Specification 821

FORMWORK
17 December 2020

Document Number
TGA-00-CN-0000-SPC-0821

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Specification 821 Formwork

TGA APPROVAL REGISTER

Revision Dates Prepared Description of Revision Reviewed Approved

By by

0 17/12/20 GW Issued for use LJD

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Specification 821 Formwork

REVISION RECORDING

Clause Description of Revision Authorised By Issue Date

Number

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Specification 821 Formwork

TABLE OF CONTENTS

Contents
GENERAL ................................................................................................. 5
821.01 SCOPE ........................................................................................5
821.02 REFERENCES .................................................................................5
821.03 – 821.05 NOT USED .........................................................................5
PRODUCTS AND MATERIALS .......................................................................... 6
821.06 GENERAL .....................................................................................6
821.07 OFF-FORM CONCRETE FINISHES ..........................................................6
821.08 TIMBER FORMWORK ........................................................................6
821.09 OTHER TEMPORARY FORMWORK .........................................................6
821.10 PERMANENT DECK SOFFIT FORMWORK ..................................................7
821.11 VOID FORMERS ..............................................................................7
821.12 – 821.25 NOT USED .........................................................................8
OPERATIONS ............................................................................................ 8
821.26 FORMWORK DESIGN ........................................................................8
821.27 FORMWORK CONSTRUCTION ..............................................................8
821.28 REMOVAL OF FORMWORK................................................................ 10
821.29 TOLERANCES FOR CONCRETE CONSTRUCTION ....................................... 10
821.30 PROVISION FOR THERMAL MOVEMENT ................................................. 11
821.31 – 821.70 NOT USED ....................................................................... 11
AS BUILT AND HANDOVER REQUIREMENTS ....................................................... 12
821.71 – 821.90 NOT USED ....................................................................... 12
CONTRACT SPECIFIC REQUIREMENTS .............................................................. 12
821.91 – 821.99 NOT USED ....................................................................... 12

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Specification 821 Formwork

SPECIFICATION 821

FORMWORK

GENERAL

821.01 SCOPE

1. The work under this specification consists of the design and construction of
formwork required for the proper construction of concrete for structures in
the permanent Works to the tolerances specified herein.

2. Specific quality requirements (including testing frequencies and delegation Quality

of Alliance Director’s authority are provided in the TGA Specification 201 Requirements
QUALITY SYSTEMS

821.02 REFERENCES

1. Australian Standards, MAIN ROADS Western Australia Standards and

MAIN ROADS Western Australia Test Methods are referred to in
abbreviated form (e.g. AS 1234, MRS 67-08-43 or WA 123). For
convenience, the full titles are given below:

Australian Standards
AS 1761 Helical Lock-Seam Corrugated Steel Pipes
AS 3610 Formwork for Concrete
AS 3610.1 Formwork for Concrete Part 1: Specifications

Australian/New Zealand Standards

AS/NZS 2271 Plywood and Blockboard for Exterior Use

Tonkin Gap Alliance (TGA) Specifications

Specification 201 QUALITY SYSTEMS

Specification 820 CONCRETE FOR STRUCTURES

821.03 – 821.05 NOT USED

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Specification 821 Formwork

PRODUCTS AND MATERIALS

821.06 GENERAL

1. Formed concrete surfaces shall comply with the requirements of Section 3

of AS 3610.1.

821.07 OFF-FORM CONCRETE FINISHES

1. Surface Finishes shall meet the requirements of AS 3610.1 and Table 5 of

the TGA Specification 820 to the classes designated on the Drawings.

2. Particular importance is attached to the achievement of good "off-the-form" Surface Finish

concrete finishes throughout the Works. Formwork shall be designed and
fabricated and erected and dismantled so that all formed concrete surfaces
achieve the specified uniform surface finish and texture without patching or
plastering or cement washing or any treatment after removal of the
formwork.

