pavingexpert - Formwork and Shuttering http://www.pavingexpert.com/formwk01.

htm

Pavingexpert Search

Shuttering and Formwork 22

Sit e M a p Ho me Ne ws In d e x Ab o u t U s To n y's B o o k Que ry Forum Blo g s Su p p lie r s Vis it o r Bo o k T& C ' s Units

F AQ s L a yo u t s For Contractor s Calculator s Vi d e o s Up d at e s/M ailo u t Y o u Tu b e C h a n n e l Follow @pavingexpert

On This Page... Related Pages

Introduction Plain Concrete

Joints for Concrete
Roadform
Reinforcement
Shuttering Formwork

Release Agent Exposed Aggregate

Deco Concrete
All about PIC
PIC Construction
Stencilling
Deco Techniques

Links

Introduction
All concrete pours need to be contained, to hold the concrete in place until it hardens sufficiently
to hold its own shape. With concrete slabs, the freshly-poured concrete may be retained by
existing features, such as walls, kerbs , edgings etc, or some form of temporary shuttering,
also known as 'Formwork' may be required. On vertical concrete structures, the construction of
the formwork can become quite complicated and is normally undertaken by specialist formwork
erectors or formwork carpenters. Ground slabs are normally much less complicated and require
only the simplest of formwork.

In all cases, the formwork must be sturdy and capable of bearing the not inconsiderable forces
created by wet concrete, plus the weight and force of any vibration equipment. Any joints in the
formwork should be taped or sufficiently tight to prevent matrix leaking out during vibration
and/or curing. The tops of any shutter or roadform should be set so as to provide an accurate
edge from which the tamper or beam screed can operate.

There are two main types of formwork used for casting ground slabs: Steel "Roadform" and
custom-made timber shuttering.

1 of 6 8/29/17, 3:37 PM
pavingexpert - Formwork and Shuttering http://www.pavingexpert.com/formwk01.htm

Roadform:
Roadform is popular amongst professional contractors
for use on site as it is sturdy and tough, more then
capable of withstanding the rough and tumble of a
busy construction site and virtually unbreakable; it
can be re-used time and time again, requires little
skill to set-up and is cheap - single lengths can be
hired for less than a couple of quid per week.

It consists of a channel-shaped steel section,

normally 3 metres in length and either 100, 150 or
200mm in depth, with 3 fastening brackets fixed
to the back edge and a sliding tongue-fitting that
enables adjacent sections to be linked together.
Units can be stacked to accommodate a greater
depth of concrete, but never more than 2 unirs
high, to a maximum height of 400mm, because of
the limitations of bracing anything higher than
that with the steel pins.

It is held in position by sturdy steel pins, normally 600mm in length,

that are positioned within the staking bracket and driven into the
ground with a hammer. Each section of roadform is aligned and then
locked in place by tightening-up the fastening wedge so that it 'grips'
the steel pin and holds the roadform in place
Plan View

Along with the rigid sections, there is also a flexible version that
can be bent to accommodate arcs and radii. It's only really
suitable for radii of 2 metres or greater, although it can be
'persuaded' into faster arcs, up to around 1 metre radius,
although 'persuading' it back afterwards can be even more
problematic.

The usual method of erecting Roadform is

to align the sections with the aid of a taut
string line or a laser level to the
required profile and to ensure that the
faces of the sections are plumb (true
vertical).

The staking pins must be firmly held by

the sub-base/sub-grade and there should
be no 'play' between sections. The tops of
the steel stake pins should be below to
top of the Roadform so that beam screeds
or other screeding equipment can
traverse the slab without hindrance.

2 of 6 8/29/17, 3:37 PM
pavingexpert - Formwork and Shuttering http://www.pavingexpert.com/formwk01.htm

Roadform - Male end with connecting tongue Roadform - Female end.

Note staking bracket and wedge fastener

Timber Shuttering:
While Roadform is the formwork of choice for simple slabs, there are situations where it is simply
not possible of feasible to use it, and so the more traditional timber shuttering is used. The great
advantage of timber shuttering over Roadform is that, because it is 'knocked-up' on site, it can be
made to accommodate any situation, ranging from odd shapes, to greater depths. Timber
shuttering is also the usual choice for vertical concrete work, although it is often used in
conjunction with modular steel bracing elements.

The part of the shutter in contact with the concrete is known

as the form lining, while the support timbers are collectively
known as 'bracing' and consists of horizontal walers and
vertical noggins. The size of timbers used for the bracing
depend upon the size of the formwork; a simple 300mm high
shutter for a ground slab may use 50x50mm timber to form
the walers and noggins, whereas a 1 metre high shutter
would be more likely to use 100x50mm timbers. The bracings
are formed from straight and true timber and are always used
end on, that is, the deepest way, to give as much support as
possible.

