SUBJECT -CET 402 Design of Formwork

UNIT-1

INTRODUCTION

Construction projects, consider being successful on the basis of objectives

i.e. completion on time with desired quality, within cost and safety is
prime requirement. There are many components of a construction project
like material, labor and equipment etc. and we can work hard on each to
prepare a strategy to achieve these objectives effectively also add value to
the organisational goal with the complementary functions of time and cost
as now a day’s best way to minimise the cost is complete the project in
short time without compromising the safety and quality.

One of the main sub-component comes under material component is

formwork. Effective formwork system is one of the key factors to ensure the
success of a construction project and achieve objectives as planned.

PURPOSE OF FORMWORK

“Formwork defined as die or mould including all supporting structure that

used to shape and support fresh concrete until it attains sufficient strength to
carry its own weight. It should be capable of carrying all imposed dead and
live loads apart from its own weight.”

Most effective way to speed up the work is to reduce the cycle time
provided that the interruptions and quality aspects such as deflection,
misalignment and misplacement need to be taken care.

FACTORS TO BE CONSIDERED

BASIC PARAMETERS

Quality

We need to ensure the quality of the form work system to satisfy strength
requirement, rigidity, position and dimensions.
Safety

The formwork should be able to ensure the safety of workers and concrete
structure as well.

Efficiency

The operation of the formwork should be easy. It should be easy in

handling, erection and dismantling at the same time able to provide as
many repetitions optimally.

Economy

We need manage least cost while maintaining the desired quality and
safety. Economy can be achieved by designing the same size of concrete
structure to the extent possible and by careful consideration in designing,
planning, quality management and safe practices.

CLASSIFICATION ACCORDING TO

Size

It is necessary to analyse the size of the formwork required because the

determination of size will provide a clear idea about the amount of labour
required for their operations, for example: small size can be operated by
labor manually on the other hand large size will require mechanical means
like cranes.

Location

Location of use is a very important factor while making the strategy. For
example: for irregular frame structure, traditional formwork is desirable. For
wall and column, climb or jump type and slab require conventional timber,
modular slab form or table form etc. Whereas, repeated regular section
required tunnel form, modular aluminium forms. Core wall shell need
climbing, jump or slip form. Aluminium and steel mould form can be used
in precast structures.
Material

Again the material greatly influenced cost, time and quality as the timber
form is most popular and having initial low cost with high adaptability to
complicated shapes however, it is labor intensive and environmentally
concerned. Steel forms are suitable for large size panels, but having heavy
weight. On the other hand, aluminium form is more stiff and light in weight
but costly as labor and material cost is higher. However, gives best finish
and quality best suited for the construction where numbers of repetition
are more.

Nature of operation

Play an important role and helps to decide the type of labor required i.e. if
the formwork required to be done manually or crane dependent, self
climbing or gantry, travelling and tunnel type.

SELECTION CRITERIA (PROJECT SPECIFIC)

Effective selection of form needs most appropriate and economical system

on the basis of detailed layout, planned schedule, cycle time and the
optimum amount required. Following are the main factors to be considered
while selecting the formwork.

Geometry of the Structure

Detailed study should be done before deciding the type of form keeping in
mind the internal layout, structural form is regular or irregular, if there is
consistency in dimensions of the structure? What is the span of the
building? And number of repetitions available.

Project planning and the speed of work

If high speed of work required, it can be expedited by proper planning by

considering logical sequencing, construction methodology, site logistics,
climate conditions, labor efficiency and by using additional sets of
formwork that will create flexibility, and more independent work fronts.
Cost

Cost of form work system should be analysed considering all components

i.e. initial cost plus transportation, assembling, erection, dismantling, reuse,
maintenance and storage cost and mark up.

In addition, availability of lifting device, simple logic of the system, concrete

surface finish, area and volume of cast per pour, use of other techniques
and provision of construction joint in structures also need to be considered
in the selection process.

All the objectives i.e. time, cost, quality and safety can be achieved by the
combined effort of client, designer, and contractor by developing strategy
for all the factors stated above. However, the structural form is the critical
one in deciding the formwork and needs special attention.

FALSEWORK VS FORMWORK: WHAT’S THE DIFFERENCE?

Fast-Form Systems manufactures and supplies both falsework systems

and formwork and while these two products are often spoken about
interchangeably, it’s important to understand that there are significant
differences between the two.

In a nutshell it’s pretty easy:

 FALSEWORK: Is typically a temporary

horizontal system onto which you cast
concrete.
 FORMWORK: Is typically a temporary
vertical structure into which you pour
concrete.

Both formwork and falsework have been used within the construction
industry for Thousands of years – even dating back to the Roman times
when building bridges and viaducts. Today, they both still play a major part
in building structures – falsework plays a vital role in the temporary support
of formwork in the construction of buildings, bridges and much more.

WHAT IS FALSEWORK?
Falsework is typically used to support a horizontal structure that is still in
the process of being built and cannot yet support itself. The falsework
systems are used as a temporary measure in order to hold the concrete in
place. This is usually in the form of Slabs, so a raised floor basically, think
of a multi-storey concrete structure, each floor would have columns cast
first, then you fit the falsework which is basically a horizontal forming
system, onto which you lay rebar and concrete and after a its poured and
set you can ‘Strike’ the falsework from underneath, though often it will need
additional ‘Back Propping’ to keep the structure safe until the concrete has
fully cured.

