Civ 367

Unit 6
 Formwork
Formwork by name means “The Mold” which means it is the casing into which the casting
material, usually concrete, is poured to obtain the desired structural shape.

In the construction industry formwork is similar to a mold to cast concrete member in different
shape and sizes using different types of materials such as timber, steel, aluminum, plastic, etc.

Or
Formwork is a Temporary but rigid structure in which the cast in situ concrete is laid for casting the
members to the required shape. Formwork is placed at the right position before pouring the
fresh concrete into it. The formwork is permitted to stay in position till the concrete achieves
the enough strength to reisit the stresses coming on it without the assistance of the formwork and
after that it is removed.
 Requirements of Formwork
Technical requirements of Formwork
•Formwork should be of the desired shape, size and fit at the location of the member in
structure according to the drawings.
•It should be carefully selected for required finish surface and linings to produce the desired
concrete surface.
•Formwork need to withstand the pressure of fresh concrete and working loads and should
not distort or deflect from their position during the concrete placement operation.
•The formwork must not damage the concrete edge or surface; or themselves
during removal from structure.
•Panels of the formwork should be tightly connected to minimize gap at the formwork
connection to prevent leakage of cement paste.
 Requirements of Formwork
Functional requirements of Formwork

•Formwork sections should be sized in a manner that can be lifted and transported easily from
one job site to another.
•It should be dismantled and moved as easily as possible.
•Interchangeability of formwork units is another functional requirement. This enables units to
be used for forming different members.
•Formwork shall be designed such that it fits and fastens together with reasonable ease.
•Simplicity in erection is another valuable functional requirement of forms.
•Formwork should be as lightweight as possible without any strength reduction.
 Requirements of Formwork
Economic requirements of Formwork

•Formwork shall be made of low-cost materials.

•Energy consumption and labor cost should be as minimum as possible.
•Repetitive utilization of formwork is another economic requirement that must not be
compromised. So, they must be able to withstand a good number of reuses without losing their
shape.
•Formwork structure must be designed so that the whole formwork system can be assembled
and dismantled with unskilled or semi-skilled labor.
•Maintenance of formwork is required to be conducted based on applicable standards.
 Requirements of Formwork
Safety requirements of Formwork
•Formwork needs to be manufactured such that workers can handle them without any safety
issue.
•Health, safety, and hygiene regulation should be considered while forms are made.
•Stability of the whole structure should be checked and ensured to avoid any undesired events
which may cause loss of life, delay construction, and increase cost.
•Emergency escape route shall be provided.
•Emergency response plan need to be established.
•All reasonably practicable steps shall be taken to eliminate any foreseeable risk arising from
the work to be done.
•If it is not possible to eliminate the expected risk totally, then control measures and safe work
procedures shall be implemented to minimize and control the risk.
 Loads on Formwork
General Introduction to Loads on Formwork

In Construction, the formwork has to bear, besides its own weight, the weight of wet concrete,
the live load due to labour, and the impact due to pouring concrete and workmen on it The
vibration caused due to vibrators used to compact the concrete should also be taken care off
Thus, the design of the formwork is an essential part during the construction of the building.

• The surfaces of formwork should be dressed in such a manner that after deflection due to
the weight of concrete and reinforcement, the surface remains horizontal, or as desired by
the designer.

• In the design of formwork for columns or walls, the hydrostatic pressure of the concrete
should be taken into account This pressure depends upon the quantity of water in the
concrete, rate of pouring, and temperature.
 Loads on Formwork
1. Vertical Loads

• Vertical loads acting on the formwork include the self-weight of the forms, the placed reinforcement, the weight of
fresh concrete, the weight of the workers, and the weight of placing equipment and tools.
• For concretes with normal reinforcement ratios, the dead load is usually estimated at 22 to 25 kN/m3. Thus, an 16
cm normal weight slab would exert a dead load of 25 kN/m3 x 0.16 m = 4 kN/m2 on a horizontal formwork.
However, in cases where the reinforcement appears to be heavy, the weights of materials should be computed
separately to determine the actual unit weight.
• The American Concrete Institute, ACI Committee 347, states that horizontal formworks should be designed for a
minimum vertical live load of 2.39 kPa to account for loads of workers and their tools such as vibrators and screeds.
This value is increased to 3.59 kPa if motorized carts or buggies are utilized.
• Additionally, ACI recommends that the minimum combined total design dead and live load should not be less than
4.79 kPa or 6 kPa when using motorized buggies.
 Loads on Formwork
1. Vertical Loads

