoring can produce catastrophic results.
 Inadequate bracing: Inadequate cross bracing and horizontal bracing of shores is one of
the factors most frequently involved in formwork accidents.
 Vibration: This occurs when shores are displaced by the vibration caused by passing
traffic, movement of workers & equipment and vibrating concrete.
 Unstable soil under mudsills (A plank, frame, or small footing on the ground used as a
base for a shore or post in formwork).Site drainage must be adequate to prevent a
washout of soil supporting the mudsills.
 Lack of attention to formwork details: Even when the basic formwork design is soundly
conceived, small differences in assembly details may cause local weakness or overstress
loading to form failure. This may be as simple as insufficient nailing, or failure to tighten
the locking devices on metal shoring.
10
2.4. Classification of formwork

Formwork can be classified according to a variety of categories; relating to the differences in
sizes, the location of use, construction materials, nature of operation, or simply by the brand
name of the products.
2.4.1. Classification According to size

In practice, there are only two sizes for formwork; small-sized and large-sized. Any size which is
designed for operation by workers manually is small-sized. The most common small sized
systems are made of timber and aluminum. [16.]
2.4.2. Classification According to Location of Use

Different elements in the structure of building have different design and performance
requirements in the use of formwork. Accordingly, classification can be made as wall formwork,
column formwork, beam formwork and slab formwork.
2.4.3. Classification According to Nature of Operation

Formwork can be operated manually or by other power-lifted methods. Some systems are
equipped with a certain degree of mobility to ease the erection and striking processes, or to allow
horizontal movement using rollers, rails or tracks. Timber and aluminum forms are among the
manually-operable types of formwork. They are designed and constructed in ways that they can
be completely handled independently without the aid of any lifting appliances. However, it is
labor intensive and is more appropriate to be used in simpler jobs. Power-lifted formwork can be
of the self-climbing and crane-lifted types. Crane-lifted systems are usually in the form of large
panels. [16.]
2.4.4. Classification According to Brand Name of the Product

Several patented or branded formwork systems have successfully entered the local construction
market in the past decade. Some firms can even provide a very wide range of services including
design support or tender estimating advice. As there are numerous international companies
which produce patented formworks, only leading firms are discussed in the following sections.
International formwork companies PERI was selected for further investigation of its product.
The detailed description of the products and discussion on suitability for Ethiopian construction
industry will be made in subsequent sections of this chapter. [16.]
11
It is known that the costs of formworks are shaped by the working methods, the features of the
structure and the wage levels of the market. This clearly shows where the success of promising
rationalization potential is in order to lower the costs for the realization of concrete structures. It
is for this reason that PERI has successfully established numerous products and system
equipment on the market. The following are some of the products of PERI which will be further
discussed in this chapter:
 Wall Formworks
 TRIO panel formwork
 VARIO GT 24 Girder Wall Formwork
 Column Formwork
 QUATTRO column formwork
 SRS circular formwork
 Slab Formworks
 GRID FLEX Grid “
 MULTIFLEX Girder “
 Beam Formwork
 UZ Beam formwork
Many aspects of PERI activities promote the economic and ecological sustainability of its
products and solutions.
2.4.4.1. Wall Formworks

 TRIO Panel
PERI TRIO panel formwork is a universal and versatile formwork system, and with its 2.70 m
and 3.30 m system heights, as well as a sensible range of widths, can be used on small and large
construction sites. PERI TRIO requires only 6different panel widths. With clearly arranged and
practical increments in panel size of 30 cm along with one 72 cm wide panel, on-site material
requirements are reduced whilst utilization rates increase. The available dimensions are widths
are 2.4m, 1.2m, 0.9m, 0.72m, 0.6m and 0.3m. [33.]
12
Figure 2.1 1 TRIO pane
 VARIO GT24 Girder Formwork
It is the wall formwork with continuously adjustable element connections for all designs and
applications. Regardless whether it is industrial or housing construction, bridge abutments or
retaining walls, any ground plan and all heights can be formed using PERI VARIO. Using
VARIO GT 24 as project formwork, elements are optimized accordingly. Hence the following
points can be freely selected:
 Type and size of plywood as well as the fixings

 Element widths and heights
 Vertical or horizontal tie arrangement
 Permissible fresh concrete pressure
The formwork is extended by means of the VARIO extension splice 24 in 30 cm increments up

to a maximum of 8.10m quickly and easily fitted through the latticework of the GT 24, without
having to drill the girders. [33.]
Figure 2.2 1 PERI VARIO wall formwork
13
Transferring the technology of PERI formworks especially VARIO formworks is crucial for our
industry as it is possible to produce from local materials and versatile system. Timber can be
cultivated for girders and metal walers can be manufactured from recycled metal by local
industries.
2.4.4.2. Column Formwork

 QUATTRO Formwork
PERI QUATTRO columns can be moved as complete units i.e. four column elements together.
Lifting the column form together with its push-pull props and concreting platform saves the site
an enormous amount of crane time. Column cross-sections from 20 x 20 cm up to 60 x 60 cm
can be concreted in 5 cm increments, square shaped or rectangular. It is has been designed for a
fresh concrete pressure of 80kN/m².Numerous combinations are achieved by connecting just
three different panel heights (0.50,1.25 and 2.75 m) with the eye bolts, which can also be used as
lifting points. [33.]
Figure 2.3 1 Complete PERI QUATTRO unit with its eyebolts

