Chapter 5 - Building

Elements
1
Course: Building Construction
Course Code: CEng-3207
Program: Civil Engineering (regular)
Credit Hours: 3
Lecture: 2hrs/wk
Lab: 3hr/wk
Course Instructor: Zerihun M.
2
5.10 Formwork and
Scaffolding
3 Presentation Outline
q Introduction
q Requirements of a good formwork
q Materials for formwork
q Factors affecting selection
of formwork
q Construction of formwork

q Formwork striking
q Releasing agent
q Formwork design principle
q Failure of formwork
q Scaffolds and false works
4 Introduction

q Formwork, sometimes known as shuttering or casing, is the boarding or

sheeting which is erected to contain and mould the wet concrete during
placing and the initial hardening period.
Ø Formwork is a temporary structure that is required to support and
form concrete members.
Ø False work is the complete structure erected to support the wet
concrete.
5 Introduction (CoNT...)

q In most of the project formwork activity accounts for 30% to 60% of

the cost of the concrete skeleton and extends 40% to 60% of the total
project duration.
q Proper selection of formwork has greater influence:
Ø On reducing materials and labor cost,
Ø Improving the quality of the produced concrete and
Ø Saving time leading to smooth running of the projects.
6 Introduction (CoNT...)
Break up of different trades of work
7 Introduction (CoNT...)

Break up of different formwork items

8 Introduction (CoNT...)

Typical Cost breakdown of concrete slabs

9 Requirements of a Good Formwork
Quality

o Desired size, shape and finish of the concrete is achieved.

Safety

o Capable of supporting all dead and live loads without collapsing or danger to
workmen and to the concrete structure.

Economy

o Efficient, saving time and money for contractor and owner

10 Requirements of a Good Formwork (CoNT...)

q A good formwork should satisfy the following:

v It should be strong enough to withstand all types of dead and live loads such as:
Ø Self weight,
Ø Weight of reinforcement,
Ø Weight of wet concrete,
Ø Loads due to workmen,
Ø Construction equipment,
Ø Other incidental loads and forces caused by placement and consolidation
of concrete imposed upon it during and aftercasting of concrete
11 Requirements of a Good Formwork (CoNT...)

v It should be rigidly constructed and efficiently propped and braced both

horizontally and vertically so as to retain its shape without undue deflection.
v The joints in the formwork should be tight against leakage of cement grout.
v It should be constructed in such a manner that it may permit the removal of
various parts in desired sequence without damaging the concrete.
v The material of the formwork should be cheap, easily available and should be
suitable for reuse several times.
v It should be set accurately to the desired line and levels and should have plain
surfaces.
12 Requirements of a Good Formwork (CoNT...)

v It should be as light as possible.

v The material of formwork should not warp or get distorted when exposed to sun,
rain or water during concreting.
v All joints of the formwork should be stiff so that lateral deformation under loads is
minimum. Also the joints should be leak proof.
13 Requirements of a Good Formwork (CoNT...)

q A good formwork should satisfy the following:

Ø Containment; Ø Resistance to leakage;
Ø Strength ; Ø Accuracy;
Ø Rigidity; Ø Ease of handling;
Ø Tightness; Ø Finish and re-use potential;
Ø Good alignment; Ø Access for concrete;
Ø Surface finish; Ø Economy, and
Ø Durability; Ø Ease of stripping and economy.
14 Materials for Formwork

o Formwork can be mainly made up of

Ø Timber, Ø Aluminium
Ø Plywood, Ø Precast concrete or fibreglass, used
separately or in combination
Ø Steel
Timber Formwork
q The timber used for the formwork should satisfy the following requirements:
Ø It should be well seasoned,
Ø It should be light in weight,
Ø It should be free from knots.
15 Materials for Formwork (CoNT...)
Ø It should be easily workable with nails without splitting, and
Ø Timber used for shuttering exposed concrete work should have smooth and
even surface on all faces, which are to come in contact with concrete.
Ø In situations where concrete surfaces are not exposed, as in the case of
foundations, undressed timber can be used to reduce cost.
Playwood Formwork
Ø Use of plywood instead of timber planks is getting popular these days.
Ø Resin bonded plywood sheets are attached to timber frames to make up
panels of required sizes.
Ø Ensures quality surface finish and is especially recommended in works
where large exposed areas of the concrete are to be constructed such as
floor slab, faces of retaining walls, etc.
16 Materials for Formwork (CoNT...)
Wood Formwork
17 Materials for Formwork (CoNT...)
Steel Formwork
Ø This consists of panels fabricated out thin steel angles.
Ø The panels can be fabricated in large numbers in any desired modular shape
or size.
Ø Although steel shuttering costs more initially, it may work out to be
economical in the long run due to its large number of reuses of the same
shuttering.
q The advantage of steel formwork over timber formwork include:
Ø It is stronger, more durable and have longer life as compared with timber
forms.
Ø It can be put to sufficient large number of reuses, as high as 100 cycles.
18 Materials for Formwork (CoNT...)

