CHAPTER 42 FORMWORK

42 FORMWORK To be done safely, each of these jobs requires

planning, knowledge, and skill from both
supervisors and workers. Design and planning
Definitions are a supervisory function that may also legally
The following definitions are used in the forming require a professional engineers involvement.
industry. Some terms may be used by other trades Small construction and renovation jobs, however,
as well, but their meanings may be different from sometimes call for typical design work (e.g.,
these depending upon the application. specific heights and sizes from the manufacturer),
which can be done on site by workers.
Falsework, in relation to a form or structure, means
the structural supports and bracing used to support Where design drawings are provided, it is
all or part of the form or structure until the concrete important to construct the formwork as designed.
is poured and is strong enough to support loads. Any confusion regarding the design should be
approved by the designer.
Flying formwork is a designed floor formwork
system that can be hoisted between levels as a unit. If site conditions require changes or the design
does not seem to suit the situation, changes
Forms are the moulds into which concrete or and approval should also be obtained from the
another material is poured. designer. Formwork failures frequently involve
Formwork is a system of forms connected deviations from the original design that were done
together. without consulting the designer. They may also
involve human error. For these reasons, formwork
Gangforms are large panels designed to be hoisted and shoring must always be inspected before
as a unit, and to be erected, stripped, and re-used. concrete is placed.
Knock-down forms are traditional formwork All large formwork installations in Ontario must be
supported by falsework and shoring, assembled designed by a professional engineer. But there are
from bulk materials, used once, and then always smaller jobs of moderate height or depth
dismantled. basements, footings, stairsthat may include
Panels are sections of form intended to be formwork with typical design arrangements from
connected together. a form tie manufacturer, which is installed and
constructed on the site.
Sheathing is the material directly supported by
wales, and against which concrete is to be placed. Every carpenter should therefore know the type
of formwork needed and how to build, install, and
Specialty formwork is designed specifically for a
dismantle it safely.
particular structure or placing technique.
Formwork must always be constructed according
Struts are vertical members of shoring that directly
to good, safe, and sound carpentry practice. It must
resist pressure from wales.
have the following:
Wales are horizontal members of shoring that are
Adequate braces and supports
placed against sheathing to directly resist pressure
Reliable bearing surfaces, especially where wood
from the sheathing.
structures are involved
Adequate ties, bolts, or bracing to prevent
Introduction movement or bulging.
In most cases, the formwork required for concrete Because wood is relatively soft, it will crush under
construction is built by carpenters. Shoring and heavy loads such as concrete when the bearing
bracing support the forms that contain the wet surface of joists on stringers, or studs on wales, is
concrete. Formwork must also support the temporary not adequate.
weight of material such as bundles of reinforcing Crushing can be avoided by increasing the bearing
steel and live loads of workers and equipment. area between members, using spreader washers
There are three stages in formwork operations: (Figure 42-1), or increasing the number of joists
or studs.
1. Assembly and erection
2. Concrete placement
3. Stripping and dismantling.

