12/27/2024

Formwork Selection, Design & Maintenance

Temporary Structure
 The term "Temporary Structures" may not fully imply the temporary, since
some forms, tie hardware, and accessories are used hundreds of times,
which necessitates high durability and maintainability characteristics and
design that maximizes productivity.
 a temporary structure is any means or methods which provide temporary
support, access, enhancement, or otherwise facilitate the construction of
permanent structures.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Necessity Temporary Structure

 Temporary Structures form the interface of design and construction.
 Most permanent structures simply could not be built without Temporary
Structures.
 Unlike conventional structures, the formwork disassembly characteristics
are severely restricted by concrete bond, rigidity, and shrinkage, which
not only restricts access to the formwork structure but causes residual
loads that have to be released to allow stripping from the concrete which
initiates disassembly.
Behailu Z. (Ph.D. Cand.)

2
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Formwork Selection, Design & Maintenance

Responsibility
Temporary Structure
 The norm in construction industry is to place the responsibility for
Temporary Structures solely on the general contractor.
 However, architects and engineers must at least have formulated their own
method of construction.
 Coordinating the design of permanent structure with the Temporary
Structures that will be required can lead to more efficient and cost-
effective construction.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Responsibility
Temporary Structure

 In many cases the contractor is the only member of the construction team with
considerable experience and practical knowledge of Temporary Structures.
 The contractor must hire his or her own engineer, if the specifications or building
codes require one, or self perform the design of Temporary Structures.
 The most complex Temporary Structures are often handled on a design-build basis.
 The design-build situation is optimal because it guarantees coordination between
design and construction

Behailu Z. (Ph.D. Cand.)

3
 12/27/2024

Formwork Selection, Design & Maintenance

Temporary Structure
 Fresh concrete is a plastic material that takes the shape of the container or
form into which it is placed.
 A form is defined as -
 A temporary structure or mould for the support of concrete while it is
setting and gaining sufficient strength to be self-supporting (ACI 116R-00).
 Thus its purpose is to provide support and containment for fresh concrete
until it can support itself.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Temporary Structure
 Formwork is a classic temporary structure in the sense that:
 it is erected quickly
 highly loaded for a few hours during the concrete placement
 and within a few days disassembled for future use.
 Also classic in their temporary nature are the connections, braces, tie
anchorages, and adjustment devices which forms need.

Behailu Z. (Ph.D. Cand.)

4
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Formwork Selection, Design & Maintenance

Temporary Structure
Common types of work which occur on construction sites are:
1. Under Pinning
2. Scaffolding

Types 3. Shoring(False-work)
4. Formwork(Shuttering)
5. Dewatering
6. Cofferdams
7. Miscellaneous (site specific)
Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Formwork
 Formwork is a mould including all supporting structures, used to shape and
support the concrete until it attains sufficient strength to carry its own
weight.
 It should be capable of carrying all imposed dead and live loads apart from its
own weight.
 The construction of formwork takes time and involves expenditure up to
20 to 25% of the cost of the structure or even more.

Behailu Z. (Ph.D. Cand.)

5
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Formwork Selection, Design & Maintenance

Formwork
Qualities of Formwork

 It should be water tight.

 It should be strong.

 It can be reusable.

 Its contact surface should be uniform.

 It should be according to the size of member.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Formwork
Requirements of Formwork
 Material should be cheap and re usable,

 It should be practically water proof, so that it should not absorb water from concrete,

 Swelling and shrinkage should be minimum,

 Strong enough to with stand all external loads,

 Deflection should be minimum,

 Surface should be smooth, and afford easy striping,

 Light in weight, so that easy to transfer,

 Joints should be stiff, so that lateral deformation and leak is minimum .

Behailu Z. (Ph.D. Cand.)

6
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Formwork Selection, Design & Maintenance

Formwork

Materials Used for Formwork

 Formwork are mainly of four types

 Wooden formwork (Timber, plywood)

 Steel formwork

 Plastic

 Aluminum

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Formwork
Materials Used

Timber formwork:
 Most common material used for bracing the member, hence
called as the traditional formwork.
 can easily be cut to size on site. Joist are replaced
with engineered wood beams and supports are replaced with
metal props. This makes this method more systematic and
reusable.
 Various sizes of members of timber

Behailu Z. (Ph.D. Cand.)

7
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Formwork Selection, Design & Maintenance

Formwork
Materials Used
Plywood
- This is by far the most common material used for the facing panel. It
is easily cut to shape on site, and if handled and stored carefully, it
can be used many times.
- A standard plywood thickness on site is 18mm. This is usually
sufficient for most pours.
- However, if the formwork is curved, a thinner plywood is used to
facilitate bending.
- Thicker plywood may be used when the weigh of concrete causes a
standard thickness plywood to bow out, distorting the concrete face.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Formwork
Materials Used
Steel 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

Behailu Z. (Ph.D. Cand.)

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Formwork Selection, Design & Maintenance

Formwork
Materials Used
Aluminium formwork
 Often used in pre-fabricated formwork, that is put together
on site.
 Aluminium is strong and light, and consequently fewer supports
and ties are required.
 The lighter sections will deflect more, but this can be avoided
by simply following the manufacturers recommendations.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Materials Used Formwork
Plastic formwork
 Glass reinforced plastics (GRP) and vacuum formed plastics are
used when complicated concrete shapes are required (e.g. waffle
floors).
 Although vacuum formed plastics will always need support, GRP
can be fabricated with integral bearers making it self supporting.
 Like steel, plastic formwork can be re-used many times, as long
as care is taken not to scour the surface whilst vibrating the
concrete.

