FORMWORK

Forms or moulds or shutters are the receptacles in

which concrete is placed, so that it will have desired
shape or outline when hardened. Once concrete
develops the adequate strength to support its own
weight they can be taken out
 Requirements of a good formwork
The essential requirements of formwork or shuttering are
• It should be strong enough to take the dead and live
loads during construction.
• The joints in the formwork should be rigid so that the
bulging, twisting, or sagging due to dead and live load is
as small as possible. Excessive deformation may
disfigure the surface of concrete.
• The construction lines in the formwork should be true
and the surface plane so that the cost finishing the
surface of concrete on removing the shuttering is the
least.
• The formwork should be easily removable without
damage to itself so that it could be used repeatedly.
 Requirements of form work
• A good form work should satisfy following requirements:
• Material of formwork should be cheap & can be reused
many time.
• It should be water proof & should not absorb water from
concrete.
• Shrinkage & swelling should be minimum.
• It should be strong enough to take all loads coming on it
(dead load of concrete, live load of labour during pouring,
compaction & curing.
• It should be stiff enough so that deflection is minimum.
• It should be light as far as possible
• Surface of form work should be smooth for easy stripping
• All joints of form work should be stiff so that lateral
deformation under load is minimum.
• Joints should be leak proof.
 Economy in formwork

• Use of irregular shapes to be avoided

• Fabricated in modular sizes

• Structural components should be designed such that it is

possible to have use of commercially available formworks
• Use of assembly line technique

• cleaned and oiled properly

• Construction joints should be minimum

• If mechanical vibrators are used , then bolts shall be used in

place of wires or nails for safety
Factor affecting selection of formwork System( Awad S.Hanna,1999)
Classification of Formwork
 Classification according to the size of formwork
• In practice, there are only two sizes for formwork;
small-sized and large-sized. Any size which is
designed for operation by workers manually is small-
sized.
• Very often, the erection process is preferably
handled by a single worker, with site work best done
independently to avoid possible waiting times.
• Due to reasons of size and weight, the materials and
construction of small-sized formwork are thus
limited.
• At present, the most common systems are made of
timber and aluminum, and are usually in the form of
small panels. There is seldom medium-sized
formwork.
 Classification according to the location of use

• There are not many effective formwork

systems for stairs and staircases.
• The complicated three-dimensional nature of
an element involving suspended panels and
riser boards, as well as the need to cope with
very different spatial and dimensional
variances as required by individual design
situations, cannot be achieved by a universally
adaptable formwork system
 Classification according to materials of construction
• Materials used for formwork are traditionally quite
limited due to finding the difficult balance between
cost and performance.
• Timber in general is still the most popular
formwork material for its relative low initial cost
and adaptability
• Steel, in the form of either hot-rolled or cold-
formed sections and in combination with other
sheeting materials, is another popular choice for
formwork materials.
• Aluminum formwork systems have been used in
some cases but the performance is still being
questioned by many users, especially in concern to
cost and labor control
 Classification according to nature of operation

• Formwork can be operated manually or by

other power-lifted methods.
• Some systems are equipped with a certain
degree of mobility to ease the erection and
striking processes, or to allow horizontal
moment using rollers, rails or tracks
 Wooden form work
Most common form work
Disadvantage
• Possibility of warping, swelling, shrinkage.
• Water impermeable coating on wood form
work is applied to reduce warping, swelling,
shrinking
• With impermeable coating shuttering can be
removed easily.
 Steel form work
Steel shuttering is used for major work.
• Advantages:
a) It can be put to use for high number of times.
b) It provides ease of stripping
c) It gives smooth & even concrete surface
d) It posses high rigidity
e) It is not liable to shrinkage or distortion
f) It is costly
 Steel form work
• This consist 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.
• The panels can be fabricated in large number in
any desired modular shape or size.
• Steel forms are largely used in large projects or in
situation where large number reuses of the
shuttering is possible.
• This type of shuttering is considered most suitable
for circular or curved structures.
• For heavy concrete work
• With reasonable care will last indefinitely
• High initial cost and high handling cost
The first floor circular columns were constructed using steel
column forms. The steel column form should be oiled before
concreting.
After concreting to the first floor columns, the steel column forms
were dismantled easily.
 Compared with timber formwork
• Steel forms are stronger, durable and have
longer life than timber formwork and their
reuses are more in number.
• Steel forms can be installed and dismantled
with greater ease and speed.
• The quality of exposed concrete surface by
using steel forms is good and such surfaces
need no further treatment.
• Steel formwork does not absorb moisture from
concrete.
• Steel formwork does not shrink or warp.
 STEEL FORMWORK AND ACCESSORIES

