For further details contact:

Building Material & Technology Promotion Council

Ministry of Housing & Urban Poverty Alleviation, Government of India Manual on Basics of
Formwork
Core 5 -A, First Floor , India Habitat Centre, Lodi Road,
New Delhi- 110 003, India
Phone: 91-11-24638096, 24638097, 24636705 Fax: 91-11-24642849
E-mail: bmtpc@del2.vsnl.net.in, Website: www.bmtpc.org

Building Materials & Technology Promotion Council

Society for Environment Protection (SEP) Ministry of Housing & Urban Poverty Alleviation
6-A, Kalamwadi Society, Nr. Shreyas Crossing, Paldi, Government of India
Ahmedabad-380 007 (Gujarat)
Phone: 91-79-65137987, Mobile: 9327201215
E mail : admin@sepindia.org, Website: www.sepindia.org
Disclaimer
It is always advisable to seek professional advice for Formwork. The Manual is only intended to provide general assistance and
guidance for formwork. While all care has been taken to make this manual self-explanatory, Indian Standards be referred to if any
difficulty arises in interpretation. The Manual does not replace any rules, regulation or code of practice in force. Therefore, any
loss or damage arising due to reliance on this Manual can not be accepted.

A joint publication of

Building Material and Technology Promotion Council (BMTPC)

Ministry of Housing & Urban Poverty Alleviation, Government of India
Core-5A, First Floor, India Habitat Centre, Lodhi Road, New Delhi - 110003
Phone: +91-11-24638096, 24636705; Fax: +91-11-24642849
E-mail: bmtpc@del2.vsnl.net.in; Website: www.bmtpc.org

and

Society for Environment Protection (SEP)

6-A, Kalamwadi Society, Nr. Shreyas Crossing, Paldi,
Ahmedabad-380 007 (Gujarat)
Phone: 91-79-65137987, Mobile: 9327201215
E mail : admin@sepindia.org, Website: www.sepindia.org

Prepared by Mr. Dipan Shah with the support from SEP Team.
Design by Mr. Rajesh Patel
Photo credits: Society for Environment Protection (SEP)
© 2012, All rights reserved
Foreword

Concrete is the most widely used versatile construction material, which can be moulded to
any shape and size depending upon the requirement. The desired shape and size of concrete
construction is achieved when it is green through a temporary structure called formwork
systems. The formwork systems not only mould the concrete to desired size & shape and
control its position and alignment but also supports its own weight, plus the weight of freshly
placed concrete and construction live loads. Formwork system, therefore, are critical
elements of the overall construction plan and require needed attention. Quality, Safety and
Economy are the three basic objectives of the formwork system, which require cooperation
and coordination between engineer/architect and the contractor with proper
understanding of the materials used, design parameters, erection, stripping, maintenance
and good engineering practices.

This publication entitled “Manual on the Basics of Formwork” has been prepared in
association with Society for Environment Protection (SEP), Ahmedabad to address all the
above aspects. The various details given in the Manual along with photographs of good and
bad practices, would help, engineers, field supervisors and contractors in developing general
understanding of the subject with a few key aspects to be borne in mind for improving quality
of formwork system. I place on record my gratitude and deep appreciation for Mr.Dipan Shah
and his team in SEP for doing such commendable work. The efforts of my Council's officers
Mr.J.K.Prasad, Chief (BM) and Mr.Dalip Kumar, Sr.Field Officer (DC&E) also deserve a
mention here for bringing the document to printable form.

7th day of September, 2012 Dr.Shailesh Kr.Agrawal

New Delhi Executive Director, BMTPC
 Introduction
Introduction
Formwork
Formwork is a temporary structure whose purpose is to provide support and containment
for fresh concrete until it can support itself. It moulds the concrete to the desired shape and
size, and controls its position and alignment. Concrete forms are engineered structures
that are required to support loads such as fresh concrete, construction materials,
equipment, workers, various impacts, and sometimes wind. The forms must support all
the applied loads without collapse or excessive deflection Formwork was once built in
place, used once, and subsequently wrecked. The trend today, however, is toward
increasing prefabrication, assembly in large units, erection by mechanical means, and
continuing reuse of forms. These developments are in keeping with the increasing
mechanization of production in construction sites and other fields.

FormWork Materials
Materials used for the construction of concrete formwork range from traditional materials
such as wood, steel, aluminum, and plywood to nontraditional materials such as fiberglass.
Wood products are the most widely used material for formwork.

FormWork System
The total system of support for freshly placed concrete including the mould or sheathing
which is in contact with the concrete as well as supporting members, hardware, and
necessary bracing together makes Formwork System.

Types of Formwork systems :

1) Conventional Formwork system:
This kind of system generally is made using
timber and plywood. But with recent
advancement one is able to find steel props and
plates too as a part of conventional formwork
system. The system with the passage of time
has synthesized itself with available
proprietary components increasing its
efficiency.

