WALL FORMWORK DESIGN (George Ilinoiu)

Technical Note

WALL FORMWORK DESIGN

George Ilinoiu
Faculty of Civil, Industrial and Agricultural Constructions
Technical University of Civil Engineering of Bucharest
Bd. Lacul Tei, no. 124, sector 2, Bucharest, Romania
Telephone: 401-242.12.08 / 157; Fax: 401-242.07.81; e-mail: [email protected]

Catatan Redaksi:
Perencanaan bekisting (Form Work) merupakan bagian penting dalam pelaksanaan struktur beton
bertulang, bila tidak direncanakan dengan baik, tidak jarang kegagalan bekisting menyebabkan
masalah pelaksanaan yang cukup rumit. Bekisting juga menjadi komponen biaya struktur beton
bertulang yang cukup besar. Makalah ini memaparkan perencanaan bekisting, yang di Romania,
merupakan bagian persyaratan untuk mendapatkan sertifikasi Insinyur Profesional.

GENERAL CONSIDERATIONS The thinner panels can be bent easily for

curved forms and liners. Plywood's excellent
All concrete sections made with poured-in-place stiffness minimizes deflection during pouring.
concrete require some temporary means of Its natural insulating qualities help provide
support for the fresh mixed concrete until it more consistent curing conditions. The large
reaches the necessary hardening rate for strike panel size and lightweight reduce form
off. Formwork is a temporary mould into which construction and stripping time.
wet concrete and reinforcement is placed to form
a particular desired shape with a predetermined Plywood is made in panels consisting of odd
strength. Depending on the complexity of the numbers of veneers, each placed at right angles
form, the relative cost of formwork to concrete to the adjacent ply, which accounts for the
can be as high as 75% of the total cost to physical properties that make it efficient in
produce the required member. A typical break- resisting bending, shear, and deflection .
down of percentage costs could be as follows [1]:
• Concrete (materials 28%; labor 12%) = 40%; Plywood sheet is the common material used for
• Reinforcement (materials 18%; labor 7%) = wall formwork but this material is vulnerable to
25%; edge and corner damage. The usual format is
• Formwork (materials 15%; labor 20%) = 35%. therefore to make wall forms as framed panels
on a timber studwork principle with a plywood-
The above breakdown shows that a building
facing sheet screwed to the studs so that it can
contractor will have to use an economic method
be easily removed and reversed to obtain the
of providing the necessary formwork if the
maximum number of uses.
contractor is to be competitive in tendering since
this is the factor over which that company has
most control. FORMWORK PRINCIPLES

PLYWOOD FORMWORK The principles behind good formwork are based

on the same basic frame theories used in the
Plywood is an ideal material for concrete design and construction of permanent structural
forming. It produces smooth concrete surfaces frames. Formwork must be able to withstand
and can be used repeatedly – 10 times up to 200 construction forces that, in many respects, can
times or more for some overlaid panels. be more severe than those experienced by the
completed structure. It is imperative that each
component of the formwork be erected according
Note: Discussion is expected before November, 1st 2004. The to the formwork drawings to ensure that all
proper discussion will be published in “Dimensi Teknik
Sipil” volume 7 number 1 March 2005. construction loads are safely supported.

Jurusan Teknik Sipil, Fakultas Teknik Sipil dan Perencanaan – Universitas Kristen Petra 101
http://puslit.petra.ac.id/journals/civil/
 DIMENSI TEKNIK SIPIL VOL 6, NO. 2, September 2004: 101 - 108

Table 1. Panel nominal dimensions

Size Components
Type of No. of Thickness
panel Length Width No. of No. of of panel
traverse
(mm) (mm) spars braces
frames
P1 2400 300 2 2 3
P2 2400 400 3 2 6
P3 2400 600 3 2 6
P4 1200 300 2 2 1
100 mm
P5 1200 400 3 2 2
P6 1200 600 3 2 2
P7 600 300 2 2 -
P8 600 400 3 2 -

Although formwork is temporary in nature, the

methods used in building formwork must adhere
to the code specifications that apply to the
particular material being used. Each component
of the form must be able to support its load from
two points of view:
(1) strength, based on the physical properties of
the material used;
(2) serviceability, the ability of the selected
sections to resist the anticipated loads
without exceeding deflection limits.

Typical deflection limits for the various com-

Figure 1. Typical plywood panel: 1. Plywood sheeting; 2.
Batten; 3. Brace; 4. Transverse frame: e = 8; 15 ponents are usually [2]:
mm, d = 92 ; 85 mm, c = 48 mm, i = 68 mm, f = § Maximum deflection L/300 – for concrete that
38 mm. provides permanent finish;
§ Maximum deflection L/200 – for concrete
surfaces with finishing.