3. All formwork made up from separate panels shall be so designed that the Panel
pattern of exposed panel joints complements the overall geometry of the Arrangement
structure and does not detract from the final appearance of the structure.
The Contractor shall detail proposed soffit and side formwork panel
arrangements on the formwork Drawings.

4. In order to minimise the number of joints, formwork panels shall be Plywood Panels
supplied in the maximum practicable width and length.

821.08 TIMBER FORMWORK

1. Timber for formwork shall be well seasoned and free from loose knots and Timber
other defects. Timber which has become warped or unsuitable for use
shall be replaced at no cost to the Alliance Director or Delegated Authority.

Plywood used in formwork lining shall comply with the relevant provisions of Plywood
AS/NZS 2271.

821.09 OTHER TEMPORARY FORMWORK

1. Forms made from materials other than plywood will be permitted provided Steel Forms
that the requirements for strength and rigidity and tightness are met and
that all bolts and rivet heads are countersunk and the finished concrete
appearance is not inferior to that obtained with good quality plywood.
Steel forms shall be suitably treated to prevent rusting of the face to be in
contact with the concrete. The minimum thickness required for steel
formwork is 3mm unless otherwise specified.

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Specification 821 Formwork

2. Polystyrene used as formwork shall be lined with a 3mm thickness of Polystyrene

plywood on the face that is to be in contact with the concrete to be poured
and such facing shall be glued with a suitable adhesive to the polystyrene.
Where polystyrene is used as a formwork for concealed surfaces, plywood
facings to the formwork can be replaced with a bond breaking layer to the
approval of the Alliance Director or delegated authority.

821.10 PERMANENT DECK SOFFIT FORMWORK

1. Where indicated on the Drawings, permanent deck soffit formwork shall be Bondek or
used between the beams. Such permanent formwork shall be "BONDEK", Similar
“CONDEK”,Fibre Reinforced Concrete (FRC) or fibre cement sheet with Approved
thickness as detailed on the Drawings or an equivalent material approved
by the Alliance Director or Delegated Authority.

2. Where indicated on the Drawings, permanent deck soffit formwork shall be Bondek or
used over voids of T-roff precast members. Such permanent formwork Similar
shall be “BONDEK”, “CONDEK” or an equivalent material approved by the Approved
Alliance Director or Delegated Authority.

3. Due care shall be exercised in achieving an effective seal at the seating Seating of
joint between the permanent formwork and the beams. The minimum Permanent
width of the seating on the beams shall not be less than that detailed on Formwork
the Drawings.

4. The Contractor's attention is drawn to the tendency of the "BONDEK" Securing and
formwork to 'walk' off the beam seating. The Contractor shall ensure it is Sealing Bondek
installed so that it cannot move during any stage of construction. The
joining ribs shall be securely fastened together with self tapping screws or
equivalent method approved by the Alliance Director or Delegated
Authority. The "BONDEK" profiled ends shall be sealed in accordance
with the manufacturer’s published recommendations.

5. The fixing of "BONDEK" formwork to the steel beams, where used, shall Fixing of
be by tack or puddle welding. Bondek

Care shall be taken to align the “BONDEK” ribs across the bridge section and Alignment
within seating rebates prior to fixing deck reinforcement.

821.11 VOID FORMERS

1. Non-recoverable formwork as shown on the Drawings shall be Polystyrene

manufactured from rigid cellular polystyrene Grade SL to AS 1366.3 unless
otherwise specified.

2. Cylindrical voids in precast planks may be formed by PVC pressure pipe Corrugated
with watertight end caps. Larger non-recoverable void formwork if shown Steel Pipe Void
on the Drawings shall be helical lock seam corrugated galvanised steel Formers
pipe of 1.6mm minimum sheet thickness. The void former and material
shall be in accordance with the relevant sections of AS 1761.

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Specification 821 Formwork

3. The Contractor shall ensure that void formers and associated anchorage Design and
systems are designed structurally in accordance with AS3610 for anchorage of
robustness and buoyancy, and that the void former is held rigidly in void formers
position until the surrounding concrete has set.

