What is Formwork?

The construction of formwork takes time and involves the expenditure of up to 20 to 25% of the cost of the
structure or even more. The design of these temporary structures is made for economic expenditure. The
operation of removing the formwork is known as stripping. Stripped formwork can be reused. Reusable
forms are known as panel forms and non-usable forms are called stationary forms.

Timber is the most common material used for formwork. The disadvantage of timber formwork is that it
will warp, swell, and shrink. The application of water-impermeable cost to the surface of wood mitigates
these defects.

Formwork Design and Layout

The design and construction of formwork must consider both safety and the required surface finish. The
formwork must be rigid and tight enough to prevent cement slurry loss from fresh concrete or the
formation of fins and honeycombing on the surface. IS 14687 can be consulted for more information on
design, detailing, and so on.

Formwork and its supports keep their correct shapes and profiles so that the final concrete structure stays
within the specified dimensional tolerances. They must be built to withstand the combination of self-
weight, reinforcement weight, wet concrete weight, concrete pressure, construction and weather loads, as
well as all incidental dynamic effects caused by placing, vibrating, and compacting the concrete. The
reinforcement steel shall never be tied to or supported by the formwork.

All horizontal and vertical formwork joints on the exposed surface must be staggered in order for the joint
lines to be visible. The size of such panels must be approved by the Engineer in charge before they are
used in the construction of the works if the contractor proposes to make up the formwork from standard-
sized manufactured formwork panels. The finished appearance of the entire elevation of the structure and
adjoining structures shall be considered when planning the pattern of joint lines caused by formwork and
by construction joints to ensure continuity of horizontal and vertical lines.

Formwork Importance

o No doubt formwork is essential for any construction; its main advantage is that it can’t be replaced
with any other technology.
o Using formwork, concrete structures can be constructed quickly and in the most affordable way.
o During all construction work periods, a formwork offers appropriate access and working platforms
that considerably enhance workers’ scaffold safety.
 o Formwork helps in lowering the timeline and costs of the project by lowering the floor-to-floor
construction cycle time, which means more projects can fulfil their budgetary demands.
o Formwork facilitates construction managers to offer exact on-time shuttering and de–shuttering of
formwork resources, which results in improving project effectiveness and resource usage.
o Formwork is mainly associated with concrete. It helps in producing a smooth finished surface of
the concrete.
o It provides good structural safety by offering solutions against all overlay loads, producing
exceptionally safe and practical structures.

Components of Formwork

The various components of formwork are shown in the figure below, and let us study them one by one.

Fig.1. Components of Formwork

o Ties: A tie is a tensile unit used to connect opposite sides of formwork. It serves as a balanced
connection or is used to resist the effective pressure of fresh concrete.
o Braces: Braces are used to keep the formwork upright by deterring form deflection under lateral
pressure.
 o Studs: Studs in the formwork are used to support sheathing panels and make a framework to keep
them in position.
o Sheathing: Sheathing panel is used to keep the concrete in its required shape and position until it
sets and hardens.
o Wales: Wales are horizontal propping members that are placed against sheathing to directly resist
sheathing pressure.
o Battens: Battens are vertical members in the formwork which keep cleats and wales uptight and
in position.
o Footing: Footing is the bottommost member which supports the entire formwork.

Cost/Economy of Formwork

Construction of formwork takes much effort and also consumes up to 20 to 25% of the cost of the whole
structure work. That’s why it is very important to keep it cost-effective parallel to its strength.

Here are some key points which can help reduce the cost of formwork.

o Try to reduce the variation in the building or structure design. It can help to reuse the shuttering
again. And the way of reusing shuttering reduces its cost.
o Economical structure design can reduce the sections of structural members. Reduction of sections
can help to fix less shuttering, as a result, costs can be reduced.
o Proper cutting of plywood and timber can also reduce the cost of shuttering.
o The use of the different engineered systems of form-work can reduce labour costs and save time
but as per material. They are costly, initially, they are not reducing the cost of shuttering. But in
large projects saving time can help to reduce the all-over project cost.

Requirements of a Good Formwork

o It is very important that the formwork is well supported and strong enough to bear all loads
applied to it.
o Formwork must be aligned and braced well from all sides to keep its original shape.
o It should be watertight to prevent the leakage of cement grout.
o It should be constructed in a proper way so that at the removal stage concrete can be safe.
o The form-work material must be available locally, cheap, and can be used more than one time.
o Try to keep it lightweight as possible to prevent the extra load on supports. Especially in
horizontal shuttering, lightweight formwork also can help to reduce labour costs or effort.
o It must be fixed in line and levels as per the drawing.
 o Form-work material should not be damaged or rusted, which affects the quality of concrete
finishing.

Types of Formworks

There are several types of formwork used in construction. They are discussed below in detail.

Timber Formwork

Timber formwork is the most common type of formwork among all others. Timber forms are extensively
used in construction since the ancient period. Timber formwork is the oldest type of form used in
construction.

Timber formwork is one most used in construction among all other types of formwork. It offers onsite
fabrication of the required shape and size. It is easily used in any construction but it may prove time–
consuming for large projects. Plywood formwork material has a short lifespan. Timber Shuttering is low-
cost and easily workable shuttering. It can be cut and joined in any shape and size.

