OVERVIEW OF FORMWORK DESIGN AND FABRICATION

BUILD
RIGHT Concrete formwork
basics
Concrete can be formed into a variety of intricate shapes with interesting surface
BY CONCRETE finishes, but this relies on quality formwork. Whether using traditional boxing or
NEW ZEALAND INC
proprietary formwork, it’s important to get the basics right.

FORMWORK must contain freshly placed and

compacted concrete until it has gained enough
strength to be self-supporting and to produce a
concrete unit of the required shape and size with
the desired finish.
Formwork is a significant part of the cost of
structural concrete units. Speed of erection and
stripping affects the rate of construction, and the
contractor working with the project team needs
to be skilled in its design and fabrication.

Design of formwork
In addition to vertical loads and horizontal pres-
sures (from wet concrete), allowance must be

PHOTO – JACKSON INDUSTRIES

made for the self-weight of the formwork, work-
ers, materials and equipment and the impact
of placing the concrete. It is usual to check that
forms can sustain a point load. Actions that may
produce load concentrations and uplift on sec-
tions of formwork must also be considered.
Concrete exerts strong horizontal pressures Formwork liners can leave interesting designs on the finished concrete.

on the vertical surfaces of formwork. With self-

compacting concrete, these horizontal pressures considered during design, particularly if working Traditional boxing used less
are much higher and must be considered during at height. These would include enough walkway Traditional boxing for concrete construction
formwork design and erection. space, no obstructions or unnecessary overhangs consists of bespoke solutions assembled on site
However, as the workability of concrete reduces and fall prevention. from timber supports – plates, braces, pegs,
over time with the loss of water through cement cleats, walings for tall walls – together with
hydration, concrete develops an increasing Fabrication generally by contractor close-butted timber boards or plywood sheets
capability to be self-supporting. The contractor will generally be responsible for to form the concrete against. Alternatively,
Forms and shores (props) must be braced planning and designing the formwork, unless it standard shutters of timber frames and plywood
to resist all lateral loads, such as wind or other is a very complex structure. This is essential since are premade to suit with infill panels made to
impacts – for example, starting and stopping the contractor can evaluate staffing, materials complete the boxing.
equipment. Lateral bracing is very important to and equipment and arrive at a design that is While steel forms are more durable, timber or
prevent misalignment and potential collapse. structurally sound, can be erected and is suitable plywood is simple to work with and lighter, and
Health and safety requirements must also be for concreting. inserts can be easily fixed.

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 ●● can be nailed close to the edge type of surface (absorbent or non-absorbent),
●● is stable when wet. type of concrete, quality of finish and ease of
To ensure maximum reuse of plywood, seal sheet application as well as any finish that might be
edges, use thin but wide wedges when stripping, applied to the concrete, such as tiles or paint.
coat sparingly before each use with a form-release
agent and clean down immediately after use. Include striking strips
Options for sheeting or form liners against Formwork reuse relies on being able to remove
which the concrete is placed: the shutters easily and quickly. There must be
●● Steel sheet typically incorporating steel angle room to move the shutter in two directions before
supports to keep the form straight. attempting to lift them clear from the surface.
●● Proprietary lightweight flexible or rigid The usual way to do this is to include some strik-
interlocking PVC planks. ing pieces or wrecking strips.
●● Hardboard – this has a limited reuse and must The time of striking is normally specified
be tempered to provide resistance to moisture. in the construction documents, otherwise
Sheets should be centre pinned to sheeting the requirements of NZS 3109:1997 Concrete
material to reduce buckling. Clean before re- construction should be applied. The requirements
PHOTO – ACROW LTD

