Form Work

HITACHI PLANT TECHNOLOGIES (PVT) LTD
BASIC INDUSTRIAL TRAINING
CHAPTER 07
FORMWORK
NATIONAL DIPLOMA IN ENGINEERING SCIENCES

INSTITUTE OF ENGINEERING TECHNOLOGY, KATUNAYAKE
7.1 Introduction
In the modern construction world, concrete is the most widely used construction material. As
concrete is a plastic material in green state it has to be kept in an enclosure till it hardens. This
enclosure is known as formwork or shuttering.
One of the easiest and most obvious ways of judging whether a concrete job is satisfactory or
not is by its finished appearance. The formwork and the way it is made and used play a greater role in
the finished appearance than anything else. It is made from expensive materials by skilled carpenters
and the total cost of fabricating, erecting and striking formwork is often comparable with the concrete.
Apart from the appearance considerations, formwork usually needs to be used many times
and this can only be done if it is carefully and properly handled, cleaned and stored- be it of timber,
steel or other material as otherwise time and money will be wasted and the job will not progress
smoothly.
The formwork must withstand the worst combination of the following loads.
Total weight of formwork, reinforcement and concrete.
Construction loads including dynamic effects of placing, compacting.
Wind loads (mainly for column)
7.2 Requirements of Formwork

There are essential requirements for formwork. Any good formwork should satisfy all of the
following requirements.
ContainmentFormwork must be capable of shaping and supporting the fresh concrete until it becomes hard.
Strength
Formwork must be strong enough to withstand the dead weight of fresh concrete placed on it. Also
formwork should be strong enough to bear the imposed loads after concrete placing.
Resistance to Leakage
All joint in the form face should be either close fittings or covered with some sheet material to make
these grout tight. Grout leakage can lead two weak concrete. It can cause honeycombing of the
surface & may produce projecting fins (snobs), which later have to be removed and touched up.
Accuracy
Formwork must be accurately set out so that the resulting concreting elements is in the right place and
is of the correct shape and dimension. The degree of accuracy concerned will be consistent with the
item being cast.
Easy of Handling
Form panels and units should be made so that they can be easily handled by hand or mechanical
means. In addition to all form work must also be designed and constructed to include facilities for
adjustment, leveling, erecting and striking without damage to the formwork or concrete.
The material of the formwork should not wrap or get distorted when exposed to sun, rain, and
water during concreting.
Formwork must be capable of gradual and easily remove
To get successful form work,
It must be accurately set out.
The shuttering should be built accurately. So that the desired size, shape, position and finish
can be attained.
The formwork should be strong enough to support all dead and live loads without collapse or
danger to site personnel and to the structure.
Using sheet materials and sealing the joints must fill with punch sheet, wetted cement paper,
polythene strips to prevent grout leakage.
The formwork should be designed to erect and dismantled easily.
The most commonly used materials for formwork are timber, plywood and steel. In our site we used
timber and plywood for formworks. The selection of materials for formwork depends on several
factors.
Economy of materials
Number of times used
Durability
The availability of sizes and shapes of materials
The shape formwork required to be constructed
The ease of handling, constructing, erecting, concreting, removing, etc.
Therefore depending on the situation we have to select the most suitable material.
7.3 Materials for Formwork

Plywood - 12mm thickness plywood are used in our site.

G.I pipes- Various size long G.I pipes were used.
P cone - To keep the exact distance
Form tie - Used to fix the column boxed and beams.
7.3.1 Timber
This is the most common material used for formwork construction. It is easy to work with and is also
cheap. The moisture content of timber should be between 15%- 20%. So if the timber is dry, it will
absorb moisture from the wet concrete that could weaken the resultant concrete member.
We used 1x 2, 2x 2, and 4 x 4 timber for form work
7.3.2 Plywood
Plywood is extensively used material for the formwork construction due to its lightweight,
availability, large sizes and due to the ease of fabricating. The selected should be of a superior
grade and the thickness should be related to the anticipated pressure. In our site we used 12mm
thick coated plywood sheets (1800x900x12mm).
Advantages of Using Plywood Sheets.

