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Date: ​01/04/14 Revision No.

: ​00
Issued by: ​VS Page No.: ​Page 1 of 9
Work Instruction Formwork ( Shuttering & De-shuttering) Ref No.: ​GPL/SAF/WI-12/FW/R0

Work Instructions on Formwork (Shuttering & De-shuttering)

1. Purpose:
The purpose of this procedure is to provide guideline and safe operating system of
formwork work for buildings; offices etc. by using construction machineries and manpower
to site contractors and ensure formwork are carried out in safe manner and in compliance
to legislation (BOCW) and GPL guidelines.
This procedure will help to ensure formwork standard and a safe & healthy work
environment at site.

2. Scope:
This Work Instruction covers the procedure for formwork preparation, erection, its usages,
dismantling and storage & handling etc…method for formwork using listed procedure and
equipments.

3. Responsibility:

GPL Project Head is responsible for adherence to the work instructions through PMC &
responsible contractors. And the respective Contractor is responsible to transmit this
work instruction to their sub-contractors and ensure that the contents are clearly
understood by them. In case of not adherence to work instructions and
non-performance by Contractor, the GPL Project Head has the right to get this done by
other contractor and back charge the same to defaulting contractors.

4. Definitions/ Abbreviations:
Definitions:
● Formwork: Formwork is a temporary structure that is erected to support and contain
concrete to the required dimensions and shape, till it attains enough strength to become
self-supporting. The formwork is designed to safely support the combined loads during
concreting, without bulging or deflecting.
● Guardrails: means a horizontal rail secured to uprights and erected along the exposed sides
of scaffolds, floor openings, runways and gangways to prevent persons from falling.
● Hazards: means danger or potential danger.
● Workplace: means all places where building workers are required to be present or to go for
work and which are under the control of an employer.

Abbreviations:
● BOCW: ​The Building & Other Construction Workers (Regulation of Emp & Conditions of
Service) Act, 1996 and Rules 1998.
● HIRA: Hazard Identification & Risk Assessment
● PMC: Project Management Consultant
● PPE: Personal protective equipment

5. Legal:

Prepared by: RM Reviewed by: VS Approved by: JP


Date: ​01/04/14 Revision No.: ​00
Issued by: ​VS Page No.: ​Page 2 of 9
Work Instruction Formwork ( Shuttering & De-shuttering) Ref No.: ​GPL/SAF/WI-12/FW/R0

● The Building & Other Construction Workers (Regulation of Emp& Conditions of Service)
Act, 1996.
● The Building & Other Construction Workers (Regulation of Emp& Conditions of Service)
Central Rules, 1998.
● BOCW Central Rules Chapter XVII Rules from 181 to 185.

6. Formwork:
6.1 Formwork Procedure: ​Formwork methodology has to be chosen carefully taking into
account the building height above ground level to be executed / constructed, type and
architecture design of building etc… Methodology of the work has to be communicated to
all the crew members. For carrying out formwork work using manually or mechanically, a
rescue plan for any possible accidental fall of wall/ building has to be prepared and the
deployed personnel has to be inducted accordingly. A rescue team should be identified,
trained and available at the place while doing the dismantling of formwork in case of
emergency.

Before commencing the formwork, it is important to consider the following.

❖ Preparation of formwork Area


❖ Erection and dismantling of formwork
❖ Access egress and illumination
❖ Storage & Transport of formwork material
❖ Lifting Appliances
❖ Warning Signs, Barricades and Floor Openings
6.1.1 Preparation of Formwork Area :
I. Formwork must be erected on a stable base to prevent the risk of collapse, suspended
slabs must be able to safely support loads that may be applied by the concrete pour,
workers and lifted material etc…
II. Work area is cleared and surface prepared for safe erection of formwork for suspended
slabs, beam, column / piers and shutters.
III. Frames and props must be located on a sound base that will not subside, fail or wash
away.
IV. Scaffold props must be erected over sole plate, base plate or over the adjustable base
plate spindle. Also ensure that 30% rotation of spindle jack must be inside the props.
( ​For more details follow WI on​ ​“​Scaffold​”​ )
V. Formwork is assembled to plans, specifications and class of surface finish, with support
system set to correct height, level and line.
VI. Bracing of formwork is placed according to support plans and specifications to maintain
rigidity and stability.
VII. Formwork support system is sequentially erected according to initial set out to job
specifications.