The form lining is normally some form of plywood. 15mm or 18mm is the most commonly used,
with WBP (Weather and Boil Proof) being preferred as it is less prone to delaminating in the damp
conditions experienced by timber shuttering in contact with wet concrete and outdoors.
Occasionally, hardboard may be used, or, increasingly, exterior grade MDF (Medium Density
Fibreboard). On projects involving a substantial quantity of timber formwork, a film-faced special
shuttering board may be used, but this is not always stocked by Builders' and Timber Merchants
and needs to be ordered in advance.

3 of 6 8/29/17, 3:37 PM
pavingexpert - Formwork and Shuttering http://www.pavingexpert.com/formwk01.htm

Formwork carpentry is a specialist trade and for

vertical structures, the bracing can become extremely
complex, requiring design by structural engineers and
the use of wedges to maintain alignment. Us simple
folk in the groundworks trade, who rarely risk
venturing above ground level, prefer to rely on
straightforward raking braces to support the formwork
we erect for ground slab construction.

The spacing between walers and between noggins also depends on the size of the shutter, but is
generally 300-600mm. Bracing timbers are usually the same size, if not bigger than the timber
used for the walers and noggins. In some cases, adjustable steel props known as 'Acrows' may be
used as raking or horizontal braces.

All brace members are securely fastened to the formwork, usually by nails, as they are easiest to
withdraw when striking the formwork on completion of the work. This fastening is essential as it
prevents the brace members 'springing', that is, flying loose under the pressure of the wet
concrete and finishing equipment.

The ground pegs should be driven in to a depth

of at least 450mm. In soft ground, a spreader
board may be needed behind the peg to prevent
it being forced back into the ground by the
weight of the concrete. Alternatively, a "sole
plate", usually a plank, will span several pegs
and help spread the loading more evenly. The
raking and horizontal braces will then be nailed
to the sole plate.

When placing formwork over an existing solid base, such as a concrete slab or macadam
surfacing, the same system of forms and bracing is used but often, rather than driving bracing
pegs into the ground, the horizontal bracing will be affixed to the surface using masonry nails,
screws, ground bolts or similar, as shown in the photograph below (kindly provided by GB
Groundworks & Construction Ltd. )

4 of 6 8/29/17, 3:37 PM
pavingexpert - Formwork and Shuttering http://www.pavingexpert.com/formwk01.htm

Formwork used to retain a concrete plinth laid over an existing base

Flexible plywood can be used to construct the form lining to arcs and radii on timber shuttering.
The plywood is traditionally 'kerfed' on one face to help the timber bend without breaking. This is
done by sawing shallow notches (2-6mm deep) into the face or back of the form lining and then
nailing it onto a pre-constructed waller bracing structure.

One face of form lining is "kerfed" Kerfing makes form lining more pliable

Release Agents
All formwork, whether is be steel roadform or timber shuttering, needs to be coated with a
Release Agent (Mould Oil) before any concrete is placed. The purpose of a Release Agent is to

5 of 6 8/29/17, 3:37 PM
pavingexpert - Formwork and Shuttering http://www.pavingexpert.com/formwk01.htm

prevent the concrete bonding to the formwork and then 'scabbing' when the formwork is
removed. They also help ensure the formwork stays clean and free from concrete, so that it can
easily be re-used elsewhere.

There are many products on the market that can be used as Release Agents for formwork, but the
most commonly used is known as 'Soap Oil'. This liquid is painted onto the formwork in advance
of the concrete being poured and it dries, leaving behind a soapy or waxy residue that has no
deleterious effect on the concrete. Where the finish of the concrete is not important, some
contractors will save themselves a few bob by using engine oil or diesel in place of a proper
release agent; while there is nothing technically wrong with this practice, it's not exactly
environmentally friendly and should be avoided whenever possible.

Other Concrete resources on this site

Plain Concrete
Reinforcement for Concrete
Jointing Concrete Slabs
Formwork and Shuttering
Written Specification for Concrete Driveway
British Standards for Concrete

Introduction to Decorative Concrete

All about PIC
PIC Construction
Stencilling
Exposed Aggregate Concretes
Other Decorative Techniques

Suppliers

Site design, content and construction © cormaic web design 1997-2017

Our Privacy Policy

Use of this website and its content implies acceptance and agreement to abide by the Terms & Conditions
All information, specification and drawings used on this site are intended for guidance only.
You are strongly advised to seek professional, onsite advice for your project.

6 of 6 8/29/17, 3:37 PM