2012

FORMWORK

SAMAD GODIL (TE-011) MUZUMMIL ( TE-038)

SAAD PASHA (TE -040) FARAZ JAFRI (TE-059)

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Table of Contents
Formwork definition Material use in formwork Qualities of formwork Types of formwork Formwork detail for different structural member Removal of formwork Time of removal of formwork Maintenance of formwork Cost of formwork Shores and scaffolding Lateral pressures Vertical load on formwork Placement of concrete Horizontal wind load on formwork Slip forming Failure of formwork

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Formwork is the term given to either temporary or permanent molds into

which concrete or similar materials are poured. It is an artificial support provided below and around the precast or in SITU concrete work .Formwork is designed according to ACI document of SP-4

MATERIAL USE IN FORMWORK

Softwood

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Hardwood Plywood Metal Hardboard Polystrene Other materials

Materials:
Various material are used in the construction of formwork. Steel and soft are used extensively as the some manufactured materials such as plywood and hardwood. Block material are also used to form indents and holes .what ever the material used is the carpenters job to construct and fix the formwork

Softwood:
Softwood has the advantage to be re used in its original form and can be cut and planed into successively smaller shapes, even to extent of wedges, stakes ,etc and eventually as firewood for cabin stove. Planed and jointed boards are used as a fastened to saw softwood framing. Waller ,struts and wedges are also made from softwood

Hardwood:
It is not specify certain species of hardwood for shuttering purposes as some disappear from general use as certain forests are cleared and other timbers take their place. Hardwood is sometimes used for indents as it has a much longer life than softwood and can be used many times . Hardwood is also used where accuracy must be maintained as the expansion and contraction rate of most hardwoods is much less than that of softwoods.

Plywood:
Plywood for general use in formwork should be 18 mm shuttering ply, the grade depending on the quality of finisgrequired . some shuttering ply will provide an excellent finish particularly when sended while others are only suitable for rough work . it can be used for circular work although the radius is naturallu limited

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Metal:
Metal forms are commonly used and easy to erect and strike . there are several manufacturer of metal forms each with their particular methods of fixing. The surface forms combine with the steel walers and soldiers in some cases a soldier forms a part of the finished surfaces . curved steel forms are available either in fixed radii or flexible. metal accessories can also be used in conjunction with timber forms.

Hardboard:
The common thickness in use for formwork is 3 mm as it is normally used for circular work. It is obtainable in the normal soft grade or as tempered . if possible use the tempered grade as it withstands the rigours of concrete much better than the soft grade. The disadvantage of the tempered grade is that if bent around a small radius . Tempered hardboard may also be used as a lining for forms in either 3mm or 6 mm thickness

Polystyrene;
Blocks of polystyrene can be cut to form indents or bolt holes in concrete . it is easily removed after concreting bit it is difficult to hold in postion on the form and must be treated with respect by the concretors

Other materials:
Formwork is often a case of making do with the material available. advantage must be taken of any materials wjich are available and suitable for a particular use of the site. I have used cork for indents on a refrigeration contract where it was available in great quantities .

QUALITIES OF FORMWORK
It should be according to ACI document of SP-4 It should be water tight It should be strong enough to hold concrete

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It can be re usable It should be according to the size of the member

TYPES OF FORMWORK
Formwork is mainly of two type 1. Steel formwork 2. Wooden formwork

Steel formwork : features large steel plates secured together with bars and couples
known as falsework. Using steel is a good choice for builders because steel will not bend, warp, or otherwise become misshapen during the concrete curing process. Steel formwork is also strong enough to withstand the weight of larger amounts of concrete. Steel is mostly unyielding, and the concrete generally will not adhere to the steel plates. These steel plates can also be stacked to create taller structures. They may interlock, and falsework can hold the panels together for added stability. The downside to steel formwork, however, is the weight: the plates can be difficult to lift into place, which means heavy machinery may be necessary to place the panels correctly. It is generally made of: 1. Steel sheets 2. Angle iron 3. Tee iron

Wooden formwork: is very commonly used to create this mold; these slats of wood or
boards are either permanent fixtures or temporary ones that will be pulled away once the concrete sets. In most cases, the wooden formwork is temporary, and it is held in place using braces known as falsework. Plywood is one of the most commonly used types of wood for formwork because it is generally inexpensive and some types of plywood are resistant to water damage.

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Wooden formwork are made of 1. Props 2. Planks battens 3. Ledgers 4. Sheeting

FORMWORK DETAIL FOR DIFFERENT STRUCTURAL MEMBERS : In concrete construction., formwork is commonly provided for the
following members Foundations Walls Beams Columns Stairs

1. Formwork for Foundation

For wall foundations formwork usually consists of Plywood Sheeting Struts

For column Foundations formwork consists of Side Supports Side Planks

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Cleat

2. Formwork for Wall

For wall, formwork consist of Timber sheeting Vertical posts Horizontal members Rackers Stakes Wedges

After completing one side of formwork reinforcement is provided at the place then the second side formwork is provided.

3.Formwork for Column

For column, formwork consists of the following 1. Side & End Planks 2. Yoke 3. Nut & Bolts Two end & two side planks are joined by the yokes and bolts

4.Formwork for Slabs & beams

Formwork consists of 1. Sole plates 2. Props 3. Head tree 4. Planks

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5. Batten 6. Ledgers Beam formwork rests on head tree. where as Slab formwork rests on battens and joints. If prop height are more than 8 provide horizontal brace.