• Finally, the own weight of the formwork is determined by using the unit weight of its material and the exact
dimensions of its various parts. It is worth noting that the weight of formworks is far less than the dead load
of the concrete and the construction live loads. Therefore, an allowance is assumed as a superimposed load
per square meter.
• At the beginning of the formwork design, the engineer can assume an initial weight for the formwork
between 0.24-0.72 kPa as a starting value. Then, this value is checked and revised when the exact members’
sizes are determined.
 Loads on Formwork
2. Lateral Pressure of Concrete on Formwork

• Unlike horizontal formworks, vertical formworks, such as those for walls and columns, are subjected to
internal lateral pressure from the accumulated depth of concrete placed. When placing, fresh concrete near the
top or sometimes at greater depths acts as a liquid during vibration and generates lateral pressures equal to the
vertical liquid head.
• On the contrast, the lateral pressures are less than the liquid head at depths below the controlled depth of
vibration due to many factors. For instance, for a slow vertical placement rate, the concrete mass in the lower
part has the time to start setting and stiffening. The friction between concrete and form, migration of pore
water, and other factors may also reduce the resulting lateral pressures.
• The next figure indicates the distribution of the pressures as revealed by tests. The pressure starts as a liquid
pressure near the top and reaching a maximum at some lower level. In the design practice, this maximum
value is usually assumed for the rest of the height. This is a conservative approach.
 Loads on Formwork
2. Lateral Pressure of Concrete on Foam work
ACI Committee 347 stated that the following equation can be used to calculate
the concrete lateral pressure if the slump of fresh concrete slump value is
greater than 175 mm and it was not placed with normal internal vibration
to a depth of 1.2 m or less.

For concretes with a slump value of less than 175 mm and placed with normal
vibration to a depth of 1.2 m or less, ACI Committee 347 defines the lateral
pressure of concrete as:
 Loads on Formwork
3. Horizontal Loads on Concrete Foam works
Horizontal loads might result from forces like wind, concrete dumping, equipment starting and stopping,
and inclined supports should be opposed by properly designed braces and shore.

ACI Committee 347 recommends the minimum horizontal loads for design to prevent lateral collapse of the
formwork to be of the greater of :

• 1.5 kN per linear meter of floor edge or;

• 2% of total dead load on the form distributed as a uniform load per meter of slab edge

• The calculated lateral wind forces using 1/30 probability for falsework and 1/10 probability for
formwork with a gust factor of two or a minimum wind pressure of 0.8 kPa.
 Loads on Formwork
4. Special Loads on Concrete Foam works
It is required to design formworks for uncommon construction conditions that could occur such as reinforcement
concentrated loads, unsymmetrical placement of concrete, machine-delivered concrete impact, uplift, form
handling loads. Constructing walls over spans of slab or beams that could impose different loading pattern before
concrete hardening than that for which the supporting structure is designed for, is an example of special
conditions that should be taken into consideration form designer.
 GENERAL Equipment and Tools in FORMWORK

Ties
A form-work tie is a tensile unit used to connect opposite sides of the formwork. It provides a balanced
connection or is used to resist the effective pressure of the fresh concrete.
Generally, it consists of an internal tensile member and an external holding device.
Form ties are usually made of steel, although some fiber-reinforced plastic ties can also be used. There
is a wide range of cable tie types and manufacturers’ rated tensile work capabilities

Anchors

The form anchor is a device used to fix the form to the pre-placed concrete with sufficient strength.
The equipment is usually embedded in the concrete during placement. The actual bearing capacity of
the anchor depends on,
•The shape and material of the anchor,
•The strength and type of the concrete embedded in the anchor,
•The contact area between the concrete and the anchor,
•The embedded depth and position in the member
 GENERAL Equipment and Tools in FORMWORK
Hangers

Formwork hanger is a device used to hang formwork load from structural steel, precast concrete, or
other components.
Spacer from side/ Spacers

The side spacer is a device that maintains the required distance between the vertical shuttering
and the steel bars.

