CHAPTER 6 - FALSEWORK, FORMWORK AND CONCRETE FINISH

DS Temple

6.1 SCOPE

This section covers the inspection and monitoring of Falsework, Formwork and Concrete Finish as per
the applicable chapter of the Specifications. It also includes special attention which must be given to
materials used, design and erection of falsework and formwork to be checked by the engineer’s
monitoring staff.

6.2 MATERIALS

The engineer’s monitoring staff should confirm the suitability of proposed materials:

6.2.1 Falsework

• Steel Grade to be provided in accordance to Design Requirements.

• Timber Grade to be provided in accordance to Design Requirements.

Condition of all materials to be used should be checked by the engineer’s monitoring staff to ensure
that the materials are fit for purpose.

6.2.2 Formwork

The most commonly used materials for the manufacture of formwork are steel and timber. The
monitoring staff should ensure that the surfaces of forms are clean and free of defects to ensure that
the required surface finishes can be obtained. In order to obtain a good quality finish in accordance
with the specifications, high quality materials must be used and attention to details and workmanship
cannot be over-emphasized.

6.3 DESIGN

The monitoring staff should ensure that the contractor submits (within the period specified in the
Project Specification) designs, drawings and calculations where required, for all falsework and
formwork for review by the engineer. The design of all temporary works should be undertaken by the
contractor, and the engineer through his representatives on site should only scrutinize the plans and
pass comment on issues that may be non-compliant in terms of the specifications. No approval should
be given for any temporary works as this could attract liability to both the employer and the engineer.
Copies of all falsework and formwork designs should be placed on the safety file on site prior to the
work being carried out.

The following matters should receive attention:

Falsework, Formwork and Concrete Finish 6-1

6.3.1 Falsework

6.3.1.1 Foundations

• Allowable bearing capacity of founding material for falsework supports to be confirmed by the
contractor (Dynamic Cone Penetrometer or other suitable means).
• Allowance should be made for the wetting of the foundation material when determining the
allowable bearing capacity of the founding material.
• Actual design bearing pressure for falsework supports to be provided by the contractor.
• Ensure all falsework for the erection of decks and slabs is provided with jacks for adjustment
for line and level.
• For river bridges the stability of foundations under minor flood events should be considered.
• Falsework should always rest on sound founding material which is properly compacted and
leveled to ensure no standing water will occur during rain.
• The adequacy of safety of the falsework should be signed off by the CCP.

6.3.1.2 Load Capacity

The load capacity and technical specifications of all elements making up the falsework including
jacks, clamps and fittings should be provided with temporary works design. Ensure jack extension
limits specified by the manufacturer of the particular type of jack in use are not exceeded.

6.3.1.3 Settlements

The contractor should provide with his calculations the expected settlements of the falsework due to
elastic deformation of the founding material and falsework.

6.3.1.4 Deflections

Levels for the construction of falsework for the construction of slabs and decks should allow for
precambering for expected long term/creep deflections due to dead loads, prestressing and
superimposed dead loads. This provision should be in accordance with the design drawings and is
especially important for very skew reinforced concrete decks. The monitoring staff should liaise with
the design office to confirm requirements, and in instances where no precamber is specified, should
ensure that this is confirmed by the designer.

• Reinforced Concrete
The total deflection can normally be assumed to be 3 times the elastic deflection under Dead
and Superimposed Dead Loads.

• Prestressed Concrete
The monitoring staff should note that the precambering for prestressed concrete decks could be
negative (in downward direction). The long-term deflection in prestressed concrete decks will
generally continue in the direction of the initial deflection.

6.3.1.5 Overall Stability and Bracing

The monitoring staff should ensure that the contractor’s design deals adequately with the overall
stability and bracing of the proposed falsework taking into account wind loading and other horizontal
actions as required.

Falsework, Formwork and Concrete Finish 6-2

 Photo 6.1: Well designed falsework and bracing

6.3.1.6 Temporary Works Vertical and Horizontal Clearance

The minimum vertical and horizontal clearances as prescribed by the roads authority and employer
should be adhered to by the contractor in his preparation of the temporary works design to be carried
out by the contractor. Generally the clearances as specified in the SANRAL Code of Procedure for the
Planning and Design of Highway and Road Structures in South Africa should be used. However,
where these clearances cannot be achieved the monitoring staff should refer to the engineer for final
verification. Temporary guardrails, concrete barriers and other protection should be used to protect
the temporary support work.