Through the use of transportation wheels, the PERI QUATTRO column formwork becomes even
more cost-effective. Formwork crews are thus in a position to carry out shuttering and striking
manually and without requiring a crane. Complete formwork units can also be moved from
column to column by hand.
 SRS Steel Circular Formwork
Manufactured according to the highest quality standards, the SRS circular column formwork
guarantees a perfect concrete surface finish. It is designed for a fresh concrete pressure of
150KN/m2 for fast and efficient concreting. The column diameters exist in 50mm increments
14
from 250 to 700mm.The elements are extended and connected with eyebolts. The formwork is
easy to assemble; a hammer is all that is needed, the bolts also serve as the lifting point for
cranes. The advantages of this column formwork are:
 Fast assembly: Only two column halves with integrated column bolt. The captive
column bolts have self-cleaning hexagonal threads and are mounted to the column
formwork halves.
 Practical extension process: The PERI SRS circular column formwork has four
element heights (3.00 m, 2.40 m, 1.20 m and 30 cm) which allows shuttering in 30 cm
increments see figure below.
 Easy and simple element stacking: Integrated stacking aids ensure that the column
elements are safely stacked and cannot slip. Costly site storage space can therefore be
more efficiently utilized.
Figure 2.4 1 Lifting eyes and stacking aids on the column elements
2.4.4.3. Slab Formwork
A. GRID FLEX Aluminum Formwork
PERI GRIDFLEX is the flexible slab formwork system complete with accessible girder grids.
Due to the lightweight aluminum components and pre-determined assembly sequence, very short
shuttering times are achieved. Telescopic filler elements ensure maximum flexibility. The panel
grid system allows safe access for laying the free choice of form lining. This formwork system
has the following advantages:
 Safe assembly at all times: With the systematic assembly sequence, elements are simply
hooked in at one end from below and swiveled upwards at the other by means of
shuttering aid. Subsequently the slab prop complete with prop head is attached to the
15
element and positioned vertically. The girder grid design of the GRIDFLEX
automatically forms an accessible working area which provides a high level of safety
when laying the plywood sheets.
Figure 2.5 1 Erection of GRIDFLEX

Only Three Main Components are required: The standard field is formed using only three system
parts: elements, plywood and prop. The easy to handle parts and an element weight of
approximately 10 kg/m² simplify the forming process.
 Flexibility: With the GRIDFLEX, simple labor saving filler are as can be realized for
any building shape. The telescopic function provides a flexible two-dimensional
adaptability in both transverse and longitudinal directions with the elements. The third
dimension is aligned via the props. Thus the GRIDFLEX is, in effect, a real 3D element
slab formwork system, for slab thicknesses up to 67 cm.
 Free choice of plywood sheeting: GRIDFLEX provides flexibility regarding the choice
of form lining, depending on the project requirements. Even though grid flex satisfies the
requirements of quality, safety and environment, it has less application for most of the
projects in Ethiopia as its initial investment is too high. But it might have applications for
special projects.
B. MULTIFLEX Girder Formwork
PERI MULTIFLEX is flexible and versatile. It can be used for any slab thickness, floor plan and
all heights. With this system, only the statically required components and the associated weight
have to be moved. The GT 24 girder allows large spans and thus reduces the number of
components required. The high load-bearing capacity increases the cost-effectiveness. The VT
20K girder can be used for smaller slab thicknesses. It is the most economical solution for
16
supporting thinner slabs. With PERI MULTIPROPs, the high permissible GT 24 support reaction
of 28kN can also be used with maximum extension lengths.
Figure 2.6 1 PERI MULTIFLEX

MULTIFLEX girder slab keeps the cost of materials down. It is therefore particularly cost
effective where labor is relatively cheap. Such system can be adapted to Ethiopian construction
industry as labor cost is cheap. It is a system which satisfies all the requirements of formwork
construction for developing country. Besides its less material cost the construction technique is
also simple which makes the system preferable.
2.4.4.4. Beam Formwork

A. UZ Beam Formwork
It is continuously adjustable to suit the beam cross-section. No formwork ties are needed for
beams up to 800 mm deep. Moreover the UZ width adjustment bars and UZ perforated rails can
be connected together for wide beams. The main advantage of UZ beam formwork is that only
two system components are necessary and beam cross-sections are continuously formed by
means of these parts: UZ Beam Bracket 40 and UZ perforated rail see the following picture. The
rigid connection with the UZ perforated rail allows larger spacing.
Figure 2.7 1 UZ beam formwork with its bracket and perforated rail
17
This formwork system resists concrete pressure and no bulging of beams.
2.4.5. Classification According to Materials of Formwork

Before the final selection of the formwork materials made for a particular job, a number of
factors should be considered, including:
 The size of the forms

 The shape of the forms
 The surface finish required
 The accuracy required
 The number of re-uses required
 The handling methods proposed
 The methods of compaction proposed
 The method of curing proposed
 Safety
 Speed of the project and the capital available.
The weighting given to each factor will vary from project to project. Thus on small projects
where multiple uses of formwork elements are unlikely and a great deal of cutting and fitting
may be required, timber sections may well be indicated. On major projects, where standardized
components can be employed, and multiple re-use achieved, heavier steel sections may well be
warranted. Modular units may be viable in such circumstances. The quality of the finish required
and the overall cost of the formwork are likely to be the principal determinants. [22.]
FE construction engineering plc needs to consider the above factors so as to have safe, quality
and economical formworks. Moreover knowledge of all formwork materials is mandatory for the
selection of best formwork system. Many materials may be used for formwork. Plywood, steel,
aluminum alloys, particle board, hard board, gypsum board (for left-in-place sub grade forms),
lumber, cardboard, rubber, polyvinyl chloride, and polystyrene are all used for forms and
supporting formwork. Description of these materials is made in the following sections.
2.4.5.1. Steel Formwork

Steel is very strong and can be used repetitively without much damage done to the form. Steel
forms are also in use in combination with timber. Steel sections are used in the fabrication of
18
different formwork components, namely: steel panel forms, horizontal and vertical shores, steel
pan and dome components used for joist and waffle slabs, and steel pipes for formwork bracing.
Steel formwork has the following advantages and disadvantages.
Advantages
 Has very high reuse rates

 Very smooth surfaces are possible
 Strong and fast to install in simple walls.
Disadvantages
 Costs are 6-10 times plywood form.