• Steel formwork systems for every size and shape

of ground plan, in practical dimension & equipped
with different features to make shuttering more
efficient.
 Flatform Panels Form Work

Application of Push-pull Prop. &

Soldier System

Column Formwork
Flat Form

Flat Form is used for forming planes such as

those of Square columns, walls, slab floors, etc.
By combining units of various sizes, flat form
can be made to serve a wide variety of
purposes.
 Corner Angle Outside Corner Form

Inside Corner Form "L" - type pin & U-clip

Steel Form for Corners

Form can be assembled easily and tightly by using the Corner Angle,
Outside Corner Form & Inside Corner Form.
We can tailor-made various sizes of corner to suit customer specific
requirements & application.
 Samples of Box Culvert Design
A combination of the Flat form Panels & corners are illustrated in the
application of common Box Culvert.

Versatile : complete systems made to meet the needs of contractors;

Easy to Use : quick assembly & fixing
Proven Design : fabricated for tough working conditions
 Indian Standard of Form work(IS :456-1964)
(1) General :
The form work :
• shall conform to the shape, lines & dimensions
as shown on the plans.
• Shall be rigid during placing & compacting of
concrete.
• Water tight to prevent loss of water from
concrete.
(2) Cleaning & treatment of forms
• All rubbish, chippings, saw dust shall be
removed from the interior of form work before
placing of concrete. Shall be wetted
 Indian Standard of Form work(IS :456-1964)

• STRIPPING TIME
• Form work should not removed until good strength has
come.
• Type of form work Time
• Vertical wall, columns 16-24 hrs
• Soffit of slab (Prop should be refixed immediately) 3
days
• Soffit of beam (Prop should be refixed immediately) 7
days
• Props to slab Span < 4.5 m 7 days
• Props to slab Span > 4.5 m 14 days
• Props of beam (Span < 6 m) 14 days
• Props of beam (Span > 6 m) 21 days
Factors Affecting Concrete Formwork Striking Times.
 Time of Removal of formwork
Sr. OPC Rapid
No (Ordinary Portland Hardening
Structural Member Cement)
Cement
1 Beam sides, walls & Columns 2-3 Days 2 Days

2 Slab (Vertical Supports remains intact) 4 Days 3 Days

3 Slab (Complete Formwork removal) 10 Days 5 Days

4 Beams (Removal of Sheeting, Props 8 Days 5 Days

remains intact)

5 Beams & Arches (Complete 14 Days 5-8 Days

formwork removal) (up to 6 m span)

6 Beams & Arches (Complete 21 Days 8-10 Days

formwork removal) (more than 6 m span)
 Strength of concrete vs. Structural Member
Type & Span for Formwork Removal

Concrete Strength Structural Member Type and Span

Lateral parts of the formwork for all

2.5 N/mm2
structural members can be removed

Interior parts of formwork of slabs and

70% of design strength beams with a span of up to 6m can be
removed

Interior parts of formwork of slabs and

85% of design strength beams with a span of more than 6m
can be removed
 Indian Standard of Form work (IS :456-1964)

(4) Procedure when removing form work

All form work shall be removed without shock or vibration as it
will damage the concrete.
Before the soffit (bottom surface ) & struts (pole) are removed, the
concrete shall be exposed, to check that the concrete has
sufficiently hardened.
Proper precautions shall be taken to allow for decrease in the rate
of hardening in cold water.

