Chapter 3 Formwork

DEPARTMENT OF BUILDING AND CONSTRUCTION ENGINEERING
FKAAS
UNIVERSITI TUN HUSSEIN ONN MALAYSIA
3 FORMWORK
3.0 Introduction
Formwork is a temporary mould into which wet concrete and reinforcement is placed to form
a particular desired shape with a predetermined strength. The main function of formwork is
to place wet concrete until it retain its shape, size and position in order to form any concrete
member. There are various of modern technology used in the formwork system such as
slipform and precasting.
There are different ways to classify the formwork systems:
1. Traditional vs system:
Old stick-by-stick vs innovative approaches
2. Reusable vs lost forms:
lost formwork forms part of permanent structure and by definition can only be used once,
e.g., precast panels, steel tubes and Bondeck, etc.
3. Static vs movable (climbing) forms:
Movable or climbing forms relocate themselves to the next location using an integral
power source, e.g. slip form, jump form.
No loss of constituents
Uncontaminated of the concrete Possible
to be dismantled
Requirements for
Formwork
Withstand safely Controlled
all the loads size & surface
Economic Reusable
Figure 3.1: Requirement for formwork
- 31 - Construction Engineering
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In determination the good formwork system, various question can be consider by the engineer
such as:
1. How formwork can be erected and de-shuttered fast.
2. How good concrete quality and surface finish can be achieved.
3. What is the optimum stock of formwork required for the size of work force, the specified
time schedule and flow of material.
4. What is the overall cost savings that can be achieved using the right type of formwork.
5. How SAFETY can be improved for the site personnel.
To achieve the requirement, three main items must be applied in the preliminary level. The
constructor must use the appropriate design, equipment and material the do the checking for
dimensions and stability. Before the formwork are ready to use, its must be clean from debris and
dirty the surface will be applied with release agent.
Cost is one the most important component in the construction works. In order to
minimize the cost, the economic essentials should be identified. In formwork, the constructor
should ensure the formworks are:
1. Low cost
2. Strength material and support members.
3. Finish method, materials and linings to produce the desired result direct from the
formwork.
4. Assembly use mechanical handling plant or patent systems.
5. Material careful in selecting material.
6. Design repetitive and adaptable.
7. Joints - tight enough to prevent grout leakage.
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Figure 3.2: Types of formwork
Each type of formwork has their own properties and disadvantages compare to advantages.
Table 3.1: Timber formworks
No Advantages Disadvantages
1 Relatively cheap Limited durability
2 Relatively light in weight for The pattern of grain tends to
handling leave an imprint
3 Easy to fix inserts on the side Its moisture content cause
of a form face for casting the significant dimensional changes
concrete
4 Easy to cut or to shape
Table 3.2: Steel formworks
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1 Durable Relatively high cost
2 Not easily modified Heavy material
3 Can be used as sheet/frame Need more time
4 Dimensionally stable Liable to rust
5 Difficult to make it proof
against leakage
Table 3.3: Aluminium formworks
1 Durable More expensive
2 Usually used as special Reaction between concrete &
extrusions as beams aluminium results in corrosion
Table 3.4: Plastic formworks
1 Used for surfaces which Require a considerable thickness
are not flat (circular etc) Of material to achieve adequate
resistance to deflection
2 More expensive
3.1 Foundation Formwork

Side and end panels will be required and should be firmly strutted against the excavation
faces. The main functions in foundation formwork are:
a) To resist the horizontal pressures of the wet concrete
b) To retain the formwork in the correct position
Ties will be required across the top of the form as a top restraint and these can be utilized
to form the kicker or used to position holding-down bolts.
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Figure 3.3: Typical foundation formwork
3.2 Column Formwork

Consists of a vertical mould which has to resist considerable horizontal pressures in the
early stages of casting. The panels forming the column sides can be strengthened by using
horizontal cleats or vertical studs which are called soldiers. The form can be constructed to the
full storey height of the column with cut-outs at the top to receive the incoming beam forms.
General practice however to cast the columns up to the underside of the lowest beam
soffit and to complete the top of the column at the same time as a beam using make-up pieces to
complete the column and receive the beam intersections. Column forms are held together by:
a) Cleats
b) Timber yokes
c) Column clamps (steel)
d)
The spacing of the yokes and clamps should vary with the anticipated pressures and the greatest
pressure occurring at the base of the column box. The Actual Pressure will vary according to:
a) Rate of placing
b) Type of mix being used generally the richer the mix the greater the pressure.
c) Method of placing if vibrators are used pressures can increase up to 50% over
hand placing and compacting.
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d) Air temperature the lower the temperature the slower is the hydration process
and consequently higher pressures are encountered.
Figure 3.4: Typical column formwork
3.3 Beam Formwork

A beam form consists of a three-sided box which is supported by cross-members called
headtrees which are propped to the underside of the soffit board. The soffit board should be
thicker than the beam sides since this member will carry the dead load until the beam has gained
sufficient strength to be self-supporting.
Generally, the beam form is also used to support the slab formwork and the two structural
members are then cast together. The construction of the beam formwork can be done by using
single or double prop. Before the construction of the beam formwork, the prop are positioned
and level enough. The soffit are placed, leveled and position checked. After that the side forms
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placed and their positioned checked before fix. Final check will be conduct before casting. The
materials of formwork will be according to its requirement.
Figure 3.5: Typical beam formwork
3.4 Slab Formwork