Figure 42-1: Spreader Washer on

Wooden Wale System

Tools and Techniques 42-1

FORMWORK

Hazards Dust and concrete Blowing dust and flying

concrete particles during the chipping or cleaning
The following are the main hazard areas in of formwork can injure unprotected eyes.
formwork operations. Access equipment Access equipment such as
Falls They are the major hazard because they are ladders and scaffolds is involved not only in falls
potentially fatal. Cramped work areas, inadequate but in slips, trips, and other accidents. Hazards
access, failure to install guardrails, failure to use fall include ladders not tied off, workers carrying
arrest systems, tools or material left underfoot, and materials while climbing, ladders obstructed at
surfaces slippery from form oil can all lead to falls. top or bottom, scaffolds not completely decked
Ladders are also frequently involved in falls. All in, and scaffolds erected or dismantled without
workers in Ontario who may be exposed to a fall fall protection.
hazard and who may use a fall protection system Lighting Inadequate lighting can create or
must have working at heights training that has been aggravate hazards when workers install or strip
approved by the Chief Prevention Officer. (See forms in dark areas or place concrete at night.
Chapter 18: Guardrails and Chapter 19: Personal
Fall Protection) Injuries
Materials handling The activity most frequently
connected with injury. Improper or excessive Formwork hazards can lead to the injuries
materials handling can result in sprains, strains, described below. Follow the safety tips to prevent
and overexertion in shoulders, arms, and back, as such injuries.
well as bruises, abrasions, and crushed fingers. Eye injuries These are quite common in
Struck against Common because formwork formwork operations. Most result from particles
operations are constantly changing and involve of wood or concrete that fall or are blown into
the movement of heavy, awkward, and pointed the eye during chipping and cleaning. The injuries
components. Wales, beams, panels, snap-ties, may not be severe but most can be prevented
nails, bolts, and rebar can cause punctures, cuts, by wearing eye protection. It is strongly
contusions, and abrasions. recommended that everyone on site wear eye
Struck by Another common cause of injury. protection at all times.
Rebar, formwork panels, concrete buckets, Cuts, scrapes, punctures The manhandling
and other material hoisted overhead can strike necessary to install and strip formwork can lead
workers. Struck-by injuries can also be caused by to cut hands, arms, and legs, as well as pinched
hammers, pry bars, stakes, wedges, and material or crushed fingers. Gloves help to prevent
such as joists and panels during stripping. injuries from rough or sharp edges on formwork
Electrical contact Power tools, extension cords, components. But workers must also have the
and temporary supply and wiring systems, used knowledge, skill, and physical ability necessary
under less-than-ideal conditions mud, ground for safe materials handling. That means knowing
water, wet excavations, fresh concrete can lead your limitations and asking for help when needed.
to ground faults, shortcircuits, and shock hazards. Formwork involves protruding objects such as
Ground fault circuit interrupters are legally nails, snap ties, conduit, and bolts that can give
required for portable tools used outdoors or in you cuts and punctures. Where possible, these
wet locations. objects should not be left sticking out or should
Collapses Even with advanced methods of be covered over.
design and installation, there is always the risk Back injuries These injuries are frequently
that formwork, slabforms, wall forms, and other related to materials handling. The most important
large components can come loose, slip out of preventive measure is back care. Exercise
place, or fall over, striking or crushing workers programs, warm-ups before work, and knowing
underneath. your limitations can help to prevent sprains and
Health hazards The spraying of form oils and strains. Wherever necessary, get help or use
curing compounds can irritate the lungs. Contact dollies, carts, or other mechanical devices.
with these chemicals can irritate the skin, leading Ankle sprains and fractures Working in
to redness, inflammation, or dermatitis. The close quarters, stepping over debris and
same conditions can result from the abrasive/ material, climbing into excavations, turning with
corrosive effect of skin contact with concrete or awkward loads, jumping down from scaffolds
cement, especially when inadvertently left inside or benchesthese can lead to ankle and other
boots all day. foot or leg injuries. Prevention starts with proper
Environmental conditions Ice, snow, and rain housekeeping and materials handling.
create slippery conditions. Wind can be a major Bruises and contusions Handling formwork
hazard. Handling sheets of plywood becomes under rushed, cramped, or slippery conditions
more difficult, panels may require more bracing, or beyond a person's physical limitations can
and hoisting gets harder, especially with large lead to bruises. Bruises and contusions also
panels or tables. result from contact with protruding formwork
components. More serious are contusions from