Good surface finish can be obtained.
Plywood formwork is economical because this can be used repeatedly although the cost of
plywood is higher than class II timber planks.
Since the plywood sheet covers large area, the time taken to construct the entire shuttering is
less.
It can be easily sawn to the required shape.
Disadvantage of Using Plywood Sheets

Even after removing the shuttering, adhered plywood particles can be seen on the surface
when normal plywood used.
Peeling of layers with the time.
Due to the slenderness of the sheet large numbers of strengthening cleats are required,
otherwise formwork gets deflected.
7.3.3 Steel
Steel is also used as a material for formworks but it is not common as plywood or timber. It is mainly
due to its economy and availability. The steel shuttering are very expensive and they cannot be
fabricated at the site. So we have to use the prefabricated steel shuttering with limited number of
sizes. But it is more suitable when the same sizes of formworks are to be constructed repeatedly. Also
in the case of circular sections we have to use steel shuttering.
Advantages of Using Steel Shuttering

Since it needs to be assembled only, less time-consuming.
Highly durable and can be used many times.
Good surface finish can be achieved
Disadvantages of Using Steel Shuttering

Available in limited sizes
Difficult to handle
Expensive
7.3.4 Other Material used for formwork
50mm diameter GI pipes, concrete nails & wire nails
Form ties (to tie the separates and GI pipes)
9mm diameter Separates (thread bar & P cone)
Pipe supports and T,U jacks.
Clamp (Fix , Free)
Turn buckles, adjustable steel props, Chain, Turn Buckles
mould oil

7.4 Release Agents

The main purpose of treating formwork with a release agent is to make it easy to strike the form from
the concrete face. There are a number of different types of release agent and the various form face
material such as timber, steel and glass fiber require different release agents. It is important to make
sure that the right one is being used.
The three most common types of release agents are:
1) Neat oil with surfactants: mainly used on steel faces, but can be used on timber and plywood.
2) Mould emulsion: for use on timber and plywood.
3) Chemical release agents: can be used on all types of form face.
Because of their absorbency, new and untreated timber and plywood should always be given a
coat of the appropriate release agent at least 36 hours before being used. A second application should
then be made before using for the first time. The most common fault with release agents is for too
much to be put on: this can stain in concrete. On the other hand, if not enough is applied, striking is
made difficult and both the concrete and form face can be damaged.
7.5 Formwork for Columns

In our site all the columns were rectangular shape. In the case of the rectangular
column, the formwork consists of four shutters or panels made out of plywood board nailed
securely to timber planks.
First, the kicker frame was placed in accordance with the kicker lines and fixed firmly.
Then, kicker was concreted and vibrated properly. After removing the kicker frame, the surface was
roughened for the purpose of well bonding with later concrete. Advantage of the kicker is that it
ensures the correct position of the column and prevents the leaking of it.
Then the four shutters were fixed together and GI pipes were hung with the nails fixed to
the plywood sheet using binding wires in each side vertically. Then the horizontal pipes also fixed to
the board by using the Form ties. The adjustable jacks were fixed between the horizontal GI pipes and
to a fixed position of the floor. The cover blocks were also tightened to the reinforcement at the top.
After set the formwork, Then a piece of plywood sheet was placed on the top of the
formwork the column formwork was checked for vertical using two plumbs, which were hanging
from the top of the formwork. The horizontal distance between the formwork and string line can be
measured at the top and the bottom to ensure the vertically of the formwork. The props should be
adjusted until the distances between formwork and string at top and bottom are equal. Finally all the
clamps and props must be checked for tightens. Then it can be concreted.
Obviously four timber framed plywood panels one for each face are used forming
the squire or rectangular shaped column side, and should be strengthened and securely hold
these box together during the placing of concrete.
7.6 Formwork for Beams and Slabs
First 1000 Finished Floor Level (FFL) was marked on columns. Beam bottoms were prepared by
referring drawings. In this case G.I. pipes, 2x2 timber planks and plywood sheets were used. Then,
the previously prepared beam bottom supports were fixed to the column by referring the 1000FFL
level. After that, beam bottom was placed by using adjustable screw jacks. Then, sideboards of beam
were fixed to bottom by considering the slab thickness and plywood thickness.
Next, 4 x 4 timber beams were placed, parallel to the shorter span of the slab and square
scaffoldings and U-base jacks were used to hold 4x 4 timber rafters. On top of timber beams 2 GI
pipes end 2 x2 timber planks were laid and fixed by nails. The plywood sheets were laid over the
GI pipes & timber planks and fixed them with sideboards of the beams
After that, mould oil was applied all over the slab as a release agent. And reinforcement bars
were placed. By drilling the sideboards of the beams the form ties & threaded bars were fixed using
P.V.C. pipes. Then, G.I. pipes were fixed to the sideboards of the beam and tightened with the form
ties. The joints were sealed using masking tape. Some formwork was left opened in order to remove
the dust or any other foreign materials on the slab.
After the arranging the reinforcement, the slab and the beams were leveled using dumpy
level.
Floor level
Z
Beam
Y
15