 The thicker the surface of the steel sheet, the greater the weight.
 Steel dents easily
 Release agents are demanded as, if not used, cleaning labor will quickly overcome any
economy gained by durable surfaces.
 Low versatility.
2.4.5.2. Plastic Formwork

Different companies innovate range of formwork products which is aimed at completely
revolutionizing the concreting procedure by saving time and resources, while providing a smooth
finish that is nothing short of excellent. Geoplast is one of such innovations. The products come
in the form of Plastic panels that can be efficiently assembled into an airtight and minutely
precise mold .Once the concrete is set, Geopanels are effortlessly removed to reveal the finished
structure. All Geopanel pieces can be comfortably assembled by just one person this enables
concrete structures to be erected with minimal manpower & tools. Needless to say, the necessity
of cranes or other heavy lifting machinery is also eliminated. Furthermore since all moulds are
produced from ABS (acrylonitrile, butadiene, and styrene) Plastic they can be easily cleaned
after use with just water and can be stored even in humid conditions. The following are some of
the plastic column formworks. [23.]
19
Figure 2.8 1 Geoplast Plastic formworks

2.4.5.3. Timber Formwork
Timber, arguably the original building material, retains its prime importance within the
construction industry because of its versatility, diversity and aesthetic properties. Approximately
a third of the annual worldwide timber harvest is used in construction, and the rest is consumed
for paper production, as a fuel, or wasted during the logging process.
In Ethiopia more than the figure stated for developed country is expected to be utilized for
construction of structures. Almost all contractors use timber as false works and others which
indicates that the construction industry of Ethiopia highly utilizes timber. Timber can be best
used for formwork if their replacement is promised. Otherwise it is a threat to Ethiopia’s
environment in particular and global environment in general. [8.]
The advantages of timber formwork are:
 Easy handling because it is light in weight

 Easy to disassemble
 Damaged parts can be replaced with new one
 Very flexible
The disadvantages of timber formwork are:
 Cannot be used for long period of time. They have limited re-use and can only be reused
5 or 6 times
 If the timber is dry, it will absorb moisture from wet concrete which could weaken the
resultant concrete member.
20
 Timber with high moisture content (more than 20 % moisture content) will shrink & cup,
leading to open joints & leakage of grout.
2.4.6. Selection of Formworks

Selecting the formwork system for cast in place reinforced concrete is a critical decision that can
affect cost, safety, quality, and speed of construction. Many factors must be considered for the
proper selection of the formwork system. Among these are:
1. Factors related to building architectural and structural design, which include slab type
and building shape and size.
2. Factors related to project (job) specification, and schedule, which includes the speed of
construction.
3. Factors related to local conditions, which include area practices, weather conditions, and
site characteristics. [27.]
21
CHAPTER THREE
3. Methodology
3.1. Introduction
As the title of this study depicts, the study paper is mainly focused on the comparison of modern
formwork techniques and traditional formwork in view of introducing beneficial and better
techniques useful to the formwork practice of FE construction and the country as a whole. To
measure and understand the problems associated with the current techniques the study pointed
out some points relative to the advancement of modern formwork techniques.
This study employed qualitative data collection approach to compare both techniques in terms of
speed, quality, cost and safety parameters and to recommend best techniques to the FE
construction and to the domestic construction industry as a whole.
3.2. Study Design

The purpose of the study is to review the current efficiency of formwork system relative to the
modern formwork system and to offer best alternative solutions to the problems and barriers that
have arisen from the traditional formwork system. As a result, the study adopted descriptive
design. Descriptive study enables to provide an accurate description of observations of
phenomena as the objective of most descriptive studies is describing the state of affairs at the
time of study.
3.3. Study population

Saunders (2007) defines study population as the full set of cases from which a sample is taken. In
line with this, Cohen et al. (2000) state that, population is a group of people who are subject to a
piece of study. The target population for this study was FE construction site engineers,
consultant, site supervisor and overall stakeholders on the site.
3.4. Data collection methods

The primary data essential for this study gathered from direct observation on the site throughout
the intern session. The data needed for this study also collected from secondary sources through
reviewing the office records and previous related studies.
22
3.5. Data analysis

The method for this project paper comprises an initial comprehensive literature survey which has
been carried out by reviewing journals, articles, and previous related studies to obtain existing
knowledge on various aspects of formwork systems. Direct observation was primarily used in
order to find a more tangible feeling over formwork techniques and its drawbacks.
Based on the findings of the reviewed literature survey, contact has been made with the site
officials has been made to discuss the problems on associated with the existing traditional
formwork systems.
Then qualitative analysis made to point out where the modern formwork system is advanced in
different ways relative to the existing one. Finally, based on the findings, conclusion and
recommendations on the future work made.
23
CHAPTER FOUR
4. Result and Discussion

4.1. Introduction
As described in the methodology part, the approaches adopted in this research were the use of
desk study and observations. Desk study was conducted in Germany. PERI’s formwork elements
and their construction methods were thoroughly studied from company’s handbooks, and
brochures. Moreover, formwork elements were observed on construction sites while assembling
and dismantling. The results show that the system is similar to that of PERI. Therefore, PERI
was mainly taken as case study to represent international modern formwork producing
companies for the purpose of this study.
4.2. Formwork materials and costs