Traditionally, timber was used for every part of falsework systems, but this
was soon replaced with more sustainable materials – aluminium and
wooden H20 beams are popular as are panel and prop based systems,
Fast-Form’s offer a wide range of systems.

WHY IS FALSEWORK IMPORTANT?

There are numerous falseworks systems available depending on the height

and depth of the slab and finish required. The example below is a Cuplock
and H20 beam system, this gives very high strength and a superior finish to
a panel system and is very versatile for openings etc. However, for very
high and deep slabs an alternative would be a heavy duty aluminium
system. We design the best system to suit the job and finish required.
WHAT IS FORMWORK?

Formwork is also used to support the casting of RC works in buildings, but

in a slightly different way. Formwork is a temporary mold that helps to
maintain the shape of concrete until it solidifies. Once the concrete dries
and sets, the formwork is then removed. A range of materials can be used
for formwork, including timber, steel, aluminium or plastic.

When it comes to choosing the type of formwork for a job, it is important to

consider the temperature at which the concrete will be poured, as well as
the type of concrete being used and the height, width and length of the wall
and the pour rate required.

All of these affect the level of pressure which is exerted, so the right
material needs to be used. The formwork sides need to be strong enough
to resist the outward pressure of the wet concrete setting. It’s a very
common error to not calculate the pressures and many pour failures are
down to poor design, at Fast Form we design the system to suit the job, we
have never had a pour failure on our designs.

WHY IS FORMWORK IMPORTANT?

The main benefit of using formwork within a construction project is that it
ensures structural safety. Another advantage is that it protects workers too,
by ensuring proper access. Just like with falsework systems, formwork can
help to reduce the overall cost of the project by reducing the amount of time
it takes to carry out the construction. Skilled labourers are also required for
a shorter amount of time.

The quality of formwork is extremely important as if this is sub-par, it could

seriously affect the safety of the construction workers. Defective concrete is
also very expensive to repair, so it is important to make sure the pouring
and setting process is carried out properly. This means that any supports
for the formwork should also be of a high quality.

FAST-FORM’S SYSTEMS

Not only is the Fast-Form System quick to erect and lightweight, we offer
the best finish on the market. It is also the lowest-carbon, greenest type of
formwork on the market and we even supply a Carbon Saving Certificate
for each job to show how much carbon has been saved. With a 25+ year
lifespan, Fast-Form’s systems are designed to last, and reduce the use of
timber for a much more sustainable solution.
Fast form is unique in it can be fitted by hand or like other systems lifting in
panels but unlike other systems, it can also cast a straight or Radius wall
with the same component parts.

If you would like to find out more about Fast-

Form falsework or wall / column formwork, please contact us today and our
team will be happy to assist.

Concrete formworks (shutterings) are required for fresh concrete constructions

such as walls, slabs, beams, columns, footings etc. Formworks requirements for
different structural members are different and they are named based on type of
structural member. Formwork (shuttering) is a temporary mould to provide support
to fresh concrete when placed in structural member until the concrete has set. This
helps the structural member to gain sufficient strength to carry its self-load and
load from other members. There are many types of structural formwork or
shuttering based on its material, their use and the type of structural members.
They can be named based on that. However, core functioning of the formwork
remains the same.

Types of Formwork (Shuttering) Based on Structural Member:

Formworks are used in construction of reinforced concrete foundations, columns,
slabs, walls etc., and these are named as follows:

 Footing Forms – Formworks for foundation

 Column Forms – Formwork for RCC Column construction
 Wall Forms – Formwork for RCC wall construction
 Floor Forms – Formwork for construction of RCC Slabs
Footing Forms – Formworks for Foundation
The first step for any concrete construction starts with the construction of
foundation. Foundation can be for columns or walls. So, based on type of structural
member, the shape and size of footing are designed. Thus formwork size and shape
depends on the type and dimension of the footing.
Components of Footing Forms:

Fig: Components of Footing Formwork – For Shallow Footing – Continuous

Footing Formwork
Column Forms – Formwork for Concrete Column Construction
Reinforced concrete column forms are subjected to lateral pressure because of their
small cross section, large heights and relatively high rates of concrete placement.
Thus It is necessary to provide tight joints and strong tie support to the formwork.
As the sizes of concrete column increases, the stiffness of the formwork must be
increased by either increasing thickness of sheathing or vertical stiffeners must be
added to prevent sheathing deflection.

Wall Forms – Formwork for RCC Wall Construction

Formwork for wall construction are subjected to relatively lower lateral pressure
than column forms due to their large cross-sectional area.

The components of wall forms are:

 Panel sheathing – It is used to shape the wall and retain the concrete until it
sets.
 Studs - to support the sheathing or Wales by forming a framework to keep
the forms aligned and support the studs.
 Braces – It is used to prevent deflection of forms under lateral pressure and
keep the formwork erect.
 Ties and spreaders – These are used to hold the sides of the forms at the
correct spacing.
 Fig: Components of a Wall Formwork
Floor Forms – Formwork for construction of RCC Slabs
Formwork for reinforced concrete slabs depends on the type of slabs to be
constructed. The floor slabs can be structural slabs supported on a steel or concrete
structural frame, or slab-on-grade. The design of formwork varies with the type of
slab. Structural Slab Formwork assembly is carried out as follows:

 Positioning of the girder or beam form at the bottom.

