ALUMINUM FORMWORK SYSTEM

- MANUAL -

HYUNDAI ALUMINUM CO., LTD

HYUNDAI ALUMINUM CO., LTD

13F, Seocho-Pyeoghwa Building, 22, Banpo-daero, Seocho-gu, Seoul, Republic of Korea

20F Seochogu, Seoul, 137-728 Republic of Korea
Tel : +82 2 2103-3106
Fax : +82 2 2103-3169
Webpage : www.hyundaiform.com
 CONTENTS
Pages
OBJECTIVE 3

1.0 INTRODUCTION 4-5

2.0 DESIGN
2.1 BUILT-ABILITY 6
2.2 DOCUMENTATION 6
2.3 ON SITE PLANNING 7

3.0 SITE COORDINATION & ADMINISTRATION

3.1 WORK PROGRAM 8
3.2 STORING 8–9
3.3 MANPOWER 9
3.4 ON SITE TRAINING 9 – 10
3.5 ACCESSIBILITY 10 – 11
3.6 HAZARDS 11 – 12
3.7 TOOLS & ACCESSORIES 12

4.0 FORMWORK ERECTION

4.1 SETTING OF LEVEL & POSITION MARKING 13
4.2 MOULD OIL APPLICATION 13
4.3 OTHER TRADES - REBAR, M&E AND PLUMBING 14
4.4 ERECTION - WALL FORMWORKS 14 – 15
4.5 ERECTION - BEAM & SLAB FORMWORKS 15 – 16
4.6 ERECTION - EXTERNAL WORKING BRACKETS 16
4.7 MARKING - FORMWORKS PANELS 16 – 17

5.0 PRE-CONCRETING
5.1 PRE-CHECK PRIOR TO CONCRETING 17
5.2 MONITORING DURING CONCRETING 17 – 18

6.0 FORMWORK STRIPPING

6.1 STRIPPING - WALL, COLUMN & BEAMS FORMWORKS 18 – 19
6.2 STRIPPING - SLAB FORMWORKS 19
6.3 STRIPPING - FLAT TIE & TIE BAR SHIELDS 20

SIMPLIFIED ILLUSTRATIONS OF FORMWORK ERECTION & STRIPPING

PROCESS
FORMWORK ERECTION PROCESS
FORMWORK STRIPPING PROCESS
PRE-CONCRETING CHECKLIST
POST-CONCRETING CHECKLIST

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 Hyundai Aluminum introduction

We, Hyundai Aluminum Co., Ltd. are very proud of introducing our great deal of
remarkable accomplishments throughout worldwide which has been fully supported by the
utmost technologies in the field of aluminum curtain walls, window & door, Aluminum
Forms and industrial products.
Since we established our business in 1978, we have faced a lot of challenges to meet our
customer requirements and this has made us more promising company up to now.
Under the environment that only the best can survive in the keen competition, it has made
us continually seek out new technologies to further our product capabilities firmly based
upon a strong, integral research mood with regard to material technology and
manufacturing skills in order to ensure our competitive position and high-quality products.
As being capable of meeting any requirements from our customers with the total service
system covering design, production, fabrication, packing, delivery, installation and
maintenance of designated products, we have always produced best quality products with
the excellent reputation being accumulated which has given us a lot of opportunities to
work foremost builders.
With it in mind that the foundation of the philosophy to put the pursuit of technology on
the first priority has been sustained under ever changing environments, we can assure that
we will give you full satisfaction and continue to the successful performance of business.

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1. INTRODUCTION

Formwork is the surface, supports and framing used to define the shape of concrete
until it is self-supporting.

Formwork includes:

 the forms on which concrete is poured

 the supports to withstand the loads imposed by the forms and concrete
 any bracing added to ensure stability

Together these components make the formwork assembly.

Hazards of formwork system

 formwork collapse (before, during and after placement of concrete)

 falls from height
 slips and trips
 falling objects
 noise
 dust
 manual tasks

To properly manage risks, a person must:

 identify hazards
 assess risks that may result because of the hazards
 decide on control measures to prevent, or minimize the level of the risks
 implement control measures
 monitor and review the effectiveness of the measures

Control measures must be the order of priority before other work commences.