6.3.2 Formwork

6.3.2.1 Load Capacity

The proposed formwork should be capable of sustaining the loads due to wet concrete and
superimposed loads due to construction activities and equipment without excessive deflection.

6.3.2.2 Deflection

The engineer’s monitoring staff should ensure that the expected deflection of the forms as provided in
the formwork design falls within the specified tolerances for surface regularity.

6.3.2.3 Grout Seals

Grout seals should be incorporated into the joints between individual formwork panels in all instances
where the panels do not fit together with sufficient tightness to prevent leakage of fines.

Falsework, Formwork and Concrete Finish 6-3

6.3.2.4 Permanent Formwork

• On beam and slab decks using permanent formwork special attention should be given to bearing
length.
• All permanent formwork should be designed to carry the loads resulting from the wet concrete
and superimposed loads due to construction activities and equipment. The deflection under
permanent loading should not exceed 50% of the construction tolerance.
• The strength and bracing of circular void formers should be sufficient to prevent distortion and
resist all the loads they will be subjected to, and must comply with the requirements of the
drawings and Specifications. The adequacy of the formers and bracing should be signed off by
the CCP.
• Void formers must be tied down to the formwork bearers and should not be tied to or be
supported on the reinforcement.
• In voided deck slabs the concrete should be cast in layers to reduce the effects of buoyancy and
to reduce the movement of void formers.

Photo 6.2: Precast concrete permanent formwork in

position before casting.

Falsework, Formwork and Concrete Finish 6-4

 Figure 6.3: Bracing and installation of void formers

6.3.2.5 Stripping
WARNING
Inadequately braced void
Minimum stripping times for falsework and formwork must be in
formers may collapse resulting
accordance with the Specifications. Any deviation in stripping
in deck cross sections which do
times should be approved by the engineer. not conform to the design. This
is likely to require demolition
6.4 INSPECTION and reconstruction of the deck.
The engineer’s monitoring staff should inspect the falsework and formwork at the completion of
erection and prior to the placing of concrete, and should insure that the CCP has signed off before
concreting. The concrete finish should be inspected on final completion of each structural element
(Refer to Chapter 8).

6.4.1 Falsework

(a) Confirm compliance with the design.

(b) Setting out - This is a very important aspect as it is fundamental to successful construction of
the structure.
(c) Safe access - Should be inspected regularly as a part of the ongoing Site Safety.
(d) Foundations - Foundation conditions should be inspected before erection of falsework. All
falsework should be inspected as soon as possible after inclement weather or flood event.
(e) Support elements - Should be inspected on completion of erection. Special attention should
be given to connections, details and areas of transfer of stress and the provision of adequate
bracing in accordance with the design. These should include the clamping of bracing and the
safe reach of screw jacks.
(f) Line and level - Alignment and levels should be in accordance with the contractor’s design.
(g) Falsework should be maintained in position for the times as prescribed in the specifications.
Back propping after early removal of falsework should not be permitted.

Falsework, Formwork and Concrete Finish 6-5

 (h) When the concrete is placed in the forms special care must be taken to ensure that no
overloading of the formwork or falsework takes place due to the dumping of large piles of
concrete in one particular position.

6.4.2 Formwork

(a) Confirm compliance with design requirements as specified on the drawings and
specifications.
(b) Setting out, line and level to be confirmed.
(c) Condition of forms - Ensure forms are fit for purpose, sealed around edges where required
and shutter release agent applied prior to fixing of reinforcement.
(d) Workmanship of shuttered areas (especially with reference to gaps where grout leakage may
occur).
(e) Where high quality surface finishes are required i.e. F2 and F3, the use of grout seals is
recommended.
(f) Permanent formwork - Confirm adequate support especially with regard to the holding down
and bracing of circular voids.
(g) Removal of formwork - Ensure methods for removal of formwork are such that no damage
occurs to the freshly cast concrete.
(h) Chamfers on exposed surfaces should be formed using new materials and be adequately
secured in position during concreting.
(i) Kickers should be formed and cast monolithically with foundation concrete. Height to be
between 75 and 100mm. The kickers should be of the class of concrete of the element
above.
(j) At horizontal construction joints ensure the existing concrete surface is free from all grit and
loose material prior to casting.

