PROCEDURE FOR FORMWORK

Doc. No: WPM.B.03

DOCUMENT RELEASE AUTHORIZATION

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 Table of Contents

Chapter
Title of chapter Page No.
No.

I History of Revisions 03

1.0 Purpose 04

2.0 Scope and Application 04

3.0 Definitions 04

4.0 Responsibility & Authority 04

5.0 Cross References 05

6.0 Flow Chart 05

7.0 Procedure 06

8.0 Quality Metrics (Effectiveness & Efficiency Measures) 11

9.0 Records 11

10.0 Attachments 12

11.0 Tolerance & Acceptance Criteria 12

12.0 Do’s and Don’t 13

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 History of Revisions

Revision Revision Chapter/clause no. &

Reason for Revision
No. issue date text affected

First Issue
0 -
Due to Brand change
1 -
Change from ISO:9001:2000 to ISO
2 Entire Procedures 9001:2008

Clause 9.0 Procedure New technology Adoption

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SOP Effectiveness Review:
4 - Checklist for Formwork added.

(Critical Action Points from

Learning’s of Group Kaizens 2012
5 - incorporated: Use drop chutes
incorporated)

6 - Change of Word Mark

7 CI 3,4,5,7,9, 11 Definitions added, Responsibility

matrix added, Retention and
disposition added and Tolerance and
Acceptance criteria added,

Cross references
Clause 5
Flowchart
Clause 6
Key requirements included in
Clause 7
Procedure
8 Clause 8
New Clause Tolerances and
Clause 11
Acceptance criteria
Clause 12 New Clause Do’s and Don’t’s

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 1. Purpose:

To document a procedure to provide a standard approach for carrying out the works associated with the formwork
on site.

2. Scope & Application:

To ensure that appropriate precautions are taken while designing, preparing and fixing of formwork.

3. Definitions:

3.1 MSDS: Material safety data sheet contains information relevant for safe use of any
chemically substance
3.2 Scaffolding: Is a temporary structure used to support people and material in the construction or repair of
buildings and other large structures.
3.3 Strut: Is a structural component designed to resist longitudinal compression. Struts provide outwards-
facing support in their lengthwise direction.
3.4 Formwork: Is the term given to either temporary or permanent molds into which
concrete or similar materials are poured.
3.5 Tie Rod: Is the steel bar having threads upon it and provided nuts to both of its end to tie opposite faces
of formwork. Tie rods are mainly provided to withstand the tension generated due to thrust on the sides
of the formwork due to concrete.
3.6 Sheathing: The contact area of concrete and the formwork or the area which gives
the finishing surface to the concrete is called as sheathing. It is made up of different materials such as
plywood, metal plates etc.
3.7 Studs: These are the vertical members to which the sheathing is attached.
3.8 Wale: These are the long horizontal members used to support the studs.
3.9 Bond breaker I Form Release Agent: Non-staining liquid product which imparts a waterproof film
to prevent adhesion of concrete and will not leave a paint impeding coating on the face of concrete.

4. Responsibility & Authority:

Task Responsibility

Completion of works as per relevant WPM Building In-charges - MIPCL, Contractor

(work procedure manual), latest GFC drawings,
latest approved revision of PQP (Project Quality
Plan)
Inspection & approval of work as per this SOP Engineer In charge – SAKTHI
ASSOCIATESS Engineer in charge - MIPCL
Random checking and inspection QC in charge- MIPCL.

Stage Clearance for next activity, Training & QC Incharge ,MIPCL Project Head
Awareness on SOP

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5. Cross References:

 Standardized Technical Specifications

 Approve Latest revision of Project Quality Plan
 Contract document & BOQ
 Tolerance & Acceptance Criteria
 IS 4990 (Latest Revision),IS 6461 (Latest Revision),IS 456 (Latest Revision)

6. Flow Chart:

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 7. Procedure: General

7.1 Form work may be of wood, plywood, Aluminum, steel, PVC or fiberglass. Sliding forms / slip
forms, system formworks may be used as per project requirement. Plywood used for formwork shall be 12mm
thick double side coated marine ply conforming to IS 4990

7.2 The form work shall consist of shores, bracings, sides of beams and columns, bottom of slabs etc.
including ties, anchors, hangers, inserts etc.

7.3 Timber used for props and bracings shall be well seasoned, free from sap, shakes, loose knots, holes,
warps or other surface defects.

