—_———— re eee. NCPDP Handbook FORMWORKS FOR Neat BUILDING CONSTRUCTION“ CONSTRUCTION MANPOWER Res DEVELOPMENT FOUNDATION Pst SIGN JAPAN INTERNATIONAL COOPERATION AGENCYALL RIGHTS RESERVED @ 1997 First Edition Construction Manpower Development Foundation Department of Trade and Industry Republic of the Philippines No part of this handbook, except for brief quotations in research studies may be produced or transmitted in any form or by any means without permission from the Construction Manpower Development Foundation. Some of the drawings and examples in this handbook are taken from various technical books about formwork and should not be used as working drawings or in place of making calculations for a particular local job. The recommendations contained herein are intended only as a general guide that would be helpful in the preparation of complete formwork plans which should be in accordance with the local conditions and conform ‘with all applicable legal requirements, Inno way is this handbook intended to supplant the qualified designer or engineer to whom formwork should be entrusted. Published by the Construction Manpower Development Foundation 6th Floor, Prudential Bank Building, 2182 Chino Roces Avenue, 1231 Makati City, Metro Manila Philippines in collaboration with Japan Intemational Cooperation Agency Shinjuku Maynds Tower Building, 1-1 Yoyogi. 2-Chome Shibuya-ku, Tokyo, 151 Japan Editorial Board ngson, Eiji Teramoto, Florencio G, Sison, and Yoshihiro Watabe Editor : Alicia A. Tiongson Technical Writer : Joji C. Valenciano, C.E., M.CM. Researcher; Domingo Basilio R. Navera, Yoshihiro Watabe, Abelardo E. Aureada, and Joji C. Valenciano Layout 2 Jeffrey F.Gumasing Inside Back Cover Illustration: Productivity improvement(s) at the plant or project site must address critical issues on Production capacity (quantity), Quality, Cost, and Delivery of products and services, as well as for the Safety and Morale of the workers, Productivity is the concem of everyone in the organization top management, middle management, staff, supervisors and workers. It is based on communication and cooperation among the total project workforce.i i arena FOREWORD Productivity improvement remains a crucial need in the Philippine construction industry today as it faces the formidable challenge of global competitiveness. This need is heightened by the rising demand and the accelerated pace of technological change in the world construction market. To be competitive in such a market, one must be highly productive, that is, able to produce more and better quality products and/or services with the same (or even less) amount of resources or inputs available to other competitors. One way, therefore, of gaining a competitive advantage in the construction market is productivity improvement at the firm level through the efficient and effective management of construction resources (manpower, methods, materials, machines, and money), As part of its commitment to governmental efforts toward global competitiveness of the construction industry through the development of a competent and productive industry work force, the Construction Manpower Development Foundation (CMD), under a technical cooperation grant received in January 1993 from the Government of Japan through the Japan International Cooperation Agency (JICA), launched the National Construction Productivity Development Project (NCPDP) to promote continuous improvement of productivity in the construction industry. The major components of the NCPDP are as follows: 1. Total Quality Management (TQM) in Construction involving the installation and institutionalization of a firm-level TQM which encompasses the overriding concern for quality by management and work force in the firm’s entire operation; 2, Supervisory Skills Training which entails the development of highly competent engineers, supervisors, and managers for the industry through training and career path development; and 3. Construction Managers’ Training and Certification Program (COMTCP) which trains, evaluates and certifies construction engineers at supervisory and managerial levels who haveshad been engaged in general building works through an organization or agency recognized by the Philippines Contractors’ Accreditation Board (PCAB). Each of the above components of the NCPDP centers on six (6) productivity improvement factors at the firm level, namely, production capacity (quantity), quality, cost, delivery, safety, and morale of workers (PQCDSM), This total quality focus and the TQM approach highlight both hardware (product, plant & equipment, materials & energy, and technology) and software (people, organization, work methods or processes, and management styles) elements in a firm’s internal environment that are vital considerations in improving productivity. The NCPDP training and these handbooks, which are part and parcel of the NCPDP's promotional activities, were designed on the basis of this frameworkThe contents of the NCPDP handbooks are focused on building construction project management and are intended for those in the supervisory and managerial ranks of construction firms. The handbooks consists of two (2) series: first, Construction Management; and second, Construction Methods. The Construction Management Series delves on the management aspects of the three stages of the project management cycle, i.e., pre-construction, construction, and post-construction. The Series provides selected and vital information on the construction industry and pertinent rules and regulations governing project development and operation. It provides a thorough disc contract administration and includes a variety of applicable management tools and techniques for project planning, execution, and control. The Construction Methods Series consists of technical handbooks which provide a detailed treatment of the major work areas in building construction. It presents construction methods and techniques designed to improve project-site productivity. The major work areas are Piling, Excavation, Concreting, Formworks, Rebar, Structural Steel, Electrical, and Mechanical Works. ‘Aside from focusing on the PQCDSM productivity improvement framework, both series of handbooks apply a basic tool in total quality management, ic. the PDCA cycle or the Plan, Do, Check, and Act cycle throughout the different stages of a construction project. It is envisioned that through the publication of these handbooks and the continuing application of a firm-level systematic management approach, increases in productivity levels sufficient for the construction industry to acquire a competitive edge in the domestic and foreign ‘markets will soon be realized. “iePREFACE The First Edition of the NCPDP Handbook on Formworks in Building Construction is part of an ongoing concern of CMDF to continuously improve and update its training courses and reference materials to better serve the needs of the Philippine construction industry. This Handbook serves as a guide for formworks in building construction sites, as it covers common materials used in formworks, codes and standards, the planning process in formworks, work execution process, and the control checkpoints during work execution. The development of the material harnessed the expertise of the short-term experts dispatched by the Japan International Cooperation Agency (JICA), as well as the professional advice of various practitioners from the construction industry. Formworks in Building Construction in the Philippines faces several challenges. One of these is the dearth of materials on planning, execution and control of formworks. Another is the strict observance of the National Structural Code of the Philippines (NSCP). This Handbook seeks to provide information on thé various tools available for the planning, execution and control of formworks as well as an awareness on the application of the Code in construction sites. ‘The Handbook Contains four parts: Part I covers common materials about formwork, and selected codes and standards; Part 2 contains the various types of work plans needed to carry out the work effectively and efficiently and these include work execution plans, resource allocation plans and control plans; Part 3 conttins the work process typical to formwork; Part 4 presents work control checkpoints and recommendations to implement the plan and this includes control for quality, cost (materials, manpower, equipment), delivery and safety. It is the NCPDP's aim to improve productivity by developing quality construction projects and consistently keep the quality of construction works. This way, productivity