Prepared by: RM Reviewed by: VS Approved by: JP


Date: ​01/04/14 Revision No.: ​00
Issued by: ​VS Page No.: ​Page 3 of 9
Work Instruction Formwork ( Shuttering & De-shuttering) Ref No.: ​GPL/SAF/WI-12/FW/R0

VIII. Formwork shutters and/or edge boxing is constructed to designed form requirements
and specified dimensions.
IX. Sawdust and other timber waste materials are removed from completed formwork area
in accordance with housekeeping policy as per ​Housekeeping – WI.
X. Handle the shuttering oil as per the manufacturer recommendation and use appropriate
PPE’s as recommended in MSDS.
XI. De-nailing should be done after dismantling and before stacking.
XII. The principle contractor is responsible for providing all information on ground condition
to the formwork engineer.

6.1.2 Erection and dismantling of Formwork:


I. Person involved in erection and dismantling work must be trained to do this safely and
same must be supervised by competent person.
II. As far as practicable the safety of workers employed on the erection and dismantling of
formwork should be ensured by appropriate means such as provision and use of:
a) Access by means of ladders, gangways or fixed platforms;
b) Platforms with protection railing of mid-rail at 450mmto 600mm, top rail at 950mm
to 1150mm, and toe board of 150mm.
c) safety harnesses and lifelines, catch nets or catch platforms;
d) Power-operated mobile working platforms.
e) For more details follow WI on ​“Height Work & Scaffold”
III. Formwork frames should be erected in a progressive manner to ensure both the
installer (erector) safety and stability of the overall structure.
IV. Ensure edge protection as chance of fall protection is high from edge formwork frame.
V. In conventional formwork diagonal braces that cross in middle are not considered to be
a suitable edge protection for complete formwork deck.
VI. Ensure the lateral stability to frame structure during erection and dismantling.
VII. Erection must be carried out so that it complies with on-site design drawing and
manufacturer requirements.
VIII. Formwork panels (i.e. Doka, steel and prefabricated panels) should be so designed and
made that they can be safely transported and erected, and each unit should be clearly
marked with its own weight and size.
IX. Formwork panel should not be removed unless and until concrete has set and hardened
sufficiently to the extent provided for in the plan and examined for any sign of damage
which may indicate weakness before use.
X. Formwork panel should be lifted by methods or appliances that prevent them from
spinning accidentally or use tag line to control the swing movement.
XI. Before lifting the formwork panel form ground, site supervisor shall ensure that
formwork panels are provided with safety devices such as railings and working
platforms to prevent falls of persons.
XII. While Formwork panels are being erected the workers should be provided with proper
communication system and its use for guiding them as they are being lifted and set
down, so as to avoid crushing of hands and to facilitate the operations.

Prepared by: RM Reviewed by: VS Approved by: JP


Date: ​01/04/14 Revision No.: ​00
Issued by: ​VS Page No.: ​Page 4 of 9
Work Instruction Formwork ( Shuttering & De-shuttering) Ref No.: ​GPL/SAF/WI-12/FW/R0