7.4 The contractor shall draw, design and prepare Shuttering scheme, method statement backed with load
calculations, required sketches, details of repetitions and handling for approval by MIPCL in charge and Structural
consultant

7.5 While Planning Contractor shall ensure number of sets of system formwork to achieve schedule as per the
planned sequence. Contractor is responsible carrying out Initial mock ups and to get approval from MIPCL. Care
shall be taken for maintenance, repairs, periodic checks etc. by the contractor

7.6 At any stage of formwork clearance till concreting, required cover gauges shall be provided by the
contractor

7.7 Contractor shall ensure Stop ends properly sealed, construction joint preparation, required guard rails and
handrails, access

7.8. Upper floor concreting shall be done only when the lower floor achieves strength ,provided with sufficient
props supported at least one floor below

7.9 Care shall be taken to see that column panels shall not be used as a walk way planks and for any other use
than for column / shear wall shuttering.

7.10 Incase of System formwork, Manufacturer’s technical representative shall be present throughout the period of
RCC or as per the instruction by the project manager

7.1. FORM WORK REQUIREMENTS:

7.1.1 The site shall ensure that the formwork design (Scheme drawings) is approved by the consultant.
Forms shall be so designed and their removal do not damage the concrete. Face of formwork shall
provide true vertical and horizontal joints, conforming to the architectural features of the structure.
7.1.2 Forms shall conform to the shapes, lines, grades and dimensions, including camber of the concrete as
specified in the drawings. Ample studs, water, braces, straps, shores etc. shall be used to hold the forms in
proper position without any distortion
whatsoever, until the concrete has set sufficiently to permit removal of forms.
7.1.3 The formwork shall be so constructed that up and down vertical adjustment can be made smoothly.
7.1.4 Forms shall be strong enough to permit the use of immersion vibrators.
7.1.5 The shuttering shall be placed in the required levels without any gaps and shall be free from

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 adhering grout, paint, projecting nails, splits or other defects.
7.1.6 Inside faces of forms for concrete surfaces, which are to be, rub finished shall be planned to
remove irregularities or unevenness in the face.
7.1.7 Joints shall be sufficiently tight to prevent loss of water and fine material from concrete. Joints may
be filled by bonding tapes / foam sheet.
7.1.8 Shores supporting successive stories shall be placed directly over those below or be so designed and
placed that the load will be transmitted directly to them. Trussed supports shall be provided for shores
that cannot be secured on adequate foundation.
7.1.9 Forms for substructure concrete may be omitted when, in the opinion of PM, the open excavation is
firm enough to act as the form.
7.1.10 AII new and used form timber shall be maintained in a good condition with respect to shape, strength,
rigidity, water tightness, smoothness and cleanliness of surfaces.
7.1.11 Wedges may be used at the top or bottom of timber shores, but not at both ends, to
facilitate vertical adjustment or dismantling of formwork.
7.1.12 Such excavations shall be slightly larger than required by the drawings to compensate for
irregularities in excavation and to ensure the design requirement.
7.1.13 Form members unsatisfactory in any respect shall not be used and if rejected by PM or QA
In-charge, shall be removed from the site.
7.1.14 Form work, during any stage of construction showing signs of distortion or distorted to such a
degree that the intended concrete work will not conform to the exact contours indicated on the
drawings, shall be repositioned and strengthened or replaced.
7.1.15 Poured concrete affected by faulty formwork, shall be corrected and the formwork shall also
be rectified, prior to placing new concrete.
7.1.16 Cutouts, Sleeves ,Inserts and Pockets shall be secured rigidly to keep them in position
7.1.17 Incase of water retaining structures, tie bolts shall not be removed but the same is cut at 25mm from the Surface
and filled with Non shrink chemical compound
7.1.18 After stripping , formwork materials shall be cleaned and neatly stacked

7.2. BRACINGS, STRUTS AND PROPS:

7.2.1. Shuttering shall be braced, strutted, propped and so supported that it shall not deform underweight and
pressure of the concrete and due to the movement of men and other materials. Bracing shall be 40nb
medium duty MS steel pipes using Swivel coupler. No binding wires or ropes shall be used for tying props and
bracings
7.2.2. Bamboos shall not be used as props or cross bracings.
7.2.3. The shuttering for beams and slabs shall be so erected that the shuttering on the sides of beams
and under the soffit of slabs can be removed without disturbing the beam bottoms.
7.2.4. Re-propping of beams shall not be done except when props must be reinstated to take care of
construction loads anticipated being in excess of the design load.
7.2.5. Vertical props shall be supported on wedges or other measures shall be taken whereby the props
can be gently lowered vertically while striking the shuttering. At any case Wooden props shall not
be used,
7.2.6. If the shuttering for a column is erected for the height of more than 2.70 m, windows may be
left for pouring concrete from the sides to limit the drop of concrete to 1.50 m or