Behailu Z. (Ph.D. Cand.)

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Formwork Selection, Design & Maintenance

Formwork Systems
Horizontal
Hand-Set
 Conventional Wood Formwork System
RCC Works Costs
 Conventional Metal Systems
Crane-Set Formwork: 50 - 70%

 Flying Formwork System Concrete: 15 - 25%

 Column-Mounted Shoring Systems Rebar: 15 - 25%
 Tunnel Formwork System
Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Formwork Systems
 Vertical
 Crane-Dependent
 Conventional Wall/Columns Forming Systems
 Ganged Forming Systems Formwork Costs
 Jump Forms
Material: 15-20%
 Crane-Independent Systems
Labor: 50-70%
 Slip forms
Other: 10-15%
 Self-Raising Formwork System
Behailu Z. (Ph.D. Cand.)

10
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Formwork Selection, Design & Maintenance

Industrialized Formwork System

1) Lift slab system

2) Tunnel form system
3) Tilt up (Ganged) system
4) Self climbing (Jump) system
5) Slip form system (Veritical & horizontal)
6) Self Raising System

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
1) Lift Slab System

Behailu Z. (Ph.D. Cand.)

11
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
1) Lift Slab System

 Lift slab construction is a method of erecting post-tensioned reinforced

concrete floor and roof slabs which have been constructed on the ground.
 uses hydraulic jacks to lift concrete slabs into place, which reduces the
need for formwork and speeds up construction.
 Basically, the method entails casting floor and roof slabs on or at ground
level and jacking them up into position.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
1) Lift Slab System
How it works
 Concrete slabs are cast on the ground, one on
top of the other, with lifting collars around
embedded columns.
 Hydraulic jacks then raise the slabs into
position.
 This allows construction of repetitive floors to
occur at ground level rather than overhead.
Behailu Z. (Ph.D. Cand.)

12
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
1) Lift Slab System
 Floor slabs cast one on top of the next with a bond breaking membrane between
them.
 Slabs hoisted one at a time up to finished position.
 Advantages:
 reduces formwork
 shortens construction time.
 mechanical, electrical, and plumbing piping may be preinstalled.
 works well with post-tensioned slabs

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System

1) Lift Slab
System

Behailu Z. (Ph.D. Cand.)

13
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
1) Lift Slab System
 Lift slab can be used for heights up to about 16 stories.
 Economical column spacing ranges from 7 to 11m.
 Columns may be pipe, tubes or wide flange sections; concrete columns may
be used in 3- to 4-story buildings not requiring splices.
 The big advantage of erecting concrete buildings using lift slab
construction is elimination of most formwork, an especially important
factor in areas where labour costs are high.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System

Behailu Z. (Ph.D. Cand.)

14
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System
 A tunnel formwork system is a modern
construction method that allows for the
casting of walls and slabs in a single
operation.
 It combines the speed and accuracy of
off-site production with the flexibility of
in-situ construction.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System

Behailu Z. (Ph.D. Cand.)

15
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System

Behailu Z. (Ph.D. Cand.)

16
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System

Behailu Z. (Ph.D. Cand.)

17
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System
Advantages :
 Seismic resistance: The monolithic slab and walls construction provides high seismic
resistance.
 Water tightness: The monolithic structure reduces the number of joints, which
improves water tightness.
 Labor costs: Tunnel formwork systems can reduce labor costs.
 Mobilization costs: Tunnel formwork systems can reduce mobilization costs on site.
 Speed: Tunnel formwork systems can cast walls and slabs in a single day.

Behailu Z. (Ph.D. Cand.)

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Formwork Selection, Design & Maintenance

Industrialized Formwork System
2) Tunnel Form System

Advantages :
 Investment cost: The investment cost of the formwork system can increase
the formwork cost per square meter for small-sized projects.
 Cash flow: A continuous and fast cash flow is essential to comply with the
speed of production.
 Management: Management-related functions are vital due to the high
production speed.

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
3) Tilt – Up or Ganged Form System

Behailu Z. (Ph.D. Cand.)

19
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
3) Tilt – Up or Ganged Form System
 Tilt-up formwork systems are used to cast concrete elements for buildings on a
concrete slab, and then tilt them into place using a crane.
 Ganged forms are large wall form units that are made of panels joined together with
special hardware and braced with strong backs or special steel or aluminium frames.
 Gang forms can be made on the site, rented, or purchased from formwork
manufacturers.
 The advantages of manufactured forms over site made is that they are precise in
dimension and can be reused a larger number of times.
Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
3) Tilt – Up or Ganged Form System

Gang Forms Assembly

 Ganged forms are assembled on the
ground, raised into place, and
stripped as one unit. For faster and
more efficient assembly, a gang
assembly tables or cranes are used.

Behailu Z. (Ph.D. Cand.)

20
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
3) Tilt – Up or Ganged Form System

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
3) Tilt – Up or Ganged Form System Wall Form Section made
for Gang Panels

Panel Sections made

for Gang Forming
Behailu Z. (Ph.D. Cand.)

