MODERN PRACTICES

IN
FORMWORK FOR CIVIL ENGINEERING
CONSTRUCTION WORKS
 MODERN PRACTICES
IN
FORMWORK FOR CIVIL
ENGINEERING
CONSTRUCTION WORKS

By
DR. JANARDAN JHA
Former Director
Amity Centre for Innovation & New Concepts
Amity University, NOIDA (U.P)
Ex. Professor and Head, Civil Engineering, Bihar Institute of Technology
Sindri (Jharkhand)
&
PROF. S.K. SINHA
Visiting Professor of Civil Engineering
Birla Institute of Technology, Patna (Bihar)
Rtd. Professor and Head, Civil Engineering
Bihar Institute of Technology
Sindri (Jharkhand)

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MODERN PRACTICES IN FORMWORK FOR CIVIL ENGINEERING CONSTRUCTION WORKS

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UFC-9734-150-FORM CIVIL ENGG CONST-JHA
ISBN 978-93-83828-38-8

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 Preface

Formwork and falsework are temporary structures that are built to support parts or the whole
of a permanent structure until it is self-supporting. Individual components of formwork and
falsework are assembled and form the temporary structure. In other words, Formwork means
the surface, support and framing used to define the shape of the concrete until it is self-
supporting.
• Formwork includes the forms on or within which the concrete is poured, the supports
which carry the forms and the concrete, the bracing which may be added to ensure
stability, as well as the foundations and footings.
• When complete, the formwork is sometimes referred to as the formwork assembly.
• The formwork supports, bracing, foundations and footings are sometimes known as
falsework.
Falsework means any temporary structure that is used to support a permanent
structure, material, plant, equipment and personnel until the construction of the permanent
structure has advanced to the stage that it is self-supporting.
• A temporary structural support system referred to as falsework includes the foundations,
footings and all structural members supporting the permanent structural elements.
• Falsework is commonly used to support spanning or arched structures, such as bridges,
while they are being constructed.
• The temporary support structures for formwork used to mould concrete to form a desired
shape and the scaffolding that might also give workers access to the structure being
constructed is sometimes referred to as falsework.
There are three stages in the formwork operations:
• Assembly and erection
• Concrete placement
• Stripping and dismantling
To be done safely, each of these operations requires planning, knowledge and skill from
both supervisors and workers besides economy. Sometimes, the cost of formwork exceeds the
actual cost of construction. The formwork and falsework may be assembled with timber, steel,
alluminium, plastic coated steel or a combination of them.
Slipform technology is a new innovation in this field. Slipforming is a construction
technique which has been used for decades for production of concrete structures. Wide range

v
vi PREFACE

of structures are slipformed, typically, vertical structures such as towers, bridge columns and
offshore platforms and horizontal structures like rigid reinforced concrete pavement, canal
lining, etc. Apart from vertical structures with uniform thickness, slipforming technique is
also used where geometry of structure and wall thickness changes. Slipforming is a continuous
working operation (24 hours a day), which requires planned supply of materials, management
and supervision.
Shoring is a general term used in construction to describe the process of supporting a
structure in order to prevent collapse so that construction can proceed.
At times, it is essential to replace or strengthen the foundation of an existing structure.
The operation of providing new permanent foundations is known as underpinning.
Scaffolding is a temporary platform, either supported from below or suspended from
above, on which workers sit or stand while performing tasks at heights above the ground. It
supports men and materials for construction or repair works at height. Scaffolding involves
sturdy connections of frames and planks by bolts and couplers, which come in many forms,
depending on the size and shape of the desired framework. It is usually a modular system of
metal pipes or tubes, although it can be from other materials.
In this book authors have tried to explain the various and latest techniques of formwork,
shoring, underpinning and scaffolding practiced all over the world. The book should prove
very useful to the civil, architecture engineering undergraduate students and practicing
engineers. A large number of figures and photographs have been provided to explain the actual
working. Any suggestion to improve upon is most welcome.
Dr. Janardan Jha
Prof. Suresh Kumar Sinha
 Contents

Preface (v–vi)