Cost of formwork and its associated labor cost is significant segment of the concrete structural
frame. The cost of formwork is influenced by;
 Initial cost,
 Reuses cost of formwork system and
 Maintenance and storage cost
According to previous surveys made in Ethiopia, almost all of the construction companies use
steel panels and timber boards as formwork materials. These materials are used for casting
concrete of almost all structural members such as footing pad, column, beam, slab and wall.
Most of them use plywood and the rest small amounts of companies use precast concrete and
wood particle boards and hardboard as formwork material.
Alternative formwork materials such as plastic, cardboards, aluminum, glass reinforced plastic
and fabric are not practiced in the construction industry of Ethiopia. Even though all contactors
use both Steel panels and timber boards, the former are relatively more used than the later.
Despite its high rate of use, the quality of the steel panels used by local contractors is not
satisfactory. The panels are not maintained well and the concrete surfaces casted using such
formworks are not good. According to the data found from different sources and direct
observation steel panels are used a number of times without caring for its maintenance and
24
cleaning. No concrete release agents are used during cleaning of steel panels. Most of the
contractors clean the panels after the concrete was set on them. Cleaning method is done by
adding water on set concrete and using sharp metals to release it. Such cleaning procedure is not
found to be useful in maintaining the quality of panels and subsequently quality of concrete
surfaces. Improper storage of steel panels has also resulted in bending and rusting of the
elements.
Concerning the reusability of steel formworks in Ethiopian construction industry, plywood is
used frequently and timber boards are used less frequently. The more the plywood and the timber
boards are used the more the quality of concrete surfaces decrease. This is mainly associated
with absorption of moisture by timber formwork from wet concrete. After stripping of the
formwork, the moisture absorbed by timber will be lost to the external environment and make it
shrink. Application of fabric or similar form lining will increase the number of reuse of timber
formwork and local contractors are recommended to use such materials.
Most of the times in our country formwork materials are owned through purchasing either from
the local or international market. Rental and self production also can be mentioned as a source of
ownership of formwork materials.
But most of contractors in our country purchase these materials from local market as they have
no adequate awareness modern formwork systems different reasons being the cause. It could be
either failing to follow the international trend in this field or lack of awareness of the benefits of
applying modern formwork systems. Most of all shortage in foreign currency could be one of the
major obstacles in having access to these modern formwork systems.
Construction companies with good financial muscle import formworks from the international
market. Such companies are known mainly in importing steel panels and modern formwork
elements like girders, steel props and plywood, which are used as slab formwork components.
But still these companies are under the assistance of the government in importing these
formwork systems in the sense of motivating their interest to apply or introduce modern
formworks.
Steel panels are the major formwork type which has been experienced by the construction
companies in our country. Most of high grade contractors owe such formworks types and they
secure additional rent cost by renting those formworks to relatively lower grade contractors.
25
As opposed to Germany, concrete material has the major cost share in Ethiopia. The formwork
costs about twenty six percent of the situ-concrete, concrete, labor, material cost comprises about
11% of the total cost in the construction industry of Ethiopia.
Concrete material is the major cost component in construction projects in Ethiopia but the
inverse trend is in the developed country that the formwork labor cost is relatively higher. It is
clear that besides workmanship and concrete mix, formworks have an effect on final quality of
concrete. Hence, the use of safe and quality formwork system is mandatory so as to produce
concrete with better surface quality, strength and durability.
Traditional formwork requires the activities like plastering and chiseling of concrete and these
activities incur cost. The application of modern formwork is helpful in minimizing costs related
to plastering and chiseling of concrete done to rectify faults in construction projects and in some
cases these costs may be avoided.
Cost of purchasing or renting these modern formworks can be reduced by the amount of saving
from not applying plastering to concrete surfaces.
Similar reduction in costs, though it is not significant, for beam, column and wall formworks will
be obtained provided that contractors use modern systems. There are other international
companies, which offer formwork systems at lesser price than PERI, and local contractors can
get alternative modern formworks at lower price from where ever suited them.
4.3. Quality analysis

The panels are not maintained well and the concrete surfaces casted using such formworks are
not good. From the survey made, steel panels are used a number of times without caring for its
maintenance and cleaning. No concrete release agents are used during cleaning of steel panels.
Most of the contractors clean the panels after the concrete was set on them. Cleaning method is
done by adding water on set concrete and using sharp metals to release it. Such cleaning
procedure affects the quality of panels and subsequently quality of concrete surfaces. Improper
storage of steel panels has also resulted in bending and rusting of the elements. This is impactful
on the quality of concrete.
It has been observed that plastering and chiseling of concrete was being done on the site. This
arises from inadequate execution of activities and defects from the formwork which causes the
rework to take place.
26
The other problem spotted was steel formwork require more buried oil to remove from the
concrete and it does not absorb the oil. The main effects of this oil are:
 Creation of unclean environment.
 Create poor bondage between re-bar and concrete if applied excessively.
 Change the color of concrete to black and architectural concrete cannot be attained.
 Curing will not be effective if excessive oil is applied as it prevents the sprinkled water
from penetration.
This effects listed above are associated with application of present formwork system (i.e., steel
formwork) and this is huge obstacle in thriving for quality of concrete.
Despite its high rate of use, the quality of the steel panels used by FE contractors is not
satisfactory. The panels are not maintained well and the concrete surfaces casted using such
formworks are not good. According to the data found from different sources and direct
observation steel panels are used a number of times without caring for its maintenance and
cleaning. No concrete release agents are used during cleaning of steel panels. Most of the
contractors clean the panels after the concrete was set on them. Cleaning method is done by
adding water on set concrete and using sharp metals to release it. Such cleaning procedure is not
found to be useful in maintaining the quality of panels and subsequently quality of concrete
surfaces. Improper storage of steel panels has also resulted in bending and rusting of the
elements.
Concerning the reusability of steel formworks in FE construction, plywood is used frequently
and timber boards are used less frequently. The more the plywood and the timber boards are used
the more the quality of concrete surfaces decrease. This is mainly associated with absorption of
moisture by timber formwork from wet concrete. After stripping of the formwork, the moisture
absorbed by timber will be lost to the external environment and make it shrink. Application of
fabric or similar form lining will increase the number of reuse of timber formwork and local
contractors are recommended to use such materials.
27
4.4. Speed analysis

Speed is one of the parameters in measuring productivity. If the formworks are standardized, the
productivity data for erecting and stripping of formworks will be easily established for the
country as well as for individual contractors. Higher variations in the unit price offered by
contractors will be minimized as labor productivity has effect on cost.
The stripping time of soffit formworks for slab and beam varies from 10 to 28 days depending on
cement type. Summary of the results of formwork stripping times is shown in figure below.
Most contractors wait for 14 days before removing soffit formworks of concrete slabs and beams
casted with OPC cement. For concrete casted with PPC, minimum of 21 days are elapsed before
removal of the soffit formworks.
The data below is obtained from previous study made by Argaw Tarekegn on Application of
modern formwork systems on construction industry of Ethiopia. According to this data the
productivity of using traditional formwork systems in our country averaged as follows.
Table 4.1 1 Productivity of Formwork Construction in Ethiopia

To justify the time to be saved in using modern systems, consider slab formwork construction of
G+6 building. Say only one crew and one formwork systems are involved .The area of each floor
slab is about 100m2 and is to be casted with PPC. The average duration until stripping of the last
floor soffit formwork using traditional construction system will be;
 Erecting time = 100m2 / (0.68m2/hr) = 147hrs which is approximately 18days.