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2. DESIGN

2.1 BUILT-ABILITY

The designers must consider the `build-ability’ of a structure or building and

minimize the risk of injury during construction.

The design of the final concrete structure can have a major effect on the ease of
formwork construction, and consequently, on the safety of persons during
construction. Generally, the more basic and simple the final concrete structure,
the safer it is to erect using formwork system.

A formwork designer should be consulted the design of formwork system to

minimize the risk of injury. And all materials and equipment used in formwork
construction must be fit for its intended purpose and meet the design
specifications.

Hyundai Aluminum Formwork System is manufactured and designed with

proprietary formwork components and rated load calculations in line with
standard requirement specifications.

A suitable formwork system must be implemented to ensure that only materials

and components that comply with the specifications of the formwork design
drawings and documentation are being used.

2.2 DOCUMENTATION

Formwork drawings will indicate the followings: -

 Plans, elevations and sections drawings to show the general arrangement

of the formwork and to identify and locate all members and components
including bracing, where necessary
 Components types and spacing
 The prop sizes and location
 Location of weep holes, inspection opening, formwork opening for
transfer of formwork, etc.

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2.3 ON SITE PLANNING

All parties involved at the project site shall coordinate and cooperate with each
other during the planning and preparation stage to determine and safeguard the
system of work based on risk assessment and control process. An effective
quality control system must be implemented for the construction of formwork.

The common defects which are likely to occur in a formwork system is

illustrates below:

 failure to check tightness of bolts, wedges, etc.

 failure to check adequacy of pin & wedges
 failure to control vertical rate of placement of concrete
 failure to control placement of concrete, causing uneven loading of forms
 inadequate allowance for uplift of concrete under inclined forms
 inadequate allowance for stresses induced by prestressing, temperature
and moisture movements
 unequal load distribution between two or more members carrying a
common load

Materials and components that are damaged or excessively worn must not be
used.

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3. SITE COORDINATION & ADMINISTRATION

3.1 WORK PROGRAM

The risk to a person’s health and safety must be considered when designing a
work program for erecting, altering and/or dismantling formwork. At the very
least consideration must be given to : -

 sufficient break time is allowed for each work activity

 coordinating trades to allow work to be completed free of obstruction
 allowing for the progressive clean up of work areas to prevent
rubbish/debris becoming a trip hazard and allowing access for mechanical
aids
 taking account of edge protection requirements and ensuring these are
designed and constructed appropriately

3.2 STORING

 Wide work area is to be identified and set up for the unloading of the
formworks material and accessories. It should be properly fenced up and
security shall be of up most priority due to the high value in the secondary
aluminum market

 Materials must be stored in order to minimize manual tasks hazard, trip

hazards and the potential for falling objects. Smaller components such as
pin & wedges, clamps, etc should be contained in material boxes. Where
practicable, props/supports and panels should be strapped until the time to
use them. These materials should be located back from the edge of the
deck or openings to prevent materials or persons accessing the materials
falling through or off the deck.

 Maintenance of formworks material is highly recommended to be set up at

the project site to minimise the time of replacement materials.

 Incorrect material delivery and storage can make significant manual

handling tasks. Safe work practices to minimize exposure to these risks
include

- Ensuring the formwork materials are delivered as close as possible to

the job. Delay in transferring or maintenance of formwork panels as
a result of the far away storage and workshop area as the project
progress will affect the daedline for completion of construction using
the formwork system.

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 - ensuring mechanical aids are used to handle loads wherever possible
- storing loads on trolleys to minimize double handling or on raised
platforms to minimize manual lifting from ground level
- having adequate storage space or lay down area to safely store
materials and equipment and to minimize double handling

3.3 MANPOWER

 Hyundai Aluminum shall provide competent formwork

specialist/supervisor(s) to the project site to assist in the first level setting.

 The number of specialist/supervisor(s) shall be depended on the quantity

of the formwork to be used on construction site.

 Enough manpower requirements for this formwork erection is required to

ensure the targeted cycle time.