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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
 Self-climbing formwork is an automatic climbing system that is lifted without using a
crane. Instead, it has hydraulic rams that lift the scaffold, formwork, and secondary
formwork to the next pouring cycle.
 Jump form systems are used where no floor is available on which to support the wall
formwork, or the wall and column proceed ahead of the floor.
 Jump forms consist of a framed panel attached to two or more strong-backs.
 They can be one-floor high, supported on inserts set in the lift below, or two sets can
also be used, each one-floor high that alternately jump past each other.
Behailu Z. (Ph.D. Cand.)

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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Behailu Modern Construction Techniques

BehailuZ.
Z. (Ph.D.
(Ph.D. Cand.)
Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
 How it works
 The formwork supports itself on a previously cast concrete, so it doesn't need
support from other parts of the building. Concrete is poured into the formwork
as it moves continuously.
 Benefits
 Jump formwork systems can simplify and speed up construction. They're also
particularly useful for building structures that are made up of sections that are
the same size and shape.
Behailu Z. (Ph.D. Cand.)

23
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Behailu Modern Construction Techniques

BehailuZ.
Z. (Ph.D.
(Ph.D. Cand.)
Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
Jump Form Components
 Jump forms consists of two parts:
a) an upper framed panel form with its supporting system and working platform, and
b) a supporting structure that is attached to the concrete wall below the wall being
placed.
 The function of the upper framed panel form is to support the freshly placed concrete.
 The supporting structure is attached to a stiff concrete wall. Its function is to support
the upper framed panel form.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

24
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Jump form
components.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
Upper Framed Panel Form
 The upper part consists of three main elements:
 framed panel form,
 supporting brace, and
 working platforms.
 The framed panel form consists of a plywood face supported by two or more strong-backs.
 The frame panel form and the strong-backs are supported by an adjustable pipe brace.
 The brace is used for plumbing and stripping of the frame panel form.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

25
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
The Supporting Structure
 The supporting structure is basically a support mechanism for the framed
panel form and its working platforms.
 The lower part of the supporting structure is used as a walkway for repair
work of concrete.
 A ladder can be used and extended between the walkway and the
horizontal beam for repair work along the wall height.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
Typical Work Cycle
i) First Lift
 The first lift is formed by the framed panel form with its strong-back and the
compression brace.
 In this case, the wall braces can be anchored directly to the ground or slab for
form alignment.
 It should be noted that a slab on grade or foundations should be available in order
to start jump forms from the ground level.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

26
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Jump form First Lift

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Slip Form Slip Form System

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

A form which moves, usually continuously, during placing of the

concrete.
Movement may be either horizontal or vertical.
Slip forming is like an extrusion process with the forms acting
as moving dies to shape the concrete.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
Typical Work Cycle
ii) Second Lift
 After placing the concrete for the first lift, the tie rods are released, and the form is
then lifted to the next pouring position.
 The second lift begins by attaching the jump shoe to the wall at the first ‘‘jump’’ elevation.
 The framed panel form is attached to the crane slings and hoisted into position above the
jump shoes.
 The lower supporting structure is then attached without the lower overhanging walkway.
Figure ahead.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Jump form Second Lift

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
Typical Work Cycle
iii) Third Lift: Walkway Platform Assembly
 A finishing walkway platform is added to the jump form.
 The jump form is now complete for all subsequent lifts.
 The purpose of the walkway platform assembly is to provide the worker access to jump
shoes, wind anchors, and wall patching and finish.
 It is recommended that when this walkway platform is used, it should be attached after
the pour at the first jump position, but prior to raising the form to the third position.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Jump form Third Lift

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
Stripping
 Stripping begins by removing all form ties and anchor-positioning bolts.
 The form panel with its strong-backs is then pulled away from the wall by tilting or rolling .
 Tilting is accomplished by releasing the wall brace, while rolling is accomplished by rollers.
 The jump shoes are then positioned and attached for the next lift.
 Additional walls or form cleaning, oiling, and repair can be performed from the walkway
platform and the lower working platform.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Stripping Jump form

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Flying
 The entire jump form assembly is then hoisted by crane into
position above the newly placed jump shoes.
 The crane lines are attached to the gang form lift brackets at the
top of the form panel.
 The gang is now ready to be set for the next pour.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Flying

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

31
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system
Resetting
 After the crane is released, wind anchors are attached at either the tie location
or the jump shoe inserts, and the gang is cleaned and oiled in preparation for the
next pour.
 The form panel is then moved forward until it comes in contact with the top of the
previous pour.
 The gang is plumbed using the wall brace, another gang is positioned on the
opposite side of the wall, and ties are installed .
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Resetting

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

32
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or
Jump system
 Form Rolls back 30” to allow
 access to rebar & form Face.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

33
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
4) Self-Climbing or Jump system

Standard Williams Type Insert

1 1/4” Landing Bolt support

the Roll Back Bracket

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System

Behailu Z. (Ph.D. Cand.)

34
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System
 Slip formwork systems are self-climbing formwork systems that use hydraulic jacks
to continuously raise formwork as concrete is poured:
 The formwork can be moved horizontally and vertically, depending on the structure
being built.
 The formwork has three platforms: the upper platform for storage and distribution,
the middle platform for working, and the lower platform for concrete finishing.
 The formwork rises at a rate of about 300 mm per hour, and construction speed can
reach up to 3.0–4.0 meters a day.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System

Behailu Z. (Ph.D. Cand.)