XIII. Before it is released from the lifting appliance a raised formwork panel should be so
secured and wall units so propped that their stability cannot be imperiled, even by
external agencies such as wind, thunderstorm and passing loads etc…
XIV. If wind velocity increases 16m/sec and if there is heavy thunderstorm stop the work
activity and do re-inspection before restart the work.
XV. At workplaces adequate instruction should be given to the workers on the work methods
and related risk, arrangements and means required for the storage, transport, lifting and
erection of formwork panel, and before erection starts, a meeting of all those
responsible should be held to discuss and confirm the requirements for safe erection.
XVI. When the method of erection does not permit the provision of other means of protection
against falls of persons, the workplaces should be protected by guard-rails, and by
toe-boards.
XVII. When adverse weather conditions such as snow, ice and wind or reduced visibility
entail risks of accidents the work should be carried on with particular care, or, if
necessary, interrupted stop the activity.
XVIII. Formwork panels of different shape & size that are to be erected at a great height
should as far as practicable be assembled on the ground level.
XIX. When formwork panels and parts are being erected, a sufficiently extended area
underneath the workplace should be barricaded or guarded.
XX. Formwork panels that are being erected should be adequately supported, braced or
guyed until they are permanently secured in position with tie rod / locking system.
XXI. Formwork shall been removed after concrete has set and hardened sufficiently and
acquire desired strength.
XXII. If the work is incomplete or suspended, access to the work areas should be prevented
by barrication and warning sign with display of tag.
During de-shuttering /dismantling following things are considered.
a. Start the de-shuttering /dismantling work from the edge of the building and proceed
for the center.
b. Strictly follow the de-shuttering /dismantling methodology and sequentially dismantle
the formworks parts from top to bottom.
c. Parts by part remove the de-shutter /dismantled material from the place and ensure
the area access must be always obstruction free.
d. Ensure proper working platform, safe access and use of safety harness.
e. De-shuttering /Dismantling should be carried out under competent supervision.
f. Do not allow formwork parts to drop freely.
g. Obstruction should be carefully watch and resolved under closed supervision while
lifting/dismantling the shutter from set / fixed box concrete.
h. Use tag line to control the swing movement while lifting the dismantled panel from
casted structures.
i. Do not leave a partly dismantled formwork in an unstable condition.
j. For large pre-fabricated formwork that are to be re-used, lift formwork using
mechanical means
k. Always use 2 persons to handle a full piece of formwork
l. Ensure all nails are removed from timber as stripping proceeds and before placing
timber on the ground or stack

Prepared by: RM Reviewed by: VS Approved by: JP


Date: ​01/04/14 Revision No.: ​00
Issued by: ​VS Page No.: ​Page 5 of 9
Work Instruction Formwork ( Shuttering & De-shuttering) Ref No.: ​GPL/SAF/WI-12/FW/R0

m. Ensure good housekeeping by clearing work areas of all loose and left over
materials and tools and store them in a designated area of storage.
n. Upon completion of work, stack all components of formwork and steel reinforcement
so that there is no obstruction either to access ways or to work areas.
o. Stack dismantled panels / shutters properly in prefabricated racks. Do not stack in
hip and at one place​.

6.1.3 Access Egress and Illumination:


I. Access roads shall be kept clear at all time during work and while shifting materials like:
formwork panels form one place to other
II. Keep all walkways, stairways, ladders, scaffold and gangways clear of materials such
as loose gravel, debris, oil spillage, tools and supplies to prevent tripping and slipping
hazards. Also safeguard such access and egress by hard overhead protection to
protect employees from falling hazards.
III. Ensure adequate illumination whether natural or artificial in the work place, staircases,
landings, passages, lift shafts and general uniform illumination of about 50 Lux across
length & breadth/ height of the work area and access roads.
IV. Any temporary electric supply should be drawn through ELCB’s and RCCB’s
V. Demarcate the dangerous area and access by hard barication and signage including
formwork in progress, overhead work etc…
VI. During formwork erection & dismantling entry of visitor / unauthorized person should be
strictly prohibited.
VII. Avoid double layer work one above other to protect from falling objects / materials.

6.1.4 Storage & Transport of Formwork Panel:


I. Store places should be so constructed that:
a) there is no risk of formwork panels falling or overturning;
b) storage conditions generally ensure stability and avoid damage having regard to
the method of storage and atmospheric conditions;
c) Racks are set on firm ground and designed so that units cannot move
accidentally.
II. While they are being stored, transported, raised or set down, formwork panels should
not be subjected to stresses prejudicial to their stability.
III. During transport, attachments such as slings and stirrups mounted on formwork panels
should be securely fastened to the parts.
IV. Formwork panel should be so transported that the conditions do not affect the stability
of the parts or the means of transport result in jolting, vibration or stresses due to blows,
or loads of material or persons.
V. Ensure material transported over the trailer should be secure tightly with PP rope.

6.1.5 Lifting Appliances:


I. Every lifting appliance should:
a) be suitable for the operations and capable to withstand accidental stoppage ;

Prepared by: RM Reviewed by: VS Approved by: JP


Date: ​01/04/14 Revision No.: ​00
Issued by: ​VS Page No.: ​Page 6 of 9
Work Instruction Formwork ( Shuttering & De-shuttering) Ref No.: ​GPL/SAF/WI-12/FW/R0

b) be approved by a competent person .


