Formworks
Formwork, a temporary structure often overshadowed by the grandeur of
finished concrete structures, plays a pivotal role in the construction
industry. It acts as a mold for fresh concrete, dictating its shape and
supporting its weight as it solidifies. This essential component ensures the
strength, durability, and aesthetic appeal of countless buildings, bridges,
and infrastructure projects.
by Arun C
The Purpose of Formwork
1 Shape and Support 2 Quality Control
Formwork serves as a template, defining The formwork's quality directly impacts
the exact form and dimensions of the the concrete's finish. Smooth, well-
concrete element. It holds the concrete in constructed formwork yields a cleaner,
place, preventing it from spreading or more aesthetically pleasing surface,
collapsing before it reaches its desired reducing the need for extensive post-
strength. construction finishing.
3 Strength and Durability 4 Design Flexibility
Properly designed and constructed Formwork allows for a wide range of
formwork ensures the concrete's structural concrete shapes and designs. This
integrity. It supports the weight of the wet flexibility empowers architects and
concrete and resists the pressure during the engineers to create complex structures,
curing process, leading to strong, durable from intricate curves to intricate details,
structures. on-site.
Types of Formwork
Traditional Wood Steel Formwork Specialized Formwork
Formwork
Stronger and more durable than This category encompasses a
Traditionally made from wood wood, steel formwork is reusable variety of formwork systems
planks, plywood, and lumber, this for multiple projects. It's ideal for designed for specific
type is cost-effective and versatile complex structures or projects applications. It includes
but requires skilled labor for with repetitive elements, ensuring prefabricated systems, fiberglass
construction. It's often used for consistent quality. formwork, and specialized molds
walls, beams, and columns. for intricate shapes and
architectural details.
Formwork Removal: A Critical Stage
1 Curing Time
The concrete must reach sufficient strength before the formwork can be
removed. This curing time varies depending on factors such as concrete mix,
temperature, and humidity.
2 Removal Process
Formwork removal is a carefully orchestrated process that involves
systematically detaching and dismantling the formwork without damaging the
cured concrete. Specialized equipment might be needed for larger projects.
3 Inspection and Finishing
After removal, the concrete surface is inspected for any imperfections. Minor
finishing work, like smoothing or patching, might be needed before the
structure is ready for further construction.
Understanding Formwork Costs
Cost Factor Impact on Cost
Wood is generally the most cost-effective, while steel
Material Selection
and specialized formwork systems are more
expensive.
Intricate shapes and designs require more complex
Project Complexity formwork, increasing labor and material costs.
Formwork installation and removal require skilled
Labor Rates labor, with costs varying based on location,
experience, and project size.
Reusable formwork systems can save costs in the long
Reusability
run, particularly for projects with repetitive elements.
Optimizing Formwork Costs
Planning and Design
Careful planning and detailed formwork design can minimize material waste
and labor requirements, reducing overall costs.
Material Selection
Choose the right formwork materials based on project requirements and
budget. Consider the reusability and cost-effectiveness of different options.
Modular Formwork Systems
Modular systems offer efficient assembly and disassembly, potentially
reducing labor costs and time spent on construction.
Construction Efficiency
Optimizing the construction process, such as scheduling formwork removal
and re-use, can lead to cost savings and faster project completion.
Formwork and Sustainability
Material Recycling Sustainable Energy Efficiency Waste Reduction
Wood formwork can Materials Optimized formwork Efficient formwork
be recycled or reused, Exploring eco- design and planning and use can
reducing waste and friendly formwork construction minimize waste
promoting sustainable options, such as techniques can generation, reducing
practices. bamboo or recycled minimize energy environmental impact
plastic, can contribute consumption during and promoting
to a greener the formwork process. responsible resource
construction industry. management.
The Future of Formwork
Advanced Materials Digital Fabrication
New materials, like composites and high- 3D printing and digital fabrication
performance plastics, are being explored for technologies are emerging as potential
their strength, durability, and reusability. solutions for creating complex, customized
formwork systems.
Sustainable Designs Smart Technologies
Formwork innovation is focused on reducing Sensors and monitoring systems are being
environmental impact, exploring sustainable integrated into formwork to monitor concrete
materials and efficient production methods. curing, optimize construction processes, and
improve safety.
Material-Based Formwork: A Closer Look
Timber Formwork Steel Formwork Plywood Formwork
This traditional formwork is Known for its strength and Often used alongside timber,
made from wood, offering durability, steel formwork is plywood provides a smooth
affordability and ease of ideal for large, complex concrete surface and can be
customization for small projects and offers multiple reused a few times. However,
projects. However, timber has reuses. However, it's more it's not as strong as steel and
a limited lifespan, requires expensive than timber and can warp with moisture
sealing for moisture requires specialized exposure.
resistance, and can warp, equipment for handling heavy
affecting the concrete finish. panels.
Material-Based Formwork: Continued
Plastic Formwork Aluminum Formwork
Lightweight and easy to handle, plastic Similar to steel in terms of reusability and
formwork is suitable for smaller projects with durability, aluminum formwork is lighter and
repetitive elements. It's cost-effective for limited easier to handle. It's a good option for projects
reuses and offers a good concrete finish. requiring frequent formwork movement. The
However, it may not be strong enough for heavy cost is higher than plastic but lower than steel.
loads and has limited size availability.
Special Formwork Systems: Expanding
the Possibilities
1 Fabric Formwork 2 Tunnel Formwork
Uses a special fabric coated with a Specifically designed for
hardening compound. This type is constructing concrete tunnels. These
lightweight and can conform to prefabricated systems are efficient
curved shapes. However, it's not for long, straight tunnels but less
suitable for high load-bearing adaptable for other shapes.
applications.
3 Climbing Formwork
Used for high-rise buildings, this formwork system is hydraulically lifted and reused
for each floor, reducing crane dependency. It's efficient for tall structures but has a
higher initial cost.
Advanced Formwork Systems: Continued
Table Formwork (Flying Formwork) Permanent Insulated Formwork (PIF)
This system uses a platform suspended from This two-in-one system combines formwork
a crane or other support structure. The with building insulation. PIF typically uses
platform holds the formwork for slabs or prefabricated foam panels that stay in place
beams, allowing workers easy access and the after the concrete cures, providing permanent
ability to reposition the formwork insulation, reducing thermal bridging, and
horizontally for repetitive pours. simplifying construction.
Advanced Formwork Systems: Efficiency and
Innovation
Self-Climbing Formwork (SCF)
A game-changer for high-rise structures, SCF is a hydraulically lifted system that
integrates wall and floor formwork. As each floor cures, the system is jacked upwards,
eliminating crane dependency and accelerating construction.
Jump Formwork
Similar to SCF, jump formwork uses jacks and brackets to raise the formwork in
predetermined increments after the concrete cures. This method is also suitable for
repetitive floor construction and offers faster construction compared to traditional
methods.
Slipform Construction
A continuous concrete forming process ideal for long, vertical structures like cores,
walls, and some foundations. The formwork is steadily raised hydraulically as the
concrete is poured continuously from above, eliminating joints and creating a smooth,
uniform concrete surface.
Thank You
achandramohan@nicmar.ac.in
+91 8688972772