Anchors

Tie Rods Tie Rods Spacer

Hangers

Anchors
 Components used in Wall Formwork
•Panel sheathing – It is used to shape the wall and retain the concrete until it sets.

•Studs - to support the sheathing or Wales by forming a framework to keep the forms aligned and
support the studs.

•Braces – It is used to prevent deflection of forms under lateral pressure and keep the formwork
erect.

•Ties and spreaders – These are used to hold the sides of the forms at the correct spacing.
 Types of Formwork
Timber Formwork
Timber formwork is the oldest type of formwork in construction. It is used in construction from ancient period.In
small construction, timber formwork is mostly used because it is easily usable and it offers an onsite
fabrication for the required size and shape of concrete.But for large construction, timber formwork becomes
a time consumptive formwork. As well as timber formwork have less life compare to other formwork.

Advantages of Timber Formwork:

The advantages of timber formwork in construction are as follows.
•Its initial cost is low.
•Timber formwork is light in weight and can be easily manipulated.
•More suitable for small works.
•It can be used for anything other than formwork.
•In houses where the size of the room does not change much, the timber cut is less, so the timber formwork is
cheaper.
 Types of Formwork
Timber Formwork

Disadvantages of Timber Formwork:

The disadvantages of timber formwork in construction are as follows

• Because of lower cost, it can be used in lesser repetitions as compared to steel formwork.

• Timber attracts termites and hence they attack it. To preserve it shall be coated with ant termite coating from
time to time.
• Surface of the timber formwork is rougher than steel, So the finishing is not that good as compared to steel.

• If the wood is not seasoned properly it would get bent with time and may produce undesired shapes.
 Types of Formwork
Steel Formwork

Steel formwork is cheaper if the formwork has to be used multiple times.

Steel formwork costs more to start with, but in large works where the formwork has to be used frequently it
becomes cheaper, in addition, steel formwork can be easily configured as well as removed.
This makes the concrete surface smooth.
Steel formwork for special works such as circular columns, curved surfaces speeds up the work.
Steel formwork is most popular due to its strength, durability, life and reuses.
 Types of Formwork
Advantages of Steel Formwork
 Types of Formwork
Disadvantages of Steel Formwork
 Types of Formwork
Plywood Formwork

Advantages of Plywood Formwork

 Types of Formwork
Disadvantages of Plywood Formwork
 Types of Formwork
Aluminum Formwork

Advantages Aluminum Formwork

Disadvantages Aluminum Formwork

 Modular Formwork

Modular formwork systems are designed with standardized panels and component items to reduce
or limit the need for cutting material on site. This speeds up the overall process and therefore
requires less labour on site. They are also interchangeable with conventional methods. Modular
Formwork Systems are generally easy to assemble and much faster than conventional Formwork,
saving time, allowing you to pour sooner. The system saves contractors by reducing the costs
associated with conventional purchases. This eliminates the need to recover purchase costs by
reusing or reselling materials once the job is complete.
Commercial, civil, and industrial contractors can replace the traditional methods of cast-in-place
concrete engineering by using modular formwork systems and quickly achieve one-time casting,
thereby minimizing the financial expenditure of labour and materials.
Modular Formwork
 Modular Formwork

Advantages of Modular Formwork

•Fast assembly when compared to conventional formwork

•Less complications and “surprises” on site,
•Re assurance of being tested prior to use
•Designed for handset applications as well acrane-dependentnt large-size formwork
•Modular design principle and well-balanced panel selection make gang-forming possible even for complicated
layout plans
•Flat steel frame for guaranteed sturdiness and a long product life cycle
•Versatile, flexible and unique
•Self-alignment – Précised dimensions
•Quick Installation
• User-friendly – easy erection and dismantling
•Smooth finish – plastering can be avoided
 Slip Form
Introduction to Slip Form
Slip Form is a construction method in which formwork is continuously risen vertically as the work process. It
is a method of vertical construction of a reinforced concrete section.