 Girder side forms overlaps the bottom form and rests on the shore heads and
the sides of the column form.
 Side forms is held in place by ledger strips nailed to the shore heads with
double-headed nails.
 Larger girders should have the side forms vertically stiffened to prevent
buckling.
 When constructing the girder and beam forms each part must be removed
without disturbing the remainder of the form; strike-off formwork will
commence with the beam and girder sides, followed later by the column
forms, and finally by the beam and gird bottoms.
 Fig: Structural Slab Formwork Components
Slab-on-Grade Forms are forms for concrete slabs placed on grade. These slab
formworks are usually quite simple as concrete is placed on compacted earth or
gravel leveled base. Thus no support is required for concrete at the bottom.

Fig: Components of a Slab-on-Grade Slab Formwork

Slab-on-Grade Formwork assembly is carried out as follows:

 Plank, plywood, or steel forms are used for forming / supporting the open
edges of concrete.
  These forms are held in place by supporting with wooden pegs.
 The reinforcement in slab (if specified in the structural drawing) should be
placed on its proper location according to the drawing on chairs, bolsters,
and spacers made of either metal or concrete.
 If the slab is to be casted in sections, construction joints must be provided
between them, which will transmit shear from one to the other. The details
of construction joints should be followed as per structural drawing.

UNIT-2

MATERIALS USED FOR FORMWORK

Formwork is a structure that is built temporarily as a mold for a permanent

structure. It is falsework that supports the shuttering molds. There are plenty
of materials available to build a formwork. Interested to know all about
formwork material, here is a list of formwork materials along with their
advantages and disadvantages.
I. POPULAR FORMWORK MATERIALS

The selection of materials suitable for formwork should be based on the price,
safety during construction, and the quality required in the finished product.
Approval of formwork materials by the engineer/architect, if required by the
contract documents, should be based on how the quality of materials affects the
quality of finished work.
Materials used for the construction of concrete formwork range from traditional
materials such as timber, steel, aluminum, and plywood to nontraditional materials
such as fiberglass. The systems used can be a combination of two materials. Wood
products are the most widely used material for formwork.
1/ Timber

Timber is widely used for many construction applications including concrete

formwork. Timber is harvested from trees and is classified as hardwood and
softwood. Hardwood comes from trees that have broad leaves such as oaks,
maples, and basswood. Softwood comes from trees that have needle-like leaves
such as pines, cedars, and firs. Softwoods are most commonly used in the
construction of formwork.
 Timber Formwork
1.1 Advantages

- Timber can even make it perfect in any size you want.

- Timber is extremely lightweight so that it can be managed rapidly.
- Timber is indeed a good thermal resistance, which helps prevent concrete harm
in colder areas.
- The fabrication process for that kind of sort of formwork is easily
understandable, so it does not involve skill labor.
1.2 Disadvantages

- Dry timber contains moisture from concrete, which also reduces the workability
of the material.
- Timber formwork should only be modified 5 to 6 times.
- Timber with such a higher moisture content (<= 20%), wet concrete would then
reduce as well as cement slurry would then spill.
2/ Plywood

Plywood is a manufactured wood product consist a number of veneer sheets, or

plies Type of plywood can be grouped as exterior and interior. For formwork,
exterior plywood is used. The adhesive used to bond the piles in the manufacturing
of exterior plywood is watertight and gives a maximum number of reuses. The
plywood industry manufactures special plywood called Ply form specifically for
use in forming concrete structures.
>> 3 kinds of formwork plywood from Vietnam<<
 Film Faced Plywood - Plywood formwork

2.1 Advantages

- Plywood can also be cut into the required size easily.

- Plywood is Strong, durable, and light in weight.
- Provides a smooth finish on the surface.
- Very Large size plywood sheets are available which makes the construction of
formwork quicker and easier.
- Curved formworks can also be prepared using plywood.
- When compared to timber, it gives more number of reuses.
2.2 Disadvantages
 - When compared to timber it is costly.
- Thin plywood sheets cannot sustain the weight of concrete they may bow out if
proper thickness is not provided.
3/ Steels

The initial cost of metal formwork is more than timber formwork but the
number of reuses of metal formwork is higher than that of timber. In the long
run metal formwork can be economical. In heavy construction works metal
formwork may require a lifting mechanism to handle the formwork panels or
props. Steel or aluminum or magnesium is the most widely used metals.
 Steel can also be used as formwork material. It is very costly but it can be used
for more times than others. They provide an excellent finish to the concrete
surfaces. For mass structures like dams, bridges, etc. steel from work is so strong
and safe.

3.1 Advantages

- Steel forms are durable and stronger.

- Provides uniform and smooth surface finish to the structure.
- Great reusability.
- Easy to fix the formwork and also easy to dismantle.

3.2 Disadvantages
 - Cost is very much higher.
- It is heavy in weight and requires lifting equipment for large structure
formworks.
- Corrosion will occur when there is frequent contact with water.
- The size and shapes of forms available are limited.

4/ Aluminum

Aluminum formwork is used often for pre-fabricated formworks. It is getting

more popular because of its lightweight and good strength. It requires fewer
supports and ties.

4.1 Advantages
- Easy to fix and easy to dismantle.
- It can be handled easily because of its lightweight.
- It can be re-used for many times.
- The walls and slabs of structures can be casted simultaneously.
- Monolithic crack free structures can be built using aluminum formwork.
4.2 Disadvantages
- When the load reaches its maximum limit, the lighter sections may deflect.
- Architectural modifications are not possible when aluminum formwork is used.

5/ Plastics

Plastic is another type of formwork material that is used for small concrete
structures or for complex portions of the structure. It is light in weight and durable
for long periods. For complicated concrete structures, Glass-reinforced plastics
(GRP) and vacuum-formed plastics are used.
5.1 Advantages

- Plastic is light in weight and can be easily handled.