Staff
3000 mm
Column
Dumpy Level
1000 FFL Line
X
Floor level
Leveling of the Beam and Slab Formwork

X = Height from 1000 FFL line
Y = Beam Depth
Z = Slab Thickness
Therefore while leveling the beam the staff reading, H = 3000 - (1000 + X + Y + 15)
Therefore while leveling the slab the staff reading
= 3000 - (1000 + X + Z + 15)
Generally supports (false work) of the formwork raised or lowered to get the required reading and by
this process the formwork for the slab and the beams can be easily leveled
Slab formwork
After laying scaffolding or pipe supports, (4x 4) timber joints can be placed
over the U jacks with are placed on scaffolding frame or pipe supports. Then 2 GI pipes can
be laid over the (4 x 4) timber joints. Interval between GI pipes should be 250 300mm.
GI pipes can be leveled by loosening or tightening scaffolding or pipes jacks. After
completing the leveling of GI pipes, plywood sheet can be laid over the GI pipes with the
help of the (2 x 2) timber and (2 x 4) timber, which is at the edge of the side board.
Stair case formwork

After reinforcement work for the staircase is done the side boards will be nailed.
On one of the sideboard the rise and the tread for the staircase will be drawn. While placing
this sideboard great care is taken to ensure that it is placed properly that is the stairs drawn
starts from the landing. The riser made as shown in Figure will be placed on the rise of the
stair drawn on the side board and nailed to the both side boards firmly. When fixing the riser
a sprit level is used check whether the riser is horizontal. Then after fixing the risers of two
adjacent steps it is checked whether the tread of the stair is correct.

7.7 Stop Board Construction

Wire mesh or
Sponge sheet
Beam bottom
Beam Stop Board (at construction joint)
2x2 timber
Plywood
Wire nail
Slab Stop Board (at construction joint)

Wire mesh or
Sponge sheet

7.8 Removal of Formwork

Form work of beams and slabs should not be removed until the concrete reaches a sufficient
strength to support its self weight and any other loads transferred. Formwork should be struck
carefully in order to prevent the load being transferred suddenly to the partly hardened
concrete.Formwork can be struck when the concrete has gained enough strength to be self
supporting. The job specification will normally give guidance on when forms can be struck
and these times may be governed by the size and shape of the member, the concrete mix, and
the weather.
The minimum period for removing formwork

Part of Structure
Period for removing

Formwork
Side of foundations, columns, beams,

And walls.
Under side of slabs up to 4.5 meters
Span
Under side of slabs of above 4.5 meters
span & under sides of beams up to 6 m
span

24 hours
7 days
14 days
Under sides of beams over 6 meters

Span
21 days
Durations for Formwork Removal
7.9 Formwork arrangement
6mm Plywood
16 mm bar
Base Reinforcement
Form Tie
Welding
1x2 Timber
Additional rebar
P-Cone

16 mm bar
16 mm bar
400
Plywood Template
150 150
2" G.I. pipes
6mm tk plywood
(900 x 1800 )
2" G.I. pipes
1'' x 2" timber
4'' x 4" timber
2" G.I. pipes

