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THE ENGINEER'SGUIDE
WORKS
IN CONSTRUCTION
Formwork for wolls and columns

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 THE ENGINEER'SGUIDE 4rrlilfil.r
IN CONSTRUCTIONWORI(S 'lqll, r.ig.rll Jlcli C
Formwork for walls and columns (trr)

Scientific Material :

Eng. MahmoudEz Al Din ComplementaryDpt

Eng. MohamedIlassanAdss ComplementaryDept.
Editor :

Eng. NarimanAdawy Training Institute( ACTI )

Approvedby :
Cairo UniversityScientilicC€nter

GeneralManager& Ilead of

Training INtitute ( ACTI )

Eng. Ahmed Zaki Ahmed Khaled

October1996
Introduction :
The use of steel as appliedto formwork is considerable,
although
st€€l for panels has largely been replaced in most proprietary
system by plywood panels surrounded and supported by steel
frames.
St€el formwork , unlike timber. cannot be cut otr the site to suit
special conditiotrsor at situations where standard steel units would
be too heavy, awkwardor impossibleto lix or bracesatisfactority,
then it is usually more economicalto usetimber panelswhere
theseconditionsor situationsexists.
Steelformwork may be classifiedin a generalwaysas follows:
1, straight walls formwork
2. Curved walls formwork
3. Climbiug formwork (one side formwork , double side
formword).
4. Square& rectangularcolumnformwork.
5. Circular columnformwork

-3-
1. Straieht Walls Formwork :
This type of walls can be achievedby two kinds of formwork :
a) The modularformwork (For Manual assembly)
b) The large - sigeformwork (For cranageassembly)

t-a) T_e modUlalformwqrk,_Basically , this systemconsists

of panels of different sizes: In gen€ral, the low weightof panels
p€rmits easymanual assembly
and stripping of forms. All formwork panels have the same
structure : solid 7,5 cm deepsteelfram€ with inserted pl'"wood of
12mmor 15 mm thickness.
Modular formwork panels are ideally sized to permit usein an
infinite variety of height/length conliguratiotr , from foundation
bas€sto the highestwalls.
As an exampl€for this system- widely used- is the
U-Form system,

The U-Form Panel:

The use of U-Form panel and its infinitely combination , ofrer
versatile possibilities of applications in the freld of concrete
construction: foundation,wall, column, beam
The plywood edges are fully protected against sit€ damageby th€
specialroll€d p€rimeter section.,Plywoodcan be reversedfor an
evengreaternumberof uses.
Componentof U-Form systems
l U- Form Panel:

( Fig 1)
2 . Clips: They are ayailablein four basicsizes.Theseclipswill
housescatTold
tube .

(Fig2)
3. Key & Wedge : Are usedto assemblethe snapties integrally
with he U-Form pan€l

(Fig 3)

4. Filler angle ; Us€d to form a liller- post minimum of 5cm and

maximum of 25cm width - to allow comformity with every
requuirement.

-6-
5. RanseofU - From

StandardForm FractionalExternal
InternalExternal
Form Corner CornerCorner
Form Form Angle

(F1gs)

-7 -
List of components
S T A N D A R OU - F O N M
Approx. wt. K9.
With Ply, Without Ply. F I L L E RA I I G l E S
240x60 44,5 7.3
210r60 39.0 210
180x 60 33-5 25.8 180
1 5 0r 6 0 za.1 21.a 150
1 2 0 x6 0 22.1 17.7 120
90x60 17.2 13.6 90 2.7
60x60 11.8 9.1 60 1.8
F N A C T I O I \ I AU
L .FONM E X T E R I I A LC O R N E RA I I G L E S
240r 50 38.1 29.9 11.8
24Ox40 34.1 27.2 210 10.3
180
150 7.4
180x40 26.3 20.4 120
180x30 23.1 19.3 90
1 5 0 x5 0 23.4 18.8 60 2.9
1 5 0r 4 0 21.5 17.0 u-FoRM ACCESSOnTCS
150x 30 19.3 15.9
120x s0 19.0 15.0 BraceNsilinePlate 1.4
1 2 0 x4 0 17,2 13.6
'12.7 4 . 5( p e r1 0 0 )
1 2 0x 3 0 15.4
4 . 1( p € r1 o 0 )
90x50 15.4 12.2
8.6 (por100)
90x40 13.6 11.1
90x39 11.8 10.0
5 ngleClips 0.7
L O B N E NF O N M S
E X T E R I \ I AC 0.9
Approx. wt, Kg. D o u b l . C l i p s w i tPhl a t e s 1,0
Size
With Ply, Without Ply 1.1
240x 50mmx 50mm 19.5 17.7 1.4
2 1 0 x 5 0 m m x 5 0 m m1 7 . 0 15.4
180x50mmxsomm14.7 13.4
150x50mmx50mnr 12.5 11.3
'l20x50mmx50mm 10-0 9.t
7.7 7.0

-8-
 6. Snap ties : Is specially designed for use with the U-Form
system. It fits snugly into the tie slot within the forms and when
necessaryis quickly installedfrom the outsideofforms. Itissetrt
a distanec ofl" back from the face. It can be suppliedwith water
sealsif required. The safeworking load 1360kog .