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 appropriate chute shall be provided for smooth flow of concrete without segregation or shall be
done as directed by EIC.
7.2.7. Props shall be placed only on firm-hard base. Shall not be placed on soil for any kind of shuttering
7.2.8.Heavy Medium and Light props shall not be mixed and used

7.3 FORM RELEASE AGENT:

7.3.1. Use of form oil shall not be permitted on the surface, which require painting unless otherwise
mentioned in the manufacturer's specifications. Form oil shall however be
applied on forms of other concrete structures. An approved non-staining mold / form releasing agent
(solvent / water based) shall be used, provided it is applied before placing reinforcing steel and
embedded parts. Diesel/waste oil shall not be used as form
releasing agent. These agents shall be of approved brands like Master finish BASF , Rebel Fosroc or
equivalent..
7.3.2. All excess oil on the form surfaces and any oil on metal or other parts to be embedded in the
concrete shall be carefully removed.
7.3.3. Before treatment with oil, forms shall be thoroughly cleared of dried splatter of concrete from
placement of previous lift.

7.4 CHAMFERS AND FILTERS - (OPTIONAL ONLY):

7.4.1. All corners and angles exposed in the finished structure shall be formed with moulding to form chamfers or
fillers on the finished concrete. The standard dimensions of chamfers and fillets, unless otherwise specified,
shall be 20 X 20 mm.
7.4.2. Care shall be exercised to ensure accurate rnouldinq . The diagonal face of the moulding shall be planed or
surfaced to the same textures the forms to which it is attached.

7.5. VERTICAL CONSTRUCTION JOINT CHAMFERS:

Vertical construction joints shall be provided, which shall be exposed on completion of work, shall
be chamfered (20 mm X 20 mm), except where not permitted by PM, for structural or hydraulic
reasons.

7.6 Wire Ties: Wire ties for external beams can be used wherever essential as per formwork scheme
drawing. Through bolts shall be permitted only where permitted by the Structural Consultant / Project
Manager.

7.7 TOLERANCE:

Following are the tolerance limits subject to approval in writing by RCC Consultant / Head of Department:
7.7.1. Variation from the plumb:
• In the line and surfaces of columns, walls and in buttresses 4mm. Per 2.5m.,
• For exposed corner columns and other conspicuous lines:
i) In any bay or 5m. maximum: (+/-)5
mm. ii) In 10m. or more (+/-)10 mm

7.7.2. Variation from the level or from the grades indicated on the drawings. a)
In slabs soffits, ceiling, beam soffits and in risers:

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 • In 2.5m. (+/-)5 mm
• In any bay or 5m. maximum: (+/-) 8 mm.
• In 10 m. or more: (+/-) 10 mm
b) For exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines.
• lrL§.D.v. bay or 5 m. maximum (+/-) 15 mm
• In 10 m or more: (+/-) 10 mm
c) Variation of the linear building lines from established position in plan and related
position of columns, walls and partitions.
• In any bay or 5m. maximum: (+/-) 10 mm.
• In 10m. or more (+/-) 20 mm.
d) Variations in the sizes and locations of sleeves, openings in walls and floors except in the
case of and for anchor bolt: (+/-) 5 mm.
e) Variation in cross-sectional dimensions of columns and beams & in the thickness of slabs
& walls: (+) 10 mm or (-) 5 mm

7.7.3. Footings:

a) Variation in dimensions in plan: (+) 50 mm / (-) 5 mm.

b) Misplacement or eccentricity: 2% of footing within the direction of misplacement but not
more than 50 mm.
c) Reduction in thickness: (-) 5% of specified thickness subject to maximum of 50 mm.