II. Lifting equipments and accessories like web and wire rope slings and chains etc… used
for loading and un- loading formwork from the truck / lorry should be of rated capacity,
good condition, and equal length and should be inspected, tested and examined by
competent person.
III. Lift formwork panel by the hooks welded in panel only and do not try to lift the panel by
hooking the same with any other section of formwork like frame, H-beam, or through
tie-rod holes etc…
IV. Use appropriate PPE i.e gloves, helmet, shoes, goggles, shoulder pad for manual
transport/ shifting etc… to protect from exposed pointed edges of formwork.
V. A safe lifting route should be planned to ensure the load would not strike against any
workers and same should be marked and barricaded with hard barrication with special
vigilance at all time.
VI. Operators should be trained and competent, and where appropriate, they should
possess valid certificates for lifting operation.
VII. Operators should have a clear and unobstructed view to ensure the lifting route is safe;
signaler should be assigned to give signals to the operators, so as to ensure safe lifting
operation.
VIII. Ensure that banksman/ signalman must be deployed for signaling/ rigging purpose and
do not allow anyone under the lifted load.
IX. Prior to the lifting operation, suitable measures should be taken to ensure the stability of
the appliance.
X. Pre communication system has to be set when there is obstructed view between the
unloading point and operator. Use appropriate communication appliances such as
walky-talky, whistles etc… for signaling purpose.
XI. While carrying out lift operation information shall be passed out to the workers likely to
be affected to alert them as the material lift is going on.
XII. Proper communication has to be set to avoid the chance of press in between or caught
in between formwork and the reinforcement while fixing the shutter with reinforcement.
XIII. Tag lines/ guide ropes should be provided to assist in controlling the movement and
swiveling of loads and to protect against struck by swing load.
XIV. Lifting radius area and working area should be adequately barricaded with display of
Signboard “lifting In Progress”
XV. Ensure area bellow lifting must free form man movement and should be well cordend
off.
XVI. Lifting hooks should be of the self-closing type or of a safety type and should have the
maximum permissible load marked on them.
XVII. Tongs, clamps and other appliances for lifting formwork panels should:
a) be of such shape and dimensions as to ensure a secure grip without damaging
the part;
b) be marked with the maximum permissible load in the most unfavorable lifting
conditions.

6.1.6 Warning Signs, Barricades and Floor Openings:


I. The contractor should ensure that barricades and warnings signs are displayed at
erection and dismantling area of formwork to prevent the entry of unauthorized person.

Prepared by: RM Reviewed by: VS Approved by: JP


Date: ​01/04/14 Revision No.: ​00
Issued by: ​VS Page No.: ​Page 7 of 9
Work Instruction Formwork ( Shuttering & De-shuttering) Ref No.: ​GPL/SAF/WI-12/FW/R0

II. Deploy flag man/ watcher/ whistler during dismantling work

6.2 General Guidelines For Formwork :


I. All formwork should be properly designed, constructed and maintained in such a way that
it supports the load that may be imposed on them.
II. All shuttering materials and scaffolding should be carefully examined for any defects and
checked with the drawings before being taken into use.
III. Formwork /Shuttering should be examined, erected and dismantled under the supervision
of qualified and experienced persons and, as far as practicable, by workers familiar with
the work.
IV. Formwork should be so designed and erected that working platforms, means of access,
bracing and means of handling are easily fixed to the formwork structure.
V. Formwork activities must comply with regulatory requirements for the erection and
dismantling of formwork scaffold.
VI. Formwork like scaffold must be erected safely and systematically and be tied in
progressively to stabilise the structure.
VII. The necessary information for the erection of shuttering, including particulars of the
spacing of stringers and props to stringers, should be provided for the workers in the form
of sketches or scale drawings.
VIII. The working platform must be at least 600mm wide and with protection railing and toe
board.
IX. Adequate precautions should be taken to guard against danger to workers arising from
any temporary state of weakness or instability of a structure /formwork.
X. Clear and concise procedures to cover all stages of formwork should be prepared.
XI. A competent person should be appointed to coordinate the work and check that the
procedures are being followed.
XII. No changes should be made without consulting the coordinator.
XIII. When formwork is delivered to the site, wherever possible, utilise mechanical plant to lift
the formwork material from the truck and place in the designated storage area.
XIV. Where formwork is awkward or heavy, use team lifts as appropriate - always use 2
persons to handle a full piece of formwork.
XV. When lifting formwork, ensure correct manual handling techniques, i.e. bend your knees
and keep your back straight.
XVI. Always use mechanical plant (e.g. crane) to lift heavy shutters into place
XVII. Beware of crushing risk in the danger area between plant and fixed objects
XVIII. Communicate with others and keep hands and fingers clear when moving or positioning
formwork / shutters
XIX. Boards/ Planks and supports for shuttering (formworks) should be adequate, having
regard to the loads to be accepted, spans (length/width of member), setting temperature
and rate of pour.
XX. Adequate support should be provided to support slabs and beams as a protection against
superimposed loads.
XXI. All adjustable supports of formwork should be locked in position when adjusted.
XXII. Supports of formwork should be so arranged that when it is being removed sufficient
props can be left in place to afford the support necessary to prevent danger.