improvement will facilitate the delivery of quality projects at reduced cost, timely delivery, and with an assurance of safety. We hope that the Handbook will serve as a guide for supervisors and managers in equipping human resources of construction projects with the necessary knowledge, skills and attitudes in initiating and sustaining the task of productivity improvement. We also hope that the Handbook will be instrumental in the continuous development of productive formwork construction work execution in the industry.ACKNOWLEDGMENT “The management and staff of the National Construction Productivity Development Project (NCPDP) of the Construction Manpower Development Foundation (CMDF) wish to acknowledge the contributions of the individuals. group of individuals, contractors, organizations and institutions who in one way ot another helped in the realization of this, NCPDP Handbook on Formwork for Building Construction. In particular, we like to acknowledge the contribution of the following: 1. Ms, Alicia A. Tiongson, Executive Director of the Construction Industry Authority of the Philippines (CIAP) and concurrently, Officer-in-Charge of CMDF for providing the inspiration, direction and support not only for this handbook but for the entire NCPDP undertakings; 2. Messrs. Domingo Basilio R. Navera, Abelardo E. Aureada and Joji C. Valenciano of CMDE and Yoshihiro Watabe of JICA, for doing the bulk of the research works for materials used, and for formulating the form and layout of the handbook; 3. Contractors, namely: AG&P, C-E Construction Corp., F.F. Jr. (Filsystem), and Kanlaon Construction Enterprises, for being cooperative with the NCPDP and for allowing the CMDF and JICA staff to visit and observe operations at their project sites; 4, The NCPDP Subcommittee on Formworks, chaired by Ms. Remedios Belleza of the Department of Public Works and Highways with members, Messrs. Jesse Orbase of E. Ganzon Inc., Nolasco Pasion of Philippine Gas Pressure Welding Inc. , Ronito Mercado of Concrete Aggregates Corp., Efren Gatmaitan of EEI Corp., Orlando Dizon of C.P. Dizon Construction, Yoshihiro Watabe HCA Advisor, and Domingo Basilio R. Navera and Joji C. Valenciano of CMDF for the guidance in the conceptualization of this handbook so it will be useful as practical reference for contractors. 5. The Government of Japan through the Japan Intemational Cooperation Agency GICA), for the technical cooperation assistance to the CMDF’s Productivity Development Program for the construction industry; 6. The long-term and short-tern Japanese experts dispatched by JICA to CMDF, for the technical advice and information on Japanese Methodologies in formworks; and 7. The other Philippine contractors who found time to sit in NCPDP's various. consultative seminar series during the formulation of this handbook. Lastly, we acknowledge the various technical writers and authors of the reference materials used in this handbook, without which our research work would have been more difficult.‘Contents eT [List of Tables axis ist of Figures xii One: Fundamentals of Formworks 2 1: Objectives and Fundamentals of Formwork 3 1.1 Definitions 3 1.2 Materials rt 5 13. Shoring and Scaffolding 9 2: Codes and Standards... 1s 2.1 Formwork Design 1s 2.2 Materials and Components 15 2.3 Fabrication and Installation of Formwor 15 2.4 — Tolerances 16 2.5 Construetion Joints 16 2.6 _ Removal of Forms and Shores 16 Two: Work Planning ssmmmnnmnns 19 3: Preliminary Survey 23 3.1 Contract Plans and Drawings ..». 23 3.2. Contract Specification 2B 3.3. Contract Terms and Conditions 24 3.4 External and Site Conditions 25 4: Work Execution Plan... 27 4.1 Selection Methods 7 4.2 Selection of Materials 28 43 Formwork Design 30 44° Design Criteria 31 4.5 Determination of Time for Form Stripping 38 4,6 Planning for Maximum Re-use 39 4.7 Formwork Fabrication Area/Shop 41 5: Resource Plan 45 5.1 Schedule Plan 45 5.2 Budget Allocation 50 5.3. Manpower Allocation Plan 51 ~vii-34 55 Chapter 6: Part Three: Chapter 7 11 12 Chapter 8: 8.1 Chapter 9: 91 Chapter 10: 10.1 10.2 103 104 105 10.6 107 Chapter 11: Chapter 12: Chapter 13: Part Four: Chapter 14: 14.1 142 Materials Allocation Plan Equipment Allocation Plan Control Plan Cost and Schedule Plan Quality Control Plan Safety Control Plan Work Execution Plans and Drawings Formwork Drawings Checklist Formwork Fabrication Practices Fabrication Practice for Inking/Markjng_.... Formwork Inking/Marking Installation Practice Ground Forms Column Forms Bracing Column Formwork Hoisting Column Forms Wall Forms... Beam or Girder Forms Slab Forms Construction Joints Formwork Stripping Practice Formwork Care and Maintenance Work Control Work Monitoring Data Gathering ss Monitoring of Work BudgetChapter 15: 15.1 15.2 153 15.4 15.5 15.6 Chapter 16: 16.1 16.2 16.3 16.4 16.5 16.6 Chapter 17: 171 17.2 173 Quality Control Quality of Formwork Material Inspection Work Inspection Allowable Tolerance eae Common Problems Encountered in Formwork Quality Control Schedule Cost Control Work Progress Report Material Cost Labor Cost Equipment Cost Problem Areas in Cost Control Efforts for Reducing Construction Cost Safety Control Analysis of the Factors Contributing to Accidents Accident Reporting Safety Problems in Construction Sample Computation for Design Work Special Formwork System Checkpoints in Formwork Gonstruction 167 167 168 168 170 170 171 175 175 178 180 181 181 183 185 185 186 186 19 201 207of Tables Fundamentals of Formworks ‘Commonly Used Nails for Formworks + Permitted Gradual or Abrupt Irregularities in Formed Surface 2-2: Minimum Remaining Time ‘Two: Work Planning 4-1: Comparison Between ACI and JASS 5 for Dead and Live Loads 4-2: Formula for Maximum Bending Moment and Maximum Deflection 4-3: Working Stress for Common Formwork Materials 4-4: Minimum Safety Factors for Formwork Accessories 5-1: Material Procurement Schedule ‘Three: Work Execution Example of Installation Drawings Inking Locations on the Building Structure Marking Symbols Tools and Instruments for Inking 10-1: Application of Edge Joints 10-2; Procedure in Formwork Installatian for Tied Columns 10-3: Various Types and Method for Clamping Tied Column Formwork 10-4: Various Formwork Methods for Round Column 10-5: Various Ways of Hoisting Column Form 10-6: Two Types of Wall Formwork ree (3) Broad Groupings of Wall Ties 10-8: Installation Procedures of Walll Ties 10-9: Various Examples of Corner Tying 10-10: Bracing Wall Forms 10-11: Various Ways of Constructing Beam Bottom : Slab Form Ereetion Procedure le 11-1: Construction Joints Methods Four: Work Control fable 14-1: Sample of Field Monitoring Report for Fabrication of Forms le 14-2: Sample of Field Monitoring Report for Installation of Forms fable 14-3: Sample of Field Monitoring Report for Stripping of Forms Sample of Work Summary Sheet for Formwork Material 16 7 31 34 35 35 53 67 15 11 8 83 1 102 107 109 M1 116 19 123 132 142 145 161 162 163‘Table 14-5: Sample of Work Summary Sheet for Labor- Installation of Forms . Table 14-6: Sample of Cost Monitoring Report Table 15-1: Inspection Items (Checklist of Formworks) Table 15-2: Allowable Tolerance (ACI Standard) Table 15-3: QC Schedule for Formwork Table 16-1: Sample of Work Progress Report Table 16-2: Sample of Material Status Report Table 16-3: Sample of Direct Labor Hours Report Table 17-1: Standard Insurance Report of Accident Form Wt Appendi Checkpoints in Formwork Construction ‘Table III-A: Checkpoints in Formwork Construction -xii- 165 166 169 170 172 176 179 182 187 208of Figures One: Fundamentals of Formworks I-1: Application of Precast Concrete Panel 1-2: Excess Water Flowing Out : Movement of Air and Surplus Water |: Types of Screws Used in Formwork 1-5: Metal Adjustable Shore Jack Fitting That S the End of a4 x 4 or 6 Wood Planks raris of Pipe Support and Wing Support Detachable Wing Support ‘A Typical Scaffold - Type Shoring xpandable Beam Support a 1-10:Commonly Available Single Member Ties 1-11:Other Single Member Ties which Have Tube Sleeves to Prevent Tic from Bonding with Concrete enn las Work Planning M-1: A Typical Processs of Making a Work Plan for Formworks 11-2: Interrelationship of Various Plans for Concrete Works 4-1: Calculation Flowchart et 4-2: Typical Shop Layout for Large Project... $-1: Process Flowchart in Scheduling 5.2: The Framework of a Master Schedule 5-3: Activity Flow of Formwork ee Work Execution $1: Cutting Workbed .... : $2: Tools Used in Formworks Fabrication 10-1: Tools for Formwork Installation. 