 Stripping time=100m2 / (1.48m2/hr) = 68hrs which is approximately 8days.
28
 Expected waiting time = 25days

 Total duration for formwork construction process of one slab = 51days.
 Total for six floors= 306days
For modern formwork systems, considering the productivity as five times that of local practice
 Erecting time = 100m2 / (3.4m2/hr) = 30hrs which is approximately 4days.

 Stripping time= 100m2 / (7.4m2/hr) =14hrs which is approximately 2days.
 Waiting time = 14days
 Total duration for formwork construction process of one slab =20days.
 Total for six floors=120days
4.5. Safety and Environment Analysis
4.5.1. Safety analysis

It is clear that handling construction equipment is very expensive. Loading and unloading,
moving and temporary storage on site can expose the workforce to various dangers. It has been
witnessed from observation that there is no officially published health, safety and environment in
the construction company and the construction industry in general and formwork construction in
particular by regulatory bodies in Ethiopia. Throughout on-site discussion with labors, it has
been noted that most of the record of injuries or death encountered during formwork
construction. This is a huge implication that the construction formwork working system and
overall guidelines are not safe for labors to perform their task.
In addition to above problem the construction project make use of formwork release agent as
most of the contractors in our country, which is us burnt oil and there exists no precautions in
dealing with dosage of the release agent by the company.
Figure 4.1 1 Unsafe column formwork

construction
4.5.2. Environmental
Analysis
The construction industry in our country
is mostly known for its consumption of trees
29
from its beginning to its completion. One of the construction works highly reliant on the trees is
formwork. For instance to cast concrete slab having area of 100m2 and 10m*10m*0.15m
dimension;
Computation for quantity of timber supports is made as follow:
 Average spacing in both sides of the props is 60cm.

 Average diameter of timber props varies from 8cm to 12cm.
 Average height of props is taken as 3.0m Props are reused for maximum of three times.
Accordingly, minimum of 324 props and minimum length of 540m horizontal members are
required. Total length of timber is about 1512m.Assuming the length of tree as five meters,
minimum of 302 trees are cut to cast concrete for 100m2 slab. To complete slab concrete work of
one multi story buildings would be in much worrying quantity. The quantity of trees to be
cleared increases as the area of the slab and story of buildings increases. Moreover the
deforestation rate depends on the rate of construction. It is clear that the current construction is
increasing is at an alarming rate and someone may expect how really this industry could
contribute to deforestation. Therefore the current 3% coverage of forest is expected to decrease
in near future if deforestation for construction and other industries continue with current
practices.
Generally, safety and environmental issues discussed in previous sections are some of the factors
which oblige the construction industry of Ethiopia to use modern formwork systems.
Construction safety in Dire Dawa in particular and Ethiopia in general is given less emphasis
which is threat to the construction industry.
Failure of formworks or associated false works is expected to occur as there is no focus on the
design and construction of proper formwork systems. Concerning environment, many trees are
cut without promising their replacements. The construction industry is the major contributor for
the deforestation of trees.
Therefore the use of modern formwork system is mandatory to alleviate the above problems
illustrated above. In an attempt to solve the problems there is no need to start from scratch, the
systems which developed countries such as Germany or others followed will make things easy.
30
Hence the modern formwork systems of PERI, Germany, are investigated from this perspective.
This is why enacting a policy in applicability of modern formwork system needs to be enacted.
4.6. Result (Suitable Formwork for Ethiopian construction industry)
4.6.1. Suitable Wall Formwork System for Ethiopia

This formwork system has many applications in construction industry of Ethiopia. For instance,
in building projects for lift shafts and concrete walls; in other civil engineering projects for water
reservoirs, retaining walls etc. As construction of such structures is booming, selection of
appropriate formwork system is mandatory. Modern wall formwork systems are believed to
alleviate many problems associated with current concreting practices of walls in Ethiopia.
Among the problems, formation of cold joint in concrete structures and loss of plumbness of
walls are the common ones. Cold joints occur as the walls are not casted monolithically and loss
of plumbness is the result of bulging of formworks due to concrete pressure. Since the modern
formwork systems are designed for the required concrete pressure and are available in different
heights, the defects in current concreting practice do not occur.
Discussions on relatively more suitable formwork systems are made in subsequent section.
TRIO Panel and VARIO GT 24 can be used to solve the problems in the construction industry of
Ethiopia. Other wall formwork systems can also be used but they are equipment intensive and
costly. TRIO panels are easy to assemble and labors can get job opportunity which is the main
issue besides quality of concrete in Ethiopian context. If such formwork systems are used, extra
cost from plastering will be avoided and the structure’s level and plumbness will be as per the
design. The dispute between contractor and designer or client due to defect in concrete quality
will also be minimized. From the site visit made in the selected site in Darmstadt, such wall
formworks and concrete surfaces were observed. The surface of concrete wall is good in both
faces. The thickness of the wall is also as per the design and no bulging occurs. It is perfectly
aligned vertically and horizontally. The following picture shows the partial view of concrete
basement wall casted using TRIO panels.
31
Figure 4.2 1 Concrete surface casted using Figure 4.3 1 Concrete surface casted using
TRIO panel, Darmstadt traditional timber formwork, Dire Dawa
In selection of standard wall formwork pieces, the geometry of the building or structure should
be taken in to consideration. Complex design may need new formworks which are not in the
standard and contractor is obliged to purchase or produce the formworks for the particular
project. Consequently the cost of the project will increase. Another factor which affects the cost
of formwork especially the labor cost is size. Small size panels require many joints and more
labor time as compared to the larger one. Since labors are paid on hourly base, longer working
time implies higher cost. Hence the labor cost for wall formwork is variable. It depends on the
design and choice of elements by the contactor. In general larger formworks are preferred if the
shuttering area is large. The optimum formwork elements combination is chosen by patented
software developed by PERI for the desired project.
4.6.2. Suitable Slab Formwork System for Ethiopia