Sieeltiesfor concrete
wallconslruction

_L
E
r

(Fig 6)

7. Shoring &bracing : The adjustableprop simplifesthe plumbing

and bracing ofthe formwork. The complet€assemblyconsistsof
push-pull props, swivel footplate.

-9-
Applicatior of U-Form Panelin Walls :

(Fis7)
- 1 0_
The large - size Formwork ; Thesepanelswere regard€d as
supplementto the modularFormwork. This systempermit to
speed up the forming jobs even more, and obtaining at the
sametime exc€llentconcreteresults.
The large-size Formwork is mainly usedon construction sites
where large wall surface are to be concretedatrd where the
trecessarytechnical equipementis available ( cranage) With
Iarge - sizeFormworkwe can reducenumberofti€s used, This
contributesa great dealto reduceforming timesand linishing
works. As an exampleof this systemis the big st€€lpanel.

Application of big steelpanel in walls :

Fig 8

- 1 ' 1-
2- Curved walls Formworlc Circuhr structur€s can be formed
either in one or several phases. In any crse, it is possibleto form

all diameters in one phaseby using compensationmollds to close

the circle.

Varying diameters and wall thichess entail difrerences in the

formwark length which neadreassemblingofthe mould to satis&

the new dimensions.

As an exampleofthis systemis the Vari form system

Vari-Form system: Using this systemwe can carry out any curved

wall and in somecasesstraight walls also

- can be employedfor all c[rvatur€.

-Minimum radius of curvature 2 m.

- we can obtain exact curvature.

- Simple pre' assemblyofthe form,
- The radius is altered by tightening or looseningthe turnbuckles.

In all casesthe cetrtral axis of the outer girder ( openweb soldier )

and the central axis of the inner girder must be in line to ensure

the tie rod is square through the wall section.

Componentsof Vari - Form svstem:

l.Vari - Form Trough section :length oftrough section9oo mm

aod 300 mm

2. Vari - Form Turnbuckles :Onty two turnbuckles are usedper

soldier length

3. Vari - Form €dge angle :For usein joining pan€ls.The panels

are jointed together by using s self drifting seambolt

4. Slim - lite soldier.

nivsr hs.d Pin6nd 5p'in0 clts

(Fig 9)

- 1 3-
ApplicationofVari - Form in walls :
--/- a,'r

\c

(Fie 10)
Columns Formwork:

square & rectangutar cotumnsare formed with standard panelsof

the Modular formworlc

In order to b€ more flexible regarding the column sections,the use

of the variable column form is recommended.

columnsformwork are divided in two types:

l. squar€ & rectangular column formworlc
2. circular column formwork .

Square & rectatrgular column formwork : Fast emci€nt column

forming can be achieved by using the U - Form panels in

conjunction with external corner rngles atrd/ or external corner

form. The cross stifrness within th€ U - Forms serveas built - in
yokes, thus minimizing the number of column clamps required '

which are only usedfor squaring the 8ss€mbly.

ColumnClamps

Min.andma,.distance

1 4 . 5K s 1 9 K g

i<-60cm-l

(Fig 11)

- t5 -
when using U - f,'orm for columnsconstruction note the fo[owing :

1. Generally, due to the relarively small volume ofconcrete usually

associated with column construction, concreteplacing may n€edto

be contioll€d to reduce the rrte ofvertical rise.

2.As keys & wedgesare normally associatedwitb the connection

of ext€rnal corn€r anglesto U- Form for column construction it is

recomm€ndedthat th€serre litted at 30 cm spacingverticrl.

Variable column Forms : The vrriable column formwork is used

for the construction of rectrngular & square columns.

All column sectionsfrom 18-70cm can be formed , the side length
ofthe columnform can be adjustedin stepsof0,5 cm.

Extensionin height are efrectedwithout problem.

(rig 12)

- 1 6-
The column panelare erect€dat right angleto eachoth€r in such

a way , that the side part with incorporated angle lillet joins th€
steel fac€ of the next Panel.

Dependingon the sidelengthsofth€ requiredcolumnsection,th€

holeofthe connecting
screw rre push€dthrough the corresponding
rows.

Tbe vsriable column formwork is aligtredby at least2 adiustable

props with supports. They are attached to the panel frsme by

mean of a suspendingpiece. The foot plate is lixed to the ground

either by rlowelsor by ground nails.

(Fis13)
Circular column formwork : Th€se forms consists of 2 half -

moulds with b€nt steel faces with welded stifreners. A small lap
joint between the two halv€sguaranteesan eccurate closingof the

form, thus preventing the outllow of the concrete. The circular

column forms is available in severaldiameters& heights.