10-2: Details of Shallow and Deep Edge Forms 10-3: Integral Pour of Base and Pedestal 10-4: Yoke for Plastic and Metal Forms 0-5: Unfixed Column Formwork Bracing 10-6: Form Bracing Fixed at Both 10-7: Bracing for Edge of Slab Columns 1-8: Simple Formface Hoisting Point 10-9: Basement Walls 10-10: Electrical Comer Openi 0-11: Plan of Corner Junction 10-12: Plan of Comer Junction 21 2 37 46 47 49 n nD 81 82 89 101 104 105 106 106 109 N7 18 118Figure 10-13: Internal Comer Tightening Figure 10-14: Metal Angle at Internal Comer Figure 10-15: Plan of Forms at a Tee Joint Figure 10-16; Construction Joint for Tee Joint Figure 10-17: Groove Form for Tee Joints... Figure 10-18: Clamping to Existing Concrete Wall Figure 10-19: Rectangular Penetration Form Figure 10-20; Penetration Form Removal Figure 10-21: Penetration Form for a Door Figure 10-22: Small Penetration Form Figure 10-23: Large Circular Penetration Figure 10-24: Small Pipe Penentration Figure 10-25: Hoisting Arrangements Figure 10-26; Wall Form Hoisting Fittings-1 Figure 10-27: Wall Form Hoisting Fittings-4 Figure 10-28: Gussets for Comers of Formwork Figure 10-29: Gussets for Internal Framing. ....rnne Figure 10-30: Typical Components of Beam Formwork with Slab Framing In... Figure 10-31: Floor Centres Seated on Beam Sides Figure 10-32: Packing Under Floor Centras Figure 10-33: Joists Seating on the Beam Sides Figure 10-34: Separate Supports for Beam and Soffit Form Systems Figure 10-35: The Changing Forces at the Base gat Figure 10-36: Deep Beams with Two Rows of Ties Figure 10-37: Junction of Different Form Levels gure 10-38: End Cutting to Beam Soffit Form igure 10-39: Junction of Beam Side Forms ... ‘gure 10-40: Closure Angle at Beam Side Junctions Figure 10-41: Typical Edge Beam Formwork Figure 10-42: Section of Deep Edge Beam Formwork Figure 10-43: Typical Flat Slab Formwork Components Figure 10-44: Three Level Multi-Storey Shoring Figure 12-1; Formwork Stripping Tools Part Four: Work Control Figure 14.1: Typical Monitoring System Appendix 2: Special Formwork System Figure I-A: Typical Slipform with Deck and Finishing Seaffold Supported on Wales Bye Figure II-B: Traveling Formwork 5 ure II-C: Flying Form with the Combination of Wall and Slab FormsAppendix 1 SAMPLE COMPUTATION FOR DESIGN WORKCALCULATION EXAMPLE (1) WALL, COLUMNS Basic assumptions Columns 80cm x 80 cm x 3.0m high Pouring speed 20m’/hour Tolerance : 1/360 of span(!) Material selection Sheathing Board: Plywood —120em x 240cm x 12mm thickness Stud : Coco Lumber 50mm x 100mm Waler : Coco Lumber 50mm x 100mm double Tie Steel Bar 9mm diameter Working Stress Unit : kgf/em? Sheathing Board [Coco Lumber 63% | Steel Bar| (Plywood) Stress Medium Modules of Rupture in Bending 80 310 2100 Modulus of Elasticity Tosxto | 235K 10" 2Ixt Compression (Parallel 19 Grain) 8 352 ‘Shear (Parallel to Grain) 4.0 44 Step-I: Find Pressure As pouring speed is 20m’/hour, lateral pressure of columns is calculated based on the P = 0.24 x 3.0= 0.72 kgfiem? P= 0.72 kgflem? Step-2 Sheathing Board (considered as simply supported beam, uniform load) There are two ways to check bending and deflection: Case-1: Predetermine span of support and check bending stress and corapare allowable material 192Case-2: tly compute maximum span of support. A. Calculate S (Section module) and I (moment of interior) bh? _ 24012)" cooks 26 em! 6 6 a ob 20x02) _3456em! geen (Procedure Based on Step-1) ‘As column size is 80em x 80cm, span of stud is predetermined to be 80/4=20em. B. Check Bending Sheathing is considered as simply supported beam, uniformed load, then using Equation 4- 5 in part two, bending stress is wh 172.8% 20° en gig 71502 108 keflem? not OK from above result, span of stud is adjusted and determined to be 80/5 =16cm Using Equation 4-5 in part two, bending stress is 172816 8x576 =96 <108kgflem? O.K C. Check Deflection As span of stud is determined asl 6em, maximum allowable deflection is 16/360 = 0.045 cm. Use Equation 4-9 in part two and get deflection /irenldiCata 172.8 16" on = 394 EY 384” 1.05% 10" «34:56 = 0,04lem <0.045em Procedure Based on Step-2 B. Check Bending Sheathing is considered as simply supported beam, uniform load, then maximum allowable span, by Equation 4-5 is: 193nM 108 x5 2.83 x J = 16.98cm 8 Tg 7 698m ©. Check Deflection ‘As maximum allowable deflection is 1/360, maximum allowable span. by Equation from part two is: EI 34.56 x 1.05 x10" = 0604 eee m 1 = 0.60 x3] = 060 a 16.55 By result of above and size of column 80cm, space of stud will be 16.0 em Step-3 Stud Size and Spacing of Waler “There are also two ways to check bending and deflection in the same way as sheathing, mine span of support and compare with allowable figure, and directly compute maximum: support. This section shows directly computed maximum span of support. lent Find the maximum span where the lateral pressure is greatest; -0.72 kgf/em*. Eq Joad o for design of studs will be the maximum lateral pressure times the stud spacing. « (stud) = 0.72 x 16.0 = 11.52 kgffem A. Calculate S (Section module) and I (moment of interior) bh? _ 5x10? =833 6 bh’ _ 5x10" = =416. joey St B. Check Bending Stud is considered as continuous beam, uniform load, then maximum allowable Equation 4-8 from part two is: 12316 « . Cheek Deflection ‘As maximum allowable deflection is /360, maximum allowable span. by Equatis 194from part two is: teore Comparing the stud spans computed above shows that the span based on bending strength is the shortest at. 60.7em. It means that the waler, which are the stud supports, can be spaced no more than 60.7 cm. apart where there is maximum pressure. Increased wale spacing is theoretically correct near the top of the form because from the bottom up to the top of the design pressure declines from maximum to zero. 94 x [A167 235 x10" 1153) =70lem In addition, the sample shows that stud facing affects the structural calculation of sectional module and moment of interior. 0x5) Based on the above figure, the result of computation becomes: Check bending = = 42.9em Check deflection — 43.6.cm , Step-4 Wale Size and Tie Spacing As the span of stud is 16 em and the span of wale is 60cm where the lateral pressure is preatest - 0.72 kgf/em’, the equivalent concentrated load for design of waler will be P= 0,72 x 16 x 60= 691.2 kg Besides assuming that 2,100 ky (safe working load) ties are to be used, and the maximum lateral pressure is 0.72 kgffem?, maximum area by one tie material will be 2300 072 2916.7ene and as spacing of wale is 60 em, maximum spacing of tie will be 195Based on the above, considered as case-B in table formula for checking bending and c! deflection are as follows: 2Pt Ma for bending check 7Pr : Sno = 394g7 for deflection check AS MPS. M_ 22 oS from Table 4-2, ease 2 in part two A. Calculate S (section module) and I (moment of Interior) 1 Se 6 S22x = 1667 2Pl os B. Check Bending, by equation, = 4 2xPxI_ 2x 6912%48 9xS 9% 1666 443 keflem2 <51.0 OK. ©. Check Deflection A oe stee me 32487 7x 6912 x 48" 48 324x235 10" «8334 owe 360 (2) SLAB Basie Assumptions Slab thickness : Sem Pouring speed. =: 20m ‘hour Tolerance : 1/360 of span(!) Material Selection Sheathing Board Joist Plywood — 120cm x 240m x 12mm thickness Coco Lumber 50mm x 100mm.Stringer Coco Lumber 50mm x 100mm double . Shore Steel Shore 50mm diameter Working Stress Unit : kgf/em? Sheathing Board | CocoLumber 63% | Steel Bar (Plywood) Stress Medium Modules of Rupture in Bending 80 31.0 1400 kg “ Modulus of Elasticity 105 x 10° 35x10" Dix lo ‘Compression (Parallel to Grain) 48) 35.2 ‘Shear (Parallet to Grain) 40 44 Step - 1: Find Pressure Based on ACI. estimated load is : - Dead Load 0.24%15 = 360kgfim* Form Load = 40kgfim? . Construction Live Load = 244 kfm’ Total Form Design Load= 644 kgflm* Step - 2: Sheathing Board ' si ee A. Caleulate S (section module) and I (moment of interior) Using strong plywood. with face grain parallel to span: 120 (12) bh _ 120x(12)' 2 2 7.28 B. Check bending ‘As width of plywood is 120em, w= 644 kgfim? x 120em = 7.73 kgflem? Sheathing is considered as simply supported beam, uniform load, then maximum allowable span, by Equation 4-6 from part two is: 108x288 2 B 93 ie 2x {4 283 Ta 197C. Check Deflection As maximum allowable deflection is 1/360, maximum allowable span. by Equati from part two is: (ET 17.28 x 10510" 1 = 060 «J = 060 x3 —— = 37.00m D. Result Based on the result of the above check and the size of plywood, it will be determined space of joist will be 30.0.cm Step-3: Joist Size and Spacing of Stringers to Support the Joist Find the maximum span where load is 544 kgffm’, Equivalent uniform load o for design: will be the maximum lateral pressure times the stud spacing. © Goist) = 0.0644 x 30.0 = 1.932 kgf/em A, Calculate S (Section module) and I (moment of