“he Mastrauler| Apr 2046 | acter % FORMWORK: DESIGN & CODES Formwork Codes & Design - Key Points K.V. Srikanth Direcor. MisFormpro Engineers des andthe key points tobe taken into account in Dasign ‘of Formwork and most of poets presented are the key ex ‘wacts from various available Formwork cade of practice. T: article mainly focuses onthe importance of Farmorke Why is code of practice for formwvork required” The Former Code of Practice isto ge hands-on guidance about ways to manage the formwork in arms selection of ma- terials, design, assembly, and dismanting procedures and mit- igating informing the risk associated with that and also tomin- imize filures. Because failures or unsafe formwork practice will cause financial losses, accidents some time which involves fatal, ime loss ete. Certainly the losses in ime and money that {go along with construction mishaps are strong motivators for sale acti If there is specication or codal procedures for formwork, wa can fellow the same fr daing the thingsin a propar manner: So, if there is 2 code of practice, we can: (a) dowhat the code says (b1 co all othe folowing: ‘Adopt and follow another way that gives the same level of protection against the risk Take reasonable precautions Exercise proper diigence. Need For Formwork Codes ~ Since formwark isa temporary installation it isnot given ‘adequate importance even though ithas a vital bearing on cost, quality and speed ~The cadal pravisions should have minimum requirement which will create confidence in the owner = Formwork & forming practice require a rinimum speci cation to ensure that the structure is constructed satisfac torily ~ Additional specication depending on complexity of the job ‘and tolerances need to be specified bythe consultants International Standards = ACISLT-R 2014- Guide to formwork for concrete = ACISP-6| Rd) Formwork for concrete = Construction Indusiry Research and Information Associ ation (CIRIA) reports on concrete pressure an formwork, striking times, recommendations etc. 8S $975 2008: 2011 - British Standards Code practice for formuerk = CANICSA- $2693 (2008) - Canal standard on formwork = $3610 & SAA 1509 - 2010 - Australian standards for Formwork ~ _ENIZ812 - European Standard on perforance requirement ‘and general design. The above standards covers all topics in detail for selection of material, properties, various formwark application, design basics, design parameter including lateral pressure of concrete, superimposed loads ike P8&M loads, impact loads, erviron- ‘mental loads ike wind loads, method of repropping, back prop- ping, special type formwork etc Indian Standards ~~ 16687 1999 Reaffred 206), Indian Standard - False work for Concrete Structures - Guidelines The other code available for reference “IRC 87 - 2011 Guidelines on formwork falcawork and temporary structures. The above codes do not elaborate on design factors and special applications when compared to the treatise of Inter- national codes. Hence - Formwork not gen due impertance in India, = Methadlogy and design approvals are not sacrosanct. = Age ld mathads stl flowed in the construction. Purpose of Standardization & codes = To promate good engineering practice To improve workplace and overall safety during varius ac tities of construction. ~ To ensure good quality of concrete and surface fish, ~ To improve speed and economy. ~ Te create awareness inthe incustry about formmork ~ Ta get dueimpactance a that of permanent structure design = Tohave areference for variaus agencies involved Formwork Scenario in India Forrwork isan important enabing work, which has to keep pace wit the modernization of concrete constuction. The entry of gjobal formwork players and also development of indigenous. ‘ormwerk helped the mers developers structural onsutant to work tonards high rise structures, monolithic construction in concrete. Thee san increase inthe presence of lobal system formwork players in Incia and now the client / owners / can-tractors are aware ofthe system formwork and its advantages, The earliest formwork systems made use af woeden pales ‘and timber runners asit enabled easy forming and making at site. But these wooden planks and timber runners vera period of time and after repeated usage tands to lose thar structural ‘and dimensional properties thus posing safely problems. ‘Many ofthe accidents take place in RCC construction are associated with improper temporary works and scafolding, Recently we received an information about a formwork failure in a Metro project. wherein the company used sytern formwork andsiilitcollapsed. Investigation has started and they arefind- ing out the cause of faiure. Either the lack of knowledge ofthe ‘materials used or the load carrying capacity ofthe marnbers, poor detaing, non-understancing of construction methods / ‘sequence etc, can lead o such accidents. Keeping pace with ‘modernization, complexity of projects, high rises, availabilty of latest technelogy and materials it is nat possible to design & erect the formwork using rue af thumb approach without any rational approach inthe design of farmwior Importance of Formwork Design The Construction Industry sa multifaceted industry, char- actriad by a broad range a high rik actos and complax work arrangements and “Conetruction Industry haste largest ‘umber of work related daaths than any ater industry ‘The inherent risks inthe building and construction industry rake it ane ofthe priority areas for providing safe environment for Contractors, subcontractors and ther workers to face risks frorn hazards that must be managed prevent deaths, juries andiliness As already stated eater, Formwork & scaffolding isan im portant activity which needs tobe gien major attention when it comes ta Safety during Construction. Eventhough te safety and construction isthe responsibilty ofthe builder or contractor, it isnecessary that formwork desians and dravings ae reviewed and approved. In these cases, the contract document shal cicarty specify that the designs and drawing of formwork wil be reviewed and approved by Engineer -in-Charge. tis better torite down the work procedures for Shuttering and De-shut- tering operations wih clearly defined oles and responsbiltes, specications, scheme drawingsetc oncerostoftheshutering/ Ge-shuttaring acti are captured in the paper, tis easier to fxercse contol and to ensure safe working conditions insite leis also better ta provide a mock-up display offrmwark with inoult safety features fr bettar understanding forthe workers and engneersat ste Formwork Design Al formmork should be well planned before construction begins. The amount of planning required will depend on the size, complex, and importance considering reuses ofthe frm, Formwork should be designed for strength and serviceabily ‘system stablty and member buckling should be investigated inall cases, Ater the selection of the proper materials and estimating the load corning onto the forms, the form designer takes up the problem- how to make the form strong enough to carry the an- ticipated loads, safely, and stiff enaugh to hold its shape under full oad. In order to achieve safely, effciency and economy, tis better to adopt the rational design ie, once calculated on the FORMWORK: DESIGN & CODES basis of know strengths of materials and the estimated loads rather than empirical design, For extremely heavy loading and special ypes of construction, a complete and precise structural decign of frerivark would ba required. Even though there are incraacing numbers of new mater ‘ls are being introduced fr fring the basic cuppetis pro in majority of cases by timber, plywood, steel or aluminum mem bers, same general principles can be applied for ather rateri als whase strength properties are known, Common Assumptions & Desig Calculations ‘Simptfcations Greater accurate designis nat requenty used in formwork design and going into detailed design wil take and waste time Because precisie calculation of bending moments is not re quired as we wil have so many assumptions for loads, lateral concrete pressure, qualiy of materials, workmanship at site fete, Same af the simpliying assumptions are: 11 Generally ll loads are assumed 2s uniformly distributed loads on sheathing, Secondary & Primary members, uniess itis mandated for accurate loadings for complex & cntical structure. 21. Beams supported over three or more spans are regarded as continuous 31. Strength of nailed connections is neglected in determining the size of main farm member. This does nat apply when considering splices, braces, brackets, etc Generally dasiga of formwork evan though iis @ temporary structure, the same design Principles used for permanent structure wil be used with some assumptions, The formwork usually supports loads for short duration only untithe permanent structure gets its strength to support ital. Formwork stands ‘nits own weight far stability exceptin certain cases where iis ‘exposedto conditions tke wind et. Forrmavork Componentsareto be repeated & reused without losing its structural properties, butwill be assessed case to case basis Agprosirate design chacks should be caried out for simple Jrmivork system for normal Structures and also simple rule of ‘thumb checks also necessary. Farmwork design far complex structures to be checked with more accurate dasign principles ‘computer sided Structural analysis ike STAAD ete, Some ofthe branded system formwork suppliers have their own Design ‘calculation aids, Charts & tables which willbe used as a ready reckoner wiile design of formwork Its the responsibilty ofthe formwork designer to ensure that he has all