COURSE 2 FORMWORKS GENERALITIES

2. FORMWORK FOR CONCRETE STRUCTURES

2.1. INTRODUCTION

Formworks are auxiliary constructions, specific and temporary which

serve to obtain shape, dimensions and positioning of concrete, reinforced and
prestressed concrete elements in site cast structures, as well as their support until
the concrete reaches a minimum degree of hardening for strike-off.
The formwork operation involves performing the assembly operations of
formwork components in order to make an element or a monolithic structure.
Formworks play an important role in achieving concrete , reinforced
concrete and prestressed concrete structures in terms of both their quality and
economically. Depending on the type of construction and used formwork, the
formwork can represent 15% to 30% of its cost. It is therefore needed to
implement modern industrial formwork systems, always refined, which should
lead to increased productivity and lower costs.
Industrialization of formwork works pursues the following ways:
- Typing and their modulation;
- Mechanization of the main activities of the formwork works;
- Extend the improved formwork systems and introducing new systems;
- The basic construction module of dimension is 30 cm;
- Sub-module: 5 cm; 10 cm;

2.1.1. Formwork clasification

Taking into account the diversity of the compoment systems and their use,
the classification formwork can be made according to the following criteria:
2.1.1.1. After the components and use, formworks are classified into the following
categories:
- Removable formwork - made of modular and templates boards,
shoring elements, support elements, auxiliary and assembly elements.

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 The main types are: inventory formwork of modular removable
panels, sliding formworks, etc.;
- Non-removable formwork - which assembles and dismantles once at
the beginning and the end to achieve that structure. These formworks
are equipped with systems or devices that allow their displacement in
its entirety, or in the form of large subassemblies or assemblies, using
cranes. This category includes: sliding formworks, rolling
formworks, table formworks, tunnel formwork, large panels etc.
- Traditional formwork - used at elements and structures that are
unique or variable and complicated forms (domes, curved beams),
where they cannot adopt industrialized formwork systems. They are
made on site from wood and used only once or a few times.
- Lost formwork- which fulfill the normal functions of a formwork, but
are not recovered, remaining adherent to the casted element. They can
have a structural role (based on their cooperation with the concrete),
of thermal insulation or aesthetic. It may be mentioned precast slab
elements, panels with architectural character, ceilings boxes etc.

2.1.1.2. In terms of destination, relative to the construction elements at execution

of which they will be used, formworks are as follows:
- Foundation formworks;
- Wall formworks;
- Column formworks;
- Beam formworks;
- Slab formworks;
- Arches and domes formworks;
- Other elements formworks.

2.1.1.3. by the materials used for sheathing, they are formwork of:
- Timber;
- Moisture resistant plywood;
- Steel sheet;
- Profiles of aluminum alloys;
- Polymers (reinforced or unreinforced with glass or carbon fibers);
- Rubber;

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 - Combined materials - plywood covered with aluminum foil, sheet steel or
polymer.

2.1.2. Quality conditions

Formwork quality is judged by the degree of fulfillment of three categories
of conditions: technical, functional and economical. Failure to follow them,
adversely affect quality and cost of elements or structures made.

2.1.2.1. Technical conditions

- To ensure the correct shape, dimensions and relative positions of elements
in the structure;
- The sheathing surface to be rigorously comply with the required quality of
concrete elements surface;
- To withstand without deformation above the allowable limits, at physical
and mechanical loads at which they are subjected;
- To be sealed to prevent water loss and the fine part of the mix (cement, 0
0.2mm sand etc.);
- The sheathing to have a fairly high resistance at wear suh as to not be
easily damaged during reinforcement mounting, concrete casting and compaction,
cleansing, circulation etc .;
- The sheathing surface state should not favor concrete adherence to it;
- The materials from which the sheathing is made should not chemically
attack and not be attacked by the concrete.

2.1.2.2. Functional conditions

- To have modulated dimensions;
- To allow easy assembly;
- Allow a rapid disassembly and order required for formwork strike-off;
- To provide replacement of worn components, with a low workmanship;
- Their weight to be within 30 40kg for those handled by a single worker
and 60 70kg for those handled by two workers;

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 - To correspond in terms of work safety rules.

2.1.2.3. Economical conditions.

- Assembly of the formwork should lead to achieving the lowest possible
consumption of materials, energy and labor at the smallest cost;
- Ensure a great number of reuse;
- Requiring labor consumption as low as possible for their installation and
removal;
- Allow a cleaning, oiling, handling, storage and repair as easy and as
affordable as possible.