- Formwork for complex-shaped structures can be prepared easily.
- Good resistant against water.
- The damaged plastic sheets can be recycled and useful to make new sheets.
- Good quality plastic has great re-usability.

5.2 Disadvantages

- Plastic is weak against heat.

- It is a costly material.
- It does not take much load when compared with others.
CALCULATION OF LOADS AND PRESSURES ON CONCRETE
FORMWORK
February 18, 2017 TeamCivil Construction

Contents
1. 3- Horizontal Loads on Formworks
2. Share this:
3. Related

In concrete construction, forms are extremely important as they mold

the concrete to the required size
and shape. When it comes to construction, forms have to be designed
properly to provide safe support to loads incurred during the process of
building.

The possible loads that might act on formwork are many. In this article,
these types of loads are outlined along with the method of their
calculation.

1- Vertical Loads
Vertical loads acting on the formwork include the self-weight of the forms,
the placed reinforcement, the weight of fresh concrete, the weight of the
workers, and the weight of placing equipment and tools.

For concretes with normal reinforcement ratios, the dead load is usually
estimated at 22 to 25 kN/m3. Thus, an 16 cm normal weight slab would
exert a dead load of 25 kN/m3 x 0.16 m = 4 kN/m2 on a horizontal
formwork. However, in cases where the reinforcement appears to be
heavy, the weights of materials should be computed separately to
determine the actual unit weight.

The American Concrete Institute, ACI Committee 347, states that

horizontal formworks should be designed for a minimum vertical live
load of 2.39 kPa to account for the loads of workers and their tools such
as vibrators and screeds. This value is increased to 3.59 kPa if motorized
carts or buggies are utilized.

Additionally, ACI recommends that the minimum combined total design

dead and live load should not be less than 4.79 kPa or 6 kPa when
using motorized buggies.

Finally, the own weight of formwork is determined by using the unit weight
of its material and the exact dimensions of its various parts. It is worth
noting that the weight of formworks is far less than the dead load of
the concrete and the construction live loads. Therefore, an allowance is
assumed as superimposed load per square meter.

At the beginning of formwork design, the engineer can assume an initial

weight for the formwork between 0.24-0.72 kPa as a starting value. Then,
this value is checked and revised when the exact members’ sizes are
determined.

2- Lateral Pressures of Concrete on Formwork

Unlike horizontal formworks, vertical formworks, such as those for walls

and columns, are subjected to internal lateral pressure from
the accumulated depth of concrete placed. When placing,
fresh concrete near the top or sometimes at greater depths acts as a liquid
during vibration and generates lateral pressures equal to the vertical liquid
head.

On contrast, the lateral pressures are less than the liquid head at depths
below the controlled depth of vibration due to many factors. For instance,
for a slow vertical placement rate, the concrete mass in the lower part has
the time to start setting and stiffening. The friction between concrete and
form, migration of pore water, and other factors may also reduce the
resulting lateral pressures.

The next figure indicates the distribution of the pressures as revealed by

tests. The pressure starts as a liquid pressure near the top and reaching a
maximum at some lower level. In the design practice, this maximum value
is usually assumed for the rest of the height. This is a conservative
approach.
Typical and assumed distributions of concrete lateral pressure.

ACI Committee 347 stated that the following equation can be used to
calculate the concrete lateral pressure if the slump of fresh concrete slump
value is greater than 175 mm and it was not placed with normal internal
vibration to a depth of 1.2 m or less:

P = ρgh ; where:
P: Lateral pressure of concrete, kPa – : Concrete density, Kg/m3 – g:
Gravity acceleration, 9.81 m2/s – h: Depth of plastic concrete from
placement location to the specified point, m

For concretes with a slump value of less than 175 mm and placed with
normal vibration to a depth of 1.2 m or less, ACI Committee 347 defines
the lateral pressure of concrete as:

a- For Columns (vertical elements with no plan dimensions surpass 2 m)

with minimum of 30Cw kPa and not greater

than ρgh.

where:

Pm: Maximum lateral pressure of concrete, kPa – Cw: Coefficient of unit

weight (described below) – Cc: Coefficient of chemistry (described below)
– R: Concrete placement rate, m/h – T: Concrete temperature at
placing, oC

b- For Walls (vertical elements with at least one plan dimension larger
than 2 m)

This case is for walls with placement rate of less than 2.1 m/h and a
placement height equal or less than 4.2 m.

with minimum of 30Cw kPa and not greater

than ρgh

c- For Walls (vertical elements with at least one plan dimension larger
than 2 m)

This case is for walls with placement rate of greater than 2.1 m/h and a
placement height greater than 4.2 m.
 with minimum of 30Cw kPa and not
greater than ρgh

Next the values of Cw and Cc are given:

Unit weight of concrete Cw

Less than 2240 Kg/m3 Cw=0.5[1+(w/2320 Kg/m3)] but not less than 0.8

2240 to 2400 Kg/m3 1.0

More than 2400 Kg/m3 Cw=w / 2320 Kg/m3

Cement type Cc

Type I, II, and III without retardersa 1.0

Type I, II, and III with a retardera 1.2

Other types or blends containing less than 70 percent slag or 40 percent fly ash
1.2
without retardersa

Other types or blend containing less than 70 percent slag or 40 percent fly ash
1.4
with a retarder1

Blends containing more than 70 percent slag or 40 percent fly ash 1.4
a
Retarders include any admixture, such as a retarder, retarding water
reducer, retarding mid-range water reducing admixture, or high-range
water-reducing admixture (superplasticizer), that delays setting
of concrete.