Floor or roof slab formwork is sometimes called shuttering and consists of panels of size
that can be easily handled. The panels can be framed or joisted and supported by the beam forms
with any intermediate propping which is required. Adjustment for leveling purpose can be
carried out by using small folding wedges between the joists or framing and the beam box.
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Figure 3.6: Typical slab formwork

3.5 Wall Design
The construction of wall formwork are similar to others vertical structure. Because of the wall
construction involve a long span, tie rods are required in order to ensure there is no deflection in
construction.
Figure 3.7: Typical Design of Wall Formwork with Steel
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3.6 Table Formwork

Special class of formwork has been devised for use when casting large repetitive floor
slabs in medium to high-rise structures. The main objective is to reduce the time factor in
erecting, striking and re-erecting slab formwork by creating a system of formwork which can
struck as an entire unit, removed, hoisted and repositioned without any dismantling. The basic
requirements for a system of table formwork are:
a) A means of adjustment for aligning and leveling the forms.
b) Adequate means of lowering the forms so that they can be dropped clear of the
newly cast slab; generally the provision for lowering the forms can also be used
for final leveling purposes.
c) Means of maneuvering the forms clear of the structure to a point where they can
be attached to the crane for final extraction, lifting and repositioning ready to
receive the next concrete pour operation.
d) A means of providing a working platform at the external edge of the slab to
eliminate the need for an independent scaffold which would be obstructive to the
system.
e) The basic support members are usually a modified version of inverted adjustable
steel props.
f) These props, suitably braced and strutted, carry a framed decking which acts as
the soffit formwork.
g) To manoeuvre the forms into position for attachment to the crane a framed
wheeled arrangement can be fixed to the rear end of the tableform so that the
whole unit can be moved forward with ease.
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3.7 System Formwork: slabs using telescopic centres
Figure 3.8: System Formwork
3.8 Formwork Construction Practice

a) Ensure that the timber dry enough.
b) Formwork must be fasten to prevent leakage.
c) Clean the formwork from dust, mud, etc..
d) Check the level and dimension of formwork.
e) Wedges and bolts are more suitable compare to nail for repetitive usage of
formwork.
f) Use a release agent like motor oil for dismantle ease.
g) Make sure use the waterproof material for formwork.
h) Choose the correct equipments.
i) Formwork dismantling must be carefully done.
3.9 Safety Measurement

a) Follow the specification.
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b) Checking the installation.

c) Ensure the implementation of safety on site.
3.10 Form Removal
a) Do not remove forms or bracing until concrete has gained sufficient strength to carry its
own weight and other imposed loads without excessive deflection or creep.
b) Loosen forms carefully. Do not wedge pry bars, hammers, or tools against finish concrete
surfaces scheduled for exposure to view.
c) Store removed forms in manner to avoid any damage to form surfaces that will later be in
contact with fresh concrete. Discard damaged forms.
3.11 Formwork Release Agent

Formol is a chemical release agent applied to concrete formwork. It is designed to act
as a bondbreaker between formwork or moulds and freshly placed concrete. Formol can be used
as a general purpose release agent on construction sites. It can be applied to formwork or
moulds made of timber, steel or fiberglass. The advantages using formwork release agent are:
a) Equally effective on steel or timber.
b) Allows for fast and easy striking of formwork.
c) Easy to apply.
d) Extremely stable during placement and vibration of concrete.
e) Does not stain or contaminate the finished concrete surface.
f) Reduces rust build up on steel moulds.
3.12 Form Cleaning

Clean and remove foreign matter within forms as erection proceeds. Clean formed
cavities of debris prior to placing concrete. Flush with water or use compressed air to remove
remaining foreign matter. Ensure that water and debris drain to exterior through clean-out ports.
During cold weather, remove ice and snow from within forms. Do not use deicing salts or water
to clean out forms. Use compressed air or other means to remove foreign matter.

Chapter 3 Formwork

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Chapter 3 Formwork

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DEPARTMENT OF BUILDING AND CONSTRUCTION ENGINEERING

Figure 3.1: Requirement for formwork

Figure 3.2: Types of formwork

Table 3.1: Timber formworks

Table 3.2: Steel formworks

Table 3.3: Aluminium formworks

Table 3.4: Plastic formworks

3.1 Foundation Formwork

Figure 3.3: Typical foundation formwork

3.2 Column Formwork

Figure 3.4: Typical column formwork

3.3 Beam Formwork

Figure 3.5: Typical beam formwork

3.4 Slab Formwork

Figure 3.6: Typical slab formwork

Figure 3.7: Typical Design of Wall Formwork with Steel

3.6 Table Formwork

3.7 System Formwork: slabs using telescopic centres

Figure 3.8: System Formwork

3.8 Formwork Construction Practice

3.9 Safety Measurement

b) Checking the installation.

3.11 Formwork Release Agent

3.12 Form Cleaning

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