Session: #

The Effects of Self Compacting Concrete

on Formwork

Presented by:
Vaughan Burgess
Form-Scaff
OVERVIEW
• Formwork
• Concrete pressure (results from tests)
• Concrete pressure considerations
• Formwork incidents
• Formwork removal
• Formwork on support work
• Pro’s and cons
• Conclusions
WHAT IS FORMWORK ?
 Formwork is used to support
and form (mould) the shape of
fresh concrete

 It remains in position until

the fresh concrete becomes
stiff enough to maintain
its own shape
 Formwork is usually made from steel,
timber, fibre glass, plastic…
or a combination of these
materials
 The formwork may be supported on support work
 The facing of the formwork can be lined to produce
various textured or patterned concrete finishes.
 The patterned finish may be glued or screwed to the
formwork facing.
 Examples of various textured or patterned concrete
finishes.

Reduced pressure
 The facing of the formwork can be lined to produce
various textured or patterned concrete finishes.
 It can be made to any reasonable shape to accommodate
the aesthetic and practical needs of the architects and
engineers.

FORMWORK - SPECIALS
CONCRETE PRESSURE (results from tests)
• (Khayat, Bonen, Shah and Taylor) compiled a summary of
some tests/experiments.
Correctly understanding and interpreting the results…
agreements and disputes.
Listed, are some of the many statements/findings from the
numerous SCC tests that have been conducted over a
period of many years :
• Formwork test results (overview) :
 The maximum pressure of SCC depends on the speed
of casting and the rate of the continuous pressure
decrease in the SCC already cast.
 The placing method very strongly influences the
rising formwork pressure.
 SCC pumped from the base can locally surpass
hydrostatic pressure.
• Formwork tests results (overview) :
 Formwork should be designed to withstand the full
hydrostatic head of fluid concrete.
 ACI 347R-7 document stipulates, when working with SCC,
the presumed lateral pressure should be equal to
hydrostatic pressure.
 The actual pressure of SCC varies from full hydrostatic
pressure to 60% of full hydrostatic pressure.
• Formwork tests results (overview) :
 Initial low shear stress of the plastic SCC results in high
pressure.
 Concrete mixtures containing fly ash develop higher
lateral pressure.
 An increase in slump results in greater lateral pressure.
• Formwork tests results (overview) :
 Irrespective of the composition and workability of
the mixture, lateral pressure increases as the casting
rate increases.
 Thixotropy (materials gel at rest) has been identified as a
main factor that affects the initial lateral pressure and its
rate of decline.
High degree of thixotropy = higher rate of pressure drop
 There is no consensus on the rate of decline of lateral
pressure.
• Formwork tests results (overview) :
 Change in the w/c has a significant effect on SCC.
Test using a SCC with a slump flow of 550mm and a
w/c of 0.46 results in lower thixotropy and greater
initial pressure than a w/c of 0.4.
 An increase of lateral pressure may result from the
use of more cement.
 Increasing the w/c or/and superplasticiser content
increases the lateral pressure.
• Formwork tests results (overview) :
 If the content of the fines is increased, the ability of
the course aggregate to carry loads decreases and
the lateral pressure increases.
 A lower age SCC and higher flowability (slump flow)
generates higher pressures.
 The higher the initial temperature of the
concrete/ambient temperature the lower the lateral
pressure and the faster the rate of hydration…etc…etc.
CONCRETE PRESSURE CONSIDERATIONS
• Temperature :
 Concrete – Ambient (Roby)
– Concrete : lower temp = higher pressures

 Form face – Steel vs timber

• Form face – steel vs timber :

MEAN  Reduced pressure if :

FORMWORK
PRESSURE
SURFACE  Timber
(kPa)
Populus nigra (wet) 22.8  Not wet
Populus nigra 20.9  Lined
Pinus silvestris (wet) 23.7  Rough
Pinus silvestris 19.9
Plywood (wet) 24.6
Plywood 21.5
Steel 26.2
(Arslan)
• Method of placing :
- pumped T&B, bucket…
Concrete
tremie (impact)… bucket

Wall
formwork
• Method of placing :
- pumped T&B, bucket…
tremie (impact)…

Wall formwork
• Method of placing :
- pumped T&B, bucket…
tremie (impact)…

Wall formwork

A
• Formwork shape
• Formwork shape
• Form size, concrete thickness and rate of placement :
The effect of concrete pressure on formwork using SCC
relative to the thickness of concrete, rate of placement and
the presence of reinforcement has been tested.
(Khayat, Assaad and Mesbah)

Tests (slump flow = 650mm) :

Two columns were tested using pressure
sensors :
 200mm Ø x 2100 high
(12.6 mins & 5.0 mins)
 920mm Ø x 3600 high
(21.6 mins and 8.6 mins).
• Form size, concrete thickness and rate of placement :
Results :
A varying rate of rise had limited influence due to the short
casting period.
The 200mm Ø column exerted slightly less
pressure immediately after placing.
This is possibly due to the arching effect.
• Reinforcement :
The presence of reinforcing bars may slightly reduce the
concrete pressure on formwork since the reinforcement can
partially support the concrete weight.

Reduction of pressure due to thickness & rebar = negligible.

• Compaction :
 Concrete compaction – method & duration

Pressure greatest during compaction…..needle Ø,

frequency, mix….