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 FORMWORK

falling formwork materials. Formwork must be For example, the normal weight of liquid concrete
braced to ensure stability, especially under windy is 150 lb per cubic foot (2,403 kg per cubic metre).
conditions. Try to avoid areas where work such as So a form designed to withstand 600 lb per square
hoisting or stripping is being done overhead. feet (2929 kg per square metre) of pressure will be
Fall injuries All of the injuries above, and many able to support liquid concrete up to a height of 4
others, can result from falls. Most falls are caused feet (1.2 metres).
by missing or inadequate guardrails, failure to use
600 lb/ft2 150 lb/ft3 = 4 ft
fall-arrest equipment, failure to completely plank
scaffolds and other work platforms, and standing 2929 kg/m2 2403 kg/m3 = 1.2 m
or climbing on surfaces not meant to be used as Other factors determine how long concrete
such the tops of wall forms or 2 x 4 wales, for will remain liquid, such as temperature, slump,
example. Installing and stripping formwork often vibration, and admixtures. For example, concrete
requires the use of a fall-arrest system. will set much more quickly in hot summer weather
Falls also result from holes left unguarded or than in cold winter weather. As a result, the same
uncovered in formwork. These should be covered form filled at the same pour rate may be subjected
up or fitted with guardrails as quickly as possible. to greater pressure in winter than in summer.
Where this cannot be done, the area should
be roped off and posted with warning signs to Concrete pumping may cause additional pressure,
prevent unauthorized entry. as well as vibration, on forms and must be
considered at the design stage. The action of the
pump sends surges of pressure through the piping
Planning system which are often transmitted directly to
Planning is the first and most important step in the forms, especially for narrow walls or columns.
reducing hazards and preventing injuries. Vibration may move the forms or loosen bracing,
ties, or spreaders.
Because formwork operations must often be
carried out in congested areas where other trades Pressure acts perpendicular to formwork surfaces
are also working, planning is essential in making the (Figure 42-2). This causes an outward thrust for
most of the time and space available to improve typical wall or column forms. However, it can also
safety and efficiency. cause uplift for battered or sloping forms. These
require hold-down anchors or tie-down braces. The
Planning is a must for fall protection, work anchors will prevent the forms from lifting up or
platforms, material staging areas, housekeeping, floating on the concrete.
and material handling and movement.
Planning should take place at every level from
manager to supervisor to worker. Planning labour, Expansion Anchors Holding
materials, equipment, and work schedules to Down Battered Form
meet design requirements is the responsibility of
management and supervision. But supervisors and
workers should come together to plan the details
of their assigned tasks based on the most effective
work methods and safety measures.

Design
Safety and economy are the main factors in design. Figure 42-2: Pressure of Concrete on
Both have to be considered because adjustments in Vertical (left) and Battered Formwork
one affect the other.
For example, reducing the support structure for Consider using bracing systems and spreaders for
wall forms in expectation of reduced pouring rates wall forms. Concrete filling the bottom of the form
should not be considered if the rate of pour is not may cause forces at the top to push the two sides
going to be controlled on the job. together unless they are properly braced and/
or separated with spreaders. Formwork has to be
Fresh concrete exerts a pressure on formwork designed to resist such forces. During pouring,
similar to liquids. Concrete starts to set when ensure that spreaders are not removed until concrete
poured. So if the pour rate is slow, the maximum has reached at least two-thirds of the form height.
formwork design pressure can be reduced, since
concrete at the bottom will be set before concrete Where box forms are usedfor instance, on one-
at the top is poured. Similarly, if the forms are piece covers for open-cut tunnelsyou must use
filled to the top immediately, they must be able to bracing against the side thrusts caused by the
withstand the pressure of the full liquid head. uneven pouring rates of the walls. Resisting these
forces requires that the system be tied together
and securely braced (Figure 42-3).

Tools and Techniques 42-3

FORMWORK

Figure 42-3: Open-Cut Tunnel Formwork with

Bracing and Spreaders on Each Side

Formwork should be designed and constructed

with stripping and removing as well as pouring in
mind. On wooden forms, crush plates or filler strips Figure 42-5: Formwork Panel
should be used at corners such as slab-and-column
or slab-and-wall intersections (Figure 42-4). The A formwork panel or wall form to be lifted as a
plates or strips are easily removed with a wrecking single unit must be designed to withstand the
bar and, once removed, make the stripping of loads and forces exerted by hoisting (Figure
adjacent panels much easier. 42-6). In most cases, this means designing a more
substantial structure. Fastening components may
also need more attention at the design stage. For
example, simple nailing may not be enough to hold
plywood sheets.
Crush Plates

Figure 42-4: Crush Plates

The strips should be big enough to leave space at

the edges of the panels to accommodate wrecking
bars.
When formwork has to be manhandled during
assembly or dismantling, the design should ensure
that the components are manageable. Formwork
panels are not only heavy but awkward (Figure
42-5). Realistic design demands consideration of Figure 42-6: Formwork Lifted as Single Unit
the size as well as the weight of panels.
Special attention must also be applied to the design,
construction, and use of pick points for hoisting. The
strongbacks and wales must be securely attached
to the formwork. The pick points must be located
so that the panel hangs properly during installation,
concrete placement, and removal.

