FORMWORK DESIGN CONCEPTS

Formwork
How a Formwork is Designed ?

Estimate the load

Form the design Basis
Estimate the permissible stresses
Analyse & design each component
FORMWORK DESIGN CONCEPTS

LOADS ON FORMWORK
 Formwork
Loads on Formwork

Vertical loads
Lateral pressure
Horizontal Loads
Incidental loads& other loads
 Formwork
Vertical loads

Weight of wet concrete - 2500 kg/cum

Self weight of formwork 50 to 75 kg/sqm
Live load during construction 150 to 350 kg/sqm
Should account for uplift due to uneven placing
of concrete
CONCRETE DUMPING EFFECT
FORMWORK DESIGN CONCEPTS

LATERAL PRESSURE CALCULATION

 Formwork
Lateral pressure
 Formwork
Factors affecting pressure due to concrete
Density
Rate of placing
Vibration
Concrete temperature, Slump, Admixture
affecting initial setting time etc.
Thickness of concrete element.
 Lateral Pressure on wall

WALLS AND BASES

A wall or base is a section where at least one of the
plan dimensions is greater than 2 m

Form Rate of rise (m/h)

Conc. hei
CONCRETE GROUP temp. ght
(°C) (m 0.5 1.0 1.5 2.0 3.0 5.0 10
)

50 50 50 50
2 40 45 50 70 75 75
65
3 50 55 60 75 85 10
70
5 4 60 65 65 90 10 0
80
6 70 75 80 0
10
10 85 90 95
0
1) OPC, RHPC or SRPC
2 35 40 45 45 50 50 50
without admixtures
3 40 45 50 55 60 70 75
2) OPC, RHPC or SRPC with
10 4 45 50 55 60 65 75 90
any admixture except a
6 50 55 60 65 75 85
retarder
10 60 70 75 80 85 95

2 30 35 40 45 50 50 50
3 35 40 45 50 55 65 75
15 4 35 45 50 50 60 70 90
6 40 50 55 60 65 75 95
10 50 55 60 65 75 85

2 50 50 50 50 50 50 50
3 65 70 75 75 75 75 75
5 4 75 80 85 90 95 10 10
6 95 10 0 0
3) OPC, RHPC or SRPC with 10 0
a retarder
4) LHPBFC, PBFC, PPFAC or 50 50 50 50
2 40 45 50 70 75 75
a blend containing less 65
3 50 55 60 75 85 10
than 70% ggbfs or 40% 70
10 4 60 60 65 90 10 0
pfa without admixtures 80
6 70 75 80 0
5) LHPBFC, PBFC, PPFAC or 10
10 85 90 95
a blend containing less 0
than 70% ggbfs or 40%
pfa with any admixture 50 50
2 35 40 45 45 50 75
except a retarder (see Note) 70
3 40 45 50 55 60 90
75
15 4 45 50 55 60 65
85
6 50 60 65 65 75
10
10 65 70 75 80 85
0
 Lateral Pressure on column
COLUMNS
A column is a section where both
plan dimensions are less than 2 m

Conc. Form Rate of rise (m/h)

CONCRETE GROUP temp. height
(°C) (m) 2 4 6 10 15

3 75 75 75 75 75
4 85 100 100 100 100
5 6 95 115 125 145 150
10 115 135 145 170
15 130 150 165

1) OPC, RHPC or SRPC 3 65 75 75 75 75

without admixtures 4 75 90 100 100 100
2) OPC, RHPC or SRPC with 10 6 80 100 115 130 150
any admixture except a 10 95 115 130 150
retarder 15 105 125 140 165

3 60 75 75 75 75
4 65 85 95 100 100
15 6 75 90 105 130 150
10 80 100 115 140 165
15 90 110 125 150

3 75 75 75 75 75
4 100 100 100 100 100
5 6 120 130 140 150 150
3) OPC, RHPC or SRPC with 10 145 160
a retarder 15 170
4) LHPBFC, PBFC, PPFAC or
a blend containing less 75 75
3 75 75 75
than 70% ggbfs or 40% 100 100
4 85 95 100
pfa without admixtures 145 150
10 6 95 110 125
5) LHPBFC, PBFC, PPFAC or 170
10 115 130 145
a blend containing less
15 130 150 165
than 70% ggbfs or 40%
pfa with any admixture
3 65 75 75 75 75
except a retarder
4 75 90 100 100 100
(see Note)
15 6 80 100 115 135 150
10 95 115 130 155
15 105 125 140 165
 Formwork
Arching limit
 Formwork
Stiffening limit
 Formwork
Stiffening limit
 Formwork
Net effect of the three limits
 Formwork
ACI formula
For Walls, rate of placement < 2 m/hr,
P = 0.72 + 78.5 R
T + 17.8
For Walls, rate of placement 2 to 3 m/hr,
P = 0.72 + 115.6 + 24.4 R
T + 17.8 T + 17.8
Where P = Lateral pressure in t /sqm
R = Rate of Placement in m/hr
T = Temperature of concrete in the forms, deg C
 Formwork
CIRIA Table
Arching Limit

