INTRODUCTION TO FORMWORK What is Formwork?

Formwork in construction is the use of support

structures and moulds to create structures out of concrete which is poured into the moulds. Formwork
can be made using moulds out of steel, wood, aluminium and/or prefabricated forms. Formwork is an
ancillary construction, used as a mould for a structure. Into this mould, fresh concrete is placed only to
harden subsequently. The construction of formwork takes time and involves expenditure up to 20 to 25%
of the cost of the structure or even more. The operation of removing the formwork is known as
stripping. Stripped formwork can be reused. Reusable forms are known as panel forms and non-usable
are called stationary forms. Formwork is designed according to The ACI document SP-4. A good
formwork should satisfy the following requirements: Strong enough to withstand all types of dead and
live loads Rigidly constructed and efficiently propped and braced both horizontally and vertically, so
as to retain its shape The joints in the formwork should be tight against leakage of cement grout
Construction of formwork should permit removal of various parts in desired sequences without
damage to the concrete Material of the formwork should be cheap, easily available and should be
suitable for reuse The formwork should be set accurately to the desired line and levels should have
plane surface. As light as possible Material of the formwork should not warp or get distorted when
exposed to the elements Should rest on firm base The following points are to be kept in view to
effect economy in the cost of formwork: The plan of the building should imply minimum number of
variations in the size of rooms, floor area etc. so as to permit reuse of the formwork repeatedly. Design
should be perfect to use slender sections only in a most economical way. Minimum sawing and cutting
of wooden pieces should be made to enable reuse of the material a number of times. The quantity of
surface finish depends on the quality of the formwork. Conventional: The formwork is built on site out
of timber and plywood or moistureresistant particleboard. It is easy to produce but time-consuming for
larger structures, and the plywood facing has a relatively short lifespan. It is still used extensively where
the labour costs are lower than the costs for procuring reusable formwork. It is also the most flexible
type of formwork, so even where other systems are in use, complicated sections may use it. Modern-
Day Formworks: This formwork systems are mostly modular, which are designed for speed and
efficiency. They are designed to provide increased accuracy and minimize waste in construction and most
have enhanced health and safety features built-in. The main types of formwork systems in use now are:
1. Table form/flying form 2. System column formwork 3. Horizontal panel 4. Slip form 5. Tunnel form
Engineered/Pre-fabricated Formworks: This formwork is built out of prefabricated modules with a
metal frame (usually steel or aluminium) and covered on the application (concrete) side with material
having the wanted surface structure (steel, aluminium, timber, etc.). The two major advantages of
formwork systems, compared to traditional timber formwork, are speed of construction and lower
lifecycle costs (barring major force, the frame is almost indestructible, while the covering if made of
wood; may have to be replaced after a few – or a few dozen – uses, but if the covering is made with steel
or aluminium the form can achieve up to two thousand uses depending on care and the applications).
MATERIALS USED Formwork are mainly of two types Steel formwork Wooden formwork Steel
formwork is made of Steel sheets Angle Iron Tee Iron Wooden formwork consists of Props Planks
battens Ledgers Sheeting Wooden formwork Steel Formwork Sheeting for slabs, beam, column side
and beam bottom 25 mm to 40mm thick Joints, ledges 50 x 70 mm to 50 x 150 mm Posts 75 x 100mm to
100 x 100 mm Timber formwork: - Most common material used for bracing the member, hence called as
the traditional formwork. - can easily be cut to size on site. Joist are replaced with engineered
wood beams and supports are replaced with metal props. This makes this method more systematic and
reusable. - Various sizes of members of timber Plywood - This is by far the most common material used
for the facing panel. It is easily cut to shape on site, and if handled and stored carefully, it can be used
many times. - A standard plywood thickness on site is 18mm. This is usually sufficient for most pours. -
However, if the formwork is curved, a thinner plywood is used to facilitate bending. - Thicker plywood
may be used when the weight of concrete causes a standard thickness plywood to bow out, distorting
the concrete face. Steel formwork: - Steel forms are stronger, durable and have longer life than timber
formwork and their reuses are more in number - Steel forms can be installed and dismantled with
greater ease and speed. - The quality of exposed concrete surface by using steel forms is good and such
surfaces need no further treatment. - Steel formwork does not absorb moisture from concrete. - Steel
formwork does not shrink or warp Aluminium formwork - Often used in pre-fabricated formwork, that is
put together on site. - Aluminium is strong and light, and consequently fewer supports and ties are
required. - The lighter sections will deflect more, but this can be avoided by simply following the
manufacturers recommendations. Plastic formwork - Glass reinforced plastics (GRP) and vacuum formed
plastics are used when complicated concrete shapes are required (e.g. waffle floors). - Although vacuum
formed plastics will always need support, GRP can be fabricated with integral bearers making it self
supporting. - Like steel, plastic formwork can be re-used many times, as long as care is taken not to scour
the surface whilst vibrating the concrete. PROCESS OF FORMWORK CONSTRUCTION FORMWORK FOR
VARIOUS STRUCTURAL MEMBERS Construction of formwork: This normally involves the following
operations: 1. Propping and centering 2. Shuttering 3. Provision of camber 4. Cleaning and surface
treatment It consists of • Timber sheeting • Vertical posts • Horizontal members • Rackers • Stakes •
Wedges After completing one side of formwork reinforcement is provided at the place then the second
side formwork is provided. FORMWORK FOR WALL Wall Formworks and its components FORMWORK
FOR COLUMN • It consists of the following – Side & End Planks – Yoke – Nut & Bolts • Two end & two
side planks are joined by the yokes and bolts. Erection sequence for a column
Prior to positioning column formwork check that steel for the colu
mn has been inspected and cleared for casting. -
Position formwork for the column from predetermined grids. -
Plumb formwork both ways and securely support using adjustab le steel props. -
The propping angle should be 45° to the floor. -
Ensure the steel props are safely secured to the column formwo rk and the
floor, and that adjustment for pushing and pulling is operational. -
Set out the positions of column clamps from a storey rod. -
Transfer the column clamp positions from the storey rod onto co lumn formwork. -
Use nails to support the arms of column clamps while wedging. -
Position and wedge the bottom, middle and top clamps sets. -
Check the formwork at the top for square. - Position and wedge the remainder of the column clamps. -
Using a plumb bob suspended from a gauge block plumb the column.
When all the column formwork is securely propped a final check m
ust be made for plumb and column alignment before and immedia tely after the concrete
has been poured and vibrated.