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Types of Formwork

Below Grade
The first concern with formwork below grade is
the stability of the excavation walls. Walls must be
either shored or sloped according to soil type as
defined by section 226 of the Construction Projects
regulation (O.Reg. 213/91). Figure 42-7 shows
typical slopes.
Fairly
Good Soil
Good Soil

Max
1.2m
(4 ft.)
Type 1 & 2 Soil
Type 3 Soil

Poor Soil
Figure 42-8: Formwork Roped-Off
from Other Operations
Type 4 Soil

Figure 42-7: Excavation Slopes for Soil Types Mud sills must be used to support any shoring or
bracing that rests on soil in the excavation (Figure
In most cases the shoring must be designed by an 42-9). The sill must bear on the soil throughout its
engineer. Engineers may also specify slopes for length. Sills should not be used to bridge holes or
excavations. In both instances the design drawings irregular surfaces. To ensure uniform bearing, soil
must be kept on the project. should be levelled before sills are set in position.

Excavations should be kept essentially dry. Water

should be pumped out. Mud should be cleared off
and replaced by compacted granular material in
work areas and on surfaces where concrete will be
placed. Mud presents slipping hazards and can lead
to inferior construction if not removed or replaced.
Since mud has to be removed before concrete
is placed, it might as well be removed before
formwork is constructed, thereby reducing slipping
hazards at both stages.
Water and mud also contribute to electrical
hazards. Grounding and insulation must be
effective and intact. Ground fault circuit
interrupters (GFCIs) are required by law on all
portable tools used outdoors or in wet locations.
Formwork for footings and grade walls frequently Figure 42-9: Mud Sills Under Shoring Frames
begins before excavation in the area is complete.
Trucks and excavating equipment put workers on The soil must have the capacity to bear whatever
foot at the risk of being struck down or run over. loads are applied (Table 42-1). This information
may or may not be on the design drawings.
Wherever possible, formwork operations should
be roped off from other work such as excavation Table 42-1: In Situ Bearing
or pile-driving (Figure 42-8). Separate access Pressure for Dry Soil Conditions
ramps for vehicles and workers are strongly (Conservative Estimates)
recommended. Stairs are an even better alternative
for personnel on foot. Silt and clay 1,200 lb/ft2 (5,859 kg/m2)
Sands 4,000 lb/ft2 (19,530 kg/m2)
Gravelly sands 6,000 lb/ft2 (29,295 kg/m2)
Gravel 8,000 lb/ft2 (39,059 kg/m2)

Tools and Techniques 42-5

FORMWORK

Soil that supports bracing or shoring should Starting the Form

be compacted and qualify as good soil at least
Setting up the first form is always hard, heavy,
(cohesive, hard, with no water). Professional advice
manual work. It requires enough workers to do
from a geotechnical engineer may be required
the job without overexertion or injury. Whenever
for heavy structures such as elevated equipment
possible, use mechanical assistance such as a boom,
supports shored at or below grade.
truck, or crane for this operation. It will reduce the
Formwork in these situations is frequently built in risk of injury to workers and increase productivity.
place. Planning is required to store material and
Temporary bracing (Figure 42-12) is needed from the
equipment out of the way, dispose of scrap and
start and at every step to prevent wind loads from
debris, and ensure safe, efficient access (Figure
toppling the formshistorically the cause of many
42-10). Because conditions are often cramped and
serious injuries. A wind speed as low as 30 km/h can
scrap accumulates quickly, it is important to clean
create a dangerous wind load on formwork.
up as work proceeds.

Figure 42-10: Well-Planned Storage,

Access, and Setup

Wall Forms
Wall forms built in place are hazardous to
construct. Hazards include Figure 42-12: Temporary Bracing at
Dowels sticking up from concrete slabs or Start of Form Construction
footings
Unstable work surfaces and access created by Access to wall forms is not always given enough
poor planning thought. Forms more than 2 metres high will
Manual handling of heavy material such as require access platforms for workers involved in
plywood sheets, panels, wales, and buckets of concrete placing. The platforms can also be used
snap-ties, wedges, and plates to complete the upper portion of the formwork.
Slippery surfaces at and below grade
An alternative is a frame scaffold, which can also
Inadequate design
be used to install reinforcing steel (Figure 42-13).
Improper construction.
The best protection against dowels is a wood
cover built of lumber at least 1 1/2 inches thick and
wired in place or protective caps placed over the
exposed ends of rebar (Figure 42-11).