The increase of the diameter of the head

& the radius of action increases the
workability.
The vibration reduces the friction between
the particles in the concrete mix and
allows the concrete to flow.
• Concrete mix - variable proportions of :
 Aggregate
type, size, texture, shape, source…
 Sand
 Water - w/c
 Cement - type
 Extenders - fly ash, silica fume, slag…fillers…
 Admixtures - retarders, accelerators, air entrainers,
plasticizers, VMA…(types)
and,
 Lapsed time between batching and placing
 Strict control measures in place and implemented =
reliability of the mix.
• Rate of placing
The pressure developed on the form face is a result of wet
concrete being placed into the formwork.
 The faster the rate of rise
(speed at which the concrete
fills up the formwork) the
higher the concrete pressure
on the formwork face
 The stiffening of previously
placed concrete reduces this
pressure.
• The pressure envelope for normal concrete according to
CIRIA = 25kN/m2.

Wet concrete, relative to formwork design, has a

density of approximately 24kN/m3.
• The pressure envelope for normal concrete according to
CIRIA = 25kN/m2.

Wet concrete, relative to formwork design, has a

density of approximately 24kN/m3.
• Rate of placing :
Generally full hydrostatic pressure would be used for
formwork design if the form is less than 1m in height.
The pressure acts equally on opposite formwork faces and
at 90° to the face.
1m h / hr

NC
24kN/m2

24kN/m2

PRESSURE DIAGRAMS
• Rate of placing :
Maintaining 1mh/h limits the
pressure of the form face. 2m

1m h/hr
1m h / hr 1m 1m

NC NC
24kN/m2

24kN/m2

24kN/m2
48kN/m2
• Rate of placing :

1m h/hr 2m 2m at 1m h/hr

80% of Hydro ?
1m h / hr 1m 1m h / hr

NC SCC NC SCC

24kN/m2
48kN/m2
24kN/m2

24kN/m2

~_ 48kN/m2
FORMWORK INCIDENTS
The site workers must be kept safe from incidents such as
burst formwork.
A burst form can lead to fatalities or serious injuries to
workers.
PRO’S & CONS
• There are many advantages of using SCC in preference
to NC.
• SCC vs NC (formwork)
SCC Pro’s
 Vibrating equipment / labour is not required
 Free flowing - does not need compaction
 Confinement of space and congested rebar -
the cost of formwork can be reduced
• SCC vs NC (formwork)
SCC Pro’s
 Vibrating equipment / labour is not required
 Free flowing - does not need compaction
 Confinement of space and congested rebar -
the cost of formwork can be reduced
• SCC vs NC (formwork)
SCC Pro’s
 Vibrating equipment / labour is not required
 Free flowing - does not need compaction
 Confinement of space and congested rebar -
the cost of formwork can be reduced
 Removes over and under vibration concerns
 Reduces heaping possibilities
 Improved off shutter finish on walls…
SCC Cons
 Pouring rate needs to be strictly controlled
 Concrete mix/admixtures must be maintained
 Slower formwork cycle time ?
 Pressures could be as high as hydrostatic - increases the required
strength of wall formwork and therefore the cost of formwork
 Slides, open formwork and sloping upper surfaces…
• Open formwork
Depending on the variables / additives in the SCC, the flow
of concrete varies.

NC
• Open formwork
Depending on the variables / additives in the SCC, the flow
of concrete varies.

NC SCC
• Sloping upper surfaces require a relatively “stiff” mix.

NC
• Sloping upper surfaces should be screeded.

NC
• SCC flows such that the upper surface remains level.

SCC
• When casting to a fall, the SCC should be contained in a
form.

SCC
FORMWORK – SUSPENDED IN POSITION
CONCLUSIONS
• All the variable factors such as temperature, rate of
placing, varying design mix (no specific composition),
performance of the admixtures…etc. makes it difficult to
calculate and interpret the data and therefore a safe
method of estimating the expected concrete pressure on
the form face needs to be adopted.
th2
P = wR t - where th = form height/R
2t0
t0 = t400
(Gardner, Keller, Quattrociocchi & Charitou – slump flow)
• Conclusions

Pmax = (1.0m + 0.26 RtE)w > 30 kPa

where R = rate of placement per hour

tE = conc. setting time (1.13mm Vicat
needle @10MPa for 2,5mm)
w = conc. mass (kN/m3)
(DIN 18218 – setting time test)
• Conclusions
Pmax = wh{112.5 – 3.8h +0.6R – 0.6T + 10Dmin
– 0.021PVƮ0rest@15min@T=22C} ƒMSA ƒwp
(static shear strength)

where w = conc. mass (kN/m3)

h = height of placement
R = rate of placement
T = concrete temp.
D = min. form dim.
ƒMSA = max agg size factor
ƒwp = factor for delay in lifts
(Khayat & Omran – on site shear strength)
• Conclusions
DIN 18218 : Based on concrete consistency class and
concrete setting end :

Hydrostatic load height (m)

Concrete pressure (kN/m2)
F6 F4
F5
F3

F2

F1

Pour rate (m/h) (meva)

• Conclusions
 A major problem is that these factors are unknown at
tender/design stage – lab/site test communication.
 Although the designer is expected to produce the most
cost effective formwork solution, the designer is strongly
advised to err on the side of caution when using SCC,
even though the formwork cost could exceed 60% of the
contract cost.
• Conclusions
It must remain the responsibility of the contractor to
inform the temporary works designer of the :
 concrete mix (NC, General blend or SCC),
 expected temperatures on the construction site for the
region and period,
 method of placing of the concrete and
 inform the experienced concreting team of the rate of
placing, placing time limit/programme, concrete mix,
compaction method if required…etc.
• Conclusions
Designers
+
Suppliers
+
Teams
+
Conditions
=
SCC

FORMWORK - SPECIALS
• Conclusions
It is important to resist the temptation, to cast the concrete
as quickly as possible, as the only apparent limitation is the
rate at which the concrete is delivered to site.
The site workers must be kept safe from incidents such as
burst formwork.
A burst form can lead
to fatalities or serious
injuries.