To complete the picture, the pressure that acts on the column forms is
transferred to the external tie elements on the adjacent sides of the form.
Also, for walls, it is transferred from plywood, studs, or wales to the
tension ties that link the two opposite sides of the form. The following
figures illustrates some elements that are essential for resisting the
external lateral pressure that tends to overturn the wall, column, or slab
forms.

Schematic
bracing of wall formwork

Schematic bracing of slab formwork

3- Horizontal Loads on Formworks
 Horizontal loads are caused by forces such as wind loads, seismic
loads, inclined supports, and inclined dumping of concrete.

ACI Committee 347 recommends the minimum horizontal loads for design
to prevent lateral collapse of the formwork to be of the greater of :

1.5 kN per linear meter of floor edge or;

2% of total dead load on the form distributed as a uniform load per meter
of slab edge

For wall forms, bracing should be designed to meet the minimum wind load
requirements of ASCE 7-05 with wind velocity adjustment for shorter
recurrence interval as provided in ASCE 37-02.

UNIT-5

Formwork Failures:

One or more of the following can cause formwork failure:

 Lack of inspection/attention during formwork placement and
construction. ...
 Inadequate design. ...
 Defective components. ...
 Improper connections. ...
 Premature removal. ...
 Improper shoring. ...
 Insufficient foundation.

Most Common Causes of Formwork Failure

Posted on March 25, 2022 by Trekker Group
Formwork failure is of course a dangerous and disastrous occurrence during
construction. It typically happens during the stage when concrete is being poured.
Most often, one part of the formwork fails, which results in overloading or
 misaligning the structure as a whole, resulting in collapse. Understanding the most
common causes of formwork failure is essential to prevention.

Common Reasons Why Formwork Fails

 Inadequate inspection – One of the most common causes of formwork failure is
simply that it wasn’t thoroughly inspected by a qualified competent person. Never
skip inspection, and never rely on an unqualified or inexperienced person to
perform formwork inspection. A qualified party will be able to identify many of
the other potential hazards on this list.
 Design flaws – When considering the common causes of formwork failure, it’s
important to note that most design flaws relate to lateral forces and the formwork’s
overall stability. Inadequate shoring to cope with lateral forces like the concrete
load and wind can lead to collapse. Improper shoring is itself a major reason for
formwork failure. A licensed engineer should always approve formwork design.
 Using older formwork equipment – This can lead to another design flaw. Over
time, formwork’s ability to hold a load is reduced. If the formwork can’t handle its
original load, but the design calculates based on the original data, the formwork my
prove inadequate.
 Defective formwork components – Using poorly maintained or otherwise
defective formwork equipment or material can obviously lead to structural failure.
Always buy or rent formwork from a reputable supplier. Trekker Distributor is a
leader in formwork and shoring equipment, and we proudly stand by the quality
and cost-effectiveness of all our formwork products.
 Insufficient connections – Sometimes, in an attempt to assemble formwork more
efficiently and to make it easier to dismantle, workers don’t adequately secure the
connections between components. Factors like insufficient bolts, nails, splicing,
welding, or wedges easily compromises the structural integrity of formwork and
can trigger progressive collapses.
 Premature removal – Taking down formwork too soon, before proper concrete
curing, often occurs when a crew is rushed to dismantle and reuse formwork due to
budgetary or scheduling concerns. But this is not safe, and can prompt both
formwork and concrete structural failure.
 Inadequate foundation – Any structure with an insufficient foundation is at great
risk, and it’s no different with formwork. Foundations that don’t transfer the load
to the ground or that are on unstable ground are a concern, and can reduce the load
capacity of the formwork. Problematic foundations are often made using sill plates,
concrete pads, and piles, and this can lead to differential settlement and over-
stressed shoring.

Formwork Issues in MultiStory Building Construction.

1. Improper Stripping and Shore Removal

Early striping of forms and careless practices in reshoring can lead to failure of
formworks and total failure of specifically in multistory building in which
progressive collapse is highly likely.

Sometimes, premature striping causes sagging of partially cured concrete. This

leads to crack development and create maintenance issues. Insufficient spacing and
size of reshores may lead to a formwork collapse during construction as well as
damage of the concrete structure.

Fig. 1: Premature Shore Removal at Bailey's

Cross Road in Virginia, Failure Occured in 24th Floor
2. Inadequate Bracing
Insufficient cross bracing and horizontal bracing of shores are common causes of
formwork failure. This is because poor bracing generates lateral force and hence
create lateral deformation of supporting members. When a failure occurs at one
point, inadequate bracing may permit the collapse to extend to a large portion of
the structure and multiply the damage.

Fig. 2:
Inadequate Bracing
 Fi
g. 3: Lack of Bracing Led to the Failure of Formwork
3. Inadequate Control of Concrete Placement
Failure to regulate properly the rate and order of placing concrete on horizontal
formwork introduce unbalanced loadings and consequent failures of formwork.

So, concrete temperature, concrete chemistry, rate of vertical placement of

concrete, and vibration of concrete are factors affecting the development of lateral
pressures that act on the forms.