821.12 – 821.25 NOT USED

OPERATIONS

821.26 FORMWORK DESIGN

1. Formwork shall conform to the requirements of AS 3610 and AS 3610.1

and the additional requirements of this Specification.

2. Formwork shall be so designed and constructed that it can be removed

without damage to the concrete. In the case of prestressed concrete the
design of the formwork shall permit movement of the members to occur
during prestressing without damage to the permanent Works. Formwork
shall be set to the profiles and pre-cambers shown on the Drawings and
due allowance shall be made in setting the levels of the formwork to
compensate for any deflection or deformation due to the weight of the
concrete. Formwork shall be designed and constructed to withstand the
vibration required during placing and compaction of the concrete as
specified in TGA Specification 820 CONCRETE FOR STRUCTURES.

3. Where concrete is poured in more than one operation the Contractor shall Construction
take all necessary precautions to hold the formwork tight against the Joints
previous pour to avoid any discontinuities in the finished off-form surface.

4. At least two weeks prior to commencing formwork construction, HOLD POINT

other than vertical forms less than 2.4m in height, the Contractor
shall supply to the Alliance Director or Delegated Authority design
details and Drawings checked and certified by a qualified structural
engineer that the formwork complies with the Specification.

821.27 FORMWORK CONSTRUCTION

1. Forms shall be built true to line and level and braced in a substantial and
unyielding manner to maintain correct position and shape.

2. On all exposed concrete surfaces the joints and splices in formwork panels Joints
shall be arranged in a manner suitable to the shape and area being
formed. Wherever possible, joints in adjoining panels shall be positioned
to be either staggered by half panel lengths or placed in line.

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3. Forms shall be mortar tight and the edges of all joints shall be sealed with Sealing
a suitable type of sealant. Forms subject to external water pressure shall
be watertight.

4. Forms shall be held in correct alignment and spacing by bolt and rod Bolt and Rod
assemblies designed so that when the forms are removed no metal shall Assemblies
be closer to the surface of the concrete than the minimum cover specified
on the Drawings. The rods shall be held in place by devices capable of
developing the strength of the rod attached to the walings. Bolt and rod
assemblies shall be arranged so that cavities caused by their removal shall
form a regular pattern appropriate to the area being formed. All such
cavities shall be wetted and carefully packed with colour matched mortars
and brought to an even surface.

5. The use of wires and/or bolts extending to the surface of the concrete shall Cover
not be permitted except where shown on the Drawings. Wires or bolts or
fastenings for forms or fixing reinforcement shall have the same concrete
cover as specified for reinforcement.

6. All balustrade and traffic barrier sockets and hole formers and all other Fittings
fittings shall be accurately located. Bolts, pipes and bars used to form
holes in the structure shall be well greased and arranged so that they may
be removed from the concrete without excessive jarring or hammering
before removal of forms.

7. The interior surface of formwork shall be thoroughly cleaned out and Lubricant
treated with form lubricant to prevent adhesion of the exposed concrete
surface, in accordance with the manufacturer’s instructions. Form
lubricants shall be of the non-staining type which do not adversely affect
the surface of the concrete. Lubricants shall be used after the fabrication
of forms and prior to the placing of any reinforcing steel or other embedded
item. The lubricant shall be uniformly applied in a thin film and any surplus
shall be removed prior to placing concrete. Care shall be taken that such
coatings do not soil the surface of reinforcement.

8. Where the bottom of a panel is inaccessible from within then access Access Panels
panels shall be provided to permit thorough removal of rubbish before
placing concrete.

9. Prior to concreting all forms shall be clean and free from sand and Cleaning
shavings and tie wire ends and other debris. Surplus water shall be
drained and any temporary openings closed in a proper manner.

