Formwork

Formwork is a structure, usually temporary, used to contain poured concrete and 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. Formwork systems used for concrete frame construction have continued to develop significantly since the early 1990s. The major innovations have focused on on-site efficiency of production, health and safety, and environmental issues, driving the concrete construction industry towards ever-increasing efficiency. Different formwork systems provide a wide range of concrete construction solutions that can be chosen to suit the needs of a particular development. Traditional formwork for concrete construction normally consisted of bespoke solutions requiring skilled craftsmen. This type of formwork often had poor safety features and gave slow rates of construction on-site and huge levels of waste. The main types of formwork systems in use now are:

Table form/flying form System column formwork Horizontal panel Slip form Tunnel form

The modern formwork systems listed above are mostly modular, which are designed for speed and efficiency. They are designed to provide increased accuracy and minimize waste in construction and most have enhanced health and safety features built-in.

Slip form
Slip form is similar in nature and application to jump form, but the formwork is raised vertically in a continuous process. It is a method of vertically extruding a reinforced concrete section and is suitable for construction of core walls in high-rise structures lift shafts, stair shafts, towers, etc. It is a self-contained formwork system and can require little crane time during construction.

This is a formwork system which can be used to form any regular shape or core. The formwork rises continuously, at a rate of about 300mm per hour, supporting itself on the core and not relying on support or access from other parts of the building or permanent works. Commonly, the formwork has three platforms. The upper platform acts as a storage and distribution area while the middle platform, which is the main working platform, is at the top of the poured concrete level. The lower platform provides access for concrete finishing.

Benefits

Careful planning of construction process can achieve high production rates Slip form does not require the crane to move upwards, minimising crane use. Since the formwork operates independently, formation of the core in advance of the rest of the structure takes it off the critical path enhancing main structure stability. Availability of the different working platforms in the formwork system allows the exposed concrete at the bottom of the rising formwork to be finished, making it an integral part of the construction process.

Certain formwork systems permit construction of tapered cores and towers. Slip form systems require a small but highly skilled workforce on site. Working platforms, guard rails, ladders and wind shields are normally built into the completed system. Less congested construction site due to minimal scaffolding and temporary works. Completed formwork assembly is robust. Strength of concrete in the wall below must be closely controlled to achieve stability during operation. Site operatives can quickly become familiar with health and safety aspects of their job High levels of planning and control mean that health and safety are normally addressed from the beginning of the work.

Safety

Other considerations

This formwork is more economical for buildings more than seven storeys high. Little flexibility for change once continuous concreting has begun therefore extensive planning and special detailing are needed. Setting rate of the concrete had to be constantly monitored to ensure that it is matched with the speed at which the forms are raised.

The structure being slipformed should have significant dimensions in both major axes to ensure stability of the system. Standby plant and equipment should be available though cold jointing may occasionally be necessary.

Table form/flying form

A table form/flying form is a large pre-assembled formwork and falsework unit, often forming a complete bay of suspended floor slab. It offers mobility and quick installation for construction projects with regular plan layouts or long repetitive structures, so is highly suitable for flat slab, and beam and slab layouts. It is routinely used for:

Residential flats Hotels Hostels Offices Commercial buildings Fast construction for large floor layouts. Fully assembled units can be manoeuvred quickly into place. Using appropriate quality control, high quality surface finishes can be achieved. Reduced long-term workforce requirement on site. The need for infill areas and decking joints is minimised. Individual components of the formwork system can be precisely adjusted. Repetitive nature of the work makes it easier to plan construction activities. Decking with non-slip surfaces can be used to enhance safety. Interconnected truss members provide a stable working platform. Repetitive nature of work ensures quick familiarity of safety procedures. Falsework units can be assembled at ground level minimising work at height. Table formwork systems can include standard health and safety features such as guard rails.

Benefits

Safety

Other considerations

The system requires enough space around the new construction to fly the table unit beyond the building line on everyday use.