(5) Camber
It is desirable to give form an upward camber (slope) to ensure
that beams do not sag when they have taken up their deflection.
This should be done only when allowed in the design calculation
of the beam.
 Guidelines for False works for Concrete
(IS-14687-1999) Revised 2005
Tolerances
Form work shall be so constructed that the internal dimensions are
within the permissible tolerance specified by the designed.
Deviation from specified - 6mm
dimensions of cross-section of + 12 mm
columns and beams

Deviation from dimensions of

footings
1) Dimensions in plan -12 mm
+50 mm
2) Eccentricity 0.02 times the width of the footing in the direction
of deviation but not more than 50 mm

3) Thickness 0.05 times the specified thickness

 LOADS ON FORM WORK

• The form work has to take following loads:

• a)Live load due to labour
• b)Weight of wet concrete
• c)Hydrostatic pressure of the fluid concrete acting
against the vertical or inclined faces of form
• d)Impact due to pouring of concrete.

• Live loads of labour & equipment including impact

may be taken as 370 Kg/Sq.m.
• ACI 347-04: Guide to
Formwork of Concrete
specify that, to allow for
workers and their placing
tools such as screeds,
vibrators, and hoses, at least
2.4Kpa live load should be
used for the design of
horizontal formworks and a
minimum live load of 3.6
kPa should be employed in
cases where motorized carts
and buggies are utilized.
 LOADS ON FORM WORK

• HYDROSTATIC PRESSURE:
• Hydro static pressure due to fluid of concrete
depends on :
• a)Quantity of water in concrete
• b)Size of aggregate
• c)Rate of pouring
• d)Temperature
 HYDROSTATIC PRESSURE

• Hydrostatic pressure is maximum during pouring and

decreases when concrete becomes hard.
• Setting time may be taken as ¾ to 1 hour.
• Only height of concrete poured in ¾ to 1 hour is
taken into account for calculation of hydrostatic
pressure on form work.
• For 1.5 m height of concrete, equivalent weight of
concrete may be taken as 2300 kg/m3.
 HYDROSTATIC PRESSURE

• For higher height, the equivalent weight of concrete

is reduced. When height of concrete in one pour is 6
m, the equivalent fluid weight may be 1200 kg/m3.
• For intermediate heights between 1.5 to 6 m poured
within the setting time of ¾ hour linear interpolation
of unit weight between 1200 to 2300 kg/m3 may be
taken
Source : IS-14687.1999-Concrete-Falsework
 SHUTTERING FOR BEAM & SLAB FLOOR

• The slab is continuous over number of beams.

• The slab is supported on 2.5 cm thick sheathing laid
parallel to main beam.
• The sheathing is supported on wooden battens which are
laid between the beams, at suitable spacing.
• In order to reduce deflection, the battens may be
propped at middle of the span through joists.
• The side forms of the beam consists 3 mm thick
sheathing.
• The bottom sheathing of the beam form may be 5 to 7
cm thick
 SHUTTERING FOR BEAM & SLAB FLOOR
• The end of the battens are supported on ledger which
is fixed to cleats throughout the length.
• Cleats 10 cm x 2 cm x 3 cm are fixed to the forms at
the same spacing as that of battens, so that battens
may be fixed to them.
• The beam forms is supported on a head tree.
• The shore or post is connected to head tree through
cleats.
• At the bottom of shore, two wedges of hard wood are
provided over a sole piece
 MERITS OF ALUMINIUM FORMWORK
• In contrast to most of the modern construction
systems, which are machine and equipment oriented,
the formwork does not depend upon heavy lifting
equipment and can be handled by unskilled labors.
• Fast construction is assured and is particularly suitable
for large magnitude construction of respective nature
at one project site.
• Construction carried out by this system has
exceptionally good quality with accurate dimensions
for all openings to receive windows and doors, right
angles at meeting points of wall to wall, wall to floor,
wall to ceiling, etc, concrete surface finishes are good
to receive painting directly without plaster.
 MERITS OF ALUMINIUM FORMWORK