Figure 42-11: Protective Covers

Over Dowels and Rebar Figure 42-13: Scaffolding for Access

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 FORMWORK

Fall arrest systems or scaffolds with guardrails

must be used where workers may fall more than
3 m (10 ft), or onto hazards such as projecting
dowels (Figure 42-14). In some circumstances, you
must use fall protection when the height is 2.4 m
(8 ft) or more. (See chapters on Guardrails and
Personal Fall Protection.)

Figure 42-15: Formwork Properly Tied and Braced

Recommended design pressures for various pour

rates and environmental conditions are set out
in CAN/CSA S269.1-16: Falsework and Formwork.
The standard defines a number of other design
considerations and should be consulted by field staff.

Slab Forms or Falsework Built in Place

With slab forms built in place the major hazard is
falls. Injuries are also connected with the manual
Figure 42-14: Workers Wear Fall Arrest While handling of heavy materials and components.
Attaching Wales to Threaded Rods Forms built in place usually have to be taken
down in place after the concrete has hardened
Materials should be distributed along the work sufficiently. This should be considered at the
location to minimize further handling. But traffic construction stage. Stability may also be a
and work areas must be kept clear for the safe consideration where the structure is high, carries
movement and installation of material. heavy loads, and is placed on grade as in bridge
and overpass construction.
Form Construction
Fall protection is difficult to provide for workers
Wall forms must be constructed as designed. building slab forms in place. Thats why planning is
The design must indicate clearly what is required. essential in the design and erection procedure.
Some wall forms are designed for specific concrete
placement rates expressed in metres of height per Workers should wear a safety harness with the
hour (m/hr). A wall form in which concrete is lanyard tied off to the structure of the formwork
placed to a height of one metre in one hour would (Figure 42-16). This means tying off to the support
have a placement rate of 1 m/hr. Slower pouring structure where shoring frame structures are being
rates result in lower formwork pressure because constructed, tying off to a lifeline when placing
the bottom concrete has started to set. plywood panels at a leading edge, constructing
a guardrail at the edge of the formwork, or tying
Note: Using a concrete vibrator will increase the off to the support structure when connecting it
liquid (hydraulic) pressure on the form in the together with tube and clamp. Dont wait for the
immediate area of the vibration. Over-vibrating the structure to be completed before tying-off.
concrete while increasing the pour rate can cause
the formwork to fail.
Ensure that ties and braces are installed where
indicated on design drawings. Ties should be
snugged up. Braces should be securely fastened to
formsand wedged or fastened to a support that
will not settle or deform under load (Figure 42-15).
Formwork platforms must be:
Capable of bearing at least 50 lb/ft2
Adequately supported
Equipped with guardrails
Secured at the level or levels where work such as
pouring and stripping will be done. Figure 42-16: Workers Tie Off to
Shoring Frames While Placing Stringers

Tools and Techniques 42-7

FORMWORK

Make sure you have fall protection at all stages of

formwork construction. Wherever possible, cranes or
other equipment should be used to move material,
thereby reducing the amount of manual carrying,
lifting, and handling.
Shoring towers require special consideration.
Towers must remain stable during construction
and dismantling. Guys or other bracing and
supports may be necessary to maintain stability
(Figure 42-17).
If towers are to be tied together and braced
horizontally, this should be done as work Figure 42-19: Typical Shoring Tower with
progresses (Figure 42-18). Stringers, Adjustable Base Plates, and U-Heads
Shoring towers and shores should be installed so
they are plumb to within 1/8 inch in 3 feet.
Shoring towers should be snugged up under the
stringers with adjustable base plates and U-heads
(Figure 42-19).
If frames do not ride tightly on top of one Replace this frame.
another after tightening, one or more are out of
square and should be replaced (Figure 42-20).
With single-post shores, provide adequate lateral
bracing (Figure 42-21). Stairwells and balconies
are places where horizontal bracing for single-
post shoring systems may be required.