2.2. FORMWORK DESIGN

The calculation is made in elastic range at normal operating limit state.
Design of formwork is done such as not to exceed the calculation
strengths of the materials that each of the components formwork, under the
action of maximum probable loads and their combined effect.

I.2.1. Loads, load groups and materials characteristics

2.2.1.1. Loads clasification
Formwork loads considered in the calculation are classified as follows:
a) After mode of production:
- static load uniformly distributed, and / or concentrated;
- dynamic loads, uniformly distributed.
b) After the direction of action:
- vertical direction;
- horizontal direction.
c) After the nature of loads:
- self weight of the formwork;
- self weight of fresh concrete and reinforcement;
- dead load coming from people, traffic routes, transportation of
concrete (wheelbarrows, cans, buckets, etc.)
-
2.2.1.2. Loads on the vertical direction (acting on horizontal formworks for
slabs)

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 a) Self-weight of the proper formwork (plywood sheathing and the bearing
structure braces, studs and transverse frames), established according to the
specific weights of the materials they are made of:

Timber:
- hardwood (beech, durmast, acacia, oak):
dried in air (15% humidity): 8,0 kN/m 3;
freshly cut or humid: 10,0 kN/m 3;

- softwood (fir, larch, spruce, pine):

dried in air (15% humidity): 6,0 kN/m 3;
freshly cut or humid: 8,0 kN/m3;

Plywood sheathing:
- TEGOFILM type: 8,5 kN/m3;
- beech plywood type F or S having a humidity of 12%: 8,0 kN/m 3;
- beech plywood covered in glass yarns, having a thickness of 15 mm and a
humidity of 6,5%: 7,7 kN/m3;
- poplar plywood covered in glass yarns, having a thickness of 15 mm and a
humidity of 6,5%: 4,8 kN/m3.

Additional joining elements between the plywood sheathing and the

bearing structure:
- nails, screws, etc. according to the specific weights of the materials
(steel: 78,5 kN/m3).
b) Self weight of the fresh concrete:
concrete
plain: 24 kN/m3
reinforced: 25 kN/m3
lightweight concrete: 1,10 x b
heavyweight concrete: 1,15 x b
where: b = density of concrete in hardened state.

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 c) Technological loading (dead load), uniformly distributed on the surface, due
to runways installed on formworks and in workers crowding:
- for proper formwork computation 2,5 kN/m2;
- for horizontal supporting elements (i.e.: joists) computation: 1,5
kN/m2;
- for vertical supporting elements computation (props, columns, scaffolds)
1,0 kN/m2.

d) Concentrated loading, from the weight of one worker who carries a load
(materials) or from the weight of the loaded means of transportation, acting upon
the formwork and upon the horizontal propping elements:
- for one worker who carries materials 1,3 kN;
- for wheelbarrow transportation (under the wheel) 1,7 kN;
In the case of other methods used for the transport of concrete, the
concentrated loads will be determined accordingly, but not being less than 1,3 kN.

e) Uniformly distributed, temporary loading due to the vibration of the concrete

(this loading does not act at the same time with c) and d) type loadings): 1,2
kN/m2.

2.2.1.3. Loads on the horizontal direction (acting on vertical formworks for

columns and walls)
f) Static horizontal loading, from lateral thrust of concrete (poured and then
compacted by vibration) upon formwork walls, that is distributed function of the
concreting speed vb, according to the diagrams in figure 10.
The concreting speed represents the ratio between the height of the element that
will be casted, H, and the probable time necessary for the filling of the formwork
with concrete on that height. It can also be defined as the ratio between the
discharge of the poured concrete, Q, and the horizontal surface of the formwork, S.
(vb=Q/S)

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 - The position of the maximum pressure is determined with the following
relation:
hp= 1 H
- The value of the maximum pressure is computed with the relation:
pmax=1 2 3 4 b H

Level of concrete Pressure diagram function of concreting speed

in the formwork

Base of the
formwork

Figure 1: Lateral thrust of concrete function of the concreting speed

a) for vb10 m/hour; b) for 1 m/hour < v b < 10m/hour; c) for v b1 m/hour.
- The pressure at the inferior part p inf is determined using the
relationship:
Pinf= pmax

Table 1: Coefficients , 1, 2, 3, 4.