 In addition to that, the manpower requirement for other supplementary

trades which shall complement the formwork installation such as
Mechanical & Electrical (M&E) services, steel/rebar works and
concreting works should also be conveyed to these trades coordinator to
ensure it can keep up with the cycle time.

 A joint effort of all operations from formworks installer, rebar, plumbing,

electrical and concreting workers need to be synchronised to achieve the
required cyclical time.

 Segregation and systematically approached of duties for each formwork

team are required in ensuring optimisation of productivity and prevention
of chaotic working environment at project work site. Hence, each team
shall be delegated or assigned to do specific job tasks on a daily basis to
resemble a manufacturing production line. However, due consideration
should be used in determining the level of experience and compatibility of
person when allocating tasks to minimise the risks.

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3.4 ON SITE TRAINING

 All persons who may be exposed to workplace health and safety risks
resulting from formwork construction must be provided with information
and training that is specific to the formwork system.

 Such training and information must include details of : -

- the formwork system, tasks, activities and components

- the way the manufacturer or designer of the formwork system
intended the system to be erected, installed, used, moved, altered or
dismantled
- specific training and information required to undertake or participate
in specific tasks or activities
- control measures to minimize exposure to the risks, correct use of
controls, and how to ensure they are kept in full working order
- safe working procedures, including the use of mechanical aids and
devices, where appropriate
- how to use and maintain equipment, including any specific conditions
and prohibitions on the use of the formwork equipment
- any special safety information needed such as safety precautions for
working under certain conditions or weather
- personal protective equipment required, including instruction in
fitting, use, cleaning, maintaining and storing of this formwork
equipment
- details of how accidents have occurred in the past involving the same
work process(s), where applicable

 Persons involved in formwork activities must also be provided with more

general workplace health, safety information and training including : -

- the effects of noise on their hearing and health

- the workplace’s health and safety policies, and relevant procedures
and work method statements
- the risk management process
- inspection and maintenance programs in place at the workplace
- how to access information such as manufacturer’s instructions about
hazards
- emergency procedures, including person with specific emergency
roles and responsibilities

3.5 ACCESSIBILITY

 Clear access is important for the safe movement of materials, equipment

and persons on site.

 Designated access ways must be provided and be kept clear and free of
obstructions because of the constantly changing work environment,
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 restricted access through frames and supports and due to the large quantity
of formwork materials and accessories. Persons must be instructed to use
the access ways and keep them clear of any rubbish, plant or materials.

 Considerations of the number of persons working on the formwork

equipment should be taken into account including the tools requirement to
carry to/from worksite areas.

 All materials and accessories must be properly stored in systematically

and orderly manner to minimise manual trip and slip hazards and the
potential of falling objects.

 It is advisable to store accessories part and components in material

buckets or boxes and the formwork panels lay on the ground instead of
leaning the panels against the structures.

 Emergency access and egress must be considered and provided to all parts
of the worksite where persons are required to work.

 Unauthorised persons should be prevented from entering the work area.

Physical barriers and proper hazard warning signage are prominently
displayed around and within the work area.

3.6 HAZARDS

 Control measures should be taken to identify and minimise the hazards

associated with work involving the assembly and dismantling of
formwork equipment such as falls from height, slips and trips, falling
objects, noise, dust and manual tasks.

 It is preferable to lay the formworks panels flat on the ground instead of

leaning them against structures or other forms such as props/supports,
external working brackets/platforms or scaffoldings. This will lead to the
persons working on it expose to additional hazards in relation to trips and
slips or collapse of the props/supports, external working
brackets/platforms or scaffolding.

 Minimise the working heights for persons performing the assembly and
dismantling formwork.

 Mixing of formwork components should be avoided to prevent unsafe

installation such as mixing pins and braces which may lead to collapse of
the formwork.

 Partially assembled or dismantled formwork should be secured during

break time or end of the day to prevent against overturning or collapsing
due to strong wind or accidentally/unintentionally knock over by workers.

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  Do not allow drop stripping of formwork as it is an unsafe practice.

 Electrical safety should be implemented for the safe use of electrical

equipment.

 Protruding flat ties or projecting nails should be removed immediately

with appropriate tools at dismantling stage.