oiling for reuse. for beam sides and walls are 2–6 days depending
●● Textured rubber linings that can be used with on temperature conditions, but this may vary.
any formwork system. It is essential to ensure Removal of any soffit formwork is related to
the rubber is well fixed to the backing. Using structural propping and should be covered in the
Proprietary formwork system. the correct release agent is also important. specification to allow the concrete’s required
●● Thin plastic sheeting requiring backing support strength.
Sheeting and decking can be used to produce a smooth surface
Sawn or dressed timber can be used as sheeting finish. Many uses can be achieved. However, Proprietary systems
and decking. It can eliminate studs on slab work the impervious face of the liner can trap air As many formwork requirements are common
when supported on runners or stringers. Edges bubbles and so form blow holes. across projects, a number of reusable proprietary
may be square cut or tongue and groove. To formwork systems have been developed.
prevent grout loss, joints should be sealed with a Release agents These mostly modular systems are designed
flexible foamed strip. Most form materials require the application of for speed and efficiency, with health and safety
The advantages of using exterior grade plywood a release agent to the surfaces that will be in built in. There are a variety of main systems:
as a form supported by timber framing include it: contact with the concrete to make removal of ●● Table form/flying form – large preassembled
●● is rapidly fixed the formwork easier. As well as effecting release, units, often creating an entire bay of a
●● can provide large smooth surface areas release agents can also influence the concrete suspended floor slab, offer mobility and rapid
without joints surface appearance and durability. erection for projects with consistent or
●● has high resistance to impact When selecting the release agent, consider the repetitive layouts.

Build 170 — February/March 2019 — 25

 PHOTO – BANNAN CONSTRUCTION
A wall formwork system.
C

M
●● System column formwork – these are modular, Other developments include: is placed the slab, which then ties the floor
Y
allowing quick installation of column forms on ●● lightweight, adjustable formwork metal/ elements together.
site and are available in a variety of materials. plywood interlocking forms that can Permanent formwork is not restricted to hori- CM

This type of formwork comes with different incorporate handrails and full access platforms zontal surfaces. Systems are available that make MY

internal surfaces depending on the finish to give a complete formwork/shuttering and it possible to pour vertically and create walls. CY

required. access solution Insulating concrete formwork (ICF) is a type of CMY

●● Horizontal panel systems – these lightweight ●● proprietary metal boxing brackets to support vertical permanent formwork made of expanded
K

modular systems provide versatile solutions wide horizontal planks for slab edge formation  polystyrene blocks into which reinforcing steel
on site and can be used for most types ●● proprietary one-piece adjustable brackets that and concrete are placed.
of construction. They are generally made incorporate locating pins specifically design for
from aluminium, high-tensile steel or use with polystyrene pod slabs on ground Slab on grade
fibreglass. ●● proprietary interlocking aluminium panels There are polystyrene and plastic dome systems
●● Vertical panel systems – these crane-lifted supported by galvanised steel pipes that are available for residential or light commercial
modular panel systems are commonly used clamped together to provide a slab edge form. slab on grade and are sometimes referred to
on building sites to form vertical elements as permanent formwork, although the slab
and usually consist of a steel frame with Permanent formwork edging tends to be formed using timber or steel
plywood, steel, plastic or composite facing Permanent formwork remains in place after the formwork. However, there are slab edge-forming
material. concrete has gained adequate strength. It may systems available that incorporate bracing ele-
●● Jump form – not reliant on support from other contribute to the load-carrying capacity of the ments to eliminate form deflection.
parts of the building or permanent works, this structure or simply contain the concrete while it is
system supports itself on the concrete cast being cast and gaining its initial strength. Pay attention to the details
earlier and is suitable for construction of multi- Permanent forms for suspended floors are Time spent before placing concrete to ensure the
storey vertical concrete elements. typically: exactness of formwork design and fabrication
●● Slip form – these are like jump form, but the ●● interlocking long-span profiled metal trays details is never wasted. In addition to health and
formwork is continuously raised vertically to installed over a supporting structure – the safety considerations, design and fabrication
extrude a reinforced concrete section and is floor slab is then cast over the metal form shortcuts can prove troublesome and costly, with
suitable for construction of core walls in high- ●● timber infill between spanning precast significant hours and money required to remedy
rise structures. concrete beams (rib and infill) over which defects.

26 — February/March 2019 — Build 170