the information required to complete the design. Honever, information an all factors affecting a design will not necessarily be available at an early stage, so wherever assump- tions tobe made should be done and later on it can be cross- checked and the design can be amended. All materials and equipment usedin formwork construction must be fit forthe intended purpose and meet design specifica- tions. Materials and equipment must be designed to conform to relevant Standards or equivalent. Materials and equipment must be manufactured in accordance with a quality assurance system that ensures compliance with the design specification. How a formwork is designed Estimate the load rniseu oe Ee Way MASE a, 6“The Mastraulser| Apa 2046 |avovmacterbulaers9in ® FORMWORK: DESIGN & CODES Form the design basis Estimate the permissible stresses Analyze & design each component Basic Information required Formwork design whether itis Simple or complex requires certain information prior tocommencing of desig. his also the responsibility ofthe formwork designer to ensure that he has allrelevant input to complete the schemes andthe design. Incase of any missing details, the same has to be sought fram the rel- evant person. Mast of the branded system formwork company before submitting quote ar before preparation of schemes & design will have format tobe filed by the contractor / client comaining projact dots etc, which are requleed as Input Any ‘missing information assumptions can be made and to be re- checked before releasing “Good for Construction formwork schemes’ ~All details and GA dranings, construction schedule, relevant specification = Types finish ~ Through tes allowed or not, Water retaining structures re- quires water barre ties, = Method of placing of conerete- Pump, crane bucket et, = Deshultering time or iit is Pest tensioned means the time for deshuttering = Rate of conerate pouring = Pour sequence = Capacity of batching plant = Type of cemenr, retardars ete, = Available formwork materials and ther status, Date of submittals required Basic formwork systems -Design consideration A formuork designer or engineer may provide certcation ofa ‘basic formwork system’, A basic formwork system is un- derstood as the formwork fora floor, wall rcolurnn, ‘asic formwork system includes ~ standard formwork frames which have a known tested loading capacity spaced at no more than the recommended distances apart for anormal lor thickness with secondary {& Primary member and sheathing on top of therm, and ~ specially manufactured and designed formwork systems with proprietary formiverk components and rated load cal- Culationsin line with the manufacturers’ specications, ‘Abasic formwork systemis limited bythe following conditions: Te hightoftheformworkmnustnatbegreatarthan arequalte & ‘metas tothe soft of the new lar fram the supporting feo. ~ Walls and columns must nat be greater than & metres free standing from the flaar on which the formar willbe sup ported, Where any ofthese conditions occur, the system is classified 2s.anon-basic formwork system, and this code requires that an engineer isthe only person who may certify such a formwork system, 'Non-basie formwork systams -Design consideration Formwork systerns which exceed the description ofa ‘basic formwork system’ are, categorised as ‘non-basic formwork systems. As per BS 5875 an engineer isthe only person who may certify: = the design of ll temporary or permanent formwork struc- tures categorised as non-basic formwork systems’, and ~ ary back propping used for either basic formmork systems ‘or non-basic formwork systems, As per the code, non-basic formwork systems include formwork structures higher than three frames or metres (or three times the least base width) Formwork drawings & Detailing Formwork drawings must explain plans, elevations and sections to show the general arrange ment ofthe formwork and ta identify and locate all mer: bers and components incluging bracing = the maximum point loadings tobe apalied = the component types and spacings =the maximum stirrup head & base jack extensions = the secondary & primary supporting member type, the di- mensions and spacings = the prop sizes and maximum extensions = the methods for tying the structure together and spacing between tes lf required) ~ the plywood layout Where eccentric loading isto be applied to U-heads lie. Pr mary members s are positioned ta ane side ofthe U-head] the formwork drawings rust state that this permitted, ‘ter completion ofthe formwork design, detated Formwork ‘scheme tobe prepared so that the ste Engheers labourers can directly do the shuttering work as per that Preparing formwork scheme with more details like Ac- sembly / making of panels, spacings, construction Joints, et, willbe helpful tothe site to plan for the exact