interior) B. Check Bending Stud is considered as continuous beam, uniform load, then maxi Equation 4-8 from part two is: Fs E ‘6x, SBS “Ve 1932, C. Check Deflection Asmaximum allowable deflection is 1/360, maximum allowable span. by Equatic from part two is: El [4167x235 x 107 _ Thx = 0.74 ay TemD. Result " Comparison o the three spans calculated above shows that bending governs design and the maximum spacing of stringer is 127 em. However size of plywood is 120cm x 240cm, therefore it is determined that spacing of stringer is 120 cm Step-4: Stringer Size and Shore Spacing . Find their maximum span where load is 644 kgf?'m?. Equivalent uniform load @ for design of joist will be the load times the stringer spacing. © (joist) = 0.0644 x 120.0 = 7.728 kgflem A. Calculate S (section module) and I (moment of Interior) = 1667 B. Check Bending Stringer is considered as continuous beam, uniform load, then maximum allowable span, by Equation 4-8 from part two is: ©. Check Deflection 104.8cm ‘Asmaximum allowable deflection is 1/360, maximum allowable span, by Equation 4-12 from part two is: EL 1833.4 x 2.35 x 10° = 0.74 x §|—— = 0.74 x 4] == — = 100.9 12074 xy- = 0.74 TT 100.9cm D. Result Comparison of the three spans calculated above shows that bending governs design and the ‘maximum spacing of shore is 100.9 cm and it will be determined that spacing of shore is 100 em. : 199ee eT Step - 5: Shore Design Stringers are spaced at 120cm. supported by shore spaced at 100m. This gives an area x 1.0m of form load to be carried by each shore. Total load per shore will be: 1.2 x 1.0 x 644 = 772.8 < 1400 kef OK. 200Appendix 2 SPECIAL FORMWORK SYSTEMSI-A: SLIPFORM CONSTRUCTION Slipform construction also frequently referred to as sliding form construction is similar extrusion process. Plastic concrete is placed in the forms and the forms act as dies to sl concrete. The rate of movement of the form is regulated so that the concrete after itis strong, to retain its shape is supporting its own weight. Vertical slipforming can be performed ona ous basis or can be planned to stop at desired elevations, resuming the later with resulting joi different from those between lifts of fixed-form construction. Slipform construction can be used for structures such as silos, storage bins, shearwall buil and for high-rise elevators, stairways, and utility cores. Itis also suitable for bridges. piers, containment vessels, chimneys, underground shafts, and for horizontal structures such as inverts, water conduits, drainage channels, canal linings, and highway pavements, Major advantages of slipforms are speed and economy. plus the fact that continuous slidi produce a monolithic structure. if desired. In many cases, the cost of materials and building slipforms are about the same as for fixed forms that would do the same job. ‘The economy from shorter construction time. Slipform construction is most efficient if there are few projections to the direction of: must also be remembered that the process requires a more experienced crew at all level should be designed and built by individuals experienced in slipform work, and the sliding of must be carried out under careful, experienced supervision. Slipping also requires complete: ning of delivery and installation of all embedded items-dowels. rebar, weld plates. door bucks, ph blockouts and the like. Vertical Slipforms Vertical slipforms are moved upward by jacks which ride on smooth rods or st tubing embedded in the hardened conerete. These jacks may be manual, pneumatic, el hydraulic, Working decks and finishers’ scaffolds are attached to and carried up with the as shown in Figure I-A The form is made up of three sections-yokes, wales, and sheathing. The yoke's fi are to keep the forms from spreading and to transfer the load of the forms to the jack. The: stiffen the forms and are braced to carry the load to the yokes. Finishers" scaffolds and deck are connected to the wales. and the wale-yoke connections should be designed to: stand these loads. Plywood or board sheathing is attached to the wales with vertical face $0 as to cause the least drag when it turns to move up. -B: TRAVELING FORMS, Traveling forms are reusable forms mounted on movable frames or scaffolding called ti Once the concrete has been cured sufficiently, the forms are released and moved to the next to be conereted. This type of special formwork system offers maximum reuse of forms with ‘mum labor.{lt Seattotd braver Wood blocking at filling points }—Silipfoen y¢—Pinishors seal Figure 11-A: Typical Slipform with Deck and Finishing Seaffold Supported on Wales “The basie principles on the application of traveling forms are relatively simple. although details may become complex for large. long span travelers. The forms are attached to a traveler which is mounted on skids or wheels, which in turn travel on a conerete pad, or any suitable surface. Move~ ment of the traveling form can be done by hand, crane, tractor. or any means compatible with the size ofthe traveler, design of the structure. and the available equipment. In this regard, the traveler must be able to move freely and easily in order to obtain th€ maximum benefits from this type of operation. the traveling form is built to be backed off from the hardened concrete. moved to a new posi- tion, and precisely adjusted for concreting the next section, Jacks between the traveler and forms are usually used to back off the forms and make adjustments. Care in planning and building is necessary so that form units do not become keyed into the concrete and complicate this stripping operation. ‘Afier the bond with the hardened conerete has been broken and the forms have been backed off. slightly additional movement of the forms may be necessary to clear beams, columns. and other structural features. For forms like these for folded plates shown in Figure [/-B..a straight vertical drop of a few feet is sufficient to force the forms for lateral movement Traveling formwork designs vary widely. as shown by the three different methods of vertical form movement foressentially similar folded plate hangar roofs. TOP- glue-laminated wood falsework vas raised 6ft, with 12-ton hydraulic jacks. one on each of cight columns, then shored on tripats during concrete placement. Forms are lowered the same way. except that the first 4¥2 in. of drop is made by draining sand jacks atop the tripods. CENTER- Wood framed traveler made in two prtrts «with an inclined plane as the common face between top and bottom sections. To raise the root form 6 fh. the bottom section is forced under the top section which is guyed to prevent lateral motios BOTTOM- Wood falsework raised and lowered about 12 fi. with scissors ja including fresh concrete when the forms are up. which carry total toa teFigure II-B. Traveling FormworkIL-C: FLYING FORM SYSTEMS Flying forms are large mechanically handled sections of formworks which frequently includes supporting trusses, beams, or scaffolding units. Although the term can be applied to any form which is mechanically lifted and moved through the air, it is most widely used to describe unitized slab forming systems. One-way and two-way joist span forms can be attached to the deck surfaces and “flown” right along with many of these systems. ‘There are three principal types of support for the flying slab forms now in common use: 1 Truss-supported slab forms- Trusses may be made of steel, but aluminum trusses are used increasingly because of their weight advantage. Wood joists, or aluminum joists with a nailer strip on top. are fastened to the trusses and plywood deck surface is attached to the joists, The trusses, commonly 5 or 6 ft deep, are supported on shores or jacks resting on a previously cast floor. For stripping. the form is lowered by jack adjustment. In some cases the shore may be telescoped or folded out of the way before the entire truss assembly is tolled out and lifted by crane to the next casting position. Figure 11-C is another version of flying form combined wall and slab forms with necessary bracing and shoring in a single unit called tunnel form, for use in bearing wall structures, Wall forms are hinged or adjustable to move inward in a small amount so that the form assembly can be stripped for movement to the next casting position. These forms are similar to some used repetitively in rectangular culvert construction, but instead of moving only horizontally to the next position they are “flown” upward by crane. Slab forms supported by column- of wall-mounted hardware- Deck panels are usually framed by wide flange beams carrying adjustable shoring beams, open web steel joists. or