Depending on the project types and availability of finance, aluminum slab formworks of PERI
such as Sky deck and Grid flex can be used for construction in Ethiopia. Such formworks are
very easy to handle and the labor cost is low. But the material cost is too high and usually
recommended for projects which are intended to be completed in short period of time. For
instance, investors who want their projects completed early can use such system. PERI MULTI
flex is more suitable for the construction industry of Ethiopia. Local contractors will get the
following benefits from such formwork:
 Better concrete surfaces are obtained than the conventional formwork system.
 Its Assembly is easy.
32
 It creates job opportunity for labor as relatively more labors participate than other
formwork systems.
 It is not as costly as other formwork types.
 It is relatively easy to transfer the technology of MULTI flex.
 That is local material can be used for the production of girders.
Improving the competence of local labor in using such system is an important issue in
construction industry of Ethiopia. One means of doing it is to train, identify and manage the
factors which affect their productivity.
The labor cost for laying one square meter of MULTI flex ranges from 52.3 to 75.6euros. If the
labor is productive, the cost decreases accordingly. If the technical capacity of local labor is
built, the cost will be reduced in case of construction projects in Ethiopia. The material cost of
MULTI flex is less than 100€/m2. As shown in table below the cost of table module which is
assembled by PERI is about 104€/m2 and MULTI flex are assembled on site by contractor which
costs less than the pre-assembled modules. Hence MULTI flex is suitable for the construction
industry of Ethiopia as it fulfills the cost, quality and safety requirements in formwork
construction.
The durability of the formwork in general depends on how it is treated during construction. If
proper care is not given to forms, their number of uses will decrease. Hence care during
transportation, storage, assembly and stripping need to be made so that the formworks will be
durable. Durability may also depend on the choice of form lining material or Ply wood.
Hardwood ply wood such as Fin-ply can be used for more than 70 times and softwood ply wood
such as FinNa-ply can be used on average 25 times. Therefore both plywoods can be used based
on the financial capacity of the contractor. It is also possible to produce plywood locally and
replace the old form lining.
No. Element Price

1 TRIO270/240 steel panel 1708euro/pc or 263.58euro/m2
3. TRIO270/90 Aluminum panel 808 euro/pc or 332.51euro/m2
5 Table ModuleVT200/215*400 944euro/pc or 118euro/m2
33
6 Table ModuleVT250/265*500 1302euro/pc or 104euro/m2

7 Circular Column panel diam.25cm h=3m 264euro/pc or 111.86euro/m2
8 TRIO column panel TRS270*90 958.50euro/pc or 394.4euro/m2
10 VARIO panel 250*240 1026.00euro/pc or 171.0euro/m2
11 DOMINO panel 250*100 485euro/pc or 194euro/m2
12 Steel Prop PEP20-300 63.70euro/pc
13 PERI Girder VT 20 145cm long 9.45euro/pc
14 PERI Girder GT 24 90cm long 14.9euro/pc
15 Fin ply 21mm 1500*2500mm 22.0euro/pc
16 Peridian Fabric 2.8*25m 2110.0euro/pc
Table 4.2 1 Material Costs of PERI products

4.6.3. Suitable Column and Beam Formwork Systems for Ethiopia
In some construction projects in Ethiopia, many quality problems were observed on beams and
columns construction which has to be rectified through the use of modern and standard
formworks systems. Among the problems, the following are the major ones:
The column cross sections are not the same at top, middle and bottom, the cross section at the
bottom is larger due to the increase in the pressure of concrete on the formworks. This is
attributed to the improper design and construction of formworks. The change in cross section has
influence on wall to be constructed between the columns. Blocks are cut to compensate for the
decrease in space at the bottom owing to bulging of columns. Therefore blocks are being wasted
due to change in dimension between columns.
Extension of column formwork is not properly done in case where it is required to cast relatively
high column concrete. The lower and top cross sections of column are completely different. As
there is weak joint between lower and extended formwork, the upper section is thicker than the
lower. The situation is also true for beams. Chiseling of concrete surface is made to rectify such
errors. Besides adding cost to contractor, over chiseling may affect the structure. Over chiseling
can affect the durability of concrete as new concrete which is not well compacted is applied to
the affected area. Such problems can easily be alleviated by the standardization of formworks.
34
Moreover design of temporary works need to be submitted by contractor and approved by the
competent consultant.
In some circumstances, the cross section of beam is not uniform due to the fact that formwork tie
materials and methods are inappropriate. Black wire is mostly used to tie side formworks of the
beam. The wire may not sustain the concrete pressure and the beam bulges. More over the
spacing and the strength of the ties need to be designed properly to avoid such problems. But
most local contractors lack the practice of designing formwork ties. Not only bulging out of
beams occurs but also over tying and reduction of cross-section is common. The latter is made in
anticipation that the dimension of will be adjusted after casting concrete and vibrating. This is
sheer trial and error as the dimension may return through pressure or not. Therefore UZ beam
formwork will solve such problems. [33.]
All the above factors enforces the contractors to look for modern formwork systems such as
PERI Trio, QUATTRO and Vario which are easy to assemble and not as costly as aluminum
forms. Good surface finish is obtained with these formworks. This was confirmed through
construction site visits made in Germany. See figures below
Figure 4.4 1 Concrete column formwork Figure 4.5 1 Concrete column formwork
casted using PERI formwork, Darmstadt casted using Timber formwork, Dire Dawa
The edges of columns can be chamfered or sharp as shown in the above figure. No cement and
sand plastering is required to form the edges of column and beams as it is usually done in the
traditional construction in Ethiopia. With regard to labor productivity for column formwork; it is
35
between 0.9m2/hr and1.4m2/hr. For beams it is between 0.9m2/hr and1.3m2/hr. The approximate
labor costs per square meter for columns and beams are 30.6-47.6euros and 30.6-44.2 Euros
respectively.
Staircase formworks were assessed but the trend in Germany or other developed country is to use
precast elements for such members. This is done because the construction of stairs takes much
time and need precision. Steel formwork elements are used in case where stairs are casted on
site.
4.6.4. Special Formworks for Ethiopia