 Use of personal protective equipment by all persons working at work

areas (such as safety hardness, safety helmets, eye protection etc) should
be strictly implemented.

3.7 TOOLS & ACCESSORIES

 Hyundai Aluminum shall provide adequate accessories such as pin &

wedges. (A standard 10% extra for wastage shall be supplied as per
supply contract for the assembly and dismantling of the formwork panels.)

 Hyundai Aluminum will ensure sufficient handy tools related to the

erection and dismantling of formwork such as flat tie sleeve ejector and
flat tie extruder are available at project work site to ensure non disruption
in workflow at work site.

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4. FORMWORK ERECTION

4.1 SETTING OF LEVEL & POSITION MARKING

Based on the approved construction drawings, the project surveyor shall ensure
that the guideline and foundation level are properly set up, marked and peg for
walls, column etc. Leveling must be checked prior to commencement of
formwork installation to ensure accurate positioning.

4.2 MOULD OIL APPLICATION

 Cleaning of panels especially the concrete contact surface and side panel
of the formworks after each usage should be done immediately using
proper tools.

 Ensure that the concrete contact surface of formworks panels are properly
coated with recommended Mould or Form Oil (a concentrated concrete
form release agent) which are diluted either with water, kerosene or fuel
oil (depending on manufacturer specification) that will chemically reacts
with the alkalies in concrete to form a slippery soap film that prevents
from sticking and concrete buildup on aluminum form surfaces. It protects
and prolongs the useful lives of the aluminium formworks.

 Ensure that the following steps/precautions are taken when applying the
Mould or Form Oil on the formwork panels : -

- The best results are obtained when a uniform application of Form Oil
is applied immediately following stripping and subsequent cleaning
of the panels. Always ensure that the coated form surfaces are
allowed to dry prior to placing concrete.

- Do not over apply. Excess Mould or Form Oil, runs and puddles can
adversely affect performance and should be picked up promptly with
rags.

- Prevent Form Oil overspray from contacting reinforcing steel bars

and/or tensioning cables.

- Application equipment and overspray can be cleaned with detergent

and water.

The above steps should be repeated before the next cycle of usage.

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4.3 OTHER TRADES - REBAR, M&E & PLUMBING

 The support works such as rebar, Mechanical & Electrical (M&E) and
plumbing are to commence immediately once the set up is completed and
confirmed by the project surveyor.

 These works for the wall formworks section are to be coordinated

systematically among the sub-contractors to ensure the wall sections are
ready for the formworks installer to commence their works.

 The support works for the slab section commence after the slab formwork
panels are assembled.

 Spacers should be fixed to both sides of the rebar section for positioning
and eliminate the rebar from resting on the surface of the formwork panels.

 Positioning of outlets for electrical switch boxes to its correct alignment

can be done by riveting the appropriate fit size mould to the formwork
panels. The electrical switch boxes are then securely cap to the fit size
mould and fasten by way of wiring to the formwork panels. Ensure that it
is properly secured to prevent grouting from building up in the switch
boxes.

4.4 ERECTION - WALL FORMWORKS

 Formwork frames must be erected in a progressive and systematically

manner to ensure both the installers’ safety and the stability of the overall
structure. Braces, where necessary, must be attached to the frames as soon
as practical.

 Always commence wall erection from the external corner of the wall
section to ensure both joint external corner wall panels will support each
other for standing position. Pin and wedges are to be used to secure the
panels together. Always insert the pin from the inside out for easy
removal of pin after concreting.

 The formwork panels wall positioning is securely placed on the marked

gridlines and level by way of fixing timber stoppers at the base of the
outer side of the formwork panels at interval of one (1) meter. This would
ensure that the formwork panels are not disposition during the concreting
process.

 Once the initial wall corner panels are assembled, place the wall corner
panels on the allotted set up position.

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  Commence to erect simultaneously the balance of the wall panels from
either side of the external wall panel.

 Proceed to assemble the internal wall corner. Place these panels into the
correct position on the lines which were set up by the surveyor. Proceed to
assemble the balance of the internal wall at both sides.