Characteristics 1 2 3 4
1 0 0,55
2 0,25 0,65
Concreting speed (m/hour)
3 0,45 0,75
4 0,70 0,85

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 6 0,80 0,90
8 0,90 0,95
10 1,00 1,00
1 0,85
14 0,95
Workability of concrete,
59 1,00
expressed in compaction (cm)
1015 1,05
15 1,10
15 0,90
Minimum dimension of the
1654 0,95
section (cm)
55 1,00
5 1,00
Temperature of fresh concrete
624 0,95
(C)
25 0,90
where:
1, coefficients taking into account the concreting speed;
2 coefficient that depends on the workability of concrete, expressed in
terms of compaction;
3 coefficient taking into account the minimum dimension of the
element;
4 coefficient that depends on the temperature of the fresh concrete.
g) Horizontal dynamic loading on the walls of the formwork, from shocks
produced when the concrete is poured, will be considered as follows:
- bucket having the capacity of at most 0,2 m3 ....... 2,0 kN/m2
- bucket having the capacity between 0,2...0,7 m3 .... 4,0 kN/m2
- bucket having the capacity of more than 0,7 m3 ........ 6,0 kN/m2
- casting with gutters and hoppers............................... 2,0 kN/m2
- concrete pumps .................................................. 6,0 kN/m2

h) Dynamic loading due to wind, will be considered according to NP-082-04

(Design code. Basis of design and actions in constructions. Wind action).

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This loading will be taken into account only for the computations for scaffoldings
higher than 6 m, as well as for the overturning check given by wind pressure for all
surface formworks made of panels that have a total mass bigger than 250 kg.

2.2.1.4. Load groups

Load groups
Service limit
Name of the elements Ultimate limit
state
state
(deformation)
Slab or arch formworks, as well as a+b+c+d
horizontal shoring elements (joists) or a+b
a+b+e
Vertical shoring elements for
a+b+c a+b
formworks (props, scaffolding)
Bottom of beam and arches a+b+e a+b
a+b+c
Scaffoldings with maximum height of
or a+b
6m
a+b+e
a+b+c+h
Scaffoldings with height greater than
or a+b
6m
a+b+e+h
Side parts of the beam or arches
f f
formworks
Columns formworks with sides of
maximum 30 cm, and wall formworks f+g f
with maximum thickness of 10 cm
Columns formworks with sides of
more than 30 cm, and wall formworks
f f
with thickness greater than 10 cm,
massive elements
Setting the static scheme will take into account the material that the
elements is made of, bearing conditions and manner of conception and
manufacture.

2.3. Formworks components

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 Depending on the types of structural elements executed one can speak of a
great diversity of formworks, leading to different ways to assemble them.
Regardless of used the type of formwork, in their structure the following main
components are found:
- The proper formwork, consisting of:
sheathing;
sheathing stiffeners, called ribs - diversified by type of formwork
system;
- Shoring or supporting elements of the proper formwork (bearing structure);
- Auxiliaries.

2.3.1. Proper formwork

2.3.1.1. Sheathing
The sheathing is the part of the formwork that comes in direct contact with
the casted concrete, giving shape and size of elements that are executed, and the
quality of their surfaces. The sheathing is a resistance element belonging to the
proper formwork and which is intended to take the pressure (pushing) of the
fresh concrete when positioned vertically (on walls and columns) and loads from
its self weight, self weight of concrete and reinforcement, transport means of
workers, concrete transport means for horizontal arrangement (at slabs),
including dynamic stresses from casting and compacting fresh concrete .
Note: Sheathing transfers all the loads acting on it to the reinforcing ribs.
The materials from which the sheathing of the formwork structure are
currently made of are:
a) timber - in practice there are situations when the sheathing is made of
timber or boards with a thickness of 22 24 mm, respectively timber bars with
thickness 38 48 mm. In order to ensure the best possible surface quality for the
elements that are executed or to prevent adherence of concrete to the sheathing, the
boards are smoothed (by planing). Also for allowing deformation (swelling) of
boards due to moisture coming into contact, in the sheathing manufacturing, gaps
of 1 3mm are left between the planks. The disadvantages of this type of
sheathing consist of fingerprinting of joints between boards on the concrete
surface, and when the tightness is not assured (imperfect closed joints) there is
loss of grout and fine part of the mix. Also, due to repeated wetting- drying process