For special projects such as high rise buildings and other civil structures with high walls, PERI
climbing systems are also recommended in developing countries like Ethiopia. Since a lot more
of these high rise buildings are expected to be constructed in our country in the near future,
special formwork systems might have great applications by then. Therefore knowledge of such
formwork system by local professionals is mandatory.
PERI ACS self-climbing systems is recent invention which can be operated without the use of
crane. Projects which give priority for time than cost can use ACS climbing systems. As
compared to other formwork systems, the cost of self-climbing system is high and it is
recommended for the construction industry of Ethiopia for special projects only. Site visit was
also made to special projects such as Tower 185 building construction project in Germany, see
figure below. It is a project with height of 185m which is about 60 floors. Its construction is
being conducted safely with climbing systems. Since the side of climbing system is high,
workers on top floor do not feel discomfort and their productivity will not be affected. [35.]
Figure 4.6 1 Self Climbing Systems at Tower 185, Frankfurt
36
CHAPTER FIVE
5. CONCLUSION AND RECOMMENDATIONS

5.1. Conclusion
The study has made effective comparisons based on productivity parameters like speed, safety
and quality. In doing so, the paper pointed out that in terms of speed the modern formwork
system by far is preferable by taking formwork stripping duration as speed measurement.
According the analysis made using the data obtained from previous study made by Argaw
Tarekegn the total stripping time that the modern formwork saves around 186 days relative to the
stripping time for the traditional formwork.
The other parameter used to compare the two formwork systems was quality. Regarding this the
modern formwork system will be much helpful in eliminating the problems associated with the
current formwork system in FE construction like; lack of maintenance and cleaning of steel
panel, the poor quality of steel panels used in formwork, formwork reworks like chiseling and
plastering, the use of burnt oil in making formwork using steel panel
All listed here and other problems are the causes for lowering the quality of formwork which is
being made on the construction site. So, implementation of modern formwork systems would a
relief for all parties concerned as quality is one primary objectives construction project activities.
The final analysis was made on safety and environment. As we all know safety is a problem in
every construction project and activity as a whole. The traditional formwork making by its nature
require labors to climb wooden ladders so as to create effective joint between formwork
components. This practice is dangerous to labors as there was no supporting and holding
materials are being used on the site. The modern formwork allows the use of well built supports
and holding metals where labors can work in the most flexible, efficient and safest manner.
Environmental related threat is one of the most worrying features of the current formwork
system. Considering the staggering development of building sector, the consumption this sector
needs in executing construction activities especially, formwork is hugely threatening. Climate
change is becoming one of the primary challenges that we all need to deal with and the use
37
woods/trees for formwork has to change. The best way to do that is through application of
modern formwork systems discussed in this study.
 By shortening the time taken to finish formwork works and consequently in