d R (m/h)
mm 1 2 3 4 5 6 8 10 15 20 30 >40
150 3.5 3.5 4 4.5 4.5 5 5.5 6 7.5 9 12 15
200 4 4 4.5 5 5 5.5 6 6.5 8 9.5 12.5 15
300 5 5 5.5 6 6 6.5 7 7.5 9 10.5 13.5 15
400 6 6 6.5 7 7 7.5 8 8.5 10 11.5 14.5 15
500 7 7 7.5 8 8 8.5 9 9.5 11 12.5 15 15
 Formwork
CIRIA Table
Stiffening limit
Slump Conc. R (m/h)
mm Temp
C 1 1.5 2 2.5 3 4 5 6 7 >8
5 5 7 8.5 11.5 13.5 15 15 15 15 15
10 4 5.5 7 8.5 10 13.5 15 15 15 15
50
15 4 4.5 5.5 6.5 7.5 10 12.5 15 15 15
20 3.5 4 4.5 5 5.5 7 9 10.5 12.5 15
5 6 8.5 11 14 15 15 15 15 15 15
10 5 6.5 8.5 10.5 12.5 15 15 15 15 15
75
15 4 5 6.5 8 8.5 12.5 15 15 15 15
20 3.5 4 5 6 7 9 11.5 13.5 15 15
5 7 10 13 15 15 15 15 15 15 15
100 to 10 5.5 7.5 10 12 15 15 15 15 15 15
150 15 4.5 6 7.5 9 11 15 15 15 15 15
20 3.5 4.5 5.5 7 8 11 13 15 15 15
 Formwork
Sample calculation of concrete pressure
Problem: Find the Lateral Pressure for the wall of size 15m x 3m x 0.2m shown below.
Assume Rate of pour is 10 cum/hr and Ambient temperature as 20deg C.

Solution: Pour size = 15 x 3 x 0.2

= 9 cum
Rate of Pour = 10 cum/hr
Time required for concreting = 9 / 10
= 0.9 hr say 1 hr
Therefore, Rate of Rise = 3m / hr

…..contd.,
 Formwork
Sample calculation of concrete pressure
As per ACI Committee report,
Lateral Pressure P = 0.72 + (115.6 / T + 17.8) + (24.4 R / (T + 17.8))
Where P = Lateral Pressure in t / sqm
R = Rate of Placement in m / hr
T = Temperature of concrete in the forms, degC

P = 0.72 + (115.6/(20 + 17.8)) + (24.4 x 3 / (20 + 17.8))

= 5.71 t / sqm
 Formwork
Sample calculation of concrete pressure

As per CIRIA report, refer tables in section 3.1.4

2
Height limit = 7.5 t /m (From standard table, for H= 3m )
2
Arching limit = 4.5 t / m (From standard table, for d =0.2 m & R=3m/hr)
2
Stiffening limit = 5.5 t / m (from standard table, for slump = 50 mm,
0
Concrete temperature = 20 C & R= 3m/hr)

The minimum pressure of all the pressures calculated above is taken for the design of formwork.
2
Therefore concrete pressure for the design of formwork as per arching limit = 4.5 t / m
FORMWORK DESIGN CONCEPTS

OTHER LOADS
 Formwork
Horizontal loads
Mainly on alignment / supporting props
Due to wind
Due to dumping of concrete
Due to equipment
Usually 2% of vertical or 150kg/m length
Lifting tendency of Shutter
 Formwork
Other loads
Manual boom placer
Tough riders
Concrete bucket
Tough rider load
 Formwork
How a Formwork is Designed ?

Estimate the load

Form the design Basis
Estimate the permissible stresses
Analyse & design each component
FORMWORK DESIGN CONCEPTS

DESIGN PRINCIPLES
 Formwork
Design basis / Principle
Accurate design unnecessary
All loads are treated as approx. UDL
Approximation in analysis
Conservative estimate required
Basis altered depending on the project nature &
importance.
Formwork for Reactor Dome
FORMWORK DESIGN CONCEPTS

PERMISSIBLE STRESSES
 Formwork
Permissible stresses & section properties

Given in 3.3a to 3.3 d of the booklet

In Bending
Timber - 70kg/sqcm
Plywood - 140 kg/sqcm
Steel - 1200 kg/sqcm
H16 - 0.3tm moment
H16 - 600 kg shear
Couplers - 600 kg axial pull
Grains in Plywood
FORMWORK DESIGN CONCEPTS

DESIGN PROCEDURE
Wall Formwork Parts
Slab Formwork Part
 Formwork
Design Procedure

Plywood design
Check for Bending, Shear & Deflection
Secondary Beam - Soldier
Check for Bending, Shear & Deflection
Primary Beam - Waler
Check for Bending, Shear & Deflection
Staging Support / Tie rod
FORMWORK DESIGN CONCEPTS

