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Definition
A structure, usually temporary (but sometimes
wholly or partly permanent), used to contain
poured concrete to mould it to required
DIMENSIONS, FINISHES and SUPPORT it
until it is able to support itself.
Formwork consists of contact face material and
the bearers which support the face material.
1
Wall Form
Wall Form
..\Teaching_Notes\TEMP_
WK\multimedia\Wall
form001.jpg
Wall Form
..\Teaching_Notes\TEMP_
WK\multimedia\Wall
form003.jpg
Wall Form
..\Teaching_Notes\TEMP_
WK\multimedia\Wall
form004.jpg
Column Form
..\Teaching_Notes\TEMP_WK\multimedia\Columnfo
rm1.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Columnfo
rm1001.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Columnfo
rm1002.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Columnfo
rm1003.jpg
8
Soffit Form
..\Teaching_Notes\TEMP_WK\multimedia\Sof
fit Form Frame.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Sof
fit Form Frame001.jpg
Beam Form
..\Teaching_Notes\TEMP_WK\multimedia\Beam Form-Edge004.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Beam Form005.jpg
Stair Form
Permanent Formwork
10
Travelling Form..\Teaching_Notes\TEMP_WK\multimedia\Travelform.jpg
Formwork
Three general principles govern
formwork design and
construction:
QUALITY
SAFETY
ECONOMY
12
Quality of Formwork
Relating to the formed faces of the
permanent concrete structure and
refers to the following two aspects:
Accuracy of Concrete Shape
Quality of Concrete Surface
13
Quality of Formwork
Accuracy is controlled by the
deviations permitted (Tolerances)
in the :
Formwork deflection
Materials
Components
Workmanship
14
Quality of Formwork
To minimise deviations, all formwork
must have adequate means of:
Alignment and adjustment both at
construction joints and throughout the
formwork
e.g. Simple wedges, screw adjustments
on supports, camber adjustments
15
Quality of Formwork
Quality of Formwork
Classes of Finishes
Formed Finishes
F1, F2, F3, F4, F5 (CED G.S. Table 14.1)
Class F5 the best
Unformed Finishes
U1, U2, U3, U4, U5 (CED G.S. Table 14.2)
Class U5 the best
Treated Finishes
T1, T2, T3, T4, T5, T6 (CED G.S. Table 14.3)
17
Quality of Formwork
Different concrete structures buried
underground or exposed to naked eyes
require different class finishes specified by
the contract document
The formwork design requires appropriate
method of construction/treatment, different
surface irregularities requirements and
types of contact face sheeting materials
18
Quality of Formwork
Tolerances
19
Safety of Formwork
Two major aspects must be
covered:
Personal Safety of both
formworkers and the public
Safety of the formwork
structure
20
Safety of Formwork
I.
Construction phase
As a general practice, the erected formwork
shall be :
Structurally safe
Having secured and effective guard rails,
toeboards, access ladders and stairs around its
periphery
Formworkers equipped with safety helmets and
boots
For high work, safety harnesses and security
screen are to be installed
21
Safety of Formwork
II. Design phase
a) Evaluation of possible Loading
Combinations occurred in the following
stages:
Stage 1: before conc. Placement
Stage 2: during conc. Placement
Stage 3: after conc. Placement
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Safety of Formwork
b) Structural requirements
Three important aspects to be met:
STRENGTH (material strength and force
equilibrium)
STABILITY (Sliding, overturning, uplift and
sidesway)
STIFFNESS (accuracy and permissible
tolerances)
23
Economy of Formwork
Where formwork is highly repetitive
activity, a small reduction in
fabrication/stripping could result a
significant overall cost saving.
Cost involves formwork materials and
labor, erection (including hoisting),
stripping, repairing and cleaning of
formwork after concrete pour.
24
Economy of Formwork
Care of Formwork
For maximum formwork life, efficient
stripping; care in formwork handling,
storage, and maintenance are essential
After stripping, the formwork units for
reuse should be moved away from the
work area (workers of other trades may
damage it as an item of obstruction left
there).
26
Care of Formwork
They should be stored and protected
from weather to avoid surface damage
Large formwork panels should be
stacked in racks, facing away from direct
sunlight
Hardened slurry, dirt left from previous
pour should be removed from plywood
sheeting surfaces before they are getting
harder
27
Care of Formwork
Formwork
Minimum Period before Striking (BS 8110)
Formwork
Surface conc.
temperature
>16 deg C
12 h
Surface conc.