Figure 42-20: Frame Bent Out of Shape

Figure 42-17: High Towers with Guys for Support

Figure 42-21: Single-Post

Shores with Lateral Bracing

Figure 42-18: Towers Tied

Together and Braced Horizontally

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Using forms designed for typical floors in non-

typical situations has resulted in serious accidents.
Before using any flying form under non-typical
conditions, consult the designer or manufacturer.
Wall forms should not be extended in height or
width, for instance, or slab panels cantilevered
without the review and approval of a professional
engineer. Such situations usually occur with
penthouses or mechanical rooms where wall and
ceiling heights are greater than for typical floors.
Other hazards with flying forms include the
following.
Stability during initial fabrication
Figure 42-22: Two Rows of Shoring Frames with Fill-in work between slab panels
Row of Shoring Posts in Centre Wind and fall hazards during flying operations
Stripping, flying, and re-setting.
Frequently, supports for built-in-place forms are Although a flying form is designed to be stable
deliberately left out to allow other work to be when complete, it may not be stable during
done. One example might be a row of single-post fabrication or erection. Temporary bracing or
shores left out until work below is complete. Or, temporary support by a crane may be necessary
an area might be supported temporarily during to ensure stability during certain phases of the
construction by a few single-post shores that will operation (Figure 42-24).
be replaced later by a shoring tower.
In these and other instances of incomplete
formwork, heavy temporary loads such as bundles
of rebar or stacks of plywood should not be placed
on the structure. Even on completed formwork,
make sure that landed material will not overload
the structure.
Before placing concrete, the formwork must be
inspected and approved by a professional engineer
or their designate. Keep a copy of this inspection
and approval on the site in case an inspector asks
to see it.

Flying Forms
Flying forms must always be designed by a Figure 42-24: Temporary Support of Shoring
professional engineer and constructed, hoisted, System for Flying Wall Form
moved, and set strictly according to the
instructions of the designer or manufacturer. One example is setting up trusses for a flying slab
formwork table. The trusses must be held upright
to be connected or disconnected. If not adequately
supported, they can fall over on workers.
Trusses and wall panels have also been blown over
by wind during fabrication and dismantling. Set-
up procedures should indicate the maximum wind
speed where the flying form operation can be done
safely. This wind speed should be determined by the
professional engineer who designed the system.
Work with flying forms requires adequate space
for stacking materials and components. Working in
cramped quarters is not only difficult but hazardous.

Figure 42-23: Flying Forms

Tools and Techniques 42-9

FORMWORK

Fall Protection
A fall arrest system should be used by any worker
who is at risk of falling when:
Installing a panel
Pushing a panel out toward the slab edge
Pulling a panel in from the slab edge (Figure
42-24)
Helping other workers attach rigging hardware Figure 42-26: Rebar Anchor Cast in Concrete
such as slings
Getting on and off
Bolting and unbolting wall forms for exterior walls Safety Below Flying Forms
and elevator shafts (Figure 42-25) The previous section covered the safety of workers
Stepping onto a panel to attach slings to pick flying the forms. But precautions must also be
points taken to protect workers below the hoisting
operation and the public at large, since forms are
often swung out over sidewalks and streets. The
Construction Projects regulation (213/91, s. 103(2))
prohibits hoisting a load over the head of a person
who is not receiving the load or sinking a shaft.
The most efficient protection for workers is to
fence or rope off the area below the flying form to
prevent anyone from entering the area. Pedestrian
traffic on sidewalks, as well as vehicle traffic if
necessary, should be detoured around the area
while hoisting is under way.

Communication
Flying forms are heavy, large, and awkward to
move. Hoisting and moving them safely requires
clear reliable communication. While hand signals
are often necessary and are still used, direct
radio or cell phone communication between the
signaller and the crane operator is more accurate
and effective. Relying on hand signals alone is not
recommended.
Figure 42-24: Fall Protection Required when
Receiving a Flying Form Stripping
Formwork stripping is probably the most
hazardous operation in concrete construction.
Hazards include the following.
Falling material
Waste material and equipment underfoot
Manual handling of heavy or awkward forms,
panels, and other components
Prying forms loose from concrete presents risk of
overexertion, lost balance, and slips and falls.
Hazards can be reduced by
Planning and providing for stripping when
Figure 42-25: Attaching Chain Sling to Wall Form designing and constructing formwork
Stripping as soon as it is permitted by the
Each workers fall-arrest system must be attached engineer
to an individual anchor independent of the flying Supplying facilities and equipment for removing
form. Contractors can provide for anchorage by materials as they are stripped
casting rebar anchors in columns or other areas to Providing proper tools and adequate access for
be covered over or filled in later (Figure 42-26). the stripping crew
This type of anchorage must be approved by a Training personnel properly for this and other
professional engineer. aspects of formwork.