DESHUTTERING
 Formwork
Deshuttering
To be carried out only after concrete attains
sufficient strength otherwise it would result in
excessive deflection
After deshuttering cure adequately to avoid
water loss
Concrete should be strong enough to support its
own weight & super imposed load with a factor of
safety 1.5
Removal of staging in a planned sequence to
avoid load accumulation.
Bangalore stadium Destaging
Bangalore Stadium Destaging
 Formwork
Deshuttering (contd.)
Do not allow FW material to be thrown down
from height
Test cubes should be cured the same way the
original concrete is cured
 Formwork
What does IS456 say about deshuttering?
As per IS code 456, under ordinary conditions, forms and supports should remain in place for
less than the following periods of time:

(a) Walls, Columns, Vertical sides of beams 24 hours

(b) Slabs (Props left under) 3 days
(c) Beam soffits (Props left under) 7 days
(d) Removal of props for slabs
(i) Spanning upto 4.5 m 7 days
(ii) Spanning over 4.5 m 14 days
(e) Removal of props to beams and arches:
(i) Spanning upto 6.0 m 14 days
(ii) Spanning over 6.0 m 21 days

These periods are for concrete prepared using ordinary portland cement. Depending on the
concrete mix and other factors these periods may be increased at the discretion of the Engineer.
FORMWORK DESIGN CONCEPTS

DEFLECTION & TOLERANCE

 Formwork
Deflection & Tolerance
For sheathing - 1.6 mm
For members spanning upto 1.5 m - 3.0 mm
For Members spanning more than 1.5 m
- 6.0 mm or span/ 360 whichever is less

Tolerance as per Structural Engineer’s requirement

Details for Gujarat School Project given in 3.6B of
booklet
FORMWORK DESIGN CONCEPTS

TOPFORMS
 Formwork
Top Forms
Required to keep the fresh concrete from
running down on sloped surface
Below 200 not required & Above 450 it is a must
Between 200 - 450 requirement depends on
Slump & Concrete properties
Method of Placement
Type of finish required
Rate of Pour & Ambient temperature
Complex Geometry
 Formwork
Top Forms (contd.)
 Formwork
Top Forms (contd.)
 Formwork
Top Forms (contd.)
Should be in pieces to be able to place concrete
easily
Given a choice choose to use stiff concrete and
avoid top-form
Design similar to any other form
FORMWORK DESIGN CONCEPTS

CONSTRUCTION JOINTS
 Formwork
Construction Joints
A construction joint, is one where fresh concrete
has to be placed on or against concrete, which has
already hardened
Fresh concrete should get bonded to old concrete
properly
It can be either Vertical or Horizontal
In Both the cases the cementitious laitance is to
be removed & aggregates exposed
 Formwork
Construction Joints (contd.)
Steps to follow
Deshutter the end-stopper when the concrete is green
Remove the cement skin using wire brush
Hacking to be resorted if the concrete has hardened
Sand blasting, air/water jetting used if the area to be
treated is large as in the case of Dam construction
 Formwork
Masking of Construction Joints
Make it a deliberate architectural feature
Provide Grout Checks if necessary
Grout check
FORMWORK DESIGN CONCEPTS

VIBRATION OF CONCRETE
 Formwork
Vibration
Over vibration less evil than under vibration
In adequate vibration leads to sand run, Bug
holes etc.

Vibrator Diameter of internal Diameter of effective Spacing of points of

group vibrator mm range of action cm immersion cm
1 < 40 30 25
2 40 to 60 50 40
3 > 60 80 70
 Formwork
Mould Vibration
Go for low amplitude high frequency vibrators
Mould should be sturdy & joints secure
It should not loose dimensional accuracy once
vibrated
Mould preferably mounted on elastic medium
In sites general tendency is to under vibrate the
concrete which is to be avoided
FORMWORK DESIGN CONCEPTS

SAFETY IN FORMWORK
 Formwork
Safety in Formwork
Staging towers need to be adequately braced. The height of
the tower should not be more than 3 to 4 times the least
lateral dimension
The staging is to be tied to any rigid structure if the height
required is more.
Falling down of loose tools & tackles from a carpenter
working at a height is to be avoided
The formwork needs to be monitored closely at connections
while concreting.
Rate of rise should be restricted to the level of design
assumptions
Staging Buckling
Staging Buckling
 Formwork
Safety in Formwork (contd.)
The needle vibrator should not disturb the reinforcement
and damage the form surface
Create a clear passage for vibrator insertion while tying the
reinforcement. Small amount of planning will improve the
quality to a great extent.
The removal of supports should be systematic according to
the structural system
Do not allow dropping down of formwork material after
deshuttering.
Good House keeping and storing the material properly
would go a long way in improving the safety.
FORMWORK DESIGN CONCEPTS

THANK YOU