• System components are durable and can be used several

times without sacrificing the quality or correctness of
dimensions and surface.
• Monolithic construction of load bearing walls and slabs in
concrete produces structurally superior quality with very few
constructions joined compared to the conventional column
and beam slabs construction combined with filter brick work
or block work subsequently covered by plaster.
• In view of the four – day cycle of casting the floor together
with all slabs as against 14 to 20 – day cycle in the
conventional method, completed RCC structure is available
for subsequent finish trades much faster, resulting in a saving
of 10 to 15 days per floor in the overall completion period.
 MERITS OF ALUMINIUM FORMWORK
• As all the walls are cast monolithic and simultaneously
with floor slabs requiring no further plasters finish.
Therefore the time required in the conventional
method for construction of walls and plastering is
saved.
• As fully completed structural frame is made available
in one stretch for subsequent – finishing items,
uninterrupted progress can be planned ensuring,
continuity in each trade, thereby providing as cope for
employing increased labor force on finishing item.
• As the system establishes a kind of “Assembly line
production” phase – wise completion in desired groups
of buildings can be planned to achieve early utilization
of the buildings
 • WORK CYCLE
The system usually follows a four day cycle: -
• Day 1: -The first activity consists of erection of
vertical reinforcement bars and one side of the
vertical formwork for the entire floor or a part of one
floor.
• Day 2: -The second activity involves erection of the
second side of the vertical formwork and formwork
for the floor
• Day 3: - Fixing reinforcement bars for floor slabs and
casting of walls and slabs.
• Day 4: -Removal of vertical form work panels after
24hours, leaving the props in place for 7 days and
floor slab formwork in place for 2.5 days.
This study is done for a live project
currently under construction at
Hinjewadi phase-3, by PEGASUS
PROPERTIES PVT.LTD.
The details of the two buildings are as
follows:
A. MEGAPOLIS-MYSTIC ( constructed
with MIVAN formwork)
1.Saleable area (total)- 183,693 S.ft2.
No of floors- 21F3.
Floor to floor height- 3.0 m
B.SPLENDOUR HOMES (constructed
with conventional formwork)
•1. Saleable area (total)- 205,520 Sft.
• No of floors- 21F.
• Floor to floor height- 3.0 m
 Mivan Shuttering Construction versus Conventional formwork
Parameter Mivan shuttering Regular formwork
construction system
Speed of development 7 days/floor Minimum 21 days/floor
Quality of surface Excellent Putting is required
finish
Pre-planning of Required Not required
formwork system
Type of construction Cast-in-situ cellular Simple RCC
construction
Wastage Very little Comparatively higher
Accuracy in Accurate Accuracy lesser than modern systems
construction
Coordination between Essential Not required
offices
Seismic resistance Good resistance Comparatively lesser
Dismantling floor Possible Impossible
piece frames without
expelling props
• PRODUCT DESCRIPTION
• The ULMA CC-4 formwork system is mainly for
large surface areas with a good finishing surface,
where geometry and distance between columns is
regular, providing high quality finishing, directed
to the requirements of building construction.
• Its elements are built in aluminium, so the system
is lightweight.
• It is characterized by its safe and fast assembly
and dismantling, as its main parts are made of
aluminium.
ULMA FORMWORK SYSTEM
 Drop heads CC:
It is equipped with a drop system which assists
the stripping, letting the panels, beams &
Transversals descend to be easily retrieved.
Along with the prop, it is the only remaining part
of the system
• Transversals CC TE:
• It establishes the grid
width, which can be
1.5m or 0.75m between
axes. The transversal is
in contact with the
concrete. It is designed
to keep the joints
between the panel’s
tights.
• Standard boards:
• The formwork face is
plywood or composite
board which fits in the
frame. The openings in the
frame facilitate its manual
handling
 ADVANTAGES OF ULMA CC-4 OVER CONVENTIONAL
FORMWORK
• Most system elements are manufactured in aluminium, and
some elements are plastic, thus this is a very lightweight
formwork.
•This formwork stripping system is designed to facilitate the
recovery of material without permitting any of it to fall to the
ground-achieved by “drop head” system. This helps to increased
worker safety and reduces material deterioration.
•Great versatility which enables to change beam direction; one
beam can be installed at a 90º angle to its adjacent beam.
•Easy to adjust height and to level the formwork because of few
props used in setup.
•High efficiency of assembly and disassembly
 GROCON FORMWORK SYSTEM
• Grocon climbing systems form vertical elements
such as columns and walls, providing employees
with a safe work environment. The formwork,
working platforms, trailing screen assemblies and
rams are attached to overhead truss assemblies, so
with each lift the whole system rises
simultaneously.
• It can be raised in only one hour with one fully-
trained operator having control over the process.
Jacking points that raise the system are located
below the truss assemblies to give clear access to
all working platforms
• The top-working platform is left clear for storing
crane-handled equipment and provides clear
access for workers.
• Vertical formwork elements are suspended from
members located in the top chord assemblies of
the truss system allowing vertical, lateral and
horizontal adjustment.
• High-level construction accuracy is therefore
possible within the system
• In all stages of the jump from operating cycle the
workers are fully enclosures their complete
safety & that of all other workers & members of
the public.
• At no time can the workers fall or lose their to
cause accidents and hence offers full safety
• The Grocon jump from operates as one
system. This eliminates the possibility of
creating opening in the system when one
section is raised before another section.
ADVANTAGES OF GROCON OVER CONVENTIONAL FORMWORK