Figure 2. Plywood panels: 1. Plywood sheeting; 2. Wooden wedges; 3. Wale; 4. Plate washer; 5. Bolt (Nut); 6. Tie
rod; 7. Pipe spacer; 8. Plastic cone; 9. Shoe; 10. Clamp; 11. Wedge; 12. Concrete kicker.

102 Jurusan Teknik Sipil, Fakultas Teknik Sipil dan Perencanaan – Universitas Kristen Petra
http://puslit.petra.ac.id/journals/civil/
 WALL FORMWORK DESIGN (George Ilinoiu)

These limits ensure that the resulting concrete weight of the fluid above, the density of the
sections will be straight once the forms are concrete mix influences the magnitude of the
removed. force acting on the form. Nevertheless, because
fresh concrete is a composite material rather
than a true liquid, the laws of hydrostatic
FORMWORK LOADS pressure apply only approximately and only
before the concrete begins to set.
The basic consideration in formwork design is
strength-the forms ability to support, without The rate of placement also affects lateral
excessive deflections, all loads, and forces pressure. The greater the height to which
imposed during construction. Two types of concrete is placed while the whole mass remains
problems arise in formwork design: in the liquid stage, the greater the lateral
pressure at the bottom of the form.
§ Horizontal forms must support gravity loads
based on the mass of the concrete, the
The temperatures of concrete and atmosphere
construction crew and equipment, and the
affect the pressure because they affect the
weight of the formwork itself;
setting time. When these temperatures are low,
§ Vertical forms must primarily resist lateral
greater heights can be placed before the
pressures due to a particular height of plastic
concrete at the bottom begins to stiffen, and
concrete. Wall and column forms are exam- greater lateral pressures are therefore built up.
ples where lateral concrete pressures are a
prime concern, while formwork, supporting a Vibration increases lateral pressures because
structural slab must be designed to sustain the concrete is consolidated and acts as a fluid
gravity loads. for the full depth of vibration. This may cause
increases of up to 20% in pressures over those
The individual formwork panels and members
incurred by spading. Other factors that
may be limited to bending, shear, bearing, or influence lateral pressure include the consis-
deflection and all four should be checked against tency or fluidity of the mix, the maximum
the allowable values prescribed by norms and aggregate size and the amount and location of
specifications. reinforcement.

Two types of loads are considered in the design

Romania norm C11-74 [4] specifies the following
calculations:
loads for formwork design:
(1) Vertical loads. Horizontal forms must
support gravity loads based on the mass of 1. Vertical Loads, include:
the concrete, the work crew, and equipment, a). The weight of the formwork itself and the
and the weight of the formwork itself; scaffold:
(2) Horizontal loads. Vertical forms must - for lumber in panels 750 daN/m3
primarily resist lateral pressures due to a - for lumber in shoring elements 600
particular height of plastic concrete. daN/m3
- for plywood 850 daN/m3
b) The weight of fresh concrete:
FORMWORK PRESSURES - normal weight (heavy) concrete:
§ plain 2400 daN/m3
The pressure exerted by concrete on formwork is § reinforced 2500 daN/m3
determined primarily by the following factors [3] - lightweight concrete 700– 1900 daN/m3
- Rate of concrete placement. (depending on the type of aggregates
- Temperature of concrete. used in the mix)
- Weight of concrete. c). The uniform distributed load of runways
- Method of concrete vibration. for concrete transport and impact loads of
- Depth of placement. the crowding of crewmen:
- for panel design 250 daN/m2
The lateral pressure exerted by plastic concrete - for horizontal shoring (joists) of panels
on vertical formwork is rather complex in 150 daN/m2
nature and is affected by several factors. The - for vertical shoring elements (props,
freshly placed concrete initially acts as a liquid, columns etc.) 100 daN/m2
exerting fluid or hydrostatic pressure against d). The concentrated load form weight of
the vertical form. Because hydrostatic pressure work crews and transport equipment:
at any point in a liquid is the result of the

Jurusan Teknik Sipil, Fakultas Teknik Sipil dan Perencanaan – Universitas Kristen Petra 103
http://puslit.petra.ac.id/journals/civil/
 DIMENSI TEKNIK SIPIL VOL 6, NO. 2, September 2004: 101 - 108

