Chapter 3
Construction Supporting
Technologies
Formwork
What is Formwork?
Formwork is a structure, usually temporary,
used to contain poured concrete to mould it
to the required dimensions and support
until it is able to support itself.
It consists primarily of the face contact
material and the bearers that directly
support the face contact material.
The best way to choose a formwork system
is to begin considering your options during
the design phase of a project.
This can allow you to contact a number of
different formwork system providers, obtain
rough estimates, and develop a relationship
with the company of your choice, experts
who can help you make the best decisions
about different systems.
Purpose and Use of Formwork
The formwork serves as mould for concrete
structural components. It moulds the placed
fresh concrete, which in this stage normally
is viscous, to the shape specified in the
drawing.
Consequently, the formwork must already
be available when the necessary steel
reinforcement and concrete mix are placed.
Formwork is required wherever monolithic
concrete and reinforced concrete structures or
structural components are constructed, such as for
solid structures (foundations, columns...),
structures with special functions
(containers, chimneys, hydraulic
structures ...),
structures to meet great statistical
requirements (bridges, towers...),
reconstruction of structures,
public buildings and structures of irregular
arrangement.
Load Requirements of Formwork
Loading of vertical formwork
Vertical formwork is used for strip foundations,
concrete walls and columns.
Immediately after placement in the formwork
until achievement of its inherent stability, the
concrete mix, under the effect of its own load
and of compaction by vibration, exerts lateral
pressure on the formwork, which is called
lateral pressure of the concrete mix.
The lateral pressure of the concrete mix depends on
the following factors:
◦ Composition and properties of the concrete mix (density,
type of cement, quality of concrete),
◦ concrete placing technology (concreting speed, compaction,
vibration depth, total height of the concrete mix)
◦ Ambient conditions (temperature, air humidity).
The maximum lateral load with external vibration occurs at the
foot of the formwork and with internal vibration above the foot.
Tie wires (tie rods) are used to take up the lateral pressure of
the concrete mix.
Loading of horizontal formwork
Horizontal formwork is used for ceilings and
beams. Horizontal formwork is subjects to
vertical loads which are to be carried off to
solid subsoils through formwork bearers and
main bearers as well as columns.
horizontal loads are produced by:
wind effects
inclined position of columns,
backing up, etc.
The horizontal forces are taken up by
auxiliary structures, such as braces and
struts, or rigid connection to existing
structural components, such as walls and
columns.
Choosing and selecting the best formwork
factors to consider when choosing between
formwork systems are
the unique concerns of your particular
job site,
the availability of various formwork
materials, and
whether the supplier offers services
such as pre-assembly of some
components and field training for your
workers.
Requirements of a Good Formwork System
How formwork can be erected and de-shuttered fast.
How good concrete quality and surface finish can be
achieved.
What is the optimum stock of formwork required for
the size of work
force, the specified time schedule and flow of
materials.
What is the overall cost savings that can be achieved
using the right type
of formwork.
How SAFETY can be improved for the site personnel.
In order to successfully carry out its function, formwork
must achieve a balance of following requirements:
Containment.
Strength
Resistance to leakage
Accuracy
Ease of handling
Finish and reuse potential
Access for concrete
Economy
Formwork Based On Materials
i. Timber Forms
Timber is required for practically all jobs of formwork.
The timber bring used for formwork must satisfy the
following requirements:
Basic standard qualities:-
◦ Reasonable price and availability
◦ Should not be so soft
◦ Should be easily worked by hand or machine and nailed easily
◦ Should be stiff to avoid deflection
◦ Should be stable when exposed to sun or rain
◦ Should reduce defects
◦ Not suitable for green timber
◦ Moisture content not less than 20%
Advantages of using timber forms:
It is economical for small construction jobs
It is design flexible and easy to erect
It has good thermal insulation which makes
it useful to be used in colder Regions
It can easily be made into any shape or size
More economic
Easy to handle and formed into required
shape
Easy to fix insert
Disadvantage of timber formwork
Not enough strength as compared to steel
formwork to carry large pressure.