If concrete temperature drops during construction operations, the rate of concrete

placement needs to be decreased to avoid a buildup of lateral pressure overloading
the formworks.
 Fig. 4: Lack
of Proper Strategy in Concrete Placement

Fig. 5: Formwork Failure Due to Concrete Overload

4. Inadequate Concrete Strength Development
It is another factor that has been reported to be the cause of concrete formwork
system. The failure of hyperbolic cooling tower, which is located in Ohio/ USA,
during its construction is compelling example of failures due to insufficient
concrete strength development.

A jump form system was supported by anchors cast in the previous day's concrete
placement. The forms were linked together around the inside and outside of the
circular shell structure. After raising the forms and during the casting of an
additional ring level, the concrete placed the previous day failed at the anchors,
causing the scaffolding and forms to collapse.

Fig. 6: Failure of Formwork System of Hyporbolic Cooling Tower due to

Inadequate Concrete Strength Development
5. Vibration and Impact
Vibration and impact due to passing traffic, movement of workers and equipment
on formwork, and vibration because of concrete consolidation can displace
supporting shores or jacks of formwork system and cause total failure of the forms.
6. Unstable Soil under Mudsills and Out of Plumb Shores
Unstable soil and out of plumb shores are another factor that jeopardize the
stability of the formwork system. Unstable soil would lead to differential
settlement and the ability of out of plumb shores to support loads declined greatly.
Therefore, verticality of shores and the sufficient ability of soil to support loads
shall be ensured during the construction of formwork system.

Supporting elements of formwork should not be placed on frozen ground. This is

because moisture and heat from the concreting operations or changing air
temperatures may thaw the soil and allow settlement that overloads or shifts the
formwork. Finally, site drainage must be adequate to prevent a washout of soil
supporting the mudsills.

Fig. 7:
Settlement of Formwork Support Element in Soft Soil
 Fig. 8: Out of
Plumb Supporting Element
7. Lack of Attention to Formwork Details
Assemblage errors such as insufficient nailing, failure to tighten the locking
devices on metal shores, inadequate provisions to prevent rotation of beam forms
where slab forms frame into them on one side, inadequate anchorage against uplift
for sloping form faces, and lack of bracing or tying at corners can cause failure of
formworks even if its design is completed in the best possible way. So, skilled and
trained labor shall assemble the formwork system under great supervision.

UNIT-4

Flying Formwork

Flying forms (or table forms) consist of a pair of steel or aluminium trusses topped with
closely spaced joists that support a plywood deck. In this way panels of formwork up to
100 sq m can be decked out to form an entire bay of a suspended floor slab. After
striking, the forms are moved out from under the newly formed slab on a set of rollers
placed under the trusses. They are then lifted by crane to the next location.
While primarily for slabs with flat soffits, the forms can accommodate edge beams and
other features in certain circumstances. The system is clearly most suited to buildings
with a significant number of repetitions; a minimum of 7 or 8 uses are probably
required.

Table form/Flying form

A table form/flying form is a large preassembled formwork and falsework unit, often
forming a complete bay of a suspended floor slab. It provides quick installation for
projects with regular plan layouts and is routinely used for residential flats, hotels,
offices and commercial buildings. Individual falsework components are connected to
form the complete table, with a plan area of up to about 100m 2. The formwork can be
mounted on wheels, allowing it to be moved horizontally.

The assembled table formwork units are rolled into position and the joints sealed.
Reinforcement is fixed and the concrete for the slab is cast. Once the concrete has
achieved sufficient strength, the complete table is lowered, rolled out from under the
slab and moved by crane to the next position.

How does tunnel form work?

The cycle time of the tunnel formwork system lies between 1 to 3 days, which is
very little compared to other formwork systems. So tunnel formwork took a lead
in the time-saving of projects which indirectly affect the total project cost.
Slab cycle time involves the following activities

 Wall shuttering
 Slab shuttering
 Slab level
 Leveling
 Line and plumb
 Wall reinforcement
 Slab reinforcement
 Electrical fitting
 Casting of slab
 De shuttering wall
 De shuttering slab

Tunnel formwork is a mechanized system for cellular structures. It is based on

two half-shells that are placed together to form a room or cell. Several cells
make an apartment. With tunnel forms, walls and slab are cast in a single day.
The structure is divided into phases. Each phase consists of a section of the
structure that will be cast in one day. The phasing is determined by the
program and the amount of floor area that can be poured in one day. The
formwork is set up for the day’s pour in the morning. The reinforcement and
services are positioned and concrete is poured in the afternoon. Once
reinforcement is placed, concrete for walls and slabs shall be poured in one
single operation. The formwork is stripped in the early morning and positioned
for the subsequent phase. The formwork is manufactured in a fully automated
plant.

1. Stripping of the formwork from the previous day.

2. Positioning of the formwork for the current day’s phase, with the installation
of mechanical, electrical and plumbing services.
3. Installation of reinforcement in the walls and slabs.
4. Concreting and if necessary, the heating equipment.

SLIP FORM
Slipform is a construction method for reinforced concrete walls, generally lift and stair
core walls, and is often economical for buildings more than ten storeys in height.
Slipform construction involves the formwork for the walls being raised in a continuous
process as the wall concrete is poured. As the slip form rig is raised, it is supported by
already cast concrete walls below.

What are the benefits of slipform construction?

 Reduced Crane time. The slip form rig and wall construction has minimal requirements
for crane time as is mostly self-lifting
 High production rates can be achieved although careful planning is critical
 As the slipform operates independently, the construction of the core, in advance of the
rest of the RC structure, can take it off the critical path.
 Requires a small, albeit highly skilled workforce on site
 Less congestion on site due to minimal scaffolding and temporary works being required.