 The internal and external walls are to be held together by flat ties with the
flat tie sleeves (reusable) in between them. These flat tie sleeves which are
cut to exact length to maintain the wall thickness and are to be coated with
the Form Oil before each usage. By doing this, it will facilitate the
removal of the flat tie sleeves from the concrete upon striking process.

 To determine and achieve the vertical accuracy of the formwork panels

assembled before concreting process, several methods such as plump bob,
spirit level, theodolite equipment etc can be used. The simplified method
of using a plump bob with a string attached to it which is then suspended
from the upper part of the formwork panels is used as a guide to determine
the deviation from the vertical alignment of the panels.

 Additional wall panels or kickers are fixed on the external wall panels in
accordance to the required height for the formation of the slab concrete.
Check to ensure that the verticality of the kickers is correctly aligned.

 The kickers shall remain at its position for the subsequent forming of next
level wall.

4.5 ERECTION - BEAM & SLAB FORMWORKS

 Fixed the slab corner panels to on top of the wall panels with round pins
and wedges. The position of the pins should be from top down to ease the
dislodging process.

 End beam panel, mid-beam panel or prop head to be connected together

by using joint bar and long pin at ground working area and these panels
work as main beam of the slab formwork. Theologically, main beam is
designed not exceeding 10 meter.

 The main beams to be flips up and end beams are fixed to the slab corner.
Prop to be connected with main beam by slot in prop to prop head.

 The beams sections are accurately position to enable the slab panels to be
connected systematically.

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  Commence to assemble the slab panels from the corner section of the slab.
Subsequently, fixed the whole slab area by pinning the slab panels
together with the main beams (comprises of prop head, end and mid
beams).

 The height of the prop is to be properly maintained to ensure correctness.

4.6 ERECTION - EXTERNAL WORKING BRACKETS

 Steel structure external working brackets are used to provide a work area
at the external wall section if required.

 Once the first level is completed and external formwork panels removed,
fixed the external working brackets to the 1st floor level at position
slightly below the kickers which are fixed on 1st floor external slab.

 The external working brackets are secured to the external wall section
from the inside using bolts and nuts.

 Once all the external working brackets are put in place, timber planks and
strips are placed on the floors and railings respectively to create an
external working platform for the assembly of the subsequent level of the
external formwork panels and kickers.

 Another set of external working brackets are later fixed on the subsequent
level using the method as prescribed above.

 Once the subsequent level of external formwork panels are fixed, the
external working brackets at one level below are removed and moved to
the subsequent level. This process is repeated until the completion of the
subsequent floors.

4.7 MARKING - FORMWORKS PANELS

 A numbering sequence shall be allotted for each of the panel and is

identified in accordance to unit area such as rooms, living area, bathrooms,
common areas etc.

 Practice the use of color identification scheme when numbering on each

section or area to further eliminate the confusion that may arise due to the
size of some projects. It can be identified in such that for example BLUE
for Section 1, RED for Section 2, GREEN for Section 3, etc.

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  By practicing the use of numbering system in combination with the colour
identification scheme, it have been proven to avoid confusion and assist in
the process of identification of panels position once they are transferred to
the next level/floor.

5. CONCRETING

5.1 PRE-CHECK PRIOR TO CONCRETING

 Ensure that the position of the walls and column formworks are in
accordance with the set up marking.

 Check to ensure correct spacing of frames and props.

 Check the verticality and horizontality level of the wall and slab panels
respectively.

 Ensure that all pins, wedges and ties are properly secured and tightened.

 Re-check the opening such as door and window panels are correct.

 Re-check all propping stands to ensure its height are in accordance to

drawings.

 Adequate bracing to ensure stability.

5.2 MONITORING DURING CONCRETING

 Ensure site coordinators are available and on stand-by during the

concreting process.

 Always ensure that concrete pouring is distributed evenly throughout the

wall and column sections before commencing to cast the slab level areas.
This is to prevent loading pressure on the formwork panels due to uneven
casting.

 Recheck the areas whenever cement slurry leakage is noted to determine

the cause of it. Remedy work should be done to ensure the concreting
process is not affected.