Excessive shrinkage due to temperature
changes.
Leakage through joints and apertures.
Easily damage during fixing and dismantling
of formwork.
The pattern of grain, knots, bad flaws will
leave imprint to the face of concrete.
ii. Plywood forms (in combination with timber)
There are two types of plywood - internal and
exterior.
The interior type is bonded with water resistant glue
and exterior type is bonded with water proof glue.
standard:
Strong and light
Supplied in sheets - 1.2m wide
Standard length – 2.4m, 2.7m or 3.m
Thickness – from 3mm to 19mm
Thickness for lining or curved work – 16 mm
or less
Advantages of Plywood Formwork
Large panel
Leak proof
Large level surface
No casting or cupping of surface – smooth
surface
Can be nailed to edges without splitting
high resistance to impact loads
Available in several thickness
Disadvantages of Plywood Formwork
Grain pattern on concrete face
Less durable
More expensive compared to timber
iii. Aluminum Forms
Forms made from aluminum are in many respects similar
to those made of steel. However, because of their lower
density, aluminum forms are lighter than steel forms, and
this is their primary advantage when compared to steel.
As the strength of aluminum in handling, tension and
compression is less than the strength of steel, it is
necessary to use large sections.
The formwork turns out to be economical if large numbers
of reuses are made in construction. The major
disadvantage of aluminum forms is that no changes can
be made once the formwork is fabricated.
iv. Plastics
These forms have become increasingly
popular for casting unique shapes and
patterns being designed in concrete
because of the excellent finish obtained
requiring minimum or no surface treatment
and repairs.
Different types of plastic forms are available
like glass reinforced plastic, fiber reinforced
plastic and thermoplastics etc.
Fiberglass-reinforced plastic is the most
common and has several advantages such as
The material allows greater freedom of design
Unusual textures and designs can be molded into the
form
It allows the contractor to pour structural and finished
concrete simultaneously
Because sections can be joined on the job site in such a
way so as to eliminate joints, there is no size limitation If
carefully handled, a number of reuses are possible
making it highly economical
It is lightweight and easily stripped
The disadvantage of using plastic forms is
that it does not lend itself to field
fabrication
v. Steel Formwork:
Mostly used in large construction projects or
in situations where large numberof re-uses
of the same shuttering is possible.
Suitable for circular or curved shaped
structures such as tanks, columns,
chimneys. Etc. & for structures like sewer
tunnel and retaining wall.
Advantages of steel formwork over timber
form:
strong, durable & have longer life
Reuses can be assumed to vary from 100 to
120 wares timber varies from 10 to 12.
Steel can be installed & dismantled with
greater ease & speed resultingin saving in
labour cost.
Excellent quality of exposed concrete
surface obtained. Thus saving in the cost of
finishing the conc. surface.
no danger of formwork absorbing water
from the conc. & hence minimizing
honeycombing
Able to carry large concrete weight and
pressure.
Can be erected, disassembled, moved, and
re-erected rapidly using proper handling
equipment available.
Leakage can be avoided.
No shrinkage due to temperature changes.
Easy to fix the joint with bolt and nut.
Economic if there are enough re-uses.
Disadvantages of Steel Formwork
Limited to the shape of the structure.
Standard steel unit are too heavy and
difficult to handle.
Duration Taken For Removal of
Formwork
location Surface or air temperature of concrete
16°C 17°C
Vertical f/work 12 hrs 18 hrs
Slab soffit (props left under) 4 days 6 days
Removal of props 10 days 15 days
Beam soffit (props left under) 10 days 15 days
Removal of props 14 days 21 days
Current Innovations
Figure 2: Clamping mechanism wall formwork
Horizontal Inclined Climbing Vertical
Climbing Formwork System Climbing
Formwork System Formwork
System
Adjustable column
formwork
Light weight, quick strip floor
formwork