4. Formwork for Stairs

It consists of 1. 2. 3. 4. 5. Vertical & inclined posts Inclined members Wooden Planks or sheeting Stringer Riser Plank

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Time of Removal of formwork

OPC (Ordinary Portland cement Portland) 2-3 days 4 days 10 days

Sr. No

Structural Members

Rapid hardening cement

1 2 3

Beam sides, walls & Column Slab (Vertical Supports remains intact Slab (Complete Formwork removal)

2 days 3 days 5 days

Beams (Removal of Sheeting, Props remains intact) Beams & Arches (Complete formwork removal) (up to 6 m span Beams & Arches (Complete formwork removal) (more than 6 m span)

8 days

5 days

14 days

5-8 days

21 days

8-10 days

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Removal of formwork
Time of formwork removal depends on the following factors 1. Type of Cement: Rapid hardening cements require lesser time as compared to OPC (Ordinary Portland Cement) 2. Ratio of concrete mix: Rich ratio concrete gain strength earlier as compared to weak ratio concrete. 3. Weather condition: Hydration process accelerates in hot weather conditions as compared to cold and humid weather conditions

Maintenance of formwork:
Due to continuous use wooden planks & steel plates surfaces become uneven and require maintenance. For wooden formwork use cardboard or plastic fiber board. Bolt hole places must also be repaired. For steel formwork plates must be leveled by mallet and loose corners must be welded

Cost of formwork:
For normal works cost of formwork is about 30%-40% of the concrete cost. For special works cost of formwork is about 50%-60% of the concrete cost. Formwork cost is controlled by the following factors 1. Formwork Material cost 2. Formwork erecting cost 3. Formwork removal cost 4. Formwork jointing cost (Nails and Cables) 5. Labor charges.

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Shores and Scaffoldings

Vertical shores and scaffolding are used with formwork to support concrete girders, beams, floor slabs, roof slabs, bridge decks, and members until these members gain sufficient strength to be self-supporting. They may be made from wood or steel or from a combination of the two materials

Lateral Pressure of Concrete on Formwork

The pressure exerted by concrete on formwork is determined primarily by several or all of the following factors: Temperature of concrete Weight or density of concrete Cement type or blend used in the concrete Method of placement of the concrete Height of form

ACI Committee 347 identifies the maximum pressure on formwork as the full hydrostatic lateral pressure,

Pm = wh

Lateral Pressure of Concrete on Wall Form

For determining pressure of concrete on formwork ACI 347 defines a wall as a vertical structural member with at least one plan dimension greater than 6.5 ft.

Pm = CwCc[150 + 43,400/T + 2,800 R/T]

Where Pm = maximum lateral pressure, lb per sq ft Cw = unit weight coefficient Cc = chemistry coefficient

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R = rate of fill of concrete in form, ft per hr T = temperature of concrete in form, F

Lateral Pressure of Concrete on Column Form

For concrete on formwork ACI 347 For determining pressure defines a column as a vertical structural member with no plan dimensions greater than 6.5 ft

Pm = CwCc[150 + 9,000R/T]
where Pm = calculated lateral pressure, lb per sq ft Cw = unit weight coefficient Cc = chemistry coefficient R = rate of fill of concrete in form, ft per hr T = temperature of concrete in form, F Minimum value of Pm is 600cw

VERTICAL LOADS ON FORM WORK

In addition to lateral pressure, vertical loads are also imposed on formwork. These vertical loads are due to the weight of the newly placed concrete and reinforcing steel, the weight of the form materials and hardware that fasten the forms, the weight of tools and equipment, and the weight of workers. For multistory structures, the design of forms must consider the loads that are transmitted from all of the higher floors.

Placement and Consolidation of Freshly Placed Concrete

Concrete may be placed in the forms directly from a concrete delivery truck, dropped from crane buckets, or pumped from a concrete pumping truck If concrete is pumped from the base of the form, ACI Committee 347 recommends that the form be designed for a full hydrostatic head of concrete wh

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Wind Loads on Formwork Systems

The design of formwork systems must include horizontal wind forces in addition to the vertical weight of concrete and live loads that are placed on the formwork. Horizontal wind applies loads against the side of shoring and the formwork on top of the shoring. The wind can also apply uplift forces against the underside of the formwork. The impact of wind is influenced by the location, width, length, and height of the formwork system.

Slipforms
The slipform method of concrete construction is used for forming both horizontal and vertical concrete structures. The slipform method has also been used for forming various types of vertical concrete structures, such as the 568-ft-high Reunion Tower in Dallas, Texas. Typical types of concrete structures that have been constructed with the slipform method: Single-cell silos Multi-cell silos Buildings Towers Water reservoirs Vertical shafts for tunnels and mines Vertical shafts for missile launching bases Chimneys

The Forms
The forms for the slipform method of construction consist of the following basic parts: 1. Sheathing 2. Wales 3. Yokes 4. Working platform 5. Suspended scaffolding 6. Lifting jacks

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Operation of Slipforms
After a set of slipforms is completely assembled on a concrete base, the forms are filled slowly with concrete. When the concrete in the bottom of the forms has gained sufficient rigidity, the upward movement of the forms is started and continued at a speed that is controlled by the rate at which the concrete sets. Lifting rates may vary from 2 or 3 in. per hr to in excess of 12 in. per hr, depending on the temperature and other properties of the concrete.

Causes of Failures of Formwork

There are numerous causes of failures of formwork. Following is a partial list : 1. Improper or inadequate shoring 2. Inadequate bracing of members 3. Lack of control of rate of concrete placement 4. Improper vibration or consolidation of concrete 5. Improper or inadequate connections 6. Improper or inadequate bearing details 7. Premature stripping of formwork 8. Errors in placement of re shoring 9. Improper, or lack of, design of formwork 10. Inadequate strength of form material 11. Failure to follow codes and standards 12. Modifications of vendor-supplied equipment 13. Negligence of workers or supervisors

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