- for one crew member that carries loads p – lateral pressure [daN/m2]
130 daN ρ b – unit weight of fresh concrete [daN/m2]
- for wheel barrow concrete transport 280 H – height of plastic concrete above height
daN considered [m]
e) The load from the vibrating effect of the
concrete compaction:120 daN/m2 The position of the maximum pressure (Fig. 3) is
determined with the following equation:
2. Horizontal Loads, include:
f) Static load from lateral pressures due to a
h p = λ1 xH (2)
particular height of plastic concrete Where: λ1 – has the value according to Table 2.
(placed and compacted) according to the
rate of placement (see Figure 3) on the The value of the maximum pressure pmax is
panels surface. determined with the following equation:

Two factors that affect the maximum effective p max = λ1 .λ 2 .λ 3 .λ 4 .H.ρ b (daN/m2) (3)
horizontal pressure are seen to be:
Where:
- rate of rise of the concrete in the forms;
H – the height of the poured concrete (m);
- rate of setting (loss of fluidity). ρ b – density of fresh concrete (kg/m3).
Table 2. Relation between rate of concrete
pour, concrete workability, section of
element and concrete temperature
Characteristics λ1 λ2 λ3 λ4
≤1 0.55
2 0.65
3 0.75
Rate of concrete pour
(m/hour) 4 0.85
6 0.90
8 0.95
Figure 3. Lateral forces due to concrete acting on a wall ≥ 10 1.00
form. ≤1 0.85
1…4 0.95
Workability of concrete,
slump (cm) 5…9 1.00
The first depends on the size of form or forms 10…15 1.05
being filled vs. the rate at which the concrete is ≥ 15 1.10
placed. The second depends on a number of ≤ 15 0.90
Minimum section of
16…54 0.95
factors, of which the most significant is the element (cm)
≥ 55 1.00
temperature. The time of setting for concrete ≤5 1.00
according with NE 012-99 [5] is when the Concrete temperature (oC) 6…24 0.95
temperature of concrete is 10o …30o C is 35…40 ≥ 25 0.90
min and for t < 10o C is 50…70 min according to
the grade of cement used (32,5 or 42,5). The minimum pressure pinf is determined with
the following equation:
The effect of pressure in compacting the lower
fluid layers by forcing out mixing water
p inf = α.pmax (daN/m2) (4)
(bleeding) has led to the belief that for very
Where: α - has the value according to Table 3.
rapid rates of rise there is a maximum pressure
which cannot be exceeded. It will usually be Table 3. Coefficient α according to rate of
more economical to control the rate of rise than concrete placement.
to try to provide form strength to resist such
Rate of placement
high pressures. <1 2 3 4 6 8 ≥10
(m/hour)
α 0 0.25 0.45 0.70 0.80 0.90 1.00
The rate of placement the relation between the
height of the form H and the time period needed g) Dynamic load from lateral pressures due to
for the casting of the whole element. The rate of impact of falling concrete during placement:
pour is expressed in meters of concrete poured - for a capacity of the transport equipment:
per hour. 0,2 m3 ...........................200 kg/m2
0,2...0,7 m3....................400 kg/m2
The hydrostatic lateral pressure is given by the 0,7 m3............................600 kg/m2
following equation: - for placement with chutes and hoppers: 200
p = ρ.H (1) kg/m2
- for placement with concrete pumps: 600
Where: kg/m2

104 Jurusan Teknik Sipil, Fakultas Teknik Sipil dan Perencanaan – Universitas Kristen Petra
http://puslit.petra.ac.id/journals/civil/
 WALL FORMWORK DESIGN (George Ilinoiu)