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Forms can be designed with crush plates or filler

strips to facilitate removal at difficult intersections
of columns, beams, and wall forms. Later, formwork
oils should be used liberally to make stripping
easier.
Wherever possible, waste materials, plywood, and
debris should be removed from the area as work
proceeds. This will reduce the need to walk over or
work around things left on floor or ground.
Providing carts or cradles can help the crew
remove material and reduce the need for lifting
and carrying. Material on a cart can be rolled away.
Material in cradles can be hoisted off by a crane.
Climbing partially stripped formwork is not
only hazardous but unnecessary. Safe access Figure 42-27: Lowering Base Plates
such as rolling scaffolds or powered elevating and U-Heads to Release Slab Form
work platforms should be provided for stripping
formwork at elevated locations.
In practice, however, the plywood will stick to
Poor lighting may be a hazard in formwork the underside of the concrete, especially around
stripping in the early morning or late in the day beams, column caps, and similar points. Wherever
during certain times of the year. Mobile light possible, stuck sheets should be loosened and
stands are probably the best solution, since pigtail removed before the shoring structure is dismantled.
stringers can easily be knocked down and damaged
Stripping should proceed in reverse order to
during stripping.
erection. Plywood should be removed first,
Wherever possible, stripping crews should be followed by joists and stringers. The last items to
small. This is especially important with knock-down be removed are the shoring frames.
systems. In small crews, the supervisor and each
When scaffold or shoring frames are used as a
worker can more easily keep track of what the
work platform, it should be completely decked
others are doing. Workers are not as likely to create
in with planks (Figure 42-28). Otherwise planks
hazards for each other. Crews of two or three are
can shift and slide as workers pry or pull at stuck
recommended for knock-down systems. If more
pieces of formwork, lose their balance, and fall. This
workers are required, they can still be divided into
has been a frequent cause of injuries. Temporary
small crews working in separate areas.
guardrails may be required near the edge of the
Other trades and operations should not be allowed structure or workers will need to use fall protection
in areas where stripping is under way. Given the during this operation.
many hazards involved, the area should be fenced
or roped off and warning signs posted.

Knock-Down Slab Systems

Stripping these forms is physically difficult
because much of the work is overhead. The
usual arrangement involves shoring frames or a
combination of shoring frames and jacks.
Wherever possible, the work should proceed
progressively from one side. That means taking out
one row of formwork supported by a row of stringers
on shoring frames.
The first step is to back off the adjustable base plates
and U-heads in one area, which will in turn lower the
stringers, joists, and plywood (Figure 42-27).
Figure 42-28: Shoring Frame
Fully Planked for Access