What are the disadvantages of slipform construction?

 Minimal flexibility for changes once slipform concrete has commenced.

 Often requires additional steel temporary bracing to be provided to ensure cast core
walls are structurally adequate until the slabs are constructed.
 Wall thickness required may be slightly greater than otherwise due to detailing
requirements and/or temporary case conditions.
 Usually requires reinforced concrete downstands over the lift & stair openings rather
than full height openings infilled with blockwork.

Often the substructure core walls are cast traditionally with slip form commencing from
the podium slab level where access may be better for setting up of the slip form rig.

Temporary steel bracing/tie frames are usually required when more than a single core is
slip formed with the same rig. e.g. when the stair core and lift cores are not connected
other than through the future slabs. The recommended minimum wall thickness for slip
formed walls is usually in the order of 300mm based on the detailing requirements for
connection of the future slabs if couplers are required.

Reduction of the slip formed wall thickness up the building needs to be considered
taking into account costs of adjusting the slipform rig. It is most likely that any saving in
wall concrete and reinforcement would be outweighed by the costs of adjusting the
slipform rig. For this reason, unless there are advantages architecturally with regards to
increased accessible floor space then it would usually be preferable to maintain the
same wall thickness for the full height of the slip formed cores.

Slip formed walls are RC detailed differently to traditionally cast wall. Specific
requirements such as staggering the level of the laps for vertical bars and how corner
reinforcement is detailed needs to be agreed with the slipform contractor to ensure they
meet any specific preferences or requirements they have.
Slab to wall Connections

For slab to wall connections where an area of slab reinforcement greater than the
equivalent of H16@150 is required, then bars with couplers would need to be cast with
the slip formed walls. Threaded slab reinforcement would then be detailed to connect to
the couplers. (see diagram below)

Where the slab to wall reinforcement is equivalent to H16@150 or less, then continuity
strips such as Kwikastrip or Eazistrip can be cast with the walls. Due to the risk and
consequences of site error, it is usually recommended to use the same, greater size
continuity strip for all continuity strip connections.

Formwork for Precast Concrete

These formworks are designed and manufactured based on the client’s own plans in
which they are massively used in building Precast I-beam of bridges, walls, slabs and
Tetrapod.
The formwork of a prefabricated part is designed and manufactured somehow that it
can be used for numerous numbers of times in addition to its simple opening and
closing. Therefore, the stability of these formworks should be highly valued at the
designing stage. These formworks are often heavy and have huge dimensions and so
cranes are used for operating them.
On the basis of a 3D model, precision manufactuned under optimum condition in the
stationary BFS formwork construction.

Formwork Management Issues -Pre- and Post-Award

The Pre-Award phase is the first phase of the contract management process. This is
usually after the scope of works has been sufficiently defined and the Project Owner
(“Employer”) is ready to go out to the market to solicit pricing for the works to be
executed.

What is the post award phase in procurement?

This phase ensures that you are managing contract amendments properly. It focuses
your attention on tracking to make certain that all requirements of your agreement are
met throughout the life of the written commitment. Plus, you need to track and
implement changes made to the contracts, too.

Reading time: 4 minutes

Formwork is a mold in which concrete is filled until it sets, which is supported by verticle
and horizontal members. The safety during installation of shuttering, pouring concrete,
and removal is critical as the load of the fresh concrete must be withstood by the
formwork.

Fig 1: Formwork for Column.

In this article, we have discussed the safety measures that shall be followed for shuttering
works.

Safety measures for formwork installation

1. The formwork shall be designed after taking into consideration spans, dead
load, setting the temperature of concrete, and working load to be supported
and safety factors for the materials used for formwork.
2. The timber formwork shall be carefully inspected before use, and members
having cracks and excessive knots shall be discarded.
3. The timber centering usually sinks when loaded with concrete, thus while
designing, allowance for this factor shall be considered.
4. The vertical supports must be sufficiently braced or secured in position so
that they don't fail when the load is released, or the supports are accidentally
hit.
5. When timber centering and tubular steel is to be used in combination,
necessary precautions must be taken to avoid any unequal settlement of
shuttering under load.
6. A thorough inspection of tubular steel centering must be carried out before
its installation, and members showing evidence of excessive resting, dents,
kinks, or damaged welds shall be removed.
7. The buckled or broken members of the shuttering shall be replaced.
8. All the locking devices shall be checked for their efficient working, and
coupling fins should be appropriately aligned with the frames.
9. After assembling the basic skeleton of the shuttering, adjustment screws
shall be set to their final levels and plumb.
10.The shuttering frames must be tied together with sufficient braces to make
rigid struts, and diagonals braces should be installed in the proper position
so that frames develop full load-carrying capacity.
11.The connections shall typically be made with bolts and nuts.
12.The use of rusted or spoiled threaded bolts and nuts shall be avoided.
13.The centering layout must be made by a qualified engineer and shall be
followed strictly.
14.The bearing capacity of the soil must be considered for every centering job.
15.The effect of weather conditions shall also be taken into consideration as dry
clay may become very plastic after a rainfall and show a marked decrease in
its bearing capacity.
16.The stability of the props shall be assured by setting the sills firmly on the
soil.
17.Precautions shall be taken not to disturb the soil under the supports.
18.Proper drainage shall be ensured to drain away water due to the washing of
forms, rains, or during the curing of the concrete to avoid displacement in
the supporting soil strata.
19.All centering shall be inspected/checked to ensure that:
1. All the footings or sills under every post of the centering are sound.
2. All lower adjustment screws or wedges are snug against the legs of
the panels.
3. All adjustment screws or heads of jacks are in full contact with the
formwork.
4. Panels are plumb in both directions.
 5. All cross braces are correctly placed, and locking devices are in a
closed and secure position.
6. In the case of chajjas and balconies, the props shall be adequate to
transfer the load to the supporting point.
20.During the pouring of the concrete, the centering shall be continuously
inspected and strengthened.
21.If required, the wedges below the vertical supports tightened, and adjustment
screws adjusted adequately as necessary.
22.Adequate protection for the shuttering shall be secured from moving
vehicles or swinging loads.
23.Destripping of forms shall not be allowed before the time specified in the
relevant codes until it is certain that the concrete has developed sufficient
strength to support itself and all loads that will be imposed on it.
24.Only workers engaged in removing the formwork shall be allowed in the
area during these operations.
25.Those engaged in removing the formwork shall wear helmets, gloves, and
heavy-soled shoes and approved safety belts if adequate footing is not
provided above 2 m level.
26.While cutting any tying wires in tension, care shall be taken to prevent
backlash, which might hit a worker.
27.The particular order in which the supports are to be dismantled should be
followed according to the instructions of the site engineer.