requirement of formwork and saves enarmous construction time as you willbe planning the activities property. ‘formwork drawing shauld be like a pictorial representa- tion of elements and their assembly, wherein workmen under~ stands and completes their tasks as designed, Branded system formork players gives isometric/30 views to supplement and also to make the site persons to visualize the formwork job. Useful check list for details to be incorporated inthe form- work drawings 1 Sequence to concrete placement 21 Sequence ofform removal. back propping, reproping ec, 3} Anchorage, form is, braces spacing and jing of diagonal bracings 4) Requirement of opening fr vibrator 5]. Constructanjoints, expansion joints detais 4) Camber or adjusted elvatins a compensate deflections 71. Bottom precast sil under shores forheay loadings 8} Formwork release agents 91 Recheck wit Structural drawings 10) Check or the Construction ons, expansion ints required I permitted a per structural drawings 1 Any special patterns o” grooves requirement as per Archi- tectural drawings. 12) Precaution in supporting members for permanent Shut- tering alongwith the formwork“The Mastraulser| Apa 2046 |avovmacterbulaers9in 100 FORMWORK: DESIGN & CODES 13] Check to be made for release / loosening of supports for shell / dome structures as proper deflection 14) Sequence of de-shuttering is necessary to have proper stress pattern inthe structure 15] Essential provision for specialized construction techniques ‘such as taking the boom placer, concreting 16) Equipment such as boom placer / crane tobe taken along withthe self climbing equipment. 17) Embedded parts, openings, any MEP works requirements tobe checked. ae s & i Li & ‘Sample formwork tating & corcructon sequence On site coordination and verification The following documentation must be available for inspec tion onsite: ~ Certification ofthe maximum loads from stacked materials that the formwork assembly can withstand, = Spectcations for the concrete and when formork can be removed. ~ Back propping details (plans and elevations) ~ Drawings forthe formwork design. The drawings must be signed by an engineer or formwork designer or be accom- panied bya certification letter that sts the draving numbers ‘and drawing revision numbers. Sample formworkscheme for wal ermivore Asuitable systern must be implemented o ensure that only ‘materials and components that cornply wit the specications ofthe formwork design drawings and decumentation are being used Verification of Formwork design Veritication thatthe formwork structure cornplies with the design ofthe formwork system must be dacumnentad and pro- ‘vided. construction check list can be used to assist inthis pro ‘case. Relying solely upon such a checklist will nt be sufficient toverity compliance. ‘The verification and docurnentation that a design has been complied wth maybe delegated toa ‘competent person on site ‘competent person, f nat an engineer or formwork design er, must have appropriate training and knowledge to perform onsite inspections ofthe fork system, Ths delegated per ‘san needs o be experienced in formwork construction and be ‘competent in reading drawings and be able to certty that the formivork structure satistas the details on the formork dra ings, specications and any cther formwork documentation. A ‘competent person who is nata formwork designer or engineer ‘must not authorise variations to tha design. A campetent percen must ensure the remedial action has occurred prior tthe con ‘rete pour including any items referred toan engineer for cert fication and madifedas instructed by an engineer. ‘A pre-pour inspection & the check list shauld be a part of ‘any quality control system The final pre-pour inspection report should be signed jointly bythe Formwork Engineer / Site engineer and a Qualty Control engineer Lack of Attention to Formwork Details Even when the basic formwork design is soundly concetved, rll diferences in assembly details may cause local weakness (oF overstress loading to form failure. This may be as simple as, insufficient nating, of failure to tighten the locking devices on metal shoring, te ods, nuts etc, Other detais that may cause failure are = Inadequate provisions to prevent rotation of beam forms ‘where slabs frame into them on the side, ~ Inadequate anchorage against uplift fr sloping form faces. = Lackaf bracing ortying of comers, stop ends or other plac- ‘es where unequal pressure is found = Stripping procedures for special structures like domes , cantilevered structures etc, ~ Failures have ocouredin pre-sressed bridges, due to non-con sideration of post tensioning effects onthe staging toners adjacent tothe per supports, Same ofthe checklist and the commonly found defects in formwork systems Foot / Base plates lal not levelled in or