Tools and Techniques 42-11

FORMWORK

The area where stripping starts should be planned Columns

to allow access for taking away material as the
Check the following:
form is dismantled.
The proper size and type of materials are used
Sound training, effective supervision, well-
Column ties or column clamps are spaced
designed safe access facilities, and immediate and
according to design drawings
continuous cleanup can help reduce hazards in
The spacing of ties or clamps is based on a
stripping knock-down slab forms.
sound assessment of concrete pressure (generally
columns are designed for a full liquid head of
Built-in-Place Wall Forms
150 lb per cubic foot (2,403 kg per cubic metre)
These forms are frequently of only moderate height. times height)
Taller types usually make use of large panels erected Columns are adequately braced where they are
and removed by crane rather than hand. Built- not tied in to a slab-form structure.
in-place wall forms are usually a stud-and-wale
Note: For more information on column formwork
system using some type of formwork ties.
pressures, refer to CAN/CSA S269.1-16: Falsework
Where workers cannot reach the top of the wall, and Formwork or the American Concrete Institute
scaffolding should be provided for removing wales (ACI) standard Formwork for Concrete (SP-4).
on the upper level. Safe access is essential for the
dismantling and manhandling of wales that are Wall Forms
frequently long, heavy, and waterlogged. Check the following:
Material should then be removed immediately to a Materials and any manufactured components are as
staging area. specified in design drawings (size and spacing of
studs, wales, and ties are crucial to safety)
Inspection Ties are snugged up before concrete is placed
Wedges in wedged systems are tight
Before concrete placing begins, formwork must be Nuts in threaded systems are tight
inspected and signed off by a professional engineer Bracing conforms to design drawings
or a competent person designated by the engineer Free-standing formwork is braced to ensure stability
to ensure that it has been constructed to provide and resistance to loads during concrete placing
for worker safety and to meet job specifications. Specified pour rates are not exceeded (wall
A report must be completed by the person doing forms are often designed for specific pour rates;
the inspection stating whether the formwork has exceeding these rates can cause failure or collapse).
been constructed according to the design. Any
discrepancies must be approved by the design Slab Forms
engineer before concrete placing proceeds. From a safety perspective, this is the most critical
It is in everyones best interest to ensure that the type of formwork. The collapse of slab forms has
formwork has been inspected by a competent caused many injuries and deaths, whether from
person for workmanship, stability, and adherence flawed design (e.g., not considering the effect
to design drawings and specifications. Inspection of wind loading on the design), unauthorized
should begin when the forms are being constructed modifications in the field, or the failure to
and continue until concrete placing is complete. inspect, which would have located and corrected
deficiencies.
Checking line and grade is best carried out while the
formwork is being constructed. Shoring structures Competent inspection demands knowledge,
should be within the alignment limits specified on experience, and the ability to
the design drawings. Line and grade should also 1) Distinguish between similar but different
be checked during the pour to determine whether materials and shoring equipment
formwork is shifting or deflecting. 2) Read and interpret design drawings
Dimensions of special features like beams, column 3) Identify and clear up with the designer any
capitals, and inserts are best checked at the time of apparent or real discrepancies in components
construction. If inspection is delayed until formwork such as shoring frames.
is completed, some details may be covered up or
become more difficult to check.

42-12 Construction Health and Safety Manual

 FORMWORK

Check the following:

Grade beams or mud sills supporting shoring are
properly sized and located.
Hazardous soil conditions such as excessive
moisture, freezing, and uncompacted soil
conditions are reported and discussed with the
professional engineer.
Shoring frames and jacks are located and aligned
within tolerances specified on the drawings.
Shoring frames and jacks are out of plumb no
more than 1/8 inch every 3 feet.
Adjustable base plates for shoring frames and
jacks are snugged up.
U-heads are wedged in place. Figure 42-29: Crushing of Stringer Over U-Head
Stringers are the specified size and number, with
supports properly spaced.
Aluminum stringers have no bent flanges or other
damage.
Joists are the specified size and properly spaced.
Support structures and shoring for beam bottoms
and column capitals are constructed according to
design.
Lateral bracing is provided where required (for
instance, on freestanding formwork for bridges
and overpasses).
The bearing surface for lateral bracing is
adequatethat is, stable footings or well-
compacted soil. Figure 42-30: Deflection
Temporary loads such as rebar are not of Stringers Between Supports
overloading the system.

Concrete Placing
Forms should continue being observed during
concrete placing. Any signs of movement, crushing,
cracking, or deflection are cause for alarm. Placing
concrete should be suspended until the situation is
corrected.
Watch for the following warning signs:
Lateral displacement or movement of single-post
shoring for slab forms
Movement or deflection of lateral bracing for
single-post shores
Movement of stringers on U-heads
Crushing of wooden stringers on U-heads
(Figure 42-29)
Gaps or shoring that is not snugged up under
stringers
Deflection of stringers between supports
(Figure 42-30)
Deflection of wales or strongbacks on wall forms
Wall forms that are bulging or cracking
Crushing of wales or strongbacks at washers
for ties
Movement of wall forms
Uplifting of battered forms
Pour rates that exceed design pecifications.

Tools and Techniques 42-13