Steel Formwork
Ø It can be installed and dismantled with greater ease and speed.
Ø The quality of exposed concrete surface obtained by use of steel form is
excellent and most of the time it need no further treatment.
Ø There is no danger of the formwork absorbing water from the concrete
and hence the chances honey combing are minimised.
Ø They are not liable to shrink or distort an hence it is possible to achieve
better workmanship and higher accuracy by use of steel forms.
Aluminium Formwork
Ø Enables the walls and slab to be placed monolithically in the same
operation
Ø Consistent concrete shapes and finishes are obtained
19 Materials for Formwork (CoNT...)

Steel Formwork Aluminium Formwork

20 Factors Affecting Selection of Formwork

q Formwork for building nearly account for 25% of RCC work.

q Selection of formwork material to be used should be based on maximum
economy to the contractor consistent with safety and quality required in the
finished work.
q Proper selection of formwork has greater influence:
ü On reducing materials and labor cost,
ü Improving the quality of the produced concrete and
ü Saving time leading to smooth running of the projects.
 21 Factors Affecting Selection of Formwork (CoNT...)

q Factors to be considered at the time of selection :

Ø Strength
Ø Economic use
Ø Ease of handling, erection and dismantling
Ø Ability to form the desired shape
Ø Concrete quality and finish required
o For a given set of circumstances and as a result of certain specific requirements
each material may have some particular attribute that will resolve a particular
constructional problem on a work
 22 Factors Affecting Selection of Formwork (CoNT...)

Decision Making Principles:

q Knowledge base evaluation
v Factors considered
ü Type of finish
ü Shuttering shapes
ü Re-use for good finish
ü Likely concrete defects
ü Re-use for rough finish
ü Area practice
ü Formwork component applied ü Where fabricatable
ü Noise produced ü Formwork repairs
ü Fire resistance ü Ease of making openings
ü Liability of shuttering damage ü Insulation properties
23 Factors Affecting Selection of Formwork (CoNT...)
q Project data
ü Contract Specialty
ü Contract type
ü Contract conditions
ü Project duration
ü Type of concrete finish
q Building Specialty
ü Building type ( commercial, residential, industrial)
ü Structural systems and details
ü Building scale (shape, length, width, height and no. of floors)
ü Building area(total, floor-wise and phase-wise)
24 Factors Affecting Selection of Formwork(CoNT...)
q Site Specialty
ü Access to site ü Site surroundings and its relationships

ü Site size ü Space for formwork fabrications

q Contractor Specialty
ü Contractor’s experience with different formwork systems
ü Formwork available with contractor
q Construction Specialty
ü Labor available and productivity
ü Construction equipments used and frequency of use
ü Construction sequence/ program
q Site Specialty
25 Factors Affecting Selection of Formwork (CoNT...)
26 Factors Affecting Selection of Formwork (CoNT...)
27 Constructions of Formwork
q The construction of formwork normally involves the following operations

Propping and centring

Ø The props used for centring may be of steel or timber plates.

Ø In case of wooden posts are used as props, they should rest squarely on wooden
sole plates.

Ø The wooden plates should have an area of at least 0.1m2 and 40mm thickness.

Shuttering

Ø The shuttering can be made up of timber planks, or it may be in the form of panel
unit made by either by fixing plywood to timber frames

Ø The shuttering joints should be tight against leakage of cement grout.

28 Constructions of Formwork (CoNT...)
Provision of camber and cleaning
Ø It is desirable to give an upward camber in the horizontal member of the
concrete structure, especially in members having long span, to counteract the
effect of deflection.

Ø The provision of desired camber should be in the formwork itself during its
erection.