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  During concreting, always ensure that immediate step is taken to remove /
clean all the excess concrete that is stuck on the back of the formwork
panels. Non removal will result in the formwork panels getting too heavy
and also the scrapping task after the concrete has dried up becomes more
tedious.

6. FORMWORK STRIPPING

6.1 STRIPPING - WALL, COLUMN & BEAM FORMWORK

 Formwork panels shall be removed without damaging the concrete and tie
bar shield. Bars or other tools shall not be used as a lever against the
concrete in removing the formwork panels.

 The appropriate time for the stripping of formwork panels will vary
according to the environment and type of concrete used. The formwork
panels of the wall, column and beam section can be usually dismantled
after 10-12 hours. However, this process shall subject to approval of the
project structural engineer after taking into consideration the grade of
concrete used, additional props stand ordered, etc.

 Always ensure that the wall section panels are removed first follow by the
column and beam sections.

 For precautionary step, ensure that formwork panels are removed

systematically and due care is to be taken to prevent any damages to the
formwork panels and also finish surface of the concrete whenever possible.

 For safety reason, ensure that no workers are facing the pin and wedges
when removing using hammer. Pin and wedges removed are to be
collected and placed in containers to minimise lost and replacement.

 The dismantle formwork panels shall be transferred to the next level/floor

for subsequent assembly process via the slab opening or staircase areas in
an orderly manner and to the appropriate section/area immediately. This
will eliminate the confusion and congestion in the dismantling area or
level as a result of too many dismantled formwork panels lying on the
floor area.

 As the formwork panels are pre-numbered and if colour identification

scheme is implemented, the transfer of panels can be determined and
planned ahead according to the various sections / areas of one level/floor
to the subsequent level/floor.

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  Always ensure that all the formwork panels are to be properly cleaned and
applied with the Form Oil to protect the surface of the formworks before
re-used.

 For the external wall section, the kickers on the upper portion of the floor
level shall remain intact to support and align the next level/floor of
formwork panels that are going to be assembled. The assembly of the
external formwork panels can be done by using the external working
platforms that are fixed to the wall areas.

6.2 STRIPPING - SLAB FORMWORKS

 The appropriate time for the stripping of formwork panels will vary
according to the environment and type of concrete used. The formwork
panels of the slabs section are usually dismantled after 36 hours. However,
this process shall subject to approval of the project structural engineer
after taking into consideration the grade of concrete used, additional props
stand ordered, etc.

 The end beams and middle beams have to be removed first after
dismantling the wall panels. Proceed by removing the long pins and
wedges on the joint bars for the end and middle beams. However, the prop
stands are to remain undisturbed during this process to lend support for
the weight of the concrete slab.

 There shall be 2 sets of prop stands provided by Hyundai Aluminum to

support the concrete slab. The first set of the prop stands will only be
removed when the assembly of the third level/floor commences and also
upon approval and consultation with the project structural engineer.

 Proceed to dismantle the slab panels by commencing from the end of the
slab area. Once the slab panels are dismantled, continue to remove the
slab corners.

 Extra precautionary measures have to be taken to minimise damage to the

slab panels and also finish surface of the concrete during dismantling
process.

The above steps should be repeated before the next cycle of usage.

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6.3 STRIPPING - FLAT TIE & TIE BAR SHIELDS

 All the Al-Flat Ties use for the purpose of ensuring that the thickness of
the walls and column are consistent, are to be removed by using special
tools provided by Hyundai Aluminum.

 Subsequently, proceed to remove the recycle Tie Bar Shield which is

embedded in the walls and columns section by using the Tie Bar Extractor
provided by Hyundai Aluminum.

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ERECTION PROCESS OF
FORMWORK SYSTEM

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ALUMINUM FORMWORK SYSTEM SETTING PROCESS

Step. 1

For the decrease of adhesion, form oil must be applied on the surface of each panels before setting.

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ALUMINUM FORMWORK SYSTEM SETTING PROCESS

Step. 2

From inner corner, wall panel is fixed by flat tie, wedge pin and stub pin.

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ALUMINUM FORMWORK SYSTEM SETTING PROCESS

Step. 3

Complete the setting of both internal and external wall.