2) Proprietary Formwork system:

Are readymade prefabricated formwork systems which
helps improve speed of erection, quality of finish and
imparts multiple use. Such systems are a product of
standardization of the conventional system of
formwork.

2
 Basic Terminology and
Basic Terminology and
Classification
Classification
Some basic Terminology associated with the formwork interpreted as per IS
code no. is as below :

Formwork ( Shuttering ) - Complete system of Centering ( Centring ) - The temporary

temporary structure built to contain fresh supporting structure to a soffit. Centering is
concrete so as to form it to the required shape the specialized formwork used in the
and dimensions and to support it until it construction of arches, shells, space structure
hardens sufficiently to become self or any continuous structure where the entire
supporting. Formwork includes the surface in falsework is lowered ( struck or decentred ) as
contact with the concrete and all necessary a unit to avoid introducing injurious stress in
supporting structure. any part of structure.
Falsework - Falsework is the temporary Form ( Shutter ) - That part of formwork which
structure erected, to support work in the consists of the sheeting and its immediate
process of construction. It is composed of supporting or stiffening members. A
shores, formwork for beams or slabs ( or temporary structure or mould for the support
both), and lateral bracing. That part of of concrete while it is setting and gaining
formwork which supports the forms usually sufficient strength to be self supporting.
for a large structure, such as a bridge.
Form Lining ( Lining ) - Prepared timber, board
Scaffold ( Scaffolding ) - A temporary or sheets of plastics, paper or other material,
structure for gaining access to higher levels of fixed to the inside face of the form to produce
the permanent structure during construction. a special surface finish.

Various classification of formwork system based on the way

formwork is used:
Slip Form ( Moving Formwork, or Sliding Travelling Formwork ( Mobile Form or
Formwork )- A form which moves, usually Moving Formwork ) - Formwork, such as that
continuously, during placing of the concrete. used for walls and tunnel linings carried on wheels
Movement may be either horizontal or vertical. or rollers so that it may be struck and moved for re-
use without dismantling.
Climbing Formwork ( Moving Formwork) -
Formwork for vertical or near vertical structures Telescopic Form ( Retractable Form) A form
which are constructed in successive lifts and which used for work, such as tunnelling, which when
is supported by the previously poured lift . struck reduces to a size small enough to enable it to
pass through similar forms already in position for
Collapsible Forms - Forms which are activated by concreting.
mechanical means to reduce their volume or
surface area to permit striking. Permanent Form (Permanent Shutter or lost
forms) - Forms permanently left in place to
Tilt-Up Form - A wall form which is built on the
provide a facing to the concrete.
ground beside the wall to be cast and then rotated
into the vertical plane.

3
 Quality and
Quality and Speed Speed
Qualities of good formwork system

Bracing and Stability: It shall be adequately braced laterally and diagonally and should
withstand all anticipated loads and forces.

Rigidity and Deflection: The system shall be rigid enough so as to keep permissible
deflection due to dead/live load and forces caused due to placing and compaction of
concrete are well within permissible limits.

Erection and release: Falsework errection should always be done with the detailing of
falsework release sequence after concreting

Ease of inspection: All parts of the formwork system should be accessible for inspection

Shape and size: It's shape and size should confirm to the requirements of drawings

Finish: Form material in contact with concrete should not affect the concrete finish
adversely.

Reuse: It should be able to give larger reuse so as to achieve economy

Speed

The time taken and ease in errection and removal of formwork plays a vital role in
controlling overall speed of construction. In a typical multi-storey building, as per IS code
conventionally slab can be de-shuttered at the end of 10th day of casting. In a conventional
system it takes 2 to 4 days in removing and re-errecting the formwork. This time lag is very
crucial and formwork designers are constantly innovating so as to reduce this time to
minimum. The Proprietary formwork system or Moving forms are some of the examples of
minimizing this time loss.

Formwork is the largest cost component for a typical multi-storey reinforced concrete
building. Formwork cost accounts for 40 to 60 percent of the cost of the concrete frame and
for approximately 10 percent of the total building cost for steel forming and bracings.

4
Formwork process chart
Design stage
Design by competent
Drafting of detail
engineer as per relevant Proof checking
implementation drawings
regulation and codes

Issue of Formwork
Drawings for
implementation at site

Implementation stage

Design and inclusion Erection by skilled workers in total

of Safety compliance with drawings and specifications;
requirements at site under the guidance of site engineer

Inspection and approval of completed

formwork/false work by EIC or competent
authority and approved for concreting work
Stand by gang, material
along with formwork
supervisor, constantly
observing formwork system Concreting work
for any unexpected
behavior/implication

Dismantling stage
Ensuring that the permanent structure
has gained minimum design strength
for stripping

Supervision by the
site engineer for any Stripping of formwork by skilled workforce in
unexpected compliance with formwork drawing and
behavior/implication specification

Cleaning, shifting and stacking of formwork

as per standard operating system

5
 Formwork life cycle

Reinforcement
placement

Choice of
Formwork Curing of Concrete concreting
life cycle contrete life cycle methodology

Concreting

An Integrated Concrete/formwork life cycle

Criteria which play a major role in selection of formwork system are as below:
·
Scale of work or repetition of use intended
·
Quality of finish required
·Availability of unskilled and skilled labour
·
Handling equipment available and their capacity
·
Type of concrete (pump concrete or regular concrete) and pouring rate
·
Investment capacity and cash flow available
·
Speed requirements
·Modular or flexible work type
·
Acceptability of cold joints for structure

Note :
A table at the end of the document enlist some suggestive systems for various uses.