UNIT-3

Formwork Design

What is the concept of formwork?

What is formwork? The term 'formwork' referst to a temporary mould into which
concrete is poured and formed so that it can set to the required shape. Traditional
formwork is fabricated using timber shuttering, but it can also be constructed from steel,
glass fibre reinforced plastics, plywood and other materials

Formwork Systems and Design for Foundations

Foundation Formwork can be constructed out of timber, plywood, steel, precast
concrete or fibreglass used separately or in combination. Steel forms are used in
a situation where a large number of re-use of the same forms are necessary. For
small works, timber formwork proves to be more cost-effective. Fibreglass
made of precast concrete and aluminium are used in cast-in-site construction
such as slabs or members involving curved surfaces.

Basically, foundation form can be projected in several styles or ways. Usually,

the size or the height of the foundation form defines that which types of
designed it is. Individual foundation form (socket foundation) and strip
foundation form, both designs have such difference between them.

Formwork Systems and Design for Walls

Wall formwork is a reusable form that allows a manufacturer to create sections
of a concrete wall. The wall formwork originally consisted of the frame and
accessories. This results in a modular system with a wide range of applications
and long service life, and universal and high efficiency for walls in medium to
big scale projects under crane assistance. It can be adjusted individually to
adapt to complex shapes and high loads. Generally, the concrete building
structure with high requirements on the surface and the anchoring pattern can
be effectively realized using the frame wall formwork.

Wall Formwork
Advantages of wall formwork system
 Quick construction
 Energy absorption
 Variety of design choices
 Reflect, absorb, or block sounds
 Applications of wall formwork system
 Reusable
 Mold- and insect-resistant
Types of wall formwork system

Wall formwork can be divided into the following types:

 Traditional- mounted straight on site using panels and/or wooden strips with
steel spacers.
 Steel and/or aluminium prefabricated- modular elements varying in size,
assembled using
 closing and clamping accessories.
 Timber prefabricated- used for smooth fair-faced concrete.
 Plastic prefabricated- suitable for the construction of concrete columns,
pillars, walls, plinths,
 and foundations directly on-site.

Wall Formwork
Applications of wall formwork system;

 Industrial and residential buildings

 Load bearing walls
 Reservoir construction
 Shear wall construction
 Basin construction
 Corner wall construction
 Foundation wall construction
 Wall construction in existing buildings
 Bridge abutment wall construction
Formwork Systems and Design for Columns , Slabs and Beams

Columns : Column formwork is a type of concrete formwork. Concrete formwork is a

mold made of steel, aluminum, timber, plastic, or other materials in which wet concrete
is poured to achieve a desired shape and size for construction. Once the concrete sets,
formwork is often removed, although permanent formwork that remains a part of
construction exists as well. Column formwork is a vertical mold in the shape of a column,
as its name implies. Column formwork may either be box-shaped or round.

Column formwork is shaped and sized to the needs of a project. In order to help
facilitate quality control during the pouring stage of using column formwork, clamps,
which are horizontal and made of either steel or timber are often used in conjunction
with column molds. Column formwork’s head is frequently employed to support beam
formwork, or column formwork is cast to the bottom side of beams. The use of column
formwork in conjunction with beam formwork allows for quick and precise construction.

Two of the major benefits of using column formwork include that it is quick and simple
to assemble and that it reduces the amount of labor and equipment needed to
successfully produce uniform and strong vertical concrete shapes of desired dimensions.

Beam: Beam formwork is specifically designed to support and shape concrete beams
during the construction process. It consists of a combination of vertical and horizontal
supports, often made of timber, steel, or aluminum, depending on the requirements of
the project. Beam formwork holds the concrete in place while it sets and hardens,
ensuring that it attains the desired shape, size, and strength. This formwork needs to be
carefully designed and constructed to withstand the weight and pressure exerted by the
wet concrete, as well as any additional loads that may be applied.

Similarly, column formwork is designed to support and shape concrete columns. It

typically consists of vertical panels or molds that enclose the column and hold the
concrete in place until it cures. Column formwork is often adjustable, allowing for
flexibility in constructing columns of different sizes and shapes. This adaptability is
crucial, considering that columns in a structure may have varying dimensions depending
on their location and load-bearing requirements.

Slabs: