Concrete Technology

Module 1

FORMWORK
Formwork is the term used for the process of creating a temporary mould into which concrete is
poured and formed
Formwork (shuttering) in concrete construction is used as a mold for a structure in which fresh
concrete is poured only to harden subsequently. Types of concrete formwork construction
depends on formwork material and type of structural element.
Qualities of good formwork
1. It should be strong enough to withstand all types of dead and live loads.
2. It should be rigidly constructed and efficiently propped and braced both horizontally and
vertically, to retain its shape.
3. The joints in the formwork should be tight against leakage of cement grout.
4. Construction of formwork should permit removal of various parts in desired sequences
without damage to the concrete.
5. The material of the formwork should be cheap, readily available, and should be suitable
for reuse.
6. The formwork should be set accurately to the desired line, and levels should have a plane
surface.
7. It should be as light as possible.
8. The material of the formwork should not warp or get distorted when exposed to the
elements.
9. It should rest on a firm base.

Types of formwork
1. Timber Formwork
Timber for formwork should satisfy the following requirement:
It should be:
1. Well-seasoned
2. Light in weight
3. Easily workable with nails without splitting
4. Free from loose knots

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Timber used for shuttering for exposed concrete work should have smooth and even surface on
all faces which come in contact with concrete.
Table 1: Normal sizes of members for timber formwork

Sheeting for slabs, beam, column side, and beam bottom 25 mm to 40 mm thick

Joints, ledges 50 x 70 mm to 50 x 150 mm

Posts 75 x 100mm to 100 x 100 m

2. Steel Formwork
This consists of panels fabricated out of thin steel plates stiffened along the edges by small steel
angles. The panel units can be held together through the use of suitable clamps or bolts and nuts.

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The panels can be fabricated in large numbers in any desired modular shape or size. Steel forms
are largely used in large projects or in a situation where large number reuses of the shuttering is
possible. This type of shutter is considered most suitable for circular or curved structures.

Comparison between Steel and Timber Formwork

1. Steel forms are stronger, durable, and have a longer life than timber formwork and their
reuses are more in number.
2. Steel forms can be installed and dismantled with greater ease and speed.
3. The quality of exposed concrete surface by using steel forms is good and such surfaces
need no further treatment.
4. Steel formwork does not absorb moisture from concrete.
5. Steel formwork does not shrink or warp.

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Estimation of Formwork Material Requirement

While you'll be ordering concrete by volume, formwork is measured by area. Specifically, the
area that will actually be in contact with the concrete. This means calculations will be in square
meters (or square millimetres if more accuracy is needed).
To measure the area of formwork needed to support your concrete installation, multiply the
perimeter or circumference by the length/height of the structure. Each side of concrete will need
its own formwork calculation and more complex or irregular shapes will have more complex
calculations.
1. Slab
For simple square and rectangular forms, simply multiply length x width to know how much
formwork you need.
For a circular base, multiply the square of the radius by pi (πr²).
For irregular shapes, break these down into simpler squares and rectangles and add up the total
surface area.
2. Column
For square or rectangular forms, calculate the perimeter of the base and multiply it by the height.
For round or elliptical columns, calculate the area by multiplying the circumference (2πr) by the
height.
If you're making formwork yourself, plywood supported by a lumber frame is the most
economical option, but this won't be an option for round or irregularly shaped columns. These
require metal formwork, which may need to be installed by a professional.
3. Beams
Formwork for concrete beams, girders and other horizontal forms should only be fitted on three
sides, with shuttering supporting the two vertical sides and the bottom face. The top face should
be left exposed.
Add the lengths of the three sides, then multiply by the span of the beam to calculate the
formwork area needed.
Square and rectangular beams and girders may be made from plywood supported by lumber or
metal. Round formwork should be made from metal.

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Construction of Concrete Formwork

This normally involves the following operations:
1. Propping and centering
2. Shuttering
3. Provision of camber
4. Cleaning and surface treatment

Formwork for wall

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Formwork for columns

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Slab and Beams Formwork

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Stairs Formwork

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Chimney Formwork

Removal of formwork/ Striking

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.

Factors Affecting Concrete Formwork Striking Times

The striking time of concrete formwork depends on the strength of structural member. The
strength development of concrete member depends on:

 Grade of concrete – higher the grade of concrete, the rate of development of strength is
higher and thus concrete achieves the strength in shorter time.

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 Grade of cement – Higher cement grade makes the concrete achieve higher strength in
shorter time.
 Type of Cement – Type of cement affects the strength development of concrete. For
example, rapid hardening cement have higher strength gain in shorter period than the
Ordinary Portland Cement. Low heat cement takes more time to gain sufficient strength
than OPC.
 Temperature – The higher temperature of concrete during placement makes it achieve
higher strength in shorter times. During winter, the concrete strength gain time gets
prolonged.
 A higher ambient temperature makes the concrete gain strength faster.
 Formwork helps the concrete to insulate it from surrounding, so longer the formwork
remain with concrete, the less is the loss of heat of hydration and rate of strength gain is
high.
 Size of the concrete member also affects the gain of concrete strength. Larger concrete
section members gain strength in shorter time than smaller sections.
 Accelerated curing is also a method to increase the strength gain rate with the
application of heat.

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Removal/Striping of formwork:
 First free end's support should be removed.
 And then from right to left it should be proceed.
 If we are removing from the mid span then it will act as a prop cantilever. Cantilever slab
 In simply supported we have to remove the support from the mid span to the ends. • To
meet the design behavior. Simply supported slab

During stripping of formwork, following points must be remembered:

 Formwork should not be removed until the concrete has developed sufficiently strength to
support all loads placed upon it. The time required before formwork removal depends on the
structural function of the member and the rate of strength gain of the concrete. The grade of
concrete, type of cement, water/cement ratio, temperature during curing etc. influence the
rate of strength gain of concrete.
 The formwork parts and connections should be arranged in a way that makes formwork
removal easy and simple, prevents damage to concrete and formwork panels so that it can be
reused without extensive repair.
 The formwork removal procedure should be supervised by the engineer to ensure that quality
of hardened concrete in structural member, i.e. it should be free from or has minimum casting
defects such as honeycombing, size and shape defects etc. These defects in concrete
influence the strength and stability of structure. Thus immediate repair works can be done or
the members can be rejected.
 The separation of forms should not be done by forcing crowbars against the concrete. It may
damage the hardened concrete. This should be achieved by using wooden wedges.
 Beam and joist bottoms should remain in place until final removal of all shoring under them
are done.
 Joist forms should be designed and removed so that the shores may be removed temporarily
to permit removal of joist forms but must be replaced at once. The shores and joists will be
dismantled beginning from the middle of the member’s span, continuing symmetrically up
the supports.
 The approval from the engineer should be obtained for the sequence and pattern of formwork
removal.

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

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 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
o Formwork Material cost
o Formwork erecting cost
o Formwork removal cost
o Formwork jointing cost (Nails and Cables)
o Labor charges.
Advantages of steel form work:
 It can be used for a no. of times.
 It is non -absorbent.
 Smooth finish surface obtained.
 No shrinkage of formwork occurs.
 Easy to use.
 Its volume is less
 Its strength is more.
LOADS ON FORMWORK:
 Dead load –
 Self weight of formwork
 Pressure and loads from fresh concrete
 Reinforcement
• Imposed load –
 Construction workers
 Stacking of materials
• Horizontal loads
• Environmental loads
 Accidental loads
 Wind loads

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