35
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Vertical

Behailu Z. (Ph.D. Cand.)

36
 12/27/2024

Formwork Selection, Design & Maintenance

Industrialized Formwork System
Jack rod

Jack
Thin pipe around
jack rod
Yoke assembly
Splash board Working deck
5) Slip Form System
Wales
- Vertical
Bracing for Wales

Sheathing Slight batter of sheathing

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Vertical

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

37
 12/27/2024

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Vertical

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Vertical

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

38
 12/27/2024

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Vertical

Heavy Load Distribution

Space Frame

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Vertical

Section of Typical Circular Rig

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

39
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Vertical

Trussed Bridging
Walkway

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Vertical

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

40
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Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Horizontal

Modern Construction Techniques

Behailu Z. (Ph.D. Cand.)

Slip Form System

Formwork Selection, Design & Maintenance

Industrialized Formwork System
5) Slip Form System - Horizontal

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

41
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Slip Form System

Formwork Selection, Design & Maintenance
Industrialized Formwork System
5) Slip Form System - Horizontal

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Self-Raising Form

Formwork Selection, Design & Maintenance

Industrialized Formwork System
6) Self Raising Form System

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Self-Raising Form
Formwork Selection, Design & Maintenance
Industrialized Formwork System
6) Self Raising Form System
Self-Raising Form
 A form which is raised vertically for succeeding lifts of concrete in a given
structure, usually supported on anchor bolts or rods embedded in the top of
the previous lift.
 The form is moved only after an entire lift is placed and (partially) hardened.
 This should not be confused with a slip form which moves during placement of
the concrete.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Self-Raising Form

Formwork Selection, Design & Maintenance

Industrialized Formwork System
6) Self Raising Form System

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Self-Raising Form
Formwork Selection, Design & Maintenance
Industrialized Formwork System
6) Self Raising Form System

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
6) Self Raising Form System

Pouring platform Traveling unit

Formwork
Climbing bracket

Working platform

Suspended platform

Suspended
platform

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Formwork Selection, Design & Maintenance

Climbing carriage

6) Self Raising (Hydraulic cylinder)

Form System

Supporting
profile
Lifting
mechanism

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

6) Self Raising
Form System

Top Half

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Formwork Selection, Design & Maintenance

6) Self Raising
Form System

Bottom Half

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
6) Self Raising Form System
Components
 The components of the self-raising forms
may be customized to meet the different
loads and geometry of different structures.
Regardless of the system, basic similarities
do exist.

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Self-Raising Form
Formwork Selection, Design & Maintenance
Industrialized Formwork System
6) Self Raising Form System
The Lifting Towers
 The lifting towers or frames are usually two to three stories high, in
which the bottom supports of the tower are anchored to the previous lift
of concrete.
 Attached to the lifting tower are hydraulic rams or jacks that pull the
form system to the next level, raising all forming and platform areas.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Self-Raising Form

Formwork Selection, Design & Maintenance

Industrialized Formwork System
6) Self Raising Form System
Forms
 The form panels, often referred to as gang form panels, are made with
aluminium framing members and large plywood sheets for a smooth finish.
 The form panels are anchored into previous cast concrete lift below.
 For an architectural finish, form liners may be used when finishing is required.
 It should be noted that the advantage of using self-raising form over slip-
form is its ability to produce architectural concrete by using form liners.

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Self-Raising Form
Formwork Selection, Design & Maintenance
Industrialized Formwork System
6) Self Raising Form System
Rams
 The raising rams are typically pulled up by either hydraulic, air powered, or
electric power. Each type has its advantages and disadvantages, depending on
site conditions, design loads, and the designer’s preference.
Stripping Jacks
 Self-raising form systems either uses a roll-back system or stripping jacks to
remove the forms away from the finished Concrete.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Self-Raising Form

Formwork Selection, Design & Maintenance

Industrialized Formwork System
6) Self Raising Form System
Working Platform
 They allow workers comfortable and efficient working space to place steel and concrete,
and to bolt or unbolt forms at different heights.
 The installation of guard rails and toe boards provide increased safety.
Support Brackets
Support brackets are attached to the bottom of the inner form and to the bottom of the
raising ram. They are subsequently anchored to the reinforced concrete structure.
When raising either form or lifting tower, the support brackets are detached from the
structure, allowing them to travel to the next level to be anchored.

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Self-Raising Form
Formwork Selection, Design & Maintenance
Industrialized Formwork System
6) Self Raising Form System
Typical Work Cycle
A forming crew of six to ten workers may begin the typical work cycle.
 Starter Wall :
 The starter wall should be about 6 ft (1.83 m) tall and have all the necessary anchorage
in place, ready to support the forms and rams for the next level of casting.
 Second Lift : Tower cranes are used to assemble and place the form system on the starter
wall.
 Form and Ram Placement : The inner form and raising rams are attached to the anchors
when the first lift has gained sufficient strength.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Self-Raising Form