Surface treatment
Ø The shuttering can be made up of timber planks, or it may be in he form of
panel unit made by either by fixing plywood to timber frames or by welding
steel plates to angle framing.
29 Constructions of Formwork (CoNT...)
Ø Before laying concrete the formwork should be cleaned of all rubbish
particles.

Ø All surface of timber shuttering that are to come in contact with concrete
should be well wetted with water.

Ø All surface of shuttering should be given a good coating of a releasing agent

30 Constructions of Formwork (CoNT...)
Formwork for Column

Ø Columns are usually square or circular in section.

Ø The shuttering must be able to withstand the hydraulic pressure exerted on
it by the poured concrete. For this reason, the column shutter supports near
the base of the form should be closer.

Ø To prevent segregation of the concrete when pouring high columns, it may

be necessary to incorporate a trap door in the shuttering at approximately
the midpoint in height of the column, thereby allowing concrete to be
placed without it dropping full height.

Ø The alternative is pour the concrete from the top of the form using a
termite pipe.
31 Constructions of Formwork (CoNT...)

Formwork for Column

32 Constructions of Formwork (CoNT...)
Formwork for Column
33 Constructions of Formwork (CoNT...)
Formwork for Beams:
Ø This is basically a three sided box supported and propped in the correct position
and to the desired level.

Ø The beam formwork sides have to retain the wet concrete in the required shape
and be able to withstand the initial hydrostatic pressure of the wet concrete,

Ø Whereas the formwork soffit apart from retaining the concrete has to support the
initial load of the wet concrete and finally the set concrete until it has gained
sufficient strength to be self supporting.

Ø It is essential that all joints in the formwork are constructed to prevent the
escape of grout which could result in honeycombing and/or feather edging in
the cast beam.
34 Constructions of Formwork (CoNT...)
Formwork for Beams:
35 Constructions of Formwork (CoNT...)

Beam and Slab Formwork:

36 Constructions of Formwork (CoNT...)

Formwork for Slab

q Formwork to suspended slabs is similar to that for beams, except that the soffit
shuttering is far wider.
37 Constructions of Formwork (CoNT...)

Formwork for Walls

q This type of form work consists of timber sheeting supported by vertical studs
or posts and horizontal struts or walls.
38 Constructions of Formwork (CoNT...)

Formwork for Stair

q The landing is first set in position. The process for constructing the landing is the
same as that of floors.
q After the landing has been set, the flight will be constructed.
39 Formwork Striking
Ø Removal of formwork is also important as erecting it.

Ø Before formwork can be removed the concrete must have sufficient:

ü Strength to support itself

ü Surface hardness to resist damage

ü Curing

Factors Affecting Formwork Stricking

ü Grade of concrete
ü Ambient Temperature
ü Use of retarders, plasticizers,.
ü Type of cement used
ü Feasibility of removal with
ü Standards of finish required props left under
40 Formwork Striking (CoNT...)

Factors to be considered in producing required concrete finishes of uniform

color and texture

Ø The right concrete mix

Ø Consistency of the concrete

Ø Use of a constant rate of placing

Ø Uniformity of compaction

Ø Uniformity of face contact material

Ø Correct choice of formwork pre-treatment and release agents

Ø Correct curing procedures

41 Formwork Striking (CoNT...)

Formwork Stripping Periods

42 Formwork Striking (CoNT...)

q Formwork should be planned and constructed in such a manner that it is

possible to remove the different components in the following order of
sequence:

Ø Shuttering forming vertical faces of walls, of beams and columns sides,

which bear no load but are used only to retain the concrete, should be
removed first.

Ø Shuttering forming soffit of slabs should be removed next, and

Ø Shuttering forming soffit of beams, girders or other heavilyloaded

shuttering should be removed in the end.
43 Formwork Economy

q Formwork is the single largest component of concrete building.

q Considering the impact of formwork on the total cost, the engineer should
design the formwork so that the maximum economy can be obtained.

q Economy of formwork begins with the design development of the structure

itself.

q The following point should be considered while designing formwork for a

building structure.

Ø While designing the structure, consider the material and tools that will be
required to make, erect, and remove the formwork.
44 Formwork Economy (CoNT...)

Ø Design the structure with standard dimensions that will be unit multiple
of forms and centering sheets.

Ø Use the same size of columns from the foundation to the roof, this will
permit the use of column forms with out.

Ø Use beams of the same depth and spacing in every floor; this will permit
the reuse of beam forms without alteration.

Ø vSpecify the same for columns and column-support girders in order to

reduce or eliminate the cutting and fitting of girder forms into column
forms.
45 Formwork Economy (CoNT...)

q Some of the important points to achieve economy in formwork expenditure

are as follows:

Ø While designing formwork, maximum usage of material should be

achieved.

Ø High quality finish on concrete surface is not required for sides that will
not be exposed.

Ø When planning forms, consider the sequence and methods of striping.

Ø Use prefabricated panels wherever possible.

Ø Strip forms as soon as it is safe in order to facilitate maximum reuse of

forms.
46 Formwork Economy (CoNT...)

Ø Create cost awareness among carpenters and other workers involved in

formwork construction.

Ø Use long length timber or plywood with out cutting, where their
extending beyond the working area is not objectionable.

Ø After removal clean panels and store them at a safe place so that they can
be reused.
47 Releasing Agents

Ø Facilitate the striking or removal of the formwork.

Ø Prevent the concrete adhering to the form face.

Ø Most oils will fulfill the function of a release agent, but different oils can produce
blow holes or variations in the color of concrete, affect efflorescence, or retard the
hardening of the surface.
48 Formwork Design Principles

q The person designing the formwork for a project is doing much more than
planning the containers with in which the in situ concrete will be cast.

q Formwork design includes

Ø design of the formwork support structure,

Ø the formwork deck and connection details

q The design of formwork will involve decisions on the location of construction

joints, which may impinge on reinforcement detailing and will certainly relate to
the volume of concrete to be placed i one pour.

q It will also be necessary for the designer to take into account the skills available,
both quantitatively and qualitatively, for fabricating and handling the formwork.
49 Formwork Design Principles (CoNT...)

Loads on Formwork

q Wind loading

Ø Vertical elements must be fully braced

Ø Wind loading will vary depending on:

ü size of form; ü wind speed;

ü nature of the form; ü wind direction.

q Concrete Loading

Ø The force exerted by concrete is complex, because concrete starts off acting
as though it were a fluid
50 Formwork Design Principles (CoNT...)

Loads on Formwork

q Fluid pressures on forms Pressures reduced by stiffening

51 Formwork Design Principles (CoNT...)

Factors Affecting Pressure

Ø Concrete density,

Ø Rate of rise,

Ø Height of section cast,

Ø Concrete temperature,

Ø Cement type, admixtures,

latent hydraulic binders and shape and plan area of the section
52 Failure of Formwork

q The failure of formwork is always embarrassing and expensive for everyone involved in
the project.

q Failure may be collapse of entire formwork or part of it.

q Some of the reasons for the failure of formwork are given below:

Ø Improper or inadequate shoring Ø Premature striping of formwork

Ø Inadequate bracing of members Ø Improper design

Ø Lack of control of placement of concrete Ø Failure to follow codes and standards

Ø Improper connection Ø Negligence of workers or supervisors

53 Failure of Formwork (CoNT...)

q In order to prevent failure of formwork the following precautions should be taken:

Ø The formwork should be designed properly

Ø Erection and stripping should be done only under engineering supervision

Ø The sequence of removal should be pre-designed and correctly executed

54 Scaffolds and Formwork

q Where work cannot safely be done on or from the ground or from part of a building or
other permanent structure, a safe and suitable scaffold shall be provided and maintained or
other equally safe and suitable provisions should be made.

q It is essential that scaffolds should be provided with safe means of access, such as stairs,
ladders or ramps.

Material
q In the construction of scaffolds, sufficient, suitable and sound materials should be used.

q Where timber is used in the construction of scaffolds, it should be straight grained, sound,
and free from large knots, worm holes and other defects likely to affect its strength.

q The mechanical properties of fastening on wooden scaffolds should conform to the

national regulations and code of practices
55 Scaffolds and Formwork (CoNT...)

Inspections and Maintenance

q Scaffolds should be inspected at periodic intervals as prescribed by national standards or

code of practices, and the results recorded by a competent person.

q Inspection by the competent person should more particularly ascertain that:

Ø The scaffold is of suitable type and adequate for the job,

Ø Materials used in its construction are sound and of sufficient strength,

Ø It is of sound construction and stable, and

Ø That the required safeguards are in position.

56 Scaffolds and Formwork (CoNT...)
57 Scaffolds and Formwork
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The End !!!