Plywood Template
225
16 mm bar
450
2" G.I. pipes
450
Pipe supports
225
450
450
2400
1'' x 2" timber
300
Plywood Template
300
1'' x 2" timber
4'' x 4" timber
2" G.I. pipes
Form Work System of Radial type Wall

12mm tk plywood (900 x 1800 )
2'' x 2" timber

900
1'' x 2" timber
2" G.I. pipes
2" G.I. pipes
250
2000
500
2" G.I. pipes
500
500
225
250
450
225
4'' x 4" timber
Formwork type of flat wall

450
2" x 2" timber
250
12mm tk plywood
(900 x 1800 )
2" G.I. pi pes

500
pipe support
500
1" x 2" timber
2" G .I. pipe s
250
500
2" G.I. pipes

2" G .I. pipe s
1" x 2" timb er
4" x 4 " timber
Supporting system of the Form Work of Wall
Water bar (For outside only)
12mm tk plywood
(900 x 1800 )
250
2" x 2" timber
2" G.I. pipes
500
2000
500
pipe support
250
500
2" G.I. pipes
550
500
Kicker
F.B.L +5.000
450
Fig No 15: Lift 01 Form Work system
Lift 01 Form Work System

12mm tk plywood
(900 x 1800 )
LIFT 2 CONCRETE F.L + 9.500
2" x 2" timber
2" G.I. pipes

pipe support
300
2" G.I. pipes
Kicker
F.B.L. + 5.00
300
530
1930
450
Fig No 16: Lift 02 Form Work system
Lift 02 Form Work System

7.10 Scaffolding
Scaffolds are temporary working platforms erected around the perimeter of a building or
structure to provide a safe working place at a convenient height. They are usually required when the
working height is 1.5m or more above the ground level.
Scaffolding
A Scaffolding set has fallowing items
Mitsui frame (vertical support to transfer the load)
cross bracing (connect with other frame horizontally)
joint pin (connect with other frame vertically)
catwalk (working area)
steel ladder
Figure 5.2.4
Jacks & other materials
Adjustable jacks & RMD jacks
RMD jack can bear heavy load more than normal jacks. RMD jacks have its own fabricated
method.
GI pipes 50mm diameter
Timber (2 X 2, 2 X 4)
Couplers
Adjustable U head & fabricated U head
Base plate
Form tie with butterfly nut

P-cones, Thread bar
Cable, turn buckle & buldo clip
Soldgers, steel separator
Devidak bar with cchannel
upvc pipe
Maximum load on Adjustable U head, fabricated U head & Base plate is 40-45 KN with 250
mm maximum length. Some of above parts are shown in the
SCAFFOLDING ARRANGEMENT FOR WALL
SCAFFOLDING ARRANGEMENT FOR RADIOL WALL



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HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

7.2 Requirements of Formwork

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

7.3 Materials for Formwork

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

Plywood - 12mm thickness plywood are used in our site.

Advantages of Using Plywood Sheets.

Disadvantage of Using Plywood Sheets

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

Advantages of Using Steel Shuttering

Disadvantages of Using Steel Shuttering

7.3.4 Other Material used for formwork

50mm diameter GI pipes, concrete nails & wire nails

Form ties (to tie the separates and GI pipes)

9mm diameter Separates (thread bar & P cone)

Pipe supports and T,U jacks.

Clamp (Fix , Free)

Turn buckles, adjustable steel props, Chain, Turn Buckles

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

7.4 Release Agents

7.5 Formwork for Columns

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

Leveling of the Beam and Slab Formwork

= 3000 - (1000 + X + Z + 15)

Stair case formwork

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

7.7 Stop Board Construction

Beam Stop Board (at construction joint)

Slab Stop Board (at construction joint)

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

7.8 Removal of Formwork

The minimum period for removing formwork

Period for removing

Side of foundations, columns, beams,

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

Under sides of beams over 6 meters

Durations for Formwork Removal

7.9 Formwork arrangement

NATIONAL DIPLOMA IN ENGINEERING SCIENCES

HITACHI PLANT TECHNOLOGIES (PVT) LTD

BASIC INDUSTRIAL TRAINING

2" G.I. pipes

2" G.I. pipes

1'' x 2" timber