Formwork Selection, Design & Maintenance

Industrialized Formwork System
6) Self Raising Form System
Typical Work Cycle
 Once the inner form is in place, the outside form is rolled back on the trolley system,
permitting the cleaning and oiling of forms, installation of form liners, steel reinforcement,
embedments, and box-outs.
 The outside forms are then rolled into position, allowing the installation of taper ties.
 Concrete Placement:
 Once the forms and ties have been inspected and oiled, the forms are ready for
concrete. Minimum concrete strength must be attained, usually through cylinder
strength tests, before the forms can be raised.
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Self-Raising Form
Formwork Selection, Design & Maintenance
Industrialized Formwork System
6) Self Raising Form System
Typical Work Cycle
 Stripping:
 Once the concrete in the second lift has attained sufficient strength, the taper ties
and other embedded items are removed.
 The outside forms are then rolled back on the mounted trolleys.
 The interior forms, which are attached to the top grid beam, allow for small movement
and are released at this time.
 The form support bracket at the bottom is also released at this time, leaving the
system supported on the rams and the ram support brackets.
 Third Lift : The system is ready to be raised to the next level once the system is supported
on the ram and the ram support brackets.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Self-Raising Form

Formwork Selection, Design & Maintenance

Industrialized Formwork System
6) Self Raising Form System

Typical Work Cycle

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Self-Raising Form
Formwork Selection, Design & Maintenance
Industrialized Formwork System
6) Self Raising Form System
Typical Work Cycle
 Form Raising:
 Through a central console, the entire form is raised by the hydraulic rams to the next
elevation. Individual ram controls used to do the fine grading, levels the entire platform,
adjusting the plumb-ness of the core.
 The necessary cleaning and oiling of the interior form is done at this time.
 Form Placement:
 The form support brackets are attached to the anchors installed in the concrete near the
top of the previous lift.
 With the outside forms rolled back, installation of rebar, embedment's, and box-outs can
proceed. Once completed, the outside forms are rolled into position, and the taper ties
are installed ready for the next pour.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Industrialized Formwork System
6) Self Raising Form System
Typical Work Cycle
 The hydraulic ram usually remains extended and attached to the second lift below
during the casting of concrete.
 Ram Placement:
 Once the concrete has been cast, the ram support bracket is detached from
the anchors in the first lift, and the ram is retracted.
 After retraction, the ram is then reattached to anchors in the lift above.
 Stripping: Once the concrete has gained sufficient strength, the stripping process
is once again done.
 Takedown Form : When the form reaches the top of the building it is normally
disassembled in units and lowered by tower crane.
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Factors Affecting Vertical Formwork Selection
 When selecting a core forming system, time is a critical factor.
 Duration that must be considered are the movement of the form from floor to floor,
original assembly, time to set rebar and inserts within the form, stripping time,
close-in time, and final disassembly.
 the amount of labour required to strip, set, pour, and control the system;
 the amount of precision needed as far as plumb-ness and corner tolerances,
 ease of lifting, and
 the designer’s intent when developing the structural system.
 The decision between labour or crane time requires careful financial analysis.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Factors Affecting Vertical Formwork Selection
 Many other factors that affect the selection of vertical formwork systems for
buildings are similar to those factors affecting the selection of horizontal
formwork systems. However, there are some factors that are particularly
important to the selection of vertical formwork systems.
 Among these are:
a) Factors related to building architectural and structural design,
b) Factors related to project (job) specification
c) Factors related to local conditions, including area practices.
d) Factors related to the supporting organizations

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Factors Affecting Vertical Formwork Selection

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Factors Affecting Vertical Formwork Selection

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Factors Affecting Vertical Formwork Selection

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Factors Affecting Vertical Formwork Selection

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Factors Affecting Vertical Formwork Selection

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Factors Affecting Vertical Formwork Selection

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Formwork Selection, Design & Maintenance

Building Design: Lateral Load Supporting Systems
 Buildings are classified as being tall when their height is between two and three
times as great as their breadth.
 Tall buildings needs special structural elements to resist lateral forces and
prevent or minimize the building sway.
1) Type I Structure (Rigid Frame System): Consist of columns and beams. Bearing
wall is a special case of the rigid frame system.
2) Type II Structure (Shear Walls): The shear wall formation is a thin slender
beam cantilevered vertically to resist lateral forces.
 It can take the form of a rectangle or box-shaped core, which can be used to
gather vertical transportation and energy distribution systems (e.g., stairs,
elevators, toilets, mechanical shafts).

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Building Design: Lateral Load Supporting Systems

3) Type III Structure (Framed-Shear Wall Systems) : This system consists of a

combination of frames which utilize beams and columns with the shear wall designed to
resist lateral loads.
4) Type IV Structure (Framed Tube) : This tube is a structural system in which the
perimeter of the building, consisting of vertical, closely spaced supports, connected by
beams or bracing members, acts as a giant vertical internally stiffened tube.
5) Type V Structure (Tube-in-Tube Systems): This system is a combination of the
framed-shear wall (type III structure) which acts as an interior tube, and the framed
tube (type IV structure), which acts as an exterior tube. The floor structure ties the
interior and exterior tubes together to allow them to act as a unit to resist lateral
loads.