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ALUMINUM FORMWORK SYSTEM SETTING PROCESS

Step. 4

Insatall S.L(Soffit lenth) on the top portion of wall panel with wedge pin and stub pin.

SL(soffit lenth)

Wedge pin & stub pin

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ALUMINUM FORMWORK SYSTEM SETTING PROCESS

Step. 5

Combine the middle beam, end beam and DP with BJ, long pin and stub pin.

Soffit length (SL)

End beam (EB)

Deck prop head (DP)

Middle beam (MB)

Beam joint (BJ)

Stud pin

Long pin

Support

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ALUMINUM FORMWORK SYSTEM SETTING PROCESS

Step. 6

Start to fill out the slab deck from end of corner section of slab.

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ALUMINUM FORMWORK SYSTEM SETTING PROCESS

Step. 7

Additional Wall Panels (or Kickers) are fixed to the external Wall Panels to raise to the
appropriate height to contain the slab concrete when it is poured.

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ALUMINUM FORMWORK SYSTEM SETTING PROCESS

Step. 8

Completion of the installation of the Wall and Slab Panels.

A numbering should be made for each of these panels with colours. This numbering and colours
will ensure that each panels can be determined as to their exact location once they are transferred
to the next level for installation.

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DISSOLUTION PROCESS OF
FORMWORK SYSTEM

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DISSOLUTION PROCESS

Step. 1

After removing the wall panels it should be moved to upper floor through the slab opening as
shown.
The transferring of the panels should be done in a systematically and orderly manner to ensure
that the next cycle or level is not affected. Since all the panels are numbered with different colour,
these transfer process can be determined and planned in advance according to section of the
building such as Room 1, Room 2, Bathroom, etc.

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DISSOLUTION PROCESS

Step. 2

After removing the External Wall panels (the kicker should remain undistured), the dismantled
wall forms are moved to upper floor. Scaffolding is use for transfering of external wall panels
from the ground floor level. For level 1 and above, an external working platform is fixed to the
external wall. The external wall forms from level 1 onward shall be supported by the kickers.
(These steps are to be repeated from one floor to another floor.)

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DISSOLUTION PROCESS

Step. 3

After removing the Wall Panels, Slab Panels should be removed with the long pins and wedges on
the beam joint at the end and middle beam section.

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DISSOLUTION PROCESS

Step. 4

DP(Desk prop head) and support must be remained until the concrete is hard.

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DISSOLUTION PROCESS

Step. 5

Remove the Slab Panels and then transfer to the next level.

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DISSOLUTION PROCESS

Step. 6

Remove the SL(Soffit lenth)

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DISSOLUTION PROCESS

Step. 7

Remove the Tie Bar Shield in the wall with the Tie Bar Extractor.

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DISSOLUTION PROCESS

Step. 8

When slab concrete is sufficiently hard, the support and DP(deck prop head) are removed and
transferred to the next level.

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 SYSTEM FORMWORK - PRE-CASTING CHECK LIST

NO AREA TO BE CHECKED

A SETTING – OUT
1 Control line (cross line) given by client
2 Column and Wall setting - out and offset line
3 TBM - given by client
4 Base leveling and level pecking (high point > 6mm to chip off by concreter)

B VERTICAL ELEMENT AND COMPONENT

 Cleaned
1 Formwork Surface
 Coated with approval oil
 Width
2 Wall and Column Size
 length
 Internal
3 Wall and Column alignment adjusted
 external
 Internal
4 Wall and Column verticality adjusted
 external
 Wall
5 Steel and Timber waler installed accordingly
 column
 wall and column
6 Flat ties and flat ties sleeve installed correctly
 beam
 size and alignment
7 Door Opening
 verticality and door spacer
 size and alignment
8 Window Opening
 verticality
9 Pin and Wedge are installed accordingly (min. 10pcs per m2)
10 All Wall and column rockers have been installed
11 All box out on wall are properly placed and secured
12 Timber works have been properly secured (composite formwork)
13 Gaps between rocker and floor slab properly sealed by timber and mortar

