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Co bor
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mum concrete formwork, which tem is the flat slab or constant soffit.
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Concrete obtains fast paced construc- In this system, the formwork has lim-
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ited interruptions, and is the most®easily
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21.8% tion while keeping costs at a
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minimum. A structure that assembled and removed. Any drop be-
9.0 teria eme is easy to build reduces the low the soffit elevation, be it for drop
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required labor and leads beams or depressions, causes a break in
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to potential cost savings. the formwork operation. The formwork
Reinforcement must stop at this point, possibly change
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direction and be cut to fit. Any change
8.7% Designing For
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in operation leads to a decrease in form-
rk t Cost Savings work productivity and an increase in
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r ria Labor There are numerous cost. Concrete deep beams also require
Fo ate 46.7% Cop ways the concrete structur- additional beam side formwork not
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6 al design engineer can design needed in the level soffit design. Deep
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construction cost savings into beams may also increase the overall
the project. The primary savings height of the structure and require ad-
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in concrete formwork often occurs ditional cost in the vertical direction. A
in the initial concrete design stage. An variable height structure may require
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Figure 1: The real cost of in place
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structural concrete efficiently designed structure obtains different vertical formwork in the floor
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these savings at the initial bidding and support, and also different column and
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very project has unique features, throughout the construction process. wall forms. If at all possible, increase
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requirements and challenges. As
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An efficiently designed structure has the the reinforcement in the slab to act as
the design of structural concrete ability to reduce costs in several areas, a wide beam at the same depth. Drop-
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projects becomes more and more com- especially in the design of the floors, col- heads are frequently needed at column
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plex, a simple method for reducing the umns, and walls. slab intersections. An optimum design
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cost of construction is too frequently Due to the amount of concrete form- eliminates these dropheads completely by
Structural Practices
overlooked. Presently, as well as in the work required for the floor system, it is increasing the reinforcement shearheads
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past, the most common approach to here that the greatest potential of cost in the floor slab. If the dropheads can not
reducing the cost of a structure was savings exists. Several structural floor be avoided, size the vertical drop so that
solely to search for ways to reduce the systems may be designed to support standard lumber dimensions may be uti-
amount of permanent material under the structural loading requirements, lized. For example, an optimum design
the assumption that “less is best”. but frequently certain designs are more specifies a 4 3 inch vertical drop which
However, this approach overlooks the
most important component in concrete
structure cost which is the concrete
formwork. Concrete formwork consists
not only of formwork materials, but
also the cost of the labor required to use
this material.
Concrete formwork cost is significant.
The cost of formwork amounts to any-
where from 40 to 60% of the cost of a
practical knowledge beyond the textbook
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sloped formwork system. If it is necessary to sistent formwork material to be used without be contemplated. The concrete formwork
use a one way slope, also slope the beams to modification, thus increasing the reuse factor, must be simple. This concept is based on the
maintain a constant beam side dimension. increasing productivity, and lowering con- formwork being simple to erect, use, and
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A two way slope, where both the top and struction cost. Concrete wall openings add to dismantle. An overly complex formwork
bottom of the slab slopes with valleys and the formwork costs. Strive to replace multiple system leads to reduced production and
ridges in two directions, has to be carefully small openings with fewer, larger openings. higher costs. Use the simplest formwork that
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reviewed for formwork costs. The
numerous start and stop intersec- t
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tions required of the formwork p y
greatly reduces construction pro- Co The
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ductivity and should be avoided if
plate dowels
possible.
Columns are another area in the
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structural design where potential
cost savings can be obtained. Strive Not only do our products keep the integrity of your concrete slabs.
for few changes in column size and They do the same thing for your reputation.
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limit the different size columns in
the structure. Review the possibility
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of increasing the concrete strength
and reinforcement instead of
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increasing the column size to carry
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the higher loads at the lower levels.
Alternately, limit the reduction in
size of the columns at the upper
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levels, even if additional concrete is
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almost a decade ago; now see how our tapered plate dowels for saw-cut
multiple times from pour to pour contraction joints withstand the rigors of a construction site while permitting
or level to level. Columns which lateral movement.
are aligned as to provide an open PNA products in a “strategic reinforcement” design help you deliver the concrete
area for gang formwork systems is Diamond Dowel System ® flatwork your customers expect. With PNA, when the concrete slab you
another way the structural design Load Plate Basket Assembly ™
designed stands the test of time so does your reputation.