h) Wind forces on wall forms that will be taken - Allowable tolerances for panels:
into account only for bracings, scaffolds, and - for length and width of panel + 2 mm;
centres 700 daN/m2 - for thickness of panel - 5 mm;
- for length of diagonals of panel ± 5 mm.
For the design of the size and deflections of
component elements of the formwork, the loads
will be taken into account differently, according DESIGN EXAMPLE OF WALL AND
to the Table 4. SLAB FORMWORK AND SHORING
SYSTEMS [6]
Table 4. Combination of loads
Loads Symbols for cross section of rectangular beam
Item name
Strength Deflection
Slab and arch forms and horizontal props
a+b+c+d a+b
(beams)
Vertical props for floors a+b+c a+b
Column forms with the maximum face of 30
f+g f
cm and walls of maximum 10 cm thickness
Column forms and walls with bigger values f f
Lateral faces of forms for beams and arches f f
Bottom of beams a+b+e a+b
Centres and scaffolds < 6 m a + b + c (e) a+b Table 5. Nomenclature
Centres and scaffolds > 6 m a + b + c (e) + h a + b
List of U.M.
Meaning
symbols
The design of formwork components will be
X-X or Y-Y Neutral axes
made according to the following characteristics: b [cm] Width of beam face on which
- Type of material used; load or force is applied
- Nature of the load; d [cm] Depth or height of beam face
- Number of reuses; parallel to the direction inn
which the load or force is
- Moisture conditions; applied
- Deflection limitations. δ [cm] Plywood thickness
h slab [cm] Thickness of slab
M [daNcm] Bending moment
PROPERTIES OF FORM MATERIAL I = bh3/12 [cm4] Moment of inertia of the cross
section of a beam
y [cm] Distance from neutral axes to
Materials used for forms include lumber, ply- most distant fiber of beam
wood, plastics, steel, aluminum etc. Additional σe [daN/cm2] Applied bending stress
materials that are used include: nails, bolts, σa [daN/cm2] Allowable bending design
screws, ties, anchors etc. stress
W = I/y = bh2/6 [cm3] Section modulus of the cross-
section
Properties of form material are as follows: E [daN/cm2] Modulus of elasticity
- Allowable bending stress of lumber (σa) P [daN] Concentrated load due to work
120daN/cm2 crews and transport equipment
q [daN/ml] Uniformly distributed load per
- Allowable bending stress of plywood (σa) unit length (ml)
- When the face grain is parallel to the span
130 daN/cm2 Initial Design Data:
- When the face grain is perpendicular to § Member dimensions;
the span 50 daN/cm2 § Technology of concrete placement;
- Allowable bending stress of steel (σa) 2100 § Rate of concrete placement;
daN/cm2 § Temperature of concrete;
- Modulus of elasticity (E) § Workability of concrete (consistency);
for lumber 100000daN/cm2 § Story height H story ;
for plywood 70000 daN/cm2 § Thickness of slab hslab.
for steel 2,1x 106 daN/cm2
- Allowable bending deflection limitations for Technical note: The design will be made for a
the various modular panels are usually: wall with a thickness greater than 10 cm and
(L maximum clear span)/300 – for con- respectively a column with the edge greater
crete surfaces exposed to view; than 30 cm.
(L maximum clear span)/200 – for con-
crete surfaces with finishing.

Jurusan Teknik Sipil, Fakultas Teknik Sipil dan Perencanaan – Universitas Kristen Petra 105
http://puslit.petra.ac.id/journals/civil/
 DIMENSI TEKNIK SIPIL VOL 6, NO. 2, September 2004: 101 - 108

Loads b. For 60 cm width panel:

Static load from lateral pressures due to a q (daN/m)

particular height of plastic concrete (placed and
compacted) according to the rate of placement
l = 27.6 cm l = 27.6 cm
on the panel’s surface.
Verification for bending stress: Verification for deflection:
p max = λ1 .λ 2 .λ 3 .λ 4 .H.ρ b (daN/m2) M qxl 4 l
≤ σ a =130daN/cm
2
σe = fe = 0.005. ≤ fa =
p inf = α.Pmax (daN/m2) W ExI 200
M = q . l2/8; b.h3 (cm4)
h p = λ1 .H W = b . h2/6 I=
h = 15 mm 12
Where: b=1.00m, h = 8 or 15 mm
λ1 – coefficient according to work conditions. E = 70000 (daN/cm2)
H – the height of the poured concrete (level)
(m). Design of Battens (Distances Between
ρ b – density of fresh concrete (2400 kg/m3). Wales)
α – coefficient according to rate of pour.
The design will be made in the most least
favorable situation, that is the design of the
central span of the 60 cm width plywood panel.

The load is uniform distributed, with the value

of:
p + pinf 
q = f .0,276 =  max 0,276 m daN/ml
 2 

D 40 cm

D3
C

Figure 4. Pressure distribution of lateral face of panel

D2
pmax
Technical note: The design will be made for a B

plywood sheet of 30 and 60 cm width respec- D1

tively. If in the design just one of the above A
panels is used then the design will be made for pmin 15 cm
that one.
Verification for bending stress: Verification for deflection:
σ e ≤ σ a ⇒ q.D / 8 ≤ σ a ⇒
2
The design will be made for a width of panel b = q.D 4 D ⇒
f e ≤ f a ⇒ 0.007. ≤
1,00 m W E.I 200
10.σa .W E.I
D= D=3
The load is considered uniformly distributed, q 1,4.q
with the value of: σa = 120 (daN/cm2)
b.h 3 (cm4)
p + p inf  I=
q = f .1,00 =  max 1,00m (daN/ml) W = b . h2 / 6 12
 2  b=1.0 m; h = 15 mm.
b = 48 mm; h = 85 mm. E = 100 000(daN/cm 2)
Design of Plywood Sheathing
The values will be chosen as follows: D1=Dmax,
Verification of plywood panel the minimum value for “D” calculated for the
a. For 30 cm width panel: verification of resistance and deformation, but
q (daN/m) not more than 60 cm.