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of boards (timber bars), they may deform generating areas with large deviations
from flatness. Another registered disadvantage is the high consumption of wood,
the surface of the timber planks sheathing must be processed almost after every use.
The number of reuse is about 8 12 times;

b) superior products of wood (Category TEGOFILM) - most commonly,

the sheathing is made from moisture-resistant laminated plywood. In Romania,
the thickness of the TEGOFILM plywood manufacturing is 8 mm or 15 mm.
Besides the varieties mentioned, various specialized companies are selling
multilayered plywood thicknesses of 4, 8, 12, 15, 18, 20, 21mm, generally made
from species of Nordic softwood (Finnish pine), some being treated on both sides
with high-density phenolic resin. Plywood formwork is obtained from an odd
number of veneer sheets are arranged alternately with the fibers (from each
other) at angles of 90. Between the layers of veneer sheets TEGOFILM
(synthetic resin) is inserted, which ensures gluing and impregnation when
pressed at high temperature. The plywood obtained is waterproof with
smooth surfaces and wear resistant, which favors reducing adherence of
concrete. Depending on the quality of the plywood, and the actual conditions of
use, these plywood sheathings can be used approx. 10 25 times. For sheathings
made from northern softwood, one can get up to about 100 reuses;

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 Fig. 2.2: Sheathing made of superior wood products.

c) steel sheet - there are formwork systems for which the sheathingis made of
steel sheet with a thickness in the range 1.5 5 mm. Compared with laminated
plywood, the concrete's visible face quality achieved by using metal sheathing is
superior. Also, a real advantage is their insensitivity to water, and high
durability. Steel sheet sheathing can be reused up to 500 600 times, the quality
of the visible concrete face also depending on the care in using and handling the
formwork. The disadvantage is that it has heavy weight;

d) sheet of aluminum alloys - are lightweight, resistant and provides

exceptional quality of the concrete visible side. These types of formwork offers a
number of reuse up to 700 800 times, but the cost is high;

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 a) High strength polymers - to make the sheathing that are part of formwork
systems, one can also use high strength polymers, reinforced with
fiberglass or not. This category of sheathing provides high quality for the
visible concrete side, and number of reuse is high.

Fig. 2.3: Polymeric sheathing:

1high density polipropylen layer; 2aluminium reinforcement layer;
3 polipropylen layer.

Fig. 2.4: Advantages of using polymeric sheathing, when compared with the wood
product sheathing

2.3.1.2. Stiffening elements for the sheathing (ribs)

Stiffening elements for the sheathing (ribs) are resistance elements that
are designed to stiffen the sheathing and transfer from it all loads (actions) that is
subkected to.Together with the sheathing, the ribs are forming the proper
formwork.The sheathing's reinforcing ribs can be disposed, if prefered, on one
direction, case found in some modern systems of slab formwork (Fig. 2.5-a), or

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after two orthogonal directions, this situation is currently encountered for
formwork panels (fig. 2.5 b).
By pre-assembly of the sheathing with reinforcing ribs various types of formwork
can be obtained. In this case, the reinforcing ribs of the sheathing are usually made
of wood and metal. The ribs are fixed to the sheathing usually non-removable, but
some types must be able to be replaced periodically.
a) wooden ribs - are widely used to manufacture panels with the sheathing made
of multilayer plywood board (category TEGOFILM), planks or bars. They are
obtained from small beams or by cutting the width of the bars, at the set
dimensions;
b) metal ribs - are found in all metal formwork structure, or those having the
sheathing made of multilayer plywood boards or planks. The ribs are usually
carried out from light steel laminated profiles, tubular elements of pressed steel,
or of hollow aluminum elements.

c)
Fig. 2.5: Formwork panels with steel ribs:
a) ribs on one direction; b), c) ribs on two directions.

2.3.2. Formwork panels (inventory)

From the dimensional point of view, and also of the surface of the formwork,
there are modular panels with small dimensions and large surface panels (pre-
assembled).

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 The most used panels are small surface modular formwork, which can form
by joining, supporting and stiffening by certain rules, large formwork
surfaces. Such panels are referred to as modular or inventory panels.
The large surface panels are designed for elements of the same size, usually
addressing both typified civil engineering structures and specific industrial
construction. They are called generic large panels or pre-assembled panels.