1. Introduction to Formwork 1–14

1.1 Introduction ............................................................................................................................ 1
1.2 Objectives of Form Building .................................................................................................. 1
1.3 Technical Terms ..................................................................................................................... 2
1.4 How Formwork Affects Concrete Quality ............................................................................ 6
1.5 Causes of Formwork Failure ................................................................................................. 6
1.5.1 Safety ........................................................................................................................ 7
1.6 Planning for Formwork ......................................................................................................... 7
1.7 Areas of Cost Reduction ......................................................................................................... 7
1.8 Requirements of Formwork ................................................................................................... 8
1.9 Economy in Formwork ........................................................................................................... 8
1.10 Materials of Formwork .......................................................................................................... 9
1.11 The Size of Form Section ....................................................................................................... 9
1.12 Types of Formwork ................................................................................................................ 9
1.13 Indian Standards on Formwork (IS:456–2000) ................................................................. 12
1.14 Treatment of Formwork ...................................................................................................... 13
1.15 Summary ............................................................................................................................... 13

2. Principles of Formwork Design 15–26

2.1 Design Considerations ......................................................................................................... 15
2.2 Structural Design ................................................................................................................. 16
2.3 Introduction to Design Principles ....................................................................................... 16
2.3.1 Design of Formwork for Slab ................................................................................ 17
2.3.2 Vertical Loads ........................................................................................................ 17
2.4 Example of Slab Formwork Design .................................................................................... 18
2.4.1 Example .................................................................................................................. 18
2.4.2 Lateral Pressure of Fresh Concrete ..................................................................... 19

( vii )
viii CONTENTS

2.5 Form Design ......................................................................................................................... 20

2.5.1 Lateral Loads ......................................................................................................... 21
2.5.2 The Wall Form Design .......................................................................................... 21
2.5.3 Example for Slab Form Design ............................................................................. 22
2.6 Summary ............................................................................................................................... 26

3. Timber and Timber Derived Materials for Formwork 27–59

3.1 Introduction .......................................................................................................................... 27
3.2 Functional and Load Requirements of Formwork ............................................................. 27
3.2.1 Formwork Functions ............................................................................................. 27
3.2.2 Basic Principles of Formwork Making ................................................................. 28
3.3 Elements of Formwork ........................................................................................................ 29
3.3.1 The Formwork Sheeting ........................................................................................ 29
3.3.2 The Formwork Bearers ......................................................................................... 30
3.3.3 The Elements of False-work Structures .............................................................. 30
3.4 Defects Commonly Found in Formwork ............................................................................. 30
3.5 Timber Forms ....................................................................................................................... 31
3.5.1 Plywood ................................................................................................................... 33
3.6 Construction of Formwork .................................................................................................. 34
3.6.1 Propping and Centering ........................................................................................ 35
3.6.2 Shuttering .............................................................................................................. 35
3.6.3 Order and Method of Removing Formwork ......................................................... 36
3.6.4 Nailing Formwork ................................................................................................. 36
3.6.5 Treatment of Formwork ........................................................................................ 37
3.6.6 Removal of Formworks .......................................................................................... 37
3.7 Forms for Foundations ........................................................................................................ 37
3.8 Forms for Walls .................................................................................................................... 38
3.8.1 Ties .......................................................................................................................... 41
3.9 Formwork .............................................................................................................................. 43
3.9.1 Forms for Columns ................................................................................................ 43
3.9.2 Forms for Lintels and Simple Beams ................................................................... 46
3.9.3 Forms for Staircase ............................................................................................... 47
3.9.4 Forms for Slab or floor .......................................................................................... 49
3.9.5 Best Practices for Conventional Wood System .................................................... 55
3.9.6 Limitations of Conventional Wood System ......................................................... 55
3.9.7 Advantages of Conventional Wood System ......................................................... 56
3.10 Modular Slab Formwork ...................................................................................................... 56
3.10.1 Table or Flying Form Systems ............................................................................. 56
3.10.2 Structure ................................................................................................................ 56
3.10.3 Support ................................................................................................................... 57
3.10.4 Size .......................................................................................................................... 57
3.10.5 Crane Handled ....................................................................................................... 57
3.10.6 Crane Fork or Elevator Handled .......................................................................... 57
3.11 Summary ............................................................................................................................... 58
CONTENTS ix