6
 Erection
Erection of Formwork
of Formwork
Following points shall be borne in mind while checking during erection:
Any member which is to remain in position should be undamged and not visibly bent.
after the general dismantling is done, should They should have the steel pins provided
be clearly marked. by the manufacturers for use. They should
· Material used should be checked to ensure be restrained laterally near each end. They
that, wrong items/rejects are not used. should have means for centralizing beams
· If there are any excavations nearby which placed in the forkheads.
may influence the safety of form works, ·
Screw adjustment of adjustable props shall
corrective and strengthening actions must not be over extended.
be taken. ·
Double wedges shall be provided for
· The bearing soil must be sound and well adjustment of the form to the required
prepared and the sole plates shall bear position wherever any settlement /elastic
well on the ground. shortening of props occurs.
· Sole plates shall be properly seated on ·
Wedges should be used only at the bottom
their bearing pads or sleepers. end of the single prop. Wedges should not
· The bearing plates of steel props shall not be too steep and one of the pair should be
be distorted. tightend clamped down after adjustment
· The steel parts on the bearing members to prevent their shifting.
shall have adequate bearing areas. ·
No members shall be eccentric upon
· Safety measures to prevent impact of vertical member.
traffic, scour due to water etc. should be ·
The number of nuts and bolts shall be
taken. Adequate precautionary measures adequate.
shall be taken to prevent accidental ·
All provisions of the design and/or
impacts etc. drawings shall be complied with.
· Bracing, struts and ties shall be installed ·
Cantilever support shall be adequate.
along with the progress of formwork to ·
Props shall be directly under one another
ensure strength and stability of formwork in multistage constructions as far as
at intermediate stage. possible.
· Steel sections (especially deep sections) ·
Guy ropes or stays shall be tensioned
shall be adequately restrained against properly.
tilting, over turning and formwork should ·
There shall be adequate provision for the
be restrained against horizontal loads. All movement & operation of vibrators and
the securing devices and bracing shall be other construction plant and equipment.
tightened. ·
Required camber shall be provided over
· The stacked materials shall be placed as long spans.
catered for in design. ·
Supports shall be adequate, and in plumb
· When adjustable steel props are used, they within the specified tolerances.

For pump concrete, special precautions be taken in to the design of form work since the rate of
pour of concreting will increase multifold times the conventional system. Also, in some cases,
the load of fresh concrete and the live load at one place may cause uplift of the forms at another
place and thus result in displacement of the forms and danger to the props by losing wedges,
etc. Positions of such possibilities be checked.

Securing formwork at intermediate stage of erection is very important and should be designed.

7
 Conventional formwork
Conventional Formwork
Advantages of Conventional Wood System
Flexibility : Because the system is built piece by piece, it is virtually capable of forming
any concrete shape. A complicated architectural design can be formed only
by this system.
Economy : This system is not economical In terms of labor productivity and material
waste. However, the system may be economical for small projects. The
system has the advantage of low makeup cost or initial cost.
Availability : Wood is a construction material that is available virtually anywhere. In areas
where formwork suppliers are not available, a conventional wood system
may be the only feasible alternative. Availability and low labor cost are the
two main reasons behind the popularity of the conventional wood system in
the developing countries.

Limitations of Conventional Wood System

Lower Quality : Due to use of pieces of plywood and timber there are multiple joints in the
system which gives lower finish quality.
Higher time : Conventional system largely caters to single use or lower repetition. The
system is assembled a new every time using available pieces of plywood and
timber making it cumbersome and time consuming.
Higher Skill : To obtain quality formwork using such system, one requires higher skill
labour and workforce as output is totally dependent on individuals capacity
to finish.
Higher Wastage : Each time the system is fabricated a fresh catering to the size and dimension
of cast/pour. Thus it generates larger wastage.
Limited no of : Very less repetitive use is available compare to steel formwork system.
Reuse
Limited span : Since dimension wood is low strength compare to alluminium/ steel and
other materials, it has limitation of spans it can support.

Caution: Indiscriminate use of timbe is really taxing our environment beyond its equilibrium hence it will
be important as per today status to explore more of timber composites or recycle wood.
 Proprietary
Proprietary
Formwork
Formwork System System
Proprietary or commercial forms are usually