Slip form construction involves pouring concrete into the top of a continuously moving formwork. As the
concrete is poured, the formwork is raised vertically at a speed that allows the concrete to harden before it is
free from the formwork at the bottom

These types of formwork systems can be used to construct any regular shape or core. In this method of
concrete construction slip forms raised or lifted upward at a rate of about 300mm per hour, supporting
itself on the core and not relying on support or any external support.
The height of the formwork is designed such a way that, during the pouring of the upper level formwork, the
concrete poured in the below formwork would have gained initial setting. The concrete exposed when the
formwork moves up will remain firm.
 Slip Form
Introduction (contd…)
Although slip forming method is not suitable for all types of Structures. Slipform work techniques are
adopted with more than 16 m height.

Following are some of the Important Components of Slip Form-work,

•Sheathing or vertical forms

•Wales
•Yokes
•Jacks
•Jack rods
 Types of Slip Form System

1. Vertical Slip Form System

In this type the concrete is surrounded by a platform on which workers stand, placing steel
reinforcing rods into concrete and ensuring a smoother pour.
Quick Setting Property of concrete serves the dependency of Vertical Slip Form System needed in-
between of initial strength gain and also the ability to work.
The vertical slip form technique uses the extrusion concept in concrete.
Concrete placing into form-work is a practice which is done to develop strong initial strength of
concrete as normally forms slips freshly onto concrete thus avoiding ability to work.
So, during the concreting process, together the concrete form and working platform are raised in
vertical sliding motion by means of hydraulic jacks. The slip form raises at a rate that permits the
concrete to harden by the time.
 Types of Slip Form System

Vertical Slip Form System

 Types of Slip Form System
2. Horizontal Slip Form System

Horizontal slip-form construction is a method used for constructing continuous concrete elements, such as
kerbs, drainage channels, tunnels, safety barriers, and a lot more. It involves the extrusion of concrete in situ
rather than casting it in short lengths.

Horizontal slip formwork involves concrete being poured into a continuously moving plant. It is then
vibrated and extruded from a specially designed formwork mould to produce the required structure profile.

In horizontal slip formwork is used for pavements and traffic separation walls, concrete is cast, vibrated ,
worked, and settled in a place while the form itself slowly moves ahead
 Types of Slip Form System
3. Cantilever Jump Form method

This slip-form method is used for climbers which are independent of cranes. Climbers are
attached to large formwork areas of storey height.
In this system, shuttering has already been completed, which is part of the structure between
individual levels of climbers.

The cantilever jump form system gives maximum protection, providing a complete self-climbing
formwork system that is independent of cranes for walls, columns, supports and floor beers.
Types of Slip Form System

Cantilever Jump
Form Method
 Types of Slip Form System

4. Egg-shaped Slip Form System

This system is based on the jump form principle which can be adapted to any geometric
shape. Individual curvature adjustment can be done by adjusting the axis and vertical
circumferential slope.
It can be adjusted independently on each side of the wall and produces optimal working
conditions for the construction of spherical scriptures or members such as shells, domes
etc
 Types of Slip Form System

Egg-shaped Slip Egg shaped digesters made

Form System using an Egg-shaped Slip
Form System
 Advantages of Slip Form System

1.Non-stop Method of Construction

2.Increase rate of construction
3.Increase the productivity
4.Provide more working space
5.Creates safe work environment for the workers
6.Employs less accessory equipment
7.Increase flexibility in construction
8.Reduced Labor costs
9.Scaffolding and temporary works in construction is reduced
10.Uniform wall sections and layouts are obtained
 Disadvantages of Slip Form System
•Good coordination and site organization are required.
•Large quantities of equipment (e.g. Generators, lighting systems, and hoists) needed.
•Skilled labor force required for the operation of equipment and methods.
•Its initial installation required a longer time.
•Experienced and skilled supervision need for uniform movement of the slip form
system.
•When material stoking is difficult on site
Applications of Slip Form System
1. Construction of Regular core high rise structures
The slipform construction technique used in high rise building construction will be
performed by vertically extruding the reinforced concrete section. Regular shaped core
structures and buildings are easily constructed by this method.