The values for D2 and D3 will respectively be

l = 25.2 cm
40% and 60% of the distance B-D remaining
Verification for bending stress: Verification for deflection:
(where B-D = H story – 0,15 – 0,40 cm).
M 5 q.l 4 l
σe = ≤ σa = 130 daN/cm2 fe = x ≤ fa =
W 384 E.I 200
M = q . l2/8; Design of Wales (Distances Between Ties)
b.h3 (cm4)
W = b. h2/6 I=
b= 100 cm 12 The wall formwork design will be made
h = 8 or 15 mm b=1.00m, h = 15 mm
E = 70000 (daN/cm 2) according to the lateral pressure of fresh

106 Jurusan Teknik Sipil, Fakultas Teknik Sipil dan Perencanaan – Universitas Kristen Petra
http://puslit.petra.ac.id/journals/civil/
 WALL FORMWORK DESIGN (George Ilinoiu)

concrete; this may use the calculation to tion of resistance and deflection. The distance d
determine the spacing of wales. It will be ≤ dmax, will be adopted according to the
assumed that the first tie will be as close to the formwork design plan, knowing that the tie will
bottom of the form as is practical, within be put only between panels.
150…200 mm, and that the top tie will be at or
near the top. Tie Design
q (daN/ml)
Only the most loaded tie will be calculated, that
is the one placed nearest to point B (see figure).
60 cm d d The tensile stress on the tie is: T = q.d (daN)
Where:
Where:
D - correct distance between ties, according to
d – distance between ties;
formwork design drawing.
D – distances between wales (vertical).
T
D 40 cm Aa = ; Ra = 2100 (daN/cm2)
pD Ra
D3
pC C The diameter of the tie will be chosen according
to Aae ≥ Aanec
pmax D2
B
pB
D1 REFRENCES
pA A
15 cm 1. Ilinoiu, G., Construction Engineering. Con-
pmin
spress Publishing House, 2003, pp.9-26.

The values for p A, pB, pC (daN/m2) will be 2. C140-71, Concrete and reinforced concrete
calculated according to the known values pmax execution works.
and pinf (daN/ml).
3. Peurifoy, R., Oberlender G. Formwork for
The wale most stressed will be calculated (wale Concrete Structures, McGraw-Hill, 1996.
most near to the highest pressure point – point
B), with the following equations: 4. C11-74, Instructions regarding components

q A = pA .
(0,15 + D1) (daN/ml) and use of plywood for formwork.
2
(D1 + D2) 5. NE 012-1999, Practice code for the execution
q B = pB . (daN/ml) of concrete, reinforced concrete and pres-
2
tressed concrete works, Part 1 – Concrete and
q C = pC.
( D2 + D3) (daN/ml) reinforced concrete.
2

q=
(q A + 2.q B + q C ) (daN/ml) 6. Teodorescu, M., Budan, C., and Ilinoiu, G.,
4 Technology of Construction Works License
Verification for bending stress: Examination Guide,
q .d 2 / 8 10 .σ a .W
σe ≤ σa ⇒ ≤ σa ⇒ d = 7. Technical University of Civil Engineering of
W q
Bucharest Publishing House, 1998.
Wale (square shape pipe):
40 . 40 . 3,5 (W=5,73 cm3; I=11,50 cm4)
45 . 45 . 4 (W=8,25 cm3; I=18,60 cm4)
55 . 55 . 4 (W=12.9 cm3; I=35,60 cm4)
Verification of deflection:
qxd 4 d ⇒ E.I
f e ≤ f a ⇒ 0 .007 . ≤ d=3
ExI 200 1,4.q
Where:
σ = 2100 (daN/cm2)
E = 2 100 000 (daN/cm2)

Technical note: dmax will be chosen as the

minimum value resulted for both the verifica-

Jurusan Teknik Sipil, Fakultas Teknik Sipil dan Perencanaan – Universitas Kristen Petra 107
http://puslit.petra.ac.id/journals/civil/