temperature
0 10 deg C
300
h
t 10
Slab form
4 days
10 days
100
h
t 10
250
h
t 10
Prop to beam
14 days
360
h
t 10
32
Backpropping
Backpropping
Formwork Materials
Face Contact Materials (features left*)
Sawn board formwork (sawmarks*)
Plywood (fine & smooth surface*)
Steel form (variable color*)
Aluminium form (react with cement*)
Glass fibre reinforced plactics (highest quality
for sculptured profiles*)
* features/drawback
35
Formwork Materials
Waling/Bearer, Soldier/Props Materials
Solid timber
Steel in lattice configurations or cold
formed sections (standard/proprietary)
Formwork Materials
Expanded metal (stopends)
..\Teaching_Notes\TEMP_WK\multi
media\expanded metal formwork.tif
37
..\Teaching_Notes\TEMP_WK\multimedia\Tableform2.jpg
Flying forms
..\Teaching_Notes\TEMP_WK\multimedia\FlyingForm2.jpg
Form Ties
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Form Ties
Factor of safety in tension capacity
1) 1.5 for HT cold worked steel
2) 2.5 for mild steel
Bearing plates/washers to be checked if
bearing stresses acting on the timber
waling/soldiers are exceeded or not
Limitation on spacing of form ties is also a
concern for aesthetic reasons
40
Factors
Formwork Design
Concrete pressure
Cement Types/
Mix Composition (C2)
Increase
Pressure
Changes
Retarder,
PFA
Column,
Wall
41
K
T 16
43
Self-weight of Formwork
Imposed Loads (permanent work loads and
construction operation loads)
Concrete Pressure (for wall/column forms)
Environmental Loads (Wind loads, Snow/Ice
Loads)
Horizontal Loads (Imposed plant loads, skip
impact loads,.. And minimum horizontal stability
force i.e. 10% of the total form self-weight)
44
Formwork Design -
1)
2)
3)
Formwork Design
Soffit Form Stability
Stability of soffit formwork
erected at the top of falsework is
covered in BS5975 (formwork is
considered as an integral part of
the falsework)
46
Formwork Design
Wall Form Stability
1)
2)
Formwork Design
Wall Form Stability
3) Minimum Stability Force and Full
Construction Operation Loads on any
W/P
Note: Working wind means the upper
wind speed limit below which operations
could still be allowed
48
Special Formwork
Slipforms
..\Teaching_Notes\TEMP_WK\multimedia\Slipform.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Slipform001.jpg
Climbforms.
.\Teaching_Notes\TEMP_WK\multimedia\ClimbForm.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Climbform3.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Climbform4.jpg
Travellers
..\Teaching_Notes\TEMP_WK\multimedia\Travelform.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Travelform1.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Travelform2.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Travelform3.jpg
50
Special Formwork
Tilt-up Moulds
..\Teaching_Notes\TEMP_WK\multimedia\Tilt-up Mould.tif
Gang Forms
..\Teaching_Notes\TEMP_WK\multimedia\Gangform1.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Gangform2.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Gangform3.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Gangform4.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Tunnel Form.tif
51
..\Teaching_Notes\TEMP_WK\multimedia\Column Kicker.tif
..\Teaching_Notes\TEMP_WK\multimedia\Stopend Form.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Stopend Form.tif
..\Teaching_Notes\TEMP_WK\multimedia\Stopend Form001.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Stopend Form002.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Stopend Form003.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Stopend Form004.jpg
52
Wall Ties
..\Teaching_Notes\TEMP_WK\multimedia\Wall Tie.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Wall Tie001.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Wall tie002.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Wall tie003.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Wall tie004.jpg
Props
..\Teaching_Notes\TEMP_WK\multimedia\Prop.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Prop001.jpg
U-head
..\Teaching_Notes\TEMP_WK\multimedia\Soffit
..\Teaching_Notes\TEMP_WK\multimedia\Soffit
..\Teaching_Notes\TEMP_WK\multimedia\Soffit
..\Teaching_Notes\TEMP_WK\multimedia\Soffit
53
..\Teaching_Notes\TEMP_WK\multimedia\Beam-Soffit Form.tif
..\Teaching_Notes\TEMP_WK\multimedia\Columnform Bracing.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Columnform Bracing001.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Columnform Bracing002.jpg
..\Teaching_Notes\TEMP_WK\multimedia\Columnform Bracing003.jpg
54
Slipforms features
Slipforms features
Slipforms Operation
Procedures
(i) Fix steel reinforcement above the
shutter
(ii) Pour concrete into the shutter and
vibrate it in final position
(iii) Operate the jack to work against
the lower jaws to raise the yoke and the
form with it
57
58
62
Tilt-up Moulds
The unit mould is cast horizontally and may
subsequently be tilted through a designed angle
The vertical position of the cast unit on
completion of demoulding could facilitate easy
and early formwork removal, and the
subsequent vertical stacking
Horizontal processing could allow easy tiling
works, or composite sandwich/hollow units
manufacture
63
Formwork Checklist
Design concept in relation to
expected concreting rate
Material strength, stiffness,
condition and dimensions
Access adequate space,
guardrails, toeboards, ladder/stairs
65
Formwork Checklist
Assembly - layout dimensions, plumb &
stability, inserts fixed, ties tightened and
thread conditions checked, sealed against
kicker, panel joints sealed, waterstop
installed, filling over nail holes
Release agent applied
Formwork cleaned out
Stripping nails bent/removed, resuable
materials separated
66