2.3.2.1. Modular panels

Modulated formwork panels can be made either only of wood or only of
metal, or mixed system (wood and metal).
Modulated wood panels - have the largest spread, being light and relatively
inexpensive (Fig. 2.6). Usually they have the sheathing made of moisture resistant
laminated plywood (category TEGOFILM) and timber reinforcing ribs. The
sheathing not being removably mounted to the structure of the ribs, when its
degradation occures, the panels taken out of use (even though the ribs can usually
be reused). In practice, the number of re-use depends strictly on the speed of
deterioration of the sheathing, so on the way in which these panels are handled.
The panels with sheathing made of planks (called carpenter formwork),
have fewer uses than those to which the sheathing is made of laminated plywood,
while being large consumers of wood. It is used only in special cases.
Metal panels - have a wide use, are more advantageous than wooden panels
as may be provided with a heat agent circulation pipe, allowing heating or
heat treatment after casting concrete. When mounting (assembly) of metal
formwork panels more efficient methods are usually used, which leads to
productivity increase, reducing the duration of the formwork assembly or strike-off.
As disadvantages is the fact that the mass of these panels is much higher for the
same formwork area (compared to timber ones) and the cost is higher.

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 Fig. 2.6: Modular formwork panels, made of timber.
a) carpenter panels; b) multilayer plywood sheathing formwork panels;
1-sheathing; 2-studs; 3-transversal frame; 4-stiffener (rib).
Timber sheathing panels and metal ribs (mixed) - have an extreme wide
use, since they allow replacing the worn sheathing (particularly important).
The metal structure of the sheathing's reinforcing ribs can be reused a number of
times much higher than that made of timber, thereby achieving great savings in
wood. On such a mixed structure of the panels, leading industry companies have
developed efficient and versatile formwork systems used in practically all
countries (Fig. 2.7).

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Fig. 2.7: Modular plywood with steel stiffeners and TEGOFILM plywood
sheathing

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2.3.2.1. Large surface panels (pre-assembled)
Formation of large panels, provides favorable conditions of increasing the
industrialization of formwork works. The advantages of using large surface panels
are:
- It eliminates labor consumption necessary for the operations of assembly and
disassembly of all components of the formwork (macro-panel) at each cycle of use;
- It increases the reuse speed of formwork;
- Surface quality achieved is superior, especially when using metal formwork;
- Installation and removal of the formwork is simpler, thus requires less
skilled workers;
- handling large panels (macro-panels) is mechanized, with the help of cranes.
The proper formwork can be obtained either by permanent assembly of the
sheathing with the ribs, at the sizes of the designed large panel, either by
removable assembling modular panels.
Large surface panels can be made in the following versions:
a) Large panels with non-removable timber sheathing fixed on ribs. This type of
macro-panel can have the sheathing made of moisture resistant laminated
plywood (category TEGOFILM), planks or bars (Fig. 2.8 b and c). The
reinforcing ribs may be made of sawn wood or metal. The proper formwork
has a low overall stiffness (the surface is big), so that at the ground level is
secured with walers and posts systems, acting as support. Also, at the
ground level tensors, work platforms, etc. are mounted, thus obtaining a large
formwork assembly area ready for its application to execute structural
concrete walls. Except the proper formwork often which is often non-
removable, the rest of attached components (metal) are removable, and they can
be reused;

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 Fig. 2.8: Large surface panels.
a) timber modular panels ready to form a big panel; b) a big panel made of planks
(bars) assembled non-removable on fixtures (posts and tubular wales, which are
removably fixed);
c) Large panel with plywood sheathing, assembled non-removable on fixtures
(posts and tubular wales, which are removably fixed); 1 timber modular panel; 2
plank sheathing;
3 steel post; 4 fixture; 5 steel waler; 6 vise; 7 plywood sheathing.
b) Large panels with steel sheathing and non-removable joined steel ribs. This
system is used less often, since the dimensions of large panels can not be
changed (the joints between the steel sheathing and the metal ribs being
made by welding). Using these panels is profitable only if the turnover is high
(execution of large numbers of identical structures);
c) Removable large panels made of modular panels. In this category, the proper
formwork is obtained by assembling removably the modular panels (Fig. 2.8
a). Depending on the orientation of the long side of the modulated panels their
assembly is made directly on walers or posts. Typically, to obtain an adequate

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 rigidity of these assemblies, walers and also steel posts are used (inventory
elements). Modern systems of modular panels, having the sheathing's
reinforcing ribs structure especially designed so as at their assembling to obtain
macro-panels them the additional walers and posts assembly is eliminated (to
increase rigidity of the proper formwork) (Fig. 2.9 ).

Fig. 2.9: Large surface panels (macro-panels), obtained by removable assembly of

mixed structure modular panels

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