Prepared by: RM Reviewed by: VS Approved by: JP


Date: ​01/04/14 Revision No.: ​00
Issued by: ​VS Page No.: ​Page 8 of 9
Work Instruction Formwork ( Shuttering & De-shuttering) Ref No.: ​GPL/SAF/WI-12/FW/R0

XXIII. Supports of Formwork should be left in place until the concrete has acquired sufficient
strength to support safely not only its own weight but also any imposed loads. It should
not be removed until authorization has been given by a competent person.
XXIV. Shuttering (Formwork) should be adequately braced or tied together to prevent
deformation or displacement.
XXV. To prevent danger from falling parts when shuttering is being taken down, the shuttering
should be as far as practicable be taken down whole, or else remaining parts should be
supported.
XXVI. Ensure protection of safety catch net underneath the working floor level, which should not
be more than 6m beneath work level.
XXVII. Provide hard barrication around the periphery of formwork and ensure provision and use
of life line to anchor harness.
XXVIII. The mechanical lifting appliances used for handling formworks should be thoroughly
inspected by the supervisor incharge and must have a valid test certificates from
competent person (TPI).
XXIX. Ensure that all material handling equipments and tools & tackles and machineries used
for formwork should be tested and certified by Competent Person as per Rule 56 of
BOCW Central Rules and copies of certificated are submitted to GPL/ PMC Site Incharge.
XXX. Contractor should ensure use of safety helmet, safety shoes, safety goggles, hand gloves
and dust mask and wherever required full body harness/ safety belts for the project
workers and staff.
XXXI. The operating staff of above tools tackles, machineries & vehicles are competent, trained
and medically examined as per Rule 223 of BOCW Central Rules and certificates are
submitted to GPL/PMC Site Incharge.

III.

7. Emergency Procedures and Details of Site Features:


i. A pre start job meeting shall be arranged for informing about proper communication
method.
ii. Safety engineer (PMC/GPL) is responsible to train the site people for the use and
implementation of SOP’s at site. Conduct training as required as per the site
requirement or progress of work.
iii. Arrangement of first aid facilities and emergency vehicles shall be ensured.
iv. Contractor should inform to PMC/ GPL for commencement of work.
v. In condition as where work affecting by natural calamities like heavy rain, dusty
environment, thunderstorm, etc PMC/ GPL guidelines shall be followed.

8. Risk Assessment
Before commencing this activity the Safety Engineer of Contractor should evaluate the
foreseeable risk by conducting independent risk assessment in consultation with site
execution team as per site condition & topography to ensure that appropriate control
measures are established and incorporated. GPL /PMC Safety Engineer are
responsible to review & approve the same.

For preparation of HIRA use GPL SOP and standard HIRA record template available
with CMC- HO-Safety.

Prepared by: RM Reviewed by: VS Approved by: JP


Date: ​01/04/14 Revision No.: ​00
Issued by: ​VS Page No.: ​Page 9 of 9
Work Instruction Formwork ( Shuttering & De-shuttering) Ref No.: ​GPL/SAF/WI-12/FW/R0

9. Method Statement & Checklist:


The GPL Site Head & associates like PMC is responsible to prepare a suitable “Method
Statement and Formwork Checklists” based on the above procedure and HIRA
conducted at site and also keeping in view the site location topography.

10. References:
i. Contract Document
ii. GPL HSE Guideline
iii. Site EHS Plan
iv. BOCW Act & Rules.

Prepared by: RM Reviewed by: VS Approved by: JP