The supporting slab must be capable of carrying high loads at bearing locations; back propping may be needed underneath the slab

Vertical panel systems

Crane-lifted panel systems are commonly used on building sites to form vertical elements and usually consist of a steel frame with plywood, steel, plastic or composite facing material. The systems are normally modular in nature, assembly times and labour costs are considerably lower than traditional formwork methods with far fewer components required. They offer greater opportunities for reuse for different applications on site. Panel systems are extremely versatile and the larger crane-lifted versions can be used for constructing standard concrete walls, perimeter basement walls, columns and in conjunction with jump for climbing systems.

Benefits

Assembly is very simple reducing the requirement of skilled labour. Easily adaptable to varying structural geometries, wall heights, etc. Increased speed in construction in comparison to traditional wooden formwork. Engineered nature of the panel formwork systems allows quick adjustment of the formwork. Working platforms, guard rails and ladders can be built into the completed units of the formwork. Site operative can quickly become familiar with health and safety aspects of their job due to the simplicity of the assembly process and repetitive nature of the work in certain types of structure.

Safety

Usually these formwork systems require minimal use of power tools. The panel systems are designed for specific maximum concrete pressures. The concrete placement rates have to be adjusted accordingly to keep the concrete pressure within specified limits.

Other considerations

Lightweight manhandled systems are available with steel or aluminium frames and plywood facing- commonly used in groundworks construction. For a fair-faced exposed concrete finish it may be necessary to line the panels with a secondary layer of material.

For concrete where enhanced durability is required, controlled permeability formwork may be used.

Jump form
Generally, jump form systems comprise the formwork and working platforms for cleaning/fixing of the formwork, steel fixing and concreting. The formwork supports itself on the concrete cast earlier so does not rely on support or access from other parts of the building or permanent works. Jump form, here taken to include systems often described as climbing form, is suitable for construction of multi-storey vertical concrete elements in high-rise structures, such as:

Shear walls Core walls Lift shafts Stair shafts Bridge pylons

These are constructed in a staged process. It is a highly productive system designed to increase speed and efficiency while minimising labour and crane time. Systems are normally modular and can be joined to form long lengths to suit varying construction geometries. Three types of jump forms are in general use:

Normal jump/climbing form units are individually lifted off the structure and relocated at the next construction level using a crane. Crane availability is crucial.

Guided-climbing jump form also uses a crane but offers greater safety and control during lifting as units remain anchored/guided by the structure. Self-climbing jump form does not require a crane as it climbs on rails up the building by means of hydraulic jacks.

Benefits

Fast construction can be achieved by careful planning of the construction process. Self-climbing formwork cuts down the requirement for crane time considerably. By allowing the crane to be used for other construction work this may reduce the total number of cranes needed on site.

The formwork is independently supported, so the shear walls and core walls can be completed ahead of the rest of the main building structure. High quality surface finishes can be achieved. Climbing forms can be designed to operate in high winds. Highly engineered nature of jump form systems allows quick and precise adjustment of the formwork in all planes. Some formwork systems can be used at an inclined angle. A small but skilled workforce is required on site. It is easier to plan construction activities due to the repetitive nature of the work. Working platforms, guard rails, and ladders are built into the completed units of marketleading formwork systems. Self-climbing formwork systems are provided with integral free-fall breaking devices. The completed formwork assembly is robust. The reduced use of scaffolding and temporary work platforms results in less congestion on site. The setting rate of concrete in those parts of the structure supporting the form is critical in determining the rate at which construction can safely proceed. The repetitive nature of the works means site operatives are quickly familiar with health and safety aspects of their job.

Safety

Other considerations

Jump form is typically used on buildings of five storeys or more; fully self-climbing systems are generally used on structures with more than 20 floor levels. Trailing and suspended platforms are used for concrete finishing and retrieving cast-in anchor components from previous pours.