PD Basket Assembly 3 ™
can reduce construction costs. Even Call today to see how our to incorporate our load transfer, joint
maintaining consistent column protection and wet curing products into your next specification.
orientation to the building grid will
reduce the formwork cut and fit,
which lowers labor productivity and
increases construction costs.
Cost savings can also be obtained in
the economical design of structural
concrete walls. An efficient way to
reduce costs in concrete walls is by www .pna - inc .com
performance products for concrete flatwork
combining structural functions. Re- © 2007 PNA Construction Technologies, Inc. All rights reserved. phone : 800.542.0214
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ized formwork systems, such as tunnel form have the ability to be easily site adjusted in 2-
where the concrete walls and floor are cast inch increments from 8 inches to 32 inches,
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simultaneously or column mounted where or 24 inches to 48 inches. If the concrete
all floor shoring is suspended from the col- design does not permit constant column
umns, are prime examples where the con- sizes, this column form provides a method
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crete engineer designs the structure based of forming along with high production
on the formwork system going to be used savings. The column form hinges and moves
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in the construction. as a complete unit from column to column
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Cop providing additional cost savings (Figure 3).
Current Innovations For concrete floors, a light-weight panel
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The concrete formwork industry is con- form system is being used more frequently for
stantly developing innovative systems to its high productivity. Consisting of aluminum
increase construction productivity by mini- framed panels, the entire system can be
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mizing the amount of labor required to quickly assembled only using man handling.
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use the formwork material. New formwork As an added benefit, all horizontal modules
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products for concrete walls, columns and are able to be quickly dismantled while
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floors are frequently used for their cost saving maintaining vertical load carrying support
of the freshly placed concrete. In certain
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potential and their ability to be readily used
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Figure 3: Adjustable column formwork for various concrete designs. instances, the formwork for concrete slabs can
be stripped as soon as one to two days after
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For concrete walls, newer panel form
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will do the job. The concrete formwork must the concrete pour and recycled to the next
systems have been introduced into the
be easy to handle. The concrete formwork
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marketplace which can be gang formed to concreting position. This quick stripping has
must be of a size and weight that can be eas- the ability to reduce the required formwork
speed construction while reducing utili-
ily handled. If the formwork is to be man
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zation costs. A major innovation is the for the project by up to 70% (Figure 4).
handled, a light weight, ergonomic system
elimination of the bolted assembly of the
will lead to increased productivity and cost
saving. Furthermore, if the formwork is to
formwork by replacing the bolts with clamp- Conclusions
ing mechanisms. These clamping mecha- Ultimately the structural engineer must
be crane handled, a structure designed for
nisms have the ability to fasten, align, and design the concrete structure to serve the
easy formwork movement reduces costs
tighten the concrete wall formwork in one required functions with a structural system
by increasing the reuse potential. The con-
step with only a hammer. The wall form can that offers an economical cost while meeting
crete formwork must be standardized. If the
also be easily modified in both the vertical and all load requirements. Concrete formwork
concrete formwork utilizes industry standard
horizontal directions using only a hammer. plays a major role in the cost consid-
sizes, assembly costs are minimized.
If custom or special sized formwork erations of the structure. A structural
is avoided, material cost is held to a engineer who is aware of the cost of
minimum. The concrete formwork must complexity and is aware of potential
be reusable. If the design permits con- formwork costs has the advantage to
crete formwork to be easily removed pursue a structure that obtains the
and repositioned, costs are again aesthetics, quality, and function at a
minimized. A designed structure that reduced cost — a benefit to the owner,
requires little formwork modification engineer and contractor.▪
and limits potential formwork damage
saves construction time and costs.
Another option to provide an eco- Robert Lab is Chief Engineer with
nomical design is to base the design PERI –USA Formwork Systems. Located
around a concrete formwork system. at the technical/product center in Milford,
This method of design frequently is Ohio, he can be reached at
utilized in the design-build project B_Lab@ PERI –USA.com.
delivery system. A working partnership PERI Formwork Systems is one of the largest
withthe owner, design engineer, and the suppliers of formwork and shoring for the
contractor often leads to an optimum concrete construction industry worldwide.
concrete structure design. The contractor
is aware of potential cost savings which
maybe obtained through the vari- Figure 4: Light weight, quick strip floor formwork