Photo 6.4: Unacceptable formwork & ferule pop out

Falsework, Formwork and Concrete Finish 6-6

6.4.3 Concrete Finish

The inspection of concrete finish should be undertaken on removal of forms to ensure compliance with
specifications.

Where areas of substandard surface finish have been identified,

NOTE
remedial measures must be carried out in accordance with the
Bad formwork = bad finish
Project Specifications and as directed by the engineer. Method
Good formwork & good
statements for the expected repair of surface defects, e.g.
concrete practice result in
honeycombing, etc. should be in place before any concreting
good finish
commences to ensure that remedial measures can be implemented
timeously.

Photo 6.5: Very poor ferule patching

Unformed surfaces should be checked in terms of conformance to the surface finish as specified on the
drawings and in the specifications.

Photo 6.6: Very poor workmanship

Falsework, Formwork and Concrete Finish 6-7

6.4.4 Conformance with Project Specifications

The monitoring staff should also ensure that all Project Specifications regarding formwork are
complied with.

6.5 FALSEWORK, FORMWORK AND CONCRETE FINISH - CONSTRUCTION

MONITORING CHECK LIST

The monitoring staff should use the “Falsework, Formwork and Concrete Finish - Construction
Monitoring Check List” as far as possible to ensure the quality of the formed concrete surfaces.

Falsework, Formwork and Concrete Finish 6-8

 INDEX TO APPENDICES

6A - FALSEWORK, FORMWORK AND CONCRETE FINISH

CONSTRUCTION MONITORING CHECK LIST

Falsework, Formwork and Concrete Finish 6-9

 APPENDIX 6A
FALSEWORK, FORMWORK AND
CONCRETE FINISH CHECK LIST (1/2)
CONSTRUCTION MONITORING CHECKLIST
PROJECT NO. / NAME: .......................................................................................................................................
INSPECTOR’S NAME(S): ....................................................................................................................................
STRUCTURE: ........................................................... ELEMENT: ..............................................................

APPROVAL
ACTIVITY AND DETAILS SIGNED DATE
Y/N N/A Comment
1. APPROVED DESIGN AND
DRAWINGS AVAILABLE
1.1 Design drawings
1.2 Method statement
1.3 Falsework design required
1.4 Falsework drawings
2. SETTING OUT
2.1 Platform co-ordinates
2.2 Platform / Bench dimensions
2.3 Platform / Bench levels
2.4 Layout of bases and supports
3. EARTHWORKS
3.1 DCP Tests
3.2 Compaction tests
3.3 Allowable bearing capacity
3.4 In-situ support conditions wet/dry
3.5 Adequacy of bearers
3.6 Drainage of platform
4. FALSEWORK
4.1 Base jacks provided
4.2 Base jack extensions
4.3 Type of supports per drawing
4.4 Alignment of supports
4.5 Number of supports
4.6 Bracing provided
4.7 Connections in order
4.8 Top jacks provided
4.9 Top jack extensions
4.10 Main bearers / Girders
4.11 Line level and position
4.12 Safe access for traffic
4.13 Clearances for access (traffic)
4.14 Protection for safe access (barriers)
Check list continues on next page…

Falsework, Formwork and Concrete Finish 6-10

 APPENDIX 6A
FALSEWORK, FORMWORK AND
CONCRETE FINISH CHECK LIST (2/2)

APPROVAL
ACTIVITY AND DETAILS SIGNED DATE
Y/N N/A Comment
5. FORMWORK
5.1 Setting out of element
5.2 Dimensions of element
5.3 Type of formwork
5.4 Condition of forms
5.5 Cleanliness of box
5.6 Chamfers
5.7 Bracing of forms
5.8 Sealing of forms
5.9 Joint water tightness
5.10 Ferrules, ties and cones
5.11 Whalers
5.12 Contraction joints and chamfers
5.13 Access to placement point
6. PERMANENT FORMWORK
6.1 Type of formwork
6.2 Support and tiedowns
6.3 Bracing in circular void formers
6.4 Connections
6.5 Drainage of voids
7. CONCRETE FINISH
7.1 Honeycombing
7.2 F1 Finish achieved
7.3 Patching / Repairs required
7.4 F2 Finish achieved (Fin removed,
etc.)
7.5 Patching / Repairs required
7.6 F3 Finish achieved (rubbed)
7.7 Patching / Repairs required

Falsework, Formwork and Concrete Finish 6-11