4. Steel and Aluminium Formwork 60–92

4.1 Introduction .......................................................................................................................... 60
4.1.1 Concrete Construction ........................................................................................... 60
4.1.2 Concrete Formwork ............................................................................................... 60
4.2 Steel Formwork .................................................................................................................... 62
4.2.1 Elements and Accessories of Steel Formwork ..................................................... 64
4.2.2 Strength and Durability of Formwork ................................................................. 78
4.2.3 Formwork Materials affect Construction Duration ............................................ 78
4.2.4 Formwork Materials affect Quality of Concrete ................................................. 79
4.2.5 Labour Requirement ............................................................................................. 79
4.2.6 Formwork Economy ............................................................................................... 80
4.3 Aluminium Formwork ......................................................................................................... 80
4.3.1 Slab Construction .................................................................................................. 81
4.3.2 Aluminium Formwork for Walls .......................................................................... 84
4.3.3 Aluminium Formwork for Column ....................................................................... 85
4.3.4 Aluminium Formwork for Stairs .......................................................................... 87
4.3.5 Formwork for Domes and Shell Roofs .................................................................. 87
4.4 Table or Flying Form Systems ............................................................................................ 88
4.5 Easy Stripping Construction Formwork System ............................................................... 91
4.6 Summary ............................................................................................................................... 92

5. Stripping of Formwork 93–104

5.1 Introduction .......................................................................................................................... 93
5.2 Stripping the Formwork and False-work ........................................................................... 95
5.3 Knock–down Slab System ................................................................................................... 97
5.4 Built-in-place Wall Forms ................................................................................................... 98
5.5 Hydraulic Rams used in Dismantling Formwork .............................................................. 99
5.6 Stripping Time ................................................................................................................... 100
5.7 Allowable tolerances .......................................................................................................... 100
5.8 Competent Person Sign-off Prior to Stripping ................................................................. 102
5.8.1 Bond Reduction .................................................................................................... 103
5.8.2 Exclusion Zone ..................................................................................................... 103
5.8.3 Drop Stripping ..................................................................................................... 103
5.8.4 Dismantling False-work ...................................................................................... 103
5.9 Occupational Health and Safety Requirements .............................................................. 103
5.10 Risk Controls ...................................................................................................................... 104
5.11 Summary ............................................................................................................................. 104

6. Slip-Form Construction 105–129

6.1 Introduction ........................................................................................................................ 105
6.2 Slip Form Technology ........................................................................................................ 106
6.2.1 Slip Forming Process ........................................................................................... 106
6.2.2 Advantages of Slip-form Construction ............................................................... 107
6.2.3 Economics of Slip Form Construction ................................................................ 108
6.2.4 Safety .................................................................................................................... 109
x CONTENTS

6.2.5 Other Considerations .......................................................................................... 109

6.2.6 Sustainability Features of Slip Form Construction .......................................... 110
6.2.7 Strategic Application to Concrete Structures ................................................... 110
6.2.8 Pre-construction Services .................................................................................... 110
6.2.9 Project Planning .................................................................................................. 110
6.2.10 Design liaison ....................................................................................................... 111
6.2.11 Procurement ......................................................................................................... 111
6.2.12 Construction ......................................................................................................... 111
6.2.13 Quality Assurance and Control .......................................................................... 111
6.2.14 Cost Control ......................................................................................................... 111
6.3 Design of Slip Formwork ................................................................................................... 111
6.3.1 Types of Construction .......................................................................................... 111
6.3.2 Vertical Slip Form ............................................................................................... 118
6.3.3 Tapered Slip Forming .......................................................................................... 123
6.3.4 Why Choose Slip Forming ................................................................................... 124
6.4 Before Choosing Slip Forming Some of the Factors to Consider ................................... 125
6.4.1 Assembling Formwork for Slip form Methods of Construction ....................... 125
6.4.2 General Structure of Slip Form .......................................................................... 125
6.4.3 Removal of Formwork ......................................................................................... 126
6.5 Theoretical Details of Concrete Hardening in the Slip Form ......................................... 126
6.6 Slip Form Works by Concrete Pump ................................................................................ 126
6.7 Self Consolidating Concrete .............................................................................................. 128
6.7.1 Chemical Admixture ............................................................................................ 128
6.7.2 Self Consolidating Concrete Compared to Ordinary Concrete ........................ 128
6.7.3 Tests on Self Concrete Consolidating ................................................................ 129
6.8 Summary ............................................................................................................................. 129