Fig.2. Timber Formwork

Requirement of Timber Formwork

o Light in weight
o Properly seasoned
o Free from any termite attacks
o Easily workable

Advantages of Timber Formwork

 o Timber Shuttering is easy to form any shape, size, and height.
o It is proven economical for small projects.
o It can be made using locally available timber.
o Timber is light–weighted compared to steel or aluminium shuttering.

Steel Formwork

Steel formwork has become more popular due to its strength, durability, and repetitive reuse for a long
period. Steel formwork is costly for small work but can be used for a large number of projects. Steel
shuttering offers a smooth surface finish to concrete compared to timber formwork. It can be used for
circular or curved structures such as tanks, columns, chimneys, sewers, tunnels, and retaining walls.

Fig.3. Steel Formwork

Advantages of Steel Formwork

o Strong, durable and longer life

o It offers a smooth finish to the surface of the member.
o It is completely waterproof or moisture–proof and minimises the honeycombing effect.
o It can be reused more than 100 times.
o Steel formwork can be fixed and removed with greater ease.
Aluminium Formwork

As we know the density of aluminium is less compared to steel and that makes it light-weighted than steel.
This is the main advantage when compared to steel. Aluminium formwork is almost the same as formwork
made from steel. Shuttering down with aluminium form is proven economical if large numbers of
repeating usage are made in construction. Its major drawback is that no alteration is possible once the
formwork is constructed.

Fig.4. Aluminium Formwork

Plywood Formwork

Plywood formwork is one of re-moulded timber resin-bonded plywood sheets attached to timber frames to
make up panels of the required sizes. It is strong, flexible, and easy to handle. Its life is too short compared
to other materials.

Fig.5. Plywood Formwork

Formwork for Column

Formwork for columns is an essential part of the construction process, providing temporary support and
containment for the concrete until it sets and gains sufficient strength.
1. Panels: Large, flat surfaces enclosing the column area.
2. Shear Walls or Ties: Steel rods or struts securing panels against lateral pressure.
3. Waler or Strongback: Horizontal member distributing load and providing support.
4. Kickers: Inclined braces maintaining vertical alignment of formwork.
5. Form Ties: Steel ties holding formwork panels together.
6. Formwork Accessories: Wedges, clamps, bolts, and nuts for assembly and adjustments.

Formwork for Slab

Formwork for slabs, also known as decking or form decking, is used to support and contain the concrete
during the construction of horizontal slabs. Here are the key components and steps involved:

1. Joists or Beams: Horizontal supports for the formwork system.

2. Stringers: Parallel members aligning and supporting formwork panels.
3. Formwork Panels: Flat surfaces creating the slab structure.
4. Props or Shoring: Vertical supports carrying the formwork and concrete load.
5. Formwork Accessories: Clamps, wedges, bolts, and nuts for assembly.
6. Reinforcement: Steel bars or mesh enhancing slab strength.

Construction of Concrete Formwork

The construction of concrete formwork involves several steps to create temporary structures that shape and
support the poured concrete until it sets and gains sufficient strength. Here is an overview of the process:

1. Design and Planning: Determine formwork dimensions and layout based on drawings.
2. Material Selection: Choose suitable formwork material.
3. Preparation of Formwork Components: Cut and treat panels, fabricate additional components.
4. Foundation Preparation: Level and stabilize the ground.
5. Assembly of Formwork: Erect and connect formwork components securely.
6. Reinforcement Placement: Install steel reinforcement within the formwork.
7. Alignment and Levelling: Ensure formwork is aligned and level.
8. Bracing and Support: Provide adequate support and bracing for formwork.
9. Formwork Inspection: Check for defects and rectify any issues.
10. Concrete Pouring: Carefully pour concrete into the formwork.
11. Concrete Curing: Allow concrete to cure under proper conditions.
12. Formwork Removal: Remove formwork systematically, taking care not to damage the concrete.
Removal Of Formwork

The minimum period before the removal of formwork for various types of structures is tabulated below:

S.No Type of Formwork Minimum Period Before Removal Of

. Formwork
1 Vertical formwork to columns, walls and 16-24 hours
beams
2 Soffit formwork to slabs 3 days
3 Soffit formwork to beam 7 days
4 Props to slabs
Slab spanning up to 4.5 m 7 days
Slab spanning over 4.5 m 14 days
5 Props to beams and arches
Spanning up to 6 m 14 days
Spanning over 6 m 21 days

Comparison between Steel & Timber Formwork

Aspect Steel Formwork Timber Formwork

Material Made of steel, typically steel plates Made of timber, usually plywood or
lumber
Strength High strength and durability Moderate strength and durability
Reusability Highly reusable, suitable for repetitive Limited reusability, may require
use replacement after multiple uses
Weight Heavyweight, requires heavy machinery Lightweight, can be easily handled
for handling manually
Installation Requires skilled labor for assembly Requires skilled labor for assembly
Cost Relatively higher initial cost Relatively lower initial cost
Formwork Highly customizable for various shapes Limited customization options
Customization and sizes
Moisture Resistant to moisture and weather Can be susceptible to moisture
Resistance conditions damage
Fire Resistance Resistant to fire Susceptible to fire, requires fire-
retardant treatments
Sustainability Not environmentally friendly, steel Environmentally friendly, timber is a
production has a higher carbon footprint renewable resource
Surface Finish Provides smooth and consistent finishes May require additional finishing
work