other transverse members to which plywood or other deck surface is fastened. Load on the deck form is carried directly to previotssly cast walls or columns, and vertical shores are not required. Various support devices are used, usually bolted through preformed holes or an- chored to inserts set in place when the concrete is cast. One device has both high capacity screw jacks and rollers. To strip, jacks are lowered until the framing beam of the deck form rests on the rollers, and the entire form assembly is rolled out on dollies. Decks supported by metal frame shoring - A conventionally built slab form is fastened to one or more towers of metal frame shoring. The towers sit on and are fastened to continu- ous ledger members which rest on the supporting floor, ‘The deck is lowered by serew on the supporting floor. The deck is lowered by screw jacks in the shoring towers and the entire unit is moved horizontally by dollies or other devices until itis in a position to be picked up by crane. A lighter, smaller version of this method uses cross-braced post shores instead of shoring towersFigure [I-C, Flying Form with the Combination of Wall and Slab FormsAppendix 3 CHECKPOINTS IN FORMWORK CONSTRUCTIONCheek Item ‘Table III-A: Cheekpoints in Formwork Construction — Discussion Mlustration Propping. Construction joints near the midspan of the formwork fram- ing may deflect on the second pouring stage. To prevent this deflection, an extra line bearer and propping may be required along the line of the construc tion joints, HIRSESTAGE ‘Sycond eonerete poor. Formwork deflets further ahd rout penetrates under slaby SECOND ST Seconoany DErLecTion At THE JOINT Precautions must be observed ‘when placing heavy loads on the partially completed formwork. Toist span 9 Joist apans ERECTION OF COMBINED FRAMES ANDCheck Item: Table III-A: (con’t.) Discussion Illustration Propping, ‘A further problem can occur with the stacking of materials alongside a construction joint. The throc stages of this arc il- lustrated diagrammatically AAt first. the material has been stacked alongside the construc- tion joint before the first pour: the forms deflect downwards under this load and hog upwards in the adjacent span. When the concrete is placed it tends to slightly offsct this hogging but it still develops its strength on a form which is deflected up- wards When the material load is re- moved so that the next pour can be ready. the formwork reverts toa gencrally level shape. This leaves the slab without support. Depending on its age. cracking of the slab may result Sacked material Concrete slab Material removed Uplifting of form on one side may occur ifoverloading of one span on a two span continuous beam occur. If the prop is not secured. it will fall over. UpLirt oF THE END OF A BEARERCheek Item Discussion + (con’t.) Mlustration Propping, Ifthe progress of depositing con- crete is concentrated on one side, the form will be subjectto a large -centric load. This method is dangerous and should not be used (Case 1) Another potentially dangerous case of asymmetrical loading is illustrated in Case Il. A form for a very wide beam has been constructed on a support frame which is narrower than the beam, Some parts of the soffit are car- ried on the edge ofthe wide beam form. If the progress of the concrete pour is from one side, then the light weight of the empty formwork will usually be insuf= ficient to counter the eccentric action of the concrete covered soffit form. Failure will result. For safety, the points of appli- cation of the loads must always lie inside the base of support, Case III is the general framing arrangement which is recom- mended 4 A Dancenous SINGLE SUPPORT (Case D Uplift faiture LFA oentrcity AN UNSTABLE BEAM FoRM (Case I) Con, eam form § Supports 1 Loan ALMAYS INSIDE THE SUPPORTSCheck Item Discussion ‘Table III-A: (con’t.) Iilustration Propping If supports are seated on a sus- pended conerete structure, the loads on the form will cause some deflection of the structure (see Case 1). This deflection may be insignificant or it may be quite large. ‘Tominimize the load on the sup- porting stab and reduce this sup- porting slab and reduce this de~ flection, the load from the new ‘work can be shared by other sus- pended slabs below (see Case II). Top of slab sereeded level Softit form misaligned Supporting Sirueture deflects PERMANENT STRUCTURE DEFLECTING. (case D Hit Formavork TTT r Shores ft age Lower supporting slabs Tree Lever Mutt STOREY SHORING (CaseCheck Item Table III-A: (con’t.) Discussion Ulustration Propping Eccentricity of load action can quite readily occur at both the cap-plate and the base plate of the props. Perfection in the ac- curacy of erection of props and framing members is simply not realistic. Formworkers must develop an understanding of what is a sensible dividing line between normal trade practice and negligent workmanship. Two good standards to adopt are: maximum top eccentricity 20 mm and maximum out of plumb 1 in 200 and 40 mm. 20 my masimum 200 minimum FCCENTRICITY OUT OF PLUMB Limrts OF Goce WORKMANSHIP: Figure here shows the lateral ro tation, in the direction “A’, of the base of the support in response to a hard point of bearing in a generally soft area. The light steel tubular support is the only thing endeavoring to inhibit this rotation, For safety reasons. all but the hardest soils must be re- garded as soft when wet. and of- fering little restraint to this rota- tion Sot soil LATERAL ROTATION OF BASEPLATE ‘Although most concrete slabs are intended to have smooth even surfaces, variations in the con- crete surfaces do occur. These variations can cause eccentric loading and limited rotation of the base plate to the Formwork support If uneven patches like this are prevalent on the conerete sur face, then soleplates under the baseplates will be needed to pro- vide an even level beaming. Limited rotation Uneven slab EFrect OF AN UNEVEN CONCRETE SLAB,Check Item Discussion Table III-A: (con't) Mlustration To enlarge the foundation area, reduce the bearing pressures and minimize sinking, the soleplate must be made stiffer. This ean be done by adding members to the top of the soleplate, To be effective, they will also need to be stiff. Members similar in size to the bearers are used in the sof: fit framing are usually suitable. However, if only one is used there are potential stability problems (Case I), ‘As Case II shows. the pos ity of relative movement is re- duced by fixing the baseplate to the stiffening timbers. The use ‘of two or more stiffening beams provides width of bearing, and greater stability results. Note also that the soleplate must bear evenly on the ground, Care must be taken to trim the bearing sur- face accurately. oe q UNSTABLE selenite Single stiffening beam | eh 1B z~ SOLE PLATE wiTt SINOLE STIFFENER (case D JFrame tex Afustable serewjack Coen (gE) sailed to bearers SoLe PLATE WITH DOUBLE STIFFENER, (case Poor compaction of the backfill tostrip footings can cause a simi- lar problem for formwork sup- ports that are adjacent to walls. These problems of variations in bearing capacity can occur in all soils and all construction sites. ‘As well as the soft areas that can ‘come from drainage and footing work, the surface area as a whole may be disturbed by the traffic of delivery vehicles and earthmoving plant. Proof roll- ing of the surface may be neces- sary in this case. \e—Prop bends soleplate rotates Poorly compacted back ‘rip footing PROP PLACED ON TRENCH BACKFILLCheck Item Discussion Table III-A: (con’t.) Hlustration Propping, Wider formwork areas will need line of double span bearers. If they are lapped as shown in Fig- ture A, the support in the middle of each double bearer span will have the full load acting eecen- trically ‘The staggered laps shown in Fig- ure B effectively eliminate this -length eccentricity. In both ccases the laps between adjacent bearers cause each of the bear- ers to act eccentrically. omy “Uh isi Figure A SS Bearers lap left 0 Fight y~ nea is concentrically Figure B THe LAPPING OF BEARERS Where there is only one bearer ‘ona support, or the double bea ers do not totally fill the avail able width of the “U” head, the bearers may move sideways on ‘the head during formwork con- struction or concrete placing. This movement can be inhibited and general concentricity main- tained, by rotating the “U" head as shown in here, To prevent it from drifting back during con- structign. it should be fixed with anail through at least one of the holes provided in its sides. If only single span bearers are used, the staggered laps shown in Case | can be disadvantage. The