7. Shoring, Underpinning and Scaffolding 130–169

7.1 Introduction ........................................................................................................................ 130
7.2 Types of Shoring ................................................................................................................. 131
7.2.1 Raking Shores ...................................................................................................... 131
7.2.2 Horizontal or Flying Shores ................................................................................ 133
7.2.3 Dead Shores ......................................................................................................... 135
7.2.4 Trench Shoring or Timbering ............................................................................. 136
7.3 Aluminium Shores ............................................................................................................. 138
7.3.1 Trench Jacks ........................................................................................................ 138
7.3.2 Aluminium Waler Systems ................................................................................. 138
7.3.3 Hydraulic Bracing Systems ................................................................................ 140
7.3.4 Lifting Chains ...................................................................................................... 141
7.3.5 Pipe Lifters ........................................................................................................... 142
7.4 Underpinning ..................................................................................................................... 142
7.4.1 Methods of Underpinning ................................................................................... 143
7.5 Scaffolding .......................................................................................................................... 148
7.5.1 General Requirements of Scaffold ...................................................................... 150
7.5.2 Basic Scaffolding .................................................................................................. 150
CONTENTS xi

7.5.3 Scaffold Platform may be Classified as Follows ................................................ 151

7.5.4 Types of Scaffolds ................................................................................................ 152
7.6 Fittings and Accessories .................................................................................................... 165
7.6.1 Salient Features .................................................................................................. 168
7.7 Summary ............................................................................................................................. 169

Index 171–174

Colour Photograph 175–184

 1 Introduction to Formwork

1.1 INTRODUCTION
The concrete is such a wonderful material which acquires exact shape of the mould in which it
is placed. Formwork is the term given to either temporary or permanent moulds into which
concrete or similar materials are poured. In the context of concrete construction, the false
work supports the shuttering moulds. In other words, shuttering or formwork is the term used
for temporary timber, plywood, metal, plastic or other material used to provide support to
fresh concrete mix till it gets strength for self support. It provides supports to horizontal,
vertical and inclined surfaces or also provides support to cast concrete according to required
shape and size. The formwork also produces desired finish to concrete surface.
The cost of concrete also includes the cost of the formwork which is required to support the
concrete until it attains sufficient strength to support itself. Sometimes, the cost of formwork
is higher than the cost of concrete alone. Hence, any effort to effect economy in concrete structure
should be directed primarily on reducing the cost of formworks.
The construction of a concrete structure requires formwork to support the slabs (Horizontal
Formwork) as well as columns and walls (Vertical Formwork). Formwork is the contact surface
and structural backing needed to contain fresh concrete until it can safely support itself. If it
is not removed, it is called permanent formwork. If it has to be supported from below, the
structural support is called false work. The exact distinction between formwork and false
work is not very important, but it is usual to call all material and equipment used to cast walls
formwork. This is because the system of loads is self-contained, while for concrete members
such as slabs or beams, false work is used to take the loads to the ground below or to a similar
support. For such members, the actual surface material and its immediate support is considered
to be formwork.

1.2 OBJECTIVES OF FORM BUILDING

Forms mould the concrete to desired size and shape and control its position and alignment.
But formwork is more than a mould; it is a temporary structure that supports its own weight,
plus the freshly placed concrete, plus construction live loads (including materials, equipment,
and personnel).
Basic objectives in form building are:
1. Quality — In terms of strength, rigidity, position, and dimensions of the forms
2. Safety — For both the workers and the concrete structure
 Modern Practice In Formwork For Civil
Engineering Construction Works

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