eccentrcaly placed Ib) inadequate load-carrying capaciy of the ground and un- ‘even bedding [c} deterioration with time eg. Due to weather coeitons) (a) deterioration of load-carrying capac ofthe ground, [e. washouts) lel crushing due to inadequate load distribution from vertical and horizontal members Horizontal supports lal inadequate lateral and torsional bracing, fe, Between“The Mastraulser| Apa 2046 |avovmacterbulaers9in 12 FORMWORK: DESIGN & CODES telescopic props, centres carrying heavy loads over long spans, steel props supporting heavy loadsat, or near, max- imum extension and been towers supporting independent spans) (4) horizontal members not centrally placed in Stirrup heads / heads (a1 inadequate supports to cantilevers, eg. Struts supporting deep beam sides onthe outer face ofthe structure] (el inadequate support to prevent overturning of deep principal members because sirup head or fourway heads often omitted (0. bolted timber connections nt staggered creating tendency tossplitout Vertical supports (al inadequate bracing during erection (b1 support not plumb (inadequate lateral tes and/or vertical and plan bracing (d)_noties between standards at point of lading (mostimport- ‘ant where telescopic props are being supported) (el adjustable steol props with nals, mild-steol bolts and rein- forcing bars used in place of correct pins (h) top and bottom plates of steel props Generat {a} excessive tolarances in construction (o] failure to check tighinass of bolts, wedges, ete (¢) failure to contra vertical rat of placement of concrete (al falure to control placement of canrete, causing uneven loading of forms (el inadequate allowance for uplift of concrete under incined forms (9. inadequate allowance forthe effects af bration on ents (91 inadequate allowance for stresses induced by prestressing, temperature and moisture movements {h) no allowance for wind loading (0 no allowance for the est of ration en ties, strats, braces, and wedges (0. Unvealstic assessment of stresses due to over-smpitation of design assumptions (Hd nequal load distribution between tw or more members carrying a commen load Premature tipping of forms, premeture removal of sheres, and caress practices in reshering can produce catastrophic results, Eventhough de-shuttering is the last operation, but itis ‘the frst and mast important aspect which tobe taken inte con- sideration by the designer and the ste engineer. & formwork designer should keep in mind about ease of de-shutterng plant ‘& equpment availabilty while preparation ofthe scheme. The time for formwork removal or repropping removal should be based on both the specication compliance ,codsl provisions and field assessment Conclusion Formwork takes more than 50 percent of RC construction time, The cost of formwork varies between 15 to 25% of the Reinforced cancrete structure cost, Proper engineered system Jrmiork should be specified upon in the tendersto attain good ‘ermork practice, Safe working conditions and to get quality ‘and durable concrete structure, atherwiceit wil net ony leadto poor quality structures but alca wasting of resources like ma ferils, manpower and time which in tur effets construction delay and cost escalation of projects. First step of camplance ist follow the codal guidelines. By their nature codes sel for minum standards inorder to protect ‘workers andthe public, butthey can giveno absolute guarentee of safety. There are too many other wark place practices and corultions that affect the balance between safe and unsafe con: ditions. However, once a failure has accurrad investigators will, certainly check whether the cadal provisions were fllowed or violated. So, i's better to keep in touch with changing require ments in codes and standards, recagnaing that they are always necessary but not always sufficient for safety Major formwork players publish a lot of information on. formwork usage, assembly, werk procedures etc. in their websites which 2 person can access and can practice at site So, non ~avalabiliy of detailed Indian codes or specification for formwork should nat be an excuse for inferierimproper forrn- work practices. In order to bring the standard of constructions in India to International levels, the consultants should speci, systerise and implement the right formwork syster for the projects and also the standardization body of India also to lock ‘bringin more detalled Code of Formwork practice in India to ‘xt the available materials / system and formwork practices in nc, References 1 ACIOWT-R 2016. Guide to ermnor or concrete 2) 85 577508401201 Code of practice or emparay wack proce dures andthe permissible sires desgn of lseverk 9) AS3éI0-2010-Ausalan standards for Frmncrk for Concrete® 22 ibe your copy cold ~ 26558208 / 080 ~ 25705888 1 visif wan mastertaalder cin