• Standard plywood can be used up to 15 pours. By

treating two stories as one the need to replace
wall from plywood is reduced.
• Down time costs are minimised or eliminated.
• The system is as effective as a steel formwork
alternative without the associated weight & cost
penalties.
• Less pours means a saving on re-enforcement
laps bars & concrete with a consequence
increase in efficiency & productivity.
• Forming two floors at a time halves the number
of plumbing & surveying operations during
construction of the core.
ADVANTAGES OF GROCON OVER CONVENTIONAL FORMWORK

• The system does not rely on the most recent

concrete pour, with jacking beams supported by
concrete that is one cycle old.
• The top deck is free of jacking masts & other
mechanical obstacles, which protects all
operational equipment from concrete spills & the
possibility of crane damage.
• Long stroke, heavy duty hydraulic rams allow over
4 meters of travel & deep single pours, which is
particularly useful for areas such as computer
floors.
• Hydraulic safety features include non-return
valves, a complete backup system & locking
devices on each arm ram.
1. Doka India Pvt. Ltd. (The Formwork Experts )
2. GCI Wall Forms Private Ltd. (Mass Customizer of Concrete Forming Systems)
3. Indigo Multitrade Pvt. Ltd. (Composite Fiberglass Formwork System)
4. Kumkang Kind India (The Total Formwork Solutions Provider for Gang formwork, Aluminium
Formwork, System Formwork)
5. MFE Formwork Technology (I) Pvt. Ltd.
6. Nav Nirman Beam Technics (Formwork H-Beam for Column Formwork,
Circular Formwork, Wall Formwork, Slab Formwork)
7. Nova Plasmold P. Limited India's (First Modular Plastic Formwork System)
8. Paschal Formwork India Pvt. Ltd. (Paschal - The German Formwork for
Modular Panel System for Vertical Structures, Paschal Deck System and e-deck
System for Horizontal Structures)
9. Peri (India) Pvt. Ltd. (Formwork Scaffolding Engineering The light weight
Panel formwork for crane independent Forming)
10. Sparkonix (India) Pvt. Ltd. (Largest ABS Plastic Formwork Manufacturer)
Modern formwork systems Page 25 of 27
11. Ulma Formwork Systems India Pvt. Ltd. (Self Climbing and Crane Climbing
System Formwork)