2. Slipform Technique for Chimney Construction

The slipform technique used for the construction of large chimneys,
cooling towers and piers are called as tapered slipform. This
technique is used for constructing vertical structures with varying
wall thickness, or shapes or diameters.
Applications of Slip Form System

3. Construction of Water Towers

The slipform technique helps to construct the walls of water tanks uniformly with better
quality. Tanks of thousands of litres are easily constructed by this method.
 SCAFFOLDING
Scaffolding is a temporary framework having
platforms at different level of a structure which enables
the masons/labor for working at the height. They are
usually used for activities such as plastering, painting,
brickwork at heights etc.

Scaffolding is a temporary structure, usually of timber or

some other material, provided as a safe working platform for
the workers when the height above floor level exceeds
about 1.5m. It is also sometimes called a scaffold and is
mainly used for activities like construction, demolition,
maintenance, or repair works.
COMPONENTS OF SCAFFOLDING

Standards/ Uprights are perpendicular tubes that transfer the weight/loads to the baseplates.
Standards are connected using pins and socket joints to increase the scaffolding height. Standards
are also used to provide stability to the scaffolding and to create working platforms.

Ledgers in scaffolding are horizontal beams that are used to support the scaffolding. They provide a
stable platform for the workers to stand on and work. The ledgers also help to distribute the
weight of the scaffolding evenly. Without ledgers, the scaffolding would be unstable and
dangerous.
There are two types of the ledger: inside and outside. The inside ledger is attached to the building at
one end, and the other is free. The outside ledger is attached to the building at both ends. Ledgers
are an essential part of scaffolding and must be used correctly to ensure the safety of the workers.
COMPONENTS OF SCAFFOLDING
Transoms are horizontal tubes that span across ledgers, normally at right angles (90°) to the face of the
building. They may also be used to support a working platform. Transoms are an essential part of
scaffolding and provide stability and strength to the structure. Without transoms, scaffolding would not
be able to support any weight and would collapse.
Transoms are generally made of steel or aluminum and are available in various lengths. They are
connected to ledgers using clamps or bolts and to each other using couplers. Transoms must be placed
at regular intervals along the scaffold length to provide support and stability

Bracing
One of the most important aspects of scaffolding is it’s bracing. Bracing helps to keep the structure
rigid and stable, preventing it from collapsing or tipping over. Many different types of braces can be
used in scaffolding, including diagonal tubes, horizontal members, and cross braces
COMPONENTS OF SCAFFOLDING
Base Plates
Scaffolding base plates are small square metal plates that the standards (uprights) rest on to prevent
them from sinking into the ground. Base plates come in various sizes and thicknesses, depending on the
load they need to support.
When selecting base plates for your scaffolding, make sure they are compatible with the type of soil
you will be using them on. For example, softer soils may require thicker or larger base plates to provide
adequate support.

Sole Board
Sole boards are large, flat pieces of timber that are placed under the base
plates of scaffolding to distribute the load over a wide surface area. This is
especially important when scaffolding is erected on soft ground, as it
prevents the base plates from sinking into the ground and becoming
unstable.
Sole boards must be made from strong, durable timber that is capable of
supporting the weight of the scaffolding and any loads that will be placed
on it.
 COMPONENTS OF SCAFFOLDING
Working Platform
There are two types of working platforms in scaffolding: suspended scaffolds and supported scaffolds.
Suspended scaffolds are platform systems that are hung from an overhead structure by ropes or cables.
They allow workers to access hard-to-reach areas of a building or structure.
Supported scaffolds are platform systems that are supported by the structure itself rather than being
hung from an overhead structure. They are typically used for maintenance and repair work.

Suspended scaffolds
COMPONENTS OF SCAFFOLDING
Guardrails
Most scaffolding is equipped with guardrails to protect workers from falling off the structure.
Guardrails are usually made of metal or wood and are attached to the uprights of the scaffolding. They
typically consist of a top rail, a midrail, and a toe board

Toeboards

Toeboards are an important safety feature in scaffolding. They are fixed to the standards
(uprights) tooff the platform’s edge and protects workers from being struck by falling
objects. Toeboards should be secured with wire ties, screws, or other means so they cannot be
easily removed provide a lip for the platform. This prevents tools and materials from falling.
COMPONENTS OF SCAFFOLDING