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Building Design: Lateral Load Supporting Systems

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Formwork Design
LOADS ON FORMWORK:
 Dead load
 Self weight of formwork
 Pressure and loads from fresh concrete
 Reinforcement
 Imposed load
 Construction workers
 Stacking of materials
 Horizontal loads
 Environmental loads
 Accidental loads
 Wind loads
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Formwork Design
Properties of Rectangular Cross Section

 The most commonly used

cross section in the design
of formwork
 the rectangular cross
section with breadth b and
depth d .
 For rectangular cross
section, the formulas the
various properties given by:

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Formwork Design
Mechanical Properties of Lumber

 The mechanical properties used in the design of formwork are:

 Fc = compression parallel to grain,
 Fc⊥= compression perpendicular to grain
 Ft = tension parallel to grain, and
 Ft⊥ = tension perpendicular to grain
 Figure ahead helps clarify the direction of forces.

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Formwork Design

Mechanical
Properties of Lumber

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Formwork Design
Design Methodology
 In selecting the sizes of plywood, joists, and stringers for given spans and
loads, the following requirements must be considered.
1) 1The allowable working stresses for bending and for shear must not be
exceeded.
2) The allowable limits for deflection must not be exceeded.
3) The sizes of the joists and stringers should be easily obtained in the
local markets.

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Formwork Design
Design Equations

1. Design for Bending

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Formwork Design
Design Equations

2. Design for Shear

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Formwork Selection, Design & Maintenance

Formwork Design
Design Equations

3. Design to satisfy
deflection requirements

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Formwork Design
Design Equations

3. Design to satisfy
deflection requirements

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Formwork Design
Design Equations

 For cases when shear deflection is computed separately and added to

bending deflection to obtain the total deflection, E for these bending-
deflection equations should be increased by 10 percent.
 In this case the total deflection will be
Δ= Δb + Δs.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

1. Slab Form Design
Slab Form Components
 The basic elements of slab formwork are
 sheathing,
 joists,
 stringers,
 shores,
 wedges, and
 mudsills.

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1. Slab Form Design

Design Loads
 Formwork should be designed to adequately sustain all the applied loads
without failure or excessive deflection.
 ACI Committee 347- 04 is considered the industry guide for estimating
minimum and maximum loads applied on formwork.
 The following is a summary of the different load types and values.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

1. Slab Form Design
Vertical Loads
 Vertical load consists of dead load and live load.
 The weight of the formwork plus the weight of the freshly placed concrete is dead
load.
 The live load includes the weight of workers, equipment, material, storage, impact,
etc.
1. Form’s self-weight.
 The self-weight of the form is usually assumed to be 5lb/sqft. Self-weight
cannot be determined until the form is actually designed.

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1. Slab Form Design
Vertical Loads
 After carrying out the design, the assumption of 5 lb/sqft needs to be
checked.
 If the assumed value is far from the correct value, design should be
repeated.
 This process is continued until one arrives at a reasonable difference
between the two values.
 In most small and moderate spans, the 5 lb/sqft assumption holds well.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

1. Slab Form Design
Vertical Loads
2. Weight of concrete
 The weight of ordinary concrete is assumed to be 150 lb/cuft.
 Thus the load from the concrete slab on a square foot of
decking will be

Where t is the thickness of slab in inches.

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1. Slab Form Design
Live load
 The American Concrete Institute (ACI 347) specifies that different
elements used to support vertical loads should be designed for a minimum
live load of 50 psf on the horizontal projection.
 When motorized cars are present, the minimum live load should be 75
psf.
 The minimum design load for combined dead and live load should be 100
psf, or 125 psf if motorized cars are present.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

1. Slab Form Design
Horizontal Load
 Braces and shores should be designed to resist all foreseeable
horizontal loads such as
 seismic,
 wind,
 inclined support,
 starting and stopping of equipment, and
 other such loads.

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1. Slab Form Design
Design Steps
The steps in the design of forms to support concrete slabs include the
following:
1. Determine the total unit load on the floor decking, including the effect
of impact, if any.
2. Select the type of floor decking, along with its net thickness.
3. Determine the safe spacing of floor joists, based on the strength or
permissible deflection of the decking.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

1. Slab Form Design
Design Steps
4. Select the floor joists, considering the load, type, size, and length of joists.
5. Select the type, size, and lengths of stringers, if required to support the
joist.
6. Select the type, size, length, and safe spacing of shores, considering the
load, the strength of the stringers, and the safe capacity of the shores.
 Usually the most economical design of forms results when the joists are spaced
for the maximum safe span of the decking.

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1. Slab Form Design

 Likewise, reasonably large joists, which permit long spans, thus requiring
fewer stringers, will be economical in the cost of materials and in the cost of
labour for erecting and removing the forms.
 The use of reasonably large stringers will permit the shores to be spaced
greater distances apart, subject to the safe capacities of the shores, thus
requiring fewer shores and reducing the labour cost of erecting and removing
them.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

1. Slab Form Design
Size, Length, and Spacing of Joists
The selection of the size, length, and spacing of the joists will involve one of the following:
1. Given the total load on the decking, the spacing of the joists, and the size and grade of the
joists, determine the maximum span for the joists.
2. Given the total load of the decking, the size and grade of the joists, determine the
maximum spacing of the joists.
3. Given the total load on the decking, and the size and the span of the decking, determine the
minimum size joists required.
 For practical purposes, the selected span is rounded down to the next lower integer or
modular value.
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1. Slab Form Design
Stringers and Shores
 The joist span selected will be based on the spacing of the stringers.
 We can follow the same procedure that is used for analysing joists.
 Again, an integer or modular value is selected for stringer spacing.
 After calculating the stringer spacing, the span of the stringer is
checked against the capacity of the shore.
 The load on each shore is equal to the shore spacing multiplied by the
load per unit foot of the stringer.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

1. Slab Form Design
Stringers and Shores
 The maximum shore spacing will be the lower of these two values (based on joists
loading or shore spacing).
 In calculating the design load of stringers, we do not consider the effect of joists
on stringers.
 Instead, as a good approximation, we calculate load transmitted directly from
sheathing to stringers.
 Hence, it is necessary to check for crushing at the point where the joists rest on
stringers.
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1. Slab Form Design
 Finally, shores are designed as columns (compression member).
 The following equations can be used in checking the capacity of the different
elements of the form.