problem occurs when the progress of the slab pour is on a line at right angles to the bearer line. As the pour progresses, in the same direction as that which ‘occurred initially on the previ- ously loaded support, the progtess of the pour past each support generally balances out the eccentric moments, as the full load is reached on each support Nevertheless, there is an over- turning moment continuously Nail “U" head turned to st tightly against bearer CENTRALISING A SINGLE BEARER Progress of eonerete placement entre action | BEARERS THAT LAP THE Same War (Case bCheck Item: Discussion Table HH-A: (con’t.) Ulustration Propping ‘acting the one way. at the edge of the processing pour. Thishas the potential, together with other influences, to destabilize the formwork structure, ‘The danger can be minimized by lapping the single span bearers as shown in Case I. In this ar- rangement each succeeding bearer causes an initial eccentric moment on the support which acts in the opposite way to that which acted on the previously loaded one. This method of bearer framing has less tisk than the previous one. The importance of the control of deflection of the bearers was noted previously. To this must be added considerations of ma- terial strength and section stabil- ity in the determination of size. “The factors that control material strength and the need to re-as- sess the condition of the timber at each and every use should be considered. Progress of eonerete placement 7445 Eeoentrie action Bearers LAPPING ALTERNATE WAYS (Case Wall Forms Clamping of forms to a previ- ously poured conerete wall re- quires the same attention to ply- ‘wood deflection that is needed for stop ends. Packer studs are needed to stop the grout and moisture loss. Frosheonece fe roios pour Construction joint Previous pour Extra packing studs to stop plywood deflection JUNETION OF FORMS TO CONCRETE WALLCheck Item ble III-A: (con’t.) Mlustration Wall Forms Where two walls meet at a cor- ner. the formwork to the outside, at the external comer, requires special attention. Case | isa plan view showing the problem in principle. The wall forms on the outside cantilever beyond the last line of ties. Unless provisions is. made to prevent this cantilever aetion, the forms will deflect apart and severe grout losses will occur. For minimum grout loss at the comer, there must be a positive tying force to hold the formwork assemblies together at theirjunc- tion, Grout tight formwork comers start with a tight junction be- tween the two plywood faces. Case II shows the corner inter= face which is also commonly used in column formwork, (ea presi united corner Wall form EXTERNAL CORNER OPENING (case ight joint ma | a alton Lan oF CORNER JUNCTION (case Overtigh- tening of Tie Rods Care should be taken in tighten- ing the wingnut. Two problems can occur from overtightening the wingnut. Firstly, the conecan crush the surface veneer of the plywood and thus reduce its working life. OVvERTIGHTENING OF THE HE-BOUTCheck Item Table III-A: (con’t.) Discussion Mustration Overtigh- tening of Tie Rods If the walers are located above the bottom plate, even if only at a short distance. the tightening of the ties to clamp the forms to the kicker will result in the bend- ing of the forms. Even a small amount of flexure in the formfaces will produce a notice- able misalignment in the final concrete faces. The curved shape of the forms also moves the point of application of the clamping action to the top cor- ner of the kicker. Crushing of the formface and local fractur- ing of the edge of the kicker can result. i> | COvertightoning she-bolts tends to bond forms inwards IncoRRECT BOTTOM WALER LOCATION Conereting, Stage (On most projects. there is erane handling of bundles of material, conerete buckets and large formwork components, Al- though the probability may be small, there is always the possi- bility of collision between these crane loads and parts of the formwork. ‘The crane loads can horizontally strike the tops of wall or col- umns, and the edges of soffit forms. Vertical impact loads can shatter the formface of soffit forms. The effect of these im- pact loads must be considered when arranging the formwork system, These three situations are illustrated here Impact from [concrete buckets Wall forms. Iwpacr wir WALL FORMS Impact from concrete buckets HORIZONTAL IMPACT ON SOFFIT FORMS Vertical impact from ‘concrete buckets VERTICAL IMPACT ON SOFFIT FORMS 217Table III-A: (con’t.) Check Item Discussion Ilustration. Malfunction of the discharge gate ‘of a conerete bucket can easily cause mounding, (Case 1) Even ‘more common is the case where the concrete pump operator does not respond to signals to stop the pumping of concrete. ACCIDENTAL MOUNDING OF CONCRETE (case D Conereting, Stage The mounding of conerete from cgonerete boom pumps and buck- Conerete sho ets may even be deliberate. If| Limit of boom pump radius the boom will not reach the far corner of the slab then the Jconeretor may mound the con- crete as near as possible to the comer. From there it is shovelled into position (Case 11), DELIBERATE MOUNDING OF CONCRETE (case 1)Table III-A: (con’t.) Ulustration Check Item Discussion Of a more serious and danger- ous nature are cases where struc tural stability is involved. Fig- ture here shows formwork for a slab that cantilevers beyond its base of support Ifthe pour starts from the right- hand side then the situation will be STABLE. The load of the fresh concrete will increase the stability ofthe formwork assem- bly. When the last conerete is placed out on the cantilever, its overtuming effect will be resisted by the weight of the concrete placed earlier on the right hand Pe UNSTABLE But ifthe pour commences at the left-hand side, then the weight of the empty form of other end will not be able to resist overturning. wromtance oF DinecTiON oF POUR ‘The form will be UNSTABLE and failure will result. Safety in this case. can only be assured ifthe righthand end isadequately | anchored down, Progress of pour Progress of pour = Conereting Stage All structural members deflect ‘when loaded. and this includes the state when only carrying their own weight, Sometimes, this deflection is very small. but it ‘occurs nevertheless. Figure here Nee eae diagrammatically illustrates a cross section through a beam and slab structure where the beams have been stripped first. The Jbcams are partly carried by the cedges of the slab forms and a re~ verse bending action has oc- ‘Unpropped beam deflects curred. This bending action is not compatible with the rein- forcement pattern in the concrete Unacceptable cracking can re- sult. Stripping Beane Srupreo Berone Sisss,Check Item Table III-A: (con’t.) Discussion Mlustration Stripping When the slabs are stripped be- fore the beams, the bending ac- tion on the eonerete follows that designed forin the reinforcement pattern. The slab deflects to its expected shape, with its load be- ing passed onto the beams, then the beam is stripped and deflects, under load. For the RESHORING proce- dure, the slab is completely stripped first and then the beams are completely stripped. Follow- ing this the beams are reshored and then the slabs. BACKPROPPING starts with {the backpropping of the beams Jand then the slab. Atthesecond stage, the backprops to the slab are stripped first, to be followed by those to the beams. Material Loads When the surface of a formface finished, material for the next trade, the reinforcement fixing, is often stacked on it. Ifthe sup- port siructure is not complete, then care must be taken in select- ing the position for placing the reinforcement bundle, Incorrect place for stacked materials L Correct locations Limmarion on PLACING MATERIALSCheck Item Material Loads Discussion ‘Another dangerous loading prob- Jem can come from stockpiling materials for ater tradework in Table IIL-A: (con't) Mlusteation Stacked mi placed before forms started, | yr Formwork being constructed ‘multi-storey buildings. —Backprops in place ot Props sipped SS POTENTIALLY DANGEROUS LOADINGCMDF HANDBOOKS eal Technical Series: Excavation Work for Building Construction Piling Work for Building Construction Structural Steel Work for Building Construction Electrical Work for Building Construction Mechanical Work for Building Construction Concrete Work for Building Construction Rebar for Building Construction Construction Management Series: Introduction to the Construction Industry Construction Planning Project Control Construction Execution Management Contract AdministrationChapter 4 WORK EXECUTION PLAN ‘building construction is one of the most critical jobs during the