C STAIRCASE

1 Thread and Riser are properly secured

 Verticality
2 Props or Support check for  Stability
 Tightening

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D WORKING PLATFORM
1 Condition of bracket and tie rod
2 Fastening tie rod (wall and beam)
3 External netting installation
4 Correct tie rod and nut used for individual area

E HORIZONTAL ELEMENT AND COMPONENT

 Beam
1 Horizontality Level
 slab
 at lower and upper tube
2 Adjustable Prop Condition.  at collar and adjuster
 at lock pin
3 Vertical and Horizontal bracing at external beam installed

4 All external edge formwork have been properly secured and alignment check

5 All kicker bolt,nut,washer and sleeve are installed

6 All box out on beam and slab are properly placed and secured

7 Timber works (composite formwork) are properly installed and supported

8 Construction joint is correctly installed

9 All drop area up stand installation are according to size and depth

10 Pins and wedges are installed accordingly (min. 10pcs per m2)

11 Prop stability --- horizontal bracing as required

12 Beam and slab prop/support at the floor below are remains in position

F OTHER

1 All rubbish are clear away from casting zone

2 Other area connected to the formwork system (other trades eg. Pre stressing)

Unused formwork and accessories (pin,wedge,tie,pvc sleeve,bolts,nut) to be

3
collected from casting zone prior to concreting

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 SYSTEM FORMWORK -- POST CONCRETING CHECK LIST

NO AREA TO BE CHECKED

A. STRIKING OF WALL AND COLUMN FORMWORK

1 Vertical formworks are mostly strike 12 hours after casting
2 Remove all timber that are nail to concrete slab and wedge at rocker
3 Remove all steel/timber walers that are attached to the formwork
4 Remove all bracing that are attached to the prop or formwork
5 Internal corner wall ties must be removed first before striking
6 Remove all pins and wedges from formwork identified for striking
7 Remove all excess grout that are in contact with the formwork
8 Ensure that worker use the correct tool for striking. (Panel-Puller )
9 All formwork are to keep properly
10 All formwork surface must be clean before next installation
11 Ensure that all prop/support are not removed.

B STRIKING OF BEAM AND BEAM SOFFIT FORMWORK

1 Beam side and soffit are mostly strike 12 hours after casting
2 Remove all pins and wedges from formwork identified for striking
3 Ensure that worker use the correct tool for striking. (Panel-Puller )
4 All formwork are keep properly
5 All formwork surface must be clean before next installation
6 Ensure that working stool are in good condition

C STRIKING OF SLAB FORMWORK

1 Slab formwork are mostly strike 36 hours after casting
2 Striking of slab formwork begin with removal of a section of "end beam"
3 Disconnect and remove the beam bar connecting to the end and mid beam
4 Remove all pins and wedges from formwork identified for striking
5 All formwork are to keep properly
6 Ensure that worker use the correct tool for striking. (Panel-Puller )
7 All formwork surface must be clean before next installation
8 Ensure that all prop/support are not removed.
9 Ensure that working stool are in good condition

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 D STRIKING OF EXTERNAL WALL AND BEAM FORMWORK
1 Vertical formworks are strike 12 hours after casting
2 All formwork strike must be lift up to the next floor slab
3 Pin and wedge must be thrown inside the building after remove
4 Ensure worker wear safety harness
5 All formwork are keep properly
6 Ensure that worker use the correct tool for striking. (Panel-Puller )
7 Ensure that working stool are in good condition

NO AREA TO BE CHECKED

E STRIKE WALL - MOUNTED WORKING PLATFORM

1 Ensure that all external formwork have been removed
2 All bottom kicker formwork have been removed
3 All netting and extension post at platform bracket remove
4 All hand rail and joist are removed
5 Any debris on the platform floor are removed
6 Ensure rope use for looping the bracket in good condition
7 Ensure worker wearing safety harness at all time

F REMOVAL OF WALL AND COLUMN FLAT TIE / FLAT TIE SLEEV

1 All flat ties must be removed with Tie form puller
2 All flat ties stuck on wall and column must be cut off
3 Are flat ties clean and straighten?
4 Are flat ties sleeve clean and pack properly?
5 Patching of tie hole :-
--cement mortar
--non- shrink grout (external wall/column)

REMARK:

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