completing projects as early as possible.
 In creating safe working circumstances to the labors and technicians in assembling,
dismantling, and moving formworks on the site.
 In creating formworks of higher quality in all aspects.
 Most of all in hindering the trend that the current formwork system experienced in
contributing to the deforestation which is believed to be catastrophic to the nation.
5.2. Recommendations
The following recommendations are given so as to eradicate problems identified in this study to
improve the current formwork system in FE and Ethiopia in general.
 The stakeholders need to consider the limitation that the current formwork system has in
terms of speed, quality, labor and environmental safety.
 The modern formwork could grant contractors to increase their productivity and
performance in construction projects. They should be well aware of its benefits relative the
current system.
 The government should support local contractors in importing modern formwork systems
free of duty and provide loans to contractors so that they can purchase the desired
formworks.
 Consultants should prepare detailed specification by considering the modern formwork
systems. Specifications should vary from project to project depending on its complexity
and level of finishing required.
 Contractors should be able to design their formwork systems for the sake of safety of their
workmen and third party. The design will also help them in achieving economy in
formwork construction.
 As construction industry has role in deforestation of trees, policy which prohibits
contractors from using timber should be enacted. The policy should consider contractors
grade and type of construction projects.
38
References
1. Abu Dhabi Sewerage Services Company (2008),General Specification for Civil Works ,
division 3 concrete, UAE.
2. ACI 117-90, Standard Specifications for Tolerances for concrete Construction
Materials, Farmington Hills.
3. ACI 318-05, Building code requirement for Structural Concrete.
4. ACI committee E-701, Aggregates for Concrete, ACI Education Bulletin E1-07,USA
5. Andre Tovey etal. (2007), Design and Construction using Insulating Concrete
Formwork, Cromwell Press, Trowbridge, UK.
6. Alibala Group, Formwork Ties, http://www.alibaba.com/showroom/formwork-tie.html
7. American Society of Concrete Contractors ASCC (2008), The Contractor’s Guide to
Quality Concrete Construction, USA
8. Formwork Direct International LTD, Formwork Systems and Concrete Accessories,
UK.
9. Fraser Brown & Stratmore ltd, BIO-R Release Agent for concrete Formwork, Lower Hutt,
New Zealand.
10. GEOPLAGEOPLAST S.p.A, Geoplast Brochure, Grantorto(PD) – Italy
11. Handbuch Arbeitsorganizatio Bau (1986), Richtzeiten Schalarbeiten Rahmenschalung
Wände, Neu-Isenburg, Germany.
12. Hong Kong Institute of Construction Managers (2006), Timber Formwork, Practice Notes
for construction Managers, Hong Kong China.
13. Industrial Packaging ltd, Form-A round-Column, Killarney Road, ray, Wicklow Ireland.
14. JMC ltd (2006), Formwork manual, Ahmedabad, India.
15. John Richardson (2006), Supervision of Concrete Construction, London, England.
16. Kamran M. Nemati (2007), Formwork for Concrete, University of Washington,
Department of Construction Management.
17. Lanotec Australia Pty Ltd, Release Agent Product Data Sheet, www.lanotec.com.au
18. Liebherr Group (2010), Mobile Cranes brochures, Ehingen, Germany.
19. Manfred Hoffmann (2006), Zahlentafeln für den Baubetrieb, weisbaden, Germany.
39
20. Dextra Group ,Formwork ties and Accessories, Brickfields Business Park, Gillingham,
Dorset SP8 4PX,UK
21. DIY, Formworks, http://www.builderbill-diy-help.com/formwork-materials.html.
22. Douglas ,D. et al (2006), Construction Equipment Management for Engineers, Estimators,
and Owners, Boca Raton,USA
23. Edward, G. (2008), Concrete Construction Engineering Hand Book, Second Edition, New
Brunswick, New Jersey.
24. Ethiopian Building Codes Standard, EBCS2 (1995), Structural Use of Concrete, Addis
Ababa.
25. Frank International Technologies for the Construction Industry, Stremaform formwork
Hand Book.
26. Dextra Group ,Formwork ties and Accessories, Brickfields Business Park, Gillingham,
Dorset SP8 4PX,UK
27. DIY, Formworks, http://www.builderbill-diy-help.com/formwork-materials.html.
28. Douglas ,D. et al (2006), Construction Equipment Management for Engineers, Estimators,
and Owners, Boca Raton,USA
29. Ethiopian Building Codes Standard, EBCS2 (1995), Structural Use of Concrete, Addis
Ababa.
30. Frank International Technologies for the Construction Industry, Stremaform formwork
Hand Book.
31. Newman et al (2003), Advanced Concrete Technology, Butterworth-Heinemann, UK.
32. Paul Jaquin (2008), Rammed Earth Formwork, university of Durham,
http://www.historicrammedearth.co.uk.
33. PERI (2009), Formwork Scaffolding Engineering Hand book, weissenhorn Germany.
34. PERI GmbH (2003), Tie Systems Handbook, Wiessenhorn, Germany.
35. PERI GmbH(2005),Climbing Formwork Hand book ,Wiessenhorn, Germany
36. Wikipedia free encyclopedia, Formwork and False work, http:// en. Wikipedia. Org
/wiki/formwork.
37. Wikipedia free encyclopedia, Crane (machine), http://en.Wikipedia.org/ wiki/ Crane
38. Zentralverband der Deutschen Baugewerbes (1982), Arbeitszeit Richtwerte Hochbau,
Bonn, Germany.
40
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DIRE DAWA UNIVERSITY INSTITUTE OF TECHNOLOGY

SCHOOL OF CIVIL ENGINEERING AND ARCHITECTURE

TITLE: COMPARISON OF CURRENT TRADITIONAL SYSTEM OF

PREPARED BY: ID.NO

MARAKI MEAZA 1002518

ADVISOR: INS. ZEMICHAEL

DIRE DAWA, ETHIOPIA

Figure 4.2 1 Concrete surface casted using TRIO panel, Darmstadt 32

Figure 4.6 1 Self Climbing Systems at Tower 185, Frankfurt 36

Table 4.2 1 Material Costs of PERI products 34

PPC - Portland Pozzolana Cement

Advanced Techniques in Formwork

Formwork planning process is divided in 3 stages

(iii) Reusable: It can be used 80 to 100 repetitions.

(i) Conventional formwork has normal quality

not easily carried because of heavy in weight.[12.]

1.2. Statement of problem

Figure 1.1 1 Traditional formwork construction on FE construction site

1.3. Objectives of the project

4.1.1. General Objective

4.1.2. Specific Objectives

1.4. Scope of the Study Area

1.5. Significance of the study

 The study gives a direction to whomsoever engaged in construction building sector in

1.6. Limitation of the Study

2.2. Formwork Requirements

Formwork economy is achieved by considering four important factors:

i. Cost of form materials

2.2.4. Safety and Health

2.3. Causes of formwork failures

The main causes of formwork failure are:

 Faulty formwork structural design

2.4. Classification of formwork

2.4.1. Classification According to size

2.4.2. Classification According to Location of Use

2.4.3. Classification According to Nature of Operation

2.4.4. Classification According to Brand Name of the Product

2.4.4.1. Wall Formworks

Figure 2.1 1 TRIO pane

 VARIO GT24 Girder Formwork

 Type and size of plywood as well as the fixings

The formwork is extended by means of the VARIO extension splice 24 in 30 cm increments up

Figure 2.2 1 PERI VARIO wall formwork

2.4.4.2. Column Formwork

Figure 2.3 1 Complete PERI QUATTRO unit with its eyebolts

 SRS Steel Circular Formwork

Figure 2.5 1 Erection of GRIDFLEX

Figure 2.6 1 PERI MULTIFLEX

2.4.4.4. Beam Formwork

This formwork system resists concrete pressure and no bulging of beams.

2.4.5. Classification According to Materials of Formwork

 The size of the forms

2.4.5.1. Steel Formwork

 Has very high reuse rates

 Costs are 6-10 times plywood form.

2.4.5.2. Plastic Formwork

Figure 2.8 1 Geoplast Plastic formworks

The advantages of timber formwork are: