OVERVIEW OF TEMPORARY

STRUCTURES IN CONSTRUCTION
FORMWORK
CONSTRUCTION MATERIAL, METHODS AND TECHNOLOGY
 Formwork & Scaffolding Systems

Classification according to sizes Classification according to location of use

Small-sized formwork Different elements in the structure have
Operation by workers manually
different design and performance
requirements in the use of formwork.
Timber and aluminum
Some systems are more adaptive for specific
Large-sized formwork location of use, such as
Crane facilities are required in the operation Irregular frame structure traditional timber
Reduce the number of jointing and to form or aluminium form
minimize the number of lift. Cross wall gang form, climb form or jump
Stiffening components - studs and soldier. form
Floor table form
Repeated regular section tunnel form
 Formwork Systems

Aluminium formwork system for Timber formwork for irregular-grid podium

residential housing block structure

Steel panel form (Gang form)

for constructing a core wall
Table form for the flat slab structure
 Gantry form/tunnel form system for the Climb form in the
Jump form system used in public construction of station facilities construction of the 50-
housing project storey Manulife
Tower

COURTSEY:
 Formwork Systems

Classification according to materials of Classification according to nature of operation

construction
Manually operated formwork
Timber
Self-lifted formwork
Most popular formwork material low initial cost
Crane-lifted formwork
High adaptability to complicated shape
Gantry, traveling and tunnel type formwork
Labour intensive and environmental unfriendly system
Steel
Hot-rolled or cold-formed sections heavy weight
Suitable for large-sized panels
Aluminum
Stiff and light weight
Higher material and labour cost
Excellent finish
 Formwork Systems

Considerations when using formwork

Construction related considerations
Design related considerations
Complexity of the built environment
Shape of the building
Speed of work
Architectural features on building exterior
No. of possible reuses
Internal layout
Construction planning and arrangement
Structural form
Area or volume of cast per pour
Consistence in building dimensions
Involvement of other construction technique
Span and Headroom
Dependence of work
Repetitive nature
Provision of construction joint
Finishing standard
Accessibility to work
Feasibility of introducing alternative design
 Examples of some crucial built situations

very large site Sloped site

very crowded site

Examples where special techniques are involved in the construction

Incorporation of tensioning and complicated

Incorporation of precast elements
phasing arrangement
 Formwork Systems

Examples of Application
Festival Walk using traditional manual-
type timber formwork
21,000 sq. m site.
4-level basement and
7-level upper structure.
Features:
A 48m-span void constructed of 8
numbers of cast-in-situ and
posttensioned beams, supported on
the sides by bearers
 Formwork Systems

Large span structures up to 32m in

length, cast-insitu, some are
posttensioned.
3 atrium spaces, averaged 35m in
span, and with 25m headroom
Average headroom for each floor is
about 4.5m.
Basement top-down approach.
non-repeated layout
structure subdivided into 6 main
phases.
Great number of construction jointing
 Formwork Systems

Belchers Garden using traditional manual-type timber form

situates on sloped site with area around
24,000 sq m.
level difference about 65m.
Other features:
10-level podium, used as carpark,
shopping mall and recreational facilities
Six 48-storey residential towers built on top
of podium
huge size of podium and sophisticated
typographic environment of site,
demands complicated phasing and
sectioning arrangements
 Construction of the
podium structure Detail of transfer plate
before concreting

Falsework to support
the transfer plate
 Formwork Systems

Superstructure
irregularity in layout
complicated architectural
features in external envelops
large amount of short-span
slabs
large amount of shear walls
in the structure
use of manually operated
timber panel forms
 Detail of wall and floor formwork arrangement as
seen from the floor interior

Detail of the wall

formwork
 CONSTRUCTION PROCESS

Plumbing and Electrical Services Faade Exterior Finishes

Concealed works - Pipes, Conduits, Traps External Brickwork
etc.
External Plastering
Associated civil workswater-proofing etc.
External Painting
Pulling of wires generally done after
Stone Finishes
plastering etc.
Tiling
Fixtures placed mostly after completion of
painting Combination of aluminum & glass
Testing & commissioning
 CONSTRUCTION PROCESS

Interior Finishes Walls, Ceiling, Floor Doors and Windows

Internal Brickworks Holdfasts
Plasteringwalls, ceiling Door/window framesfixing & alignment
Floor preparation Fixing of doors, windows wood, steel,
aluminum, PVC
Flooringtiles, stones, cement based,
wood, specials Finishing of jambs and sills
Ceiling Paint/wood/false ceiling AccessoriesIronmongery, Locks,
Stoppers etc
Walls-Paint/tiles/stones/wood/specials
Final finish to the doors/windows
(Paint/polish in case of wooden)
 CONSTRUCTION PROCESS

Landscaping Concreting Process

Final grading, Cast in-situ
driveways, Precast/ Prefabricated
steps,
walkways,
groundcover,
Shrubs and trees.
fences,
hardscapes/water features
Plumbing work for irrigation
 Formwork

It should be strong enough to withstand all The formwork should be set accurately to the
types of dead and live loads. desired line and levels should have plane
surface.
It should be rigidly constructed and
efficiently propped and braced both It should be as light as possible.
horizontally and vertically, so as to retain its
The material of the formwork should not warp
shape.
or get distorted when exposed to the
The joints in the formwork should be tight elements.
against leakage of cement slurry.
It should rest on firm base
Construction of formwork should permit
The material of the formwork should be
removal of various parts in desired
cheap, easily available and should be
sequences without damage to the
suitable for reuse.
concrete.
 Formwork

Timber Formworks Plywood Formworks

Timber for formwork should satisfy the following Resin bonded plywood sheets are attached to
requirement; It should be timber frames to make up panels of required
sizes.
well seasoned
The cost of plywood formwork compares
light in weight favourably with that of timber shuttering and it
easily workable with nails without splitting may even prove cheaper in certain cases in
view of the following considerations:
free from loose knots
It is possible to have smooth finish in which case
Timber used for shuttering for exposed on cost in surface finishing is there.
concrete work should have smooth and even
By use of large size panels it is possible to effect
surface on all faces which come in contact
saving in the labour cost of fixing and
with concrete. dismantling.
Number of reuses are more as compared with
timber shuttering
 Formwork

Steel Formwork Steel & Timber based Formworks

This consist of panels fabricated out of thin Comparison
steel plates stiffened along the edges by small
steel angles. Steel forms are stronger, durable and have
longer life than timber formwork and their reuses
The panel units can be held together through are more in number.
the use of suitable clamps or bolts and nuts.
Steel forms can be installed and dismantled with
The panels can be fabricated in large number greater ease and speed.
in any desired modular shape or size.
The quality of exposed concrete surface by
Steel forms are largely used in large projects or using steel forms is good and such surfaces need
in situation where large number reuses of the no further treatment.
shuttering is possible.
Steel formwork does not absorb moisture from
This type of shuttering is considered most concrete.
suitable for circular or curved structures which
are repetitive. Steel formwork does not shrink or warp.
 Removal of Formwork

Shuttering forming the vertical faces of walls, beams and column sides removed first as they
bear no load but only retain the concrete.
Shuttering forming soffit of slabs removed next.
Shuttering forming soffit of beams, girders or other heavily loaded shuttering removed in the
end.
Rapid hardening cement, warm weather and light loading conditions allow early removal of
formwork.
The formwork under no circumstances be allowed to removed until all the concrete reaches
strength of at least twice the stresses to which the concrete may be subjected at the time of
removal of formwork.
All formworks should be eased gradually and carefully in order to prevent the load being
suddenly transferred to concrete.
 Economy in Formworks

The plan of the building should imply minimum number of variations in the size of
rooms, floor area etc. so as to permit reuse of the formwork repeatedly.
Design should be perfect to use slender sections only in a most economical way.
Minimum sawing and cutting of wooden pieces should be made to enable reuse of the
material a number of times. The quantity of surface finish depends on the quality of the
formwork.
Formwork can be made out of timber, plywood, steel, precast concrete or fiberglass
used separately or in combination. Steel forms are used insituation where large
numbers of re use of the same forms are necessary.
For small works, timber form work proves useful. Fibreglass made of pre-cast concrete
and aluminium are used incast-in-situ construction such as slabs or members involving
curved surfaces.
Formworks for Precast Concrete
PRECAST SEGMENT CASTING YARD
PRECAST SEGMENT CASTING YARD

Batching Plant of Capacity 30 Cum/hr caters the Casting Yard

 REINFORCEMENT CAGE

Reinforcement: Segment Type A - 243 kg, B - 191 kg, C 191 kg

 STACKING OF CAGES

Available Moulds: Segment Type A 7, B - 14, C 7

PRECAST SEGMENT CASTING MOULDS

Oil is applied before concrete pouring.

CAGE FIXED IN MOULD
MOULDS AFTER CONCRETE POURING
STEAM CURING OF SEGMENTS

Steam at 55-600 C is applied @ 5 kg/Cm2 for 6-8 hours

STEAM PIPES FOR CURING
PRECAST SEGMENTS READY FOR DEMOULDING
PRECAST SEGMENTS READY FOR DEMOULDING
PRECAST SEGMENTS DEMOULDING
PRECAST SEGMENTS DEMOULDING
PRECAST SEGMENT DEMOULDING
PRECAST SEGMENT DEMOULDING
PRECAST SEGMENTS DEMOULDING
TURNING THE SEGMENT
TURNING THE SEGMENT
APPLICATION OF CURING COMPOUND

Curing compound is applied to retain the moisture inside

SEGMENT STACKTING YARD
SEGMENT STACKING YARD
SEGMENTS READY FOR ERECTION

Complete ring: Segment Type A 1 No., B 02 Nos., C 1 No.

SHIFTING OF SEGMENTS
FROM CASTING YARD
 TO TBM FRONT
STACKING INSIDE TBM
SEGMENT ERECTION
SEGMENT ERECTION
SEGMENT ERECTION
SEGMENTS AFTER FIXING
Pre & Post Award Issues Failure of
Form Works
 Period of Removal of Formworks

S. No. DESCRIPTION OF STRUCTURAL MEMBER PERIOD OF TIME

1. Walls, columns and vertical sides of beams 1-2 days
2. Slabs(props left under) 3 days
3. Beam soffits (props left under) 7 days
4. Removal of props to slabs
a) For slabs spanning upto 4.5 m 7 days
b) For slabs spanning over 4.5 m 14 days
5. Removal of props to beams and arches
a) Spanning upto 6 m 14 days
b) Spanning over 6 m 21 days