roughing-in stage. Major includes rebar, concrete, and electro-mechanical works depend on its timely comple- ‘contractor handles his plan of formwork can make or break his profitability Snimum cost in the use of formwork in construction, it must be treated as an integral part The over-all construction sequence must be planned to use formwork in the most ‘and to permit the optimum investment in formwork and meet schedule requirements. ‘of local labor and materials should also be considered in developing the plan. should plan the formwork and job sequence at the time of making a bid. Failure to study ‘enough to arrive at the most efficient plan may cause loss of the contract, Even worse, to in reply to bid based on a superficial analysis, and then to find that some aspect of the jimpractical so that actual costs will be much higher than anticipated, can be financially planning will also help to ensure the unqualified safety of personnel engaged in formwork and the integrity of the finished structure. OF METHODS plan must be adapted to the layout of the concrete structure to a practical construction job will have some feature or combination of features that will tend to establish, more or y, the basis of an efficient formwork plan. These features may exist ‘inthe design of the ‘conditions, or in other factors. The most efficient methods can be determined initially is of fabrication and installation schedules and stripping time requirements, but practical be imposed by accessibility and site conditions and the capacity of equipment available to ons and materials. Among the major factors to be considered are. construction details and facilities for form building of forms as affected by stripping time and another requirements merits ofjob-built, shop-built, and ready-made forms ‘of surface on which formwork is supported (concrete, sand, clay, wet, frozen) ‘ing requirements, if multi-storey construction is involved of weather on protection requirements and stripping time, which will nturn affect reuse re-shoring practicesComparison of Alternate Methods Different basic objectives, or alternative plans and methods for achieving the same objective, should be examined in detail so that overall costs can be compared, Initial form construction costs, savings through reuse, and costs of setting and stripping are compared to arrive atthe lowest-cost formwork plan. In addition, for each plan a comparative analysis should be made on the estimated number and types of rigs, hoists, and other equipment required, and the efficiency with which concreting Crews, reinforcing crews, and others will fit into the schedule. In determining total cost for each plan, allowance must be made for preparation and familiarization time atthe beginning of the project and finishing up "loose ends" at its conclusion. Examination of Form Plan in Relation to Total Job ‘After selecting the most efficient plan, the contractor should review his formwork plan along with the specifications to make sure there areno special requirements or conflicts that would make some detail ofhis plan orintended form design impractical. He also should review the plan in elation to the ‘hole project to make sure that other site activities will nt interfere with transport of form sections, cause placing delays, or otherwise upset the schedule so that much ofthe plans efficiency islost on the job. The concrete contractors schedule may have to be adjusted to the schedules of other trades, and this should be taken into account. The critical path method of scheduling canbe advantageously used to coordinate complex projects. ‘Economical Form Construction In evaluating different schemes to get maximum reuse of forms and an efficient construction sequence, the contractor must make an estimate of form construction cost for each plan. He also may ‘choose between building the forms himself and buying or renting them. One plan may require many forms while another uses fewer forms for amore expensivetype. A reasonable cost estimate requires practical construction plan to detertnine whichis more economical 4.2 SELECTION OF MATERIALS Selection of materials for formwork suitable for a given job must consider the economical aspect, without sacrificing the quality and safety of the required work. The methods selected as discussed in Section 4.1, has a major impact on the selection of materials. Forms are usually tom down after single used, and salvageis limited to individual boards or timber. This practice still prevails where labor costs are Jow and industrial technology is not greatly advanced. ‘As discussed in Chapter 1, formwork requires the use of lumber asits major material. Reusable form panels and shoringhave become popular. Tying, fastening, bracing, and support accessories continue to increase in number and variety. New materials have been adapted to form construction, and new ways to use conventional materials have been found. The introduction of plywood for sheathing has been solely responsible for major changes in form planning and building, Steel, aluminum, fiberglass, and plastics both as raw materials and in patented, prefabricated shapes have simplified the forms of concrete structures. 2in more detail the various materials commonly used in formwork. ive, and Economy in the Selection of Materials sts, 7 Oe completed formwork, the materials for its construction must play its part in providing an ed for the fluid concrete carrying its weight, and simultaneously resisting the forces from | ting an, oa ion of materials for formwork, the three general principals of QUALITY, SAFETY ‘must be paramount. Materials quality can ensure safety, and significantly contribute ements of economy. Formwork failure can result in loss oflife, and always cause cata~ | loss. iti eneral guidelines can be given for formface and fiaming materials, and for the associated ra These can be covered under the headings of strength, stiffness, impact resistance, dura- )the ‘accuracy and compatibility. He ~The material strength must be adequate to resist the forces anticipated. Thisisnot only a requirement, but also an essential safety aspect. used ess - The structural movement under load must be small and predictable, These deforma- d deflections can be a significant part of the total deviationsin the formed concrete sur- | ben the formwork designer is planning the formwork system, decisions must be made on deviation that will be acceptable, and to what extent workmanship errors and structural will each contribute to this. To ensure that the total deviations do not exceed the tony the material stiffness and the workmanship accuracy must be consistent, may any et resistance - The forms must be buf to ensure that the damaged form, although unser- | lies does not generate falling debris. It follows, that the way in which the formwork material | {determine this, To comply with this important safety aspect, materials exhibiting ductile are far superior to those that fallin a precipitate and brittle manner. | lity -In the interest of economy and the achievement of a quality concrete product at ‘of the formwork, its materials must be durable, Formwork almost always built and ec) ‘inthe open, Between re-uses, its materials and components are commonly stored out in . ed in. er. Ideally, framing components and form facer materials should be resistant to the ngle ‘ofthe environment. They should have a slow rate of deterioration under the effects of | Bare andrain. Their resistance to deterioration canbe enhanced by proper care and main- Materials durability isnot only important in achieving good quality concrete surface | at es, but in ensuring that formwork structures are always safe. 1eto ~Inthe installation of formwork, most individual members and components are moved ysto mn byhand, This occurs even when the completed formwork installation is so heavy ately ‘can only be moved and positioned by crane. Ideally, for efficiency and economy, framing formwork components and formface materials should be sized such that their weight is ing ability of one carpenter. Ifthe weight exceeds that which can be carried by two noes onnel, crane handling is called for. The next level of formwork weight restrictions is set by the g limitations of the on-site crane. 