(Fig 14)

- 1 8-
Concrete pressureon Formwork:

In vertical forms, the whole of the pressur€is du€ to the fluidity of

the concrete and as soon as this becomesstifr the pressure
practically disappears. If the hourly output of concr€teis known'

the volume of this in mi divided by th€ cross- sectionalarea of the

wall column, will give the depth of till per hour thus, €nablethe

maximumpressureto be calculatedthe factorsto be consid€redare

1 Density of tbe concrete ( kg/mr )

2. Workrbility of the mix ( slump mm )

3 . R a t eo f p l a c i n g . R(m/h)

4. Concretetemperature t.oc.

5. Height of lift H (m)

6. Dimensionof sectioncastminimumdimensiond ( mm )

MaximumHydrostaticPr€sslreby calculation:
There ar€ three overall limiting criteria to be considered, the
maximumpressurebeingthe LEAST valuecalculat€d.
whichcanoccur
l.Height linit : This is the maximumpressure
wh€n the plac€mentis so fast that the whole of the lift is of

completelyunset concrete.,and is repres€ntedby the heightof

th€ lift multipliedby th€ densityof concrete.

' 1 9-
 2. Arching limit:Representthe maximumpressurewhich can occtrr

in a wall or columnnot morethan 50 mm thick

3. Stiffening limit: Dependon rat€ of placirg, slump,temperature

of th€ concrete and is lik€ly to govern the ultimate pressure

where th€ rate of lill is low , the temperatureofthe concr€t€

high and th€ workability ( slump) ofthe concreteis low.

All theselimiting crit€ria are givenin a tableto be easierfor the

us€r.
'1.Hsight limitlHydraulic pressur€
taken to b€ 25 kN/m: per
metr6 of height based on d6nsity of concrete b€ing 2500k9/m3,
Hlm) 1 2 3 5 6
P, kN/m,l 25 m h 100 125 r50

2. Archinslimit

t0 30
150 Pt: 35 35 35 40 45 45 50 55 60 75 90 120
2ffi 35 40 40 45 50 50 55 60 65 80 95
300 45 50 50 55 60 60 65 70 75 90 105 1 3 5
zto0 55 60 60 65 70 10 75 80 85 100 115 145
500 65 70 70 75 80 80 85 90 95 110 125 1 5 0

3. Stifianing limit
Slump
temp ('C) 0.75 12 1.8
5 Pz=40 50 60 70 85 95 115 135 150 150
10 35 40 45 55 65 70 85 100 135 150
50 210
35 4/0 45 50 55 65 75 100 125
20 35 35 35 40 45 45 50 55 70 90
5 45 60 70 85 100 |0 140 150 150 150
t0 35 50 55 65 75 85 105 125 150 150
75
35 40 45 50 60 65 80 95 125 150
20 35 35 35 40 45 50 60 70 90 115
5 55 70 85 100 120 130 150 150 150 150
1Cro 10 40 55 65 75 90 100 12I r50 150 150
35 45 50 60 70 75 90 110 150 150
1:O 20 35 35 44 45 50 55 70 80 110 130

-20-
Exalmpl€1 :

GivenH = 3m, Rate of placing5 ur,/h,d = 500 mm, t = 5oc

and slump=7 5 mm

R€q :Calcdate th€ madmum concretepressureon formwork

Solution
Formtable: Heightlimit Pl = 75kN/mz.
Archinglimit P2 = 80KN /m2
Stifl€tringlimit P3= 150KN/m2 d
P^ur.75 KNln'
I'
, Pmax= 75KN/m2( th€tow$t vrlue)
.'. Designpressure

Example2 :

Given: H= 6m, Rate ofplacing2 n/h , d= 300mm't = 20"c

rnd slump = 50mm

R€q : Calculate the maximum concrete pressure on

formwork
L4 |
^'*f
Solution: / | |
| | | 16^
Fromtable: Heigbtlimit. Pl = 150KN/m'?.
, ,l" I | |
limitp2 = 50KN/m2.
Arching
I L__l I
t ----r
P =45 KNlk'

-21
 Stifreninglimit P3 = 45 KN/m'.

, P max= 45KN./m2
.'. Designpressure

h= Pmrx 45
= = 1.8m
liCorne 25

f,rample3 :

Given:H= 5m , R= 2mlh , d= 250 mm, t = 100cand slump= 75mm

Req :calculalethe maximumconcretepressureon formwork

Solutiotr:

From table: H€ighrlimit Pl = 125KN./m'

Arching limit P2 = 45 KN/n2 h=La

'(
Stilfering limit P3 = 85 KN/nr2.

.'. Designpressure,Pmar = 45 KN/m2

Pmax = 45
6= = 1.gm
li conc 25 P^ax=45 KN/n'z

-22-
 Index Page

l. Introduction........... 3
2. StraighF wall formworlL .......... ...... 4
3. Application of U-form panel in walls. 10
4. The Large-sizeFormwork 11
.......... 11
5.Applicationof big steelpanelin walls. .......................
6,Curv€dwallsFormwork............ 12
7.Appficrtionofvari-Form in walls, .....................
14
8.ColumnsFormwork . ... ... 15
9.Concr€t€pr€ssure
on Formworl<. ....... 19

l0,Examplca. ... 2I
...........