10. Forms for re-entrant angles shall be chamfered and forms for corners shall Chamfers &
be filleted. The bevel in each case shall have a width of 20mm on each Fillets
side unless otherwise shown on the Drawings. Cutting or grinding of
chamfers shall not be allowed.

11. The Contractor will be responsible for any defects to the formwork,
reinforcement, embedded components or the formed concrete surface
which may become apparent during or after casting the concrete.

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Specification 821 Formwork

821.28 REMOVAL OF FORMWORK

1. Formwork shall be removed in such a manner to ensure that no damage to Removal

the concrete occurs.

2. Formwork support and formwork to reinforced concrete members that are Timing
required to support their own self-weight at any time (such as deck soffits,
beams and precast MSE wall panels) shall not be removed until the
concrete has achieved the strength specified on the Drawings, but not less
than 75% of the characteristic compressive strength of concrete (f’c). If
there are no compressive cylinder strength test results for concrete
samples taken on site or there is no guidance on the Drawings, the
minimum formwork stripping times given in AS 3610 Table 5.4.1 shall be
met.

3. Formwork support and formwork to prestressed concrete members that Timing

are required to support their own self-weight at any time (such as deck
soffits, precast concrete trough beams, and pier cap beams) shall not be
removed until the concrete has achieved the transfer strength specified on
the Drawings and the concrete has been prestressed. If there are no
compressive cylinder strength test results for concrete samples taken on
site or there is no guidance on the Drawings, the minimum formwork
stripping times given in AS 3610 Table 5.4.1 shall be met.

4. For other members or parts of the structure, formwork shall not be Timing
removed until the lesser of the concrete attaining a cylinder strength of
50% of the characteristic compressive strength of concrete (f’c) and the
minimum formwork stripping times given in AS 3610 Appendix C.

5. Sampling and testing of concrete to determine cylinder strength prior to Testing

removal or formwork support and formwork shall be in accordance with the
requirements of TGA Specification 820 CONCRETE FOR STRUCTURES.
A minimum of two samples shall be taken to determine the strength at any
designated time, and the lowest value shall be taken as the concrete
strength.

6. Concrete shall be continuously cured for the periods specified in TGA Curing
Specification 820 CONCRETE FOR STRUCTURES, including during lifting,
stacking and storage of precast concrete elements.

821.29 TOLERANCES FOR CONCRETE CONSTRUCTION

1. The materials for forms and form arrangements shall be such as to result
in finished concrete work complying with the tolerances shown in Table
821.1

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TABLE 821.1 TOLERANCES FOR CONCRETE CONSTRUCTION

Footings to Piers and Abutments:

a. Variation of dimensions in plan and elevation - 5mm + 20mm

b. Misplacement or eccentricity of centreline + 10mm

c. Variation in specified level + 10mm

Abutment Walls, Columns and Column Cap Beams:

a. Variation from vertical or specified batter. The lesser of 1:300 or

+ 5mm in full height

b. Variation in cross sectional dimensions - 5mm+ 10mm

c. Misplacement or eccentricity of centreline + 5mm

d. Variations from specified level of surfaces other than + 5mm

bearing surfaces

e. Variation from specified level of all bearing surfaces + 3mm

Bridge Superstructures:

a. Departure from specified alignment of centreline and edges + 10mm

b. Departure from specified profile + 10mm

c. Variation in cross-sectional dimensions - 3mm + 5mm

d. Variation from specified level of all bearing surfaces + 3mm

821.30 PROVISION FOR THERMAL MOVEMENT

1. The Contractor's attention is drawn to the need for the formwork for all
deck diaphragms other than the fixed piers to be supported off the steel
beams in a manner that will permit temperature movement of the deck
diaphragms relative to the cap beams during construction.

821.31 – 821.70 NOT USED

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Specification 821 Formwork

AS BUILT AND HANDOVER REQUIREMENTS

821.71 – 821.90 NOT USED

CONTRACT SPECIFIC REQUIREMENTS

821.91 – 821.99 NOT USED

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