7.7.4. Variation in staircase:

a) In a Height of stairs:
• Riser: (+/-) 3.0 mm.
• Tread: (+/-) 3.0mm. b)
In consecutive steps.
• Riser: (+/-) 2 mm.
• Tread: (+/-) 3.0 mm
7.7.5. Tolerances in other concrete structures:
A) All structures
1) Variation of the constructed linear outline from established position in plan.
• In 5m: (+/-) 10 mm.
• In 10m or more: (+/-) 15 mm.
2) Variation of dimensions to individual structure features from established positions in
plan
• In 20 m. or more: (+/-) 25 mm.
• In buried constructions: (+/-) 150 mm.
3) Variation from plumb, from specified batter or from curved surfaces of all
structures.
• In 2.5 m : (+/-) 10 mm.
• In 5.0 m: (+/-) 15 mm
• In 10.0 m. or more: (+/-) 25 mm.
• In buried constructions: (+/-) twice the above limits.
4) Variation from level or grade indicated on drawings in slabs, beams, and soffits, horizontal
grooves and visible arises
• In 2.5 m: (+/-) 5 mm.
• In 7.5 m. or more: (+/-) 10mm

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 • In buried constructions: (+/-) twice the above limits.
5) Variation in cross-sectional dimensions of columns, beams, buttresses, piers and similar
members: (+) 10 mm / (-) 5 mm.
8) Footings for column, piers, walls, buttresses and similar members:

1) Variation of dimensions in plan: (+) 50 mm. / (-) 10 mm.

2) Misplacement or eccentricity: 2% of footing within the direction of misplacement but not
more than 50 mm.
3) Reduction in thickness: 5% of specified thickness subject to a maximum of 50 mm.
7.8 REUSE OF FORMS:

7.8.1 Before reuse, all forms shall be thoroughly scraped, cleaned, nails removed; holes that may
leak suitably plugged and joints examined and when necessary repaired
.§Indthe inside retreated to prevent adhesion, to the satisfaction of EIC.
7.8.2 The Project Manager shall ensure that new forms are brought to site, by the contractor,
at the commencement of the project
7.8.3 PM and the contractor shall agree the' Repetitions' of these forms based on manufacturer specs,
at the commencement of the project. However during the
agreed repetitions, if formwork is found to give surface defects or not meeting required
tolerances, the same shall be replaced with new formwork.
7.8.4 The Contractor shall equip himself with enough shuttering to complete the job in the
stipulated time.

7.9. REMOVAL OF FORMS:

7.9.1. A record shall be maintained showing, the date upon which the concrete is placed in each part
of the work and the date on which the shuttering is removed there from.
7.9.2. For Concrete made with OPC, Following Stripping period of shuttering shall be as given
below. However, for other Cements the striking period may increase
7.9.3. For aluminum formwork: DE shuttering will depend on concrete mix design and setting
time. Trails shall be conducted at lab to ascertain the setting time for aluminum form work.
7.9.4. Striking shall be done slowly, without shock or vibration, by gently easing the Wedges. 7.9.S.
If after removing the formwork, it is found that timber has been embedded in the
concrete, it shall be removed and the concrete shall be made good.
7.9.6. Reinforced temporary openings shall be provided, as directed by PM, to facilitate removal
of form work, which otherwise may be inaccessible.
7.9.7. Tie rods, clamps, form bolts etc. which must be entirely removed from walls or similar structures shall
be loosened not sooner than 16-24 hours, nor later than 40 hours, after the concrete has been placed.
Ties, except those required to hold forms in place, may be removed at the same time.
7.9.8. Work damaged due to premature careless removal of forms shall be rectified at Sub- Contractor's
cost.
7.9.9 Any prefabricated molds shall be removed within 24 hrs. and stored properly within 48 hrs

Following timeline shall be used for Stripping of formwork after expiry of the specific period
post issue of DE shuttering clearance by MIPCL after conducting cube testing except for vertical forms.

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8. Quality Metrics: (Effectiveness & Efficiency Measures)

“The effectiveness measure is 100% compliance to this SOP”. Requirements of good

Formwork: 1.Zero Leakages

2.Smooth Surface

3.Rigidity

4.Easy Removal

5.Light Weight

6.Quality

7.Strong Supports

9.Records:

Name of Records Retention Time and Disposition

Check list for form work - CT 5 Years after completion of project post
.04.WPM.B.06
which the document will be disposed by

shredding

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10. Attachments:

Check list for form work - CT.04.WPM.B.06

Formwork Design Calculations

Formwork scheme

11. Tolerances and Acceptance Criteria:

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12. Do’s and Don’ts:

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