29Accuracy For economy. it should be possible to install formwork with the minimum of fitings ‘and cutting of materials, Consistency of size of materials, plywood sheets and framing members. isimportant to this aim. Compatibility ~The materials of the formwork must not be incompatible with either the fluid conerete or the hardened concrete. At the formface, the constituents of the form materials must not react with the hydrating cement of the concrete. For example, some timber contain wood sugars that break down the cement. Afier the concrete hardens timber, such as eucalypti.can severely stain the concrete. When water runs over this timber and onto the conerete, dark brown stains usually result, 8. Workability- Workability of material is also an important item in the selection of material. 4.3 FORMWORK DESIGN In most cases, the contractor will plan and design the formwork, except for unusual or complex structures, such as haunch slabs having tremendous thickness. This is desirable since the contractor isi the best position to evaluate men, materials. equipment, and procedures, and arrive at a design that is both structurally sound and adapted to efficient erection and concreting. Design Considerations Design requires investigation before detiding on the most suitable type of application to be con- sidered. Sometimes, most contractors rely on the experiencesand recommendations of reputable form fabrication specialists. ‘The factors that must be taken into consideration in the design of the formwork are not limited tothe following: a, Probable weather condition that may be encountered during the planned schedule of formwork, . Installation schedule sequence, restrictions and method of depositing and consolidating con- crete. Number, size. height, and profile of lifts in each pouring stages (typical for long column and walls) d. Degree of form flexibility, reusability, and methods of form handling: allowable deflections. e. Estimated cost. Design Considerations to Minimize Formwork Costs 1. Structural and architectural designers prepare their plans at the same time to be compatible with ‘an economical system of formwork Keep structural system uncomplicated so that work may be simple and economically erected and removed. Use same size of columns if possible to permit reuse of beam and column forms. Space columns uniformly or retain the same pattem from floorto floor.igh cecolumns if possible, to fit the use of plywood sheets for decking without cutting. nbers. ‘the same width for columns and column-supported girders to eliminate cutting and fitting of forms into column forms. fluid must wood ti,can Drown cify beams of the same size and depth for each floor and choose depths that will permit stan- sizes of lumber for beam sides. SN CRITERIA Pressures Vertical Loads mplex oris in is both Vertical loads on formwork include the following loads: = Dead Load (the weight of reinforced conerete freshly placed and the weight of forms) - LiveLoad (materials storage. workmen and equipment, runway impact for conerete placing) ye con table Table 4-1 is comparison table between ACI and JASS 5 for dead and live loads. Lateral Pressure of Fresh Concrete Factors affecting lateral pressures on forms imited nwork, 1, Weight ofconcrete ng.con- 2. Rateofplacing conerete | 3. Vibration mn and 4. ‘Temperature 5. Other variables | sctions. 4-1: Comparison Table Between ACI and JASS 5 for Dead and Live Loads 244 kglem*? 380 kg/cm? w/motorized carts are used se with, 40 kg/em? -slab erected Not specified 150 kg/cm? live loads 2x dead load impact load Specification)Unless the conditions on beam formulas and allowable stresses are met. formwork should be desiyned forthe lateral pressure of the fresh concrete given to Equation 4-1), Maximum and minimum values given for other pressure formulas do not apply to Equation (4-1). Equation (4-1) Equation (4-1) lateral pressure. kgffem* lateral pressure, KPa height of fresh concrete above point considered P, h, For column or other forms that may be filled rapidly before any stiffening of the concrete takes place. h should be taken as the fall height ofthe form, or the distance between construction joints when more than one placement of concrete is to be made. Forconerete made with Type I cement, containing no pozzolans or admixtures. having a slump of 10 cm or less and normal internal vibration to a depth of 120 cm. or less. formwork may be designed for a lateral pressure as follows: a. For columns BOR 0.073 + T. +178 Equation 4-2 (maximum of 1.47 keffem? or 0.24h,,, whichever is less) T85Ry or Py=72+ 74178 Equation 4-2 (maximum of 144 kPa or 23.5h,, . whichever is less) b. For wall, rate of placement not exceeding 2 m/hr 80Ry P= 0073+ F178 Equation 4-3 (maximum of 0.98 kgffem? or 0.24h,,, whichever is less) 785Ry or Py=72+ T4178 Equation 4-4 (maximum of 95.8 kPa or 23.5h,. Whichever is less)©. For wall, rate of placement 2 to 3 m/hr 1178 _249Ry Fie OO rar gs P74 178 Equation 4-4 (maximum of 0.98 kgf/cm? or 0.24h, , whichever is less) 11586 244Ry ‘ or Py=72+ TF ai7e * 7, 4178 Equation 4-4 ie (maximum of 95.8 kPa or 23.5h,,. whichever is less) nts, where: lateral pressure. kgffem® lateral pressure, KPa rate of placement, m/hr temperature of concrete in the forms, degree C height of fresh concrete above point considered mp. wu DESIGN CALCULATIONS Principles ‘Structural calculations to be based on: Vertical Loads * Horizontal Loads ” * Lateral Pressure of Fresh Concrete Vertical Load shall include weight of concrete, reinforcing bars. formwork. workmen, con- struction machinery, and other materials - external forces in the vertical direction which varies according to actual conditions. Horizontal Loads - external forces in the horizontal direction such as wind pressure, eccen- tric loads due to concrete placing. forces due to starting, running and stopping machineries. Lateral pressure of concrete varies according to speed and height of pour, ‘is pumped from the base of form, the form should be designed for full hydrostatic head of -a minimum allowance of 25 percent for pump surge pressure. In certain instances, pressures as the face pressure of the pump position. Formulas ‘two consideration- the approximate nature of many of the design assumptions. plus simpli of many of the design assumptions, and simplified modular approach desirable for actual con- ~justify a simplified approach to form design. Table 4-2 contains several formulae to arrive imum bending moment and maximum deflection.1. _Allloads are assumed to be uniformly distributed . The loads on sheathing. joists, and studs are in fact always distributed, though not always uniformly. Loads on wales and ledgers are applied at points where the studs or joists bear on them, but itis convenient and ‘generally sufficiently accurate to usean equivalent uniform load for design, so that the spac ing and the number of point loads can be neglected. 2. Beam supported over three or more spans are regarded as continuous and approximate formulas are used 3. For continuous beams over two spans, design values for simple spans may beused safely when the deflection or bending momient governs the span, 4, Strength of nailed connections is neglected in determining size of main form members. Table 4-2: Formulas for Maximum Bending Moment and Maximum Defle ‘Simple Beam Continous Beam rar Mex Bending [Max Detston | Max Bending | May Detection loment Moment. (M) Brno) (M) Brn) M= 301 pr M= 2 fle pe Begs eae po 1 0 WET 16 Ane = 3e45T M= Pl apr M= 20 we 3 Sow = GREE 2 Soe 3240 pee Case-3 p p mon wy Jays Jt M= {ha ee lor M= LPL 237" Aw = peeled me 34 ET 32 Sw = FERED Sul! 2 Aw = 384 10 Nowe DP Concentrated load, 1 Vasupported span of beam. 1° Modubus of elastiiry. 1 Moment of meriia ww Cniormbvdistribuied tocastuds Stresses gers stresses for some of the common formwork materials are given in Table 4-3. Se ‘Table 4-3: Working Stresses for Common Formwork Materials (Kg/em") made Bending | Modulusof ‘CompressiontoGain | shear Stress es pee Parallel | Perpendicular | Parallel to Gain safely 7 7.91 x 108 86.7 23.0 9.70 943 | 6.83. 10" 70.4 194 820 51.0 | 3.06x 10" 352 4 4.40 745 5.97 x 10° 57. 18.4 6.80 S10 3.52 x 10° 352 M4 4.40 32 2.35 x 10" 2S 8.20 3.10 3.1 1.05 x 10° 148 3 4.00 1600 2.1 x 10" jum safety factors for accessories are also recommended by ACI as shown in Table 4-4. Table 4-4 : Minimum Safety Factors for Formwork Accessories Type of Construction Safety Factor 20 Formwork supporting form weight and conerete pressure only 20 Formwork supporting form weight and conerete construction live loads and impact Allapplications Design for bending is based on the allowable or working stressin flexure for the material being Allowable lexural stresses for various kinds of umber. plywood. and other materials are given, =sisting moment of the member being designed is: M, fs M, = resisting moment in kef-em, f allowable stress in extreme fiber in bending kgfiem- = section modulus of the member. em 1 span E Modulus of elasticity 1 Moment of inertia