Where: l= length of span (in.), w= uniform load per foot of span (lb/ft),
E = modules of elasticity (psi), and I= moment of inertia (sqsqin)

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design

Wall Form Components

 A wall form is usually made up of
 sheathing,
 studs,
 wales,
 ties, and
 Bracing

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2. Wall Form Design

Wall Form Components

 The fresh concrete places a lateral pressure on the sheathing, which is
supported by studs.
 Studs behave structurally as a continuous beam with many spans
supported on wales.
 Wales, in turn, are assumed to act as a continuous beam that rests on ties.
 Ties finally transmit concrete lateral pressure to the ground.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design

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2. Wall Form Design
Design Loads
 The pressures exerted on wall forms during construction need to be
carefully evaluated in the design of a formwork system.
 Loads imposed by fluid concrete in walls and columns are different from
gravity loads produced on slab forms.
 Fresh concrete exhibits temporary fluid properties until the concrete
stiffens sufficiently to support itself.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
Lateral Pressure
 Formwork should be designed to resist the lateral pressure loads exerted by the
newly placed concrete in the forms.
 If concrete is placed rapidly in wall or column forms, the pressure can be equivalent
to the full liquid head pressure.
 This requires that rate of placement exceed the initial set time of the concrete mix.
 Excessive deep vibration can liquefy the initial set of concrete within the effective
coverage of the vibrations.
 Retarder additives or cool weather can also delay the initial set and result in higher
than anticipated lateral pressure.
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2. Wall Form Design

Lateral Pressure
 The formula for wall pressure established by the American
Concrete Institute (ACI-347) considers the mix temperature and
the rate of placement of concrete.
 The rate of placement is expressed in terms of meter per hour of
concrete rise in the forms.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
ACI Formula for wall pressure
1. For columns and walls with rate of placement less than 2.1 m/h;

 with a maximum of
 1.47 kgf/sqcm for columns,
 0.98 kgf/sqcm for walls,
 a minimum of
 0.29 kgf/sqcm, but no greater than 0.24hst.

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2. Wall Form Design
ACI Formula for wall pressure

2. For walls with rate of placement 2 to 3 m/h;

With a maximum of 0.98 kgf/sqcm, a minimum of 0.29 kgf/sqcm, but no

greater than 0.24hst.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
ACI Formula for wall pressure
3. If the rate of placement is greater than 3 m/h;

 These formulas can only be applied if concrete satisfies the following

conditions:
 Weighs 2403 kg/cum
 Contains no admixtures
 Has a slump of 100 mm or less.
 Uses normal internal vibrator to a depth of 1.22 m or less
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2. Wall Form Design
ACI Formula for wall pressure
 If concrete is pumped from the base of the form, the form should be
designed to resist the lateral hydrostatic pressure of fresh concrete plus
minimum allowance of 25 percent to account for pump surge.
 Caution must be taken when using external vibration or concrete made with
shrinkage-compensating or expansive cements as pressure higher than the
hydrostatic pressure is expected to occur.
 It is a good practice to reduce the allowable stresses to half its original value
when using external vibrators.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
ACI Formula for wall pressure
Horizontal Loads
 Braces should be designed to resist all foreseeable horizontal loads, such as
seismic forces, wind, cable tension, inclined supports, dumping of concrete, etc.
 Wall form bracing must be designed to meet the minimum wind load requirements
of ANSI A58.1 or the local design building code, whichever is more stringent.
 For exposed wall, the minimum wind design load should not be less than 15 psf.
 Bracing for wall forms should be designed for a horizontal load of at least 100 lb
per lineal foot of the wall, applied at the top.
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2. Wall Form Design
Method of Analysis
Step 1: The procedure for applying equations the following Bending Moment, Shear, and Deflection Equations:

Use the attached ACI

347 – 04 Guide pdf
file

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
Method of Analysis
 consider the lower 1 unit of sheathing where concrete lateral pressure is maximum.
Determine the maximum allowable span based on the allowable values of bending stress,
shear stress, and deflection.
 The lowest value will determine the maximum spacing of studs.
Step 2: Based on the selected stud spacing, the stud itself is analysed to determine its
maximum allowable spacing.
 The studs are subject to uniform pressure resulting from the fresh concrete.
 This pressure is resisted first by the sheathing which in turn transfer the loads to studs.
The selected stud span will be the spacing of the wales.
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2. Wall Form Design
Method of Analysis
Step 3: Based on the selected stud spacing, the maximum wale spacing (distance between
horizontal supports or ties) can be determined using the same procedure.
 For simplicity and economy of design, this maximum span value is usually rounded down to the
next lower integer or modular value when selecting the spacing.
Stresses Calculations
 After appropriate design loads are calculated, the sheathing, studs, and wales are analysed
in turn, considering each member to be a uniformly loaded beam supported in one of the
three conditions.(single span, two spans, or three or more spans) to determine the stresses
developed in each member.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
Method of Analysis

 Vertical supports and lateral bracing must be checked for compression

and tension stresses.
 Except for sheathing, bearing stresses must be checked at supports to
ensure safety against buckling.
 Using the methods of engineering mechanics, the maximum values of
bending moment, shear, and deflection developed in a uniformly loaded
beam of uniform cross section is shown in Tables ahead.

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2. Wall Form Design
Method of Analysis

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
Method of Analysis

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2. Wall Form Design
Method of Analysis
 Vertical supports and lateral bracing must be checked for compression and tension
stresses.
 Except for sheathing, bearing stresses must be checked at supports to ensure
safety against buckling.
 Using the methods of engineering mechanics, the maximum values of bending
moment, shear, and deflection developed in a uniformly loaded beam of uniform
cross section is shown in Tables ahead.
 The maximum fibre stresses in bending, shear, and compression resulting from a
specified load may be determined from the following equations:
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
Method of Analysis

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2. Wall Form Design
Method of Analysis
Where,
A =section area, sqin
fb = Bending Stress
M =maximum moment, in.-lb
fv =Shear Stress
fc = Compressive Stress parallel to grains P =concentrated load, lb

fc⊥ = Compressive Stress perpendicular S =section modules, cuin

to grains ,and U =maximum shearing force, lb
ft = Tensile Stress parallel to grains. lb/Q =rolling shear constant, sqin/ft

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design

Maximum Allowable Span

 Maximum span corresponding to bending, shear, and deflection can
be directly obtained using equations.
 The maximum allowable design value for the span will be the smallest
one rounded it to the next lower integer or modular value.

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2. Wall Form Design
Design of Lateral Bracing
 For wall forms, lateral bracing is usually provided by inclined rigid braces.
 Bracing is usually required to resist wind loads and other horizontal loads.
 Since wind load may be applied in either direction, braces must be
arranged on both sides of the forms.
 When rigid braces are used, they may be placed on one side of the form
if designed to resist both tension and compression.
 Figure ahead gives a visual example of form bracing.

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
Method of Analysis

Bracing of Formwork

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2. Wall Form Design
Method of Analysis

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
Design Procedure

1. Start design by selecting a certain strut size such that it satisfies

where d is the least dimension of
the cross section of the selected strut.
2. Calculate Euler’s critical buckling stress for column as follows:
where KcE = 0.3 for visually graded lumber.

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2. Wall Form Design
Design Procedure
3. Calculate the limiting compressive stress in column at zero slenderness
ratio:

Where, Load Duration Factor

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
Design Procedure
Wet Service Adjustment Factor

Temperature Factor

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2. Wall Form Design
Design Procedure

Size Adjustment Factor for Southern Pine Including Mixed

4. Calculate the column stability factor from the formula:

Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

2. Wall Form Design
Design Procedure
5. The allowable compressive stress in the strut is given by

6. If F′c < FcE, this means that the selected cross section is not enough to
resist buckling.
So increase the size of the cross section and go iteratively through steps 1 to 6
until you get FcE< F′c.
7. The maximum load that can be carried by the strut is the product of F′c and
the actual (not the nominal) cross - sectional area of the selected strut.
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2. Wall Form Design
Design Procedure
8. The maximum spacing of struts in feet that can be carried by one strut is
obtained by dividing the maximum load by strut load per foot.
 It should be noted that the strut usually carries compression or tension
force depending on the direction of the horizontal load applied to the form.
 Those two forces are equal in magnitude but differ in their sign. Designing
struts as compression members usually ensures that they are safe also in
tension because we are considering an additional precaution against buckling
associated with compression.
Behailu Z. (Ph.D. Cand.) Modern Construction Techniques

Formwork Selection, Design & Maintenance

Cost of Formwork
 For normal works cost of formwork is about 30%-40% of the concrete cost.

 For special works cost of formwork is about 50%-60% of the concrete cost.

 Formwork cost is controlled by the following factors

 Formwork Material cost
 Formwork erecting cost
 Formwork removal cost
 Formwork jointing cost (Nails and Cables)
 Labor charges.
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Time of Removal of formwork:
Time of formwork removal depends on the following factors

a) Type of Cement
 Rapid hardening cements require lesser time as compared to OPC (Ordinary Portland
Cement)

b) Ratio of concrete mix

 Rich ratio concrete gain strength earlier as compared to weak ratio concrete.

c) Weather condition

 Hydration process accelerates in hot weather conditions as compared to cold and humid
weather conditions

Behailu Z. (Ph.D. Cand.)

Formwork Selection, Design & Maintenance

Time of Removal of formwork:

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Maintenance of formwork:
 Due to continuous use wooden planks & steel plates surfaces become uneven
and require maintenance.

 For wooden formwork use cardboard or plastic fiber board. Bolt hole places
must also be repaired.

 For steel formwork plates must be leveled by mallet and loose corners must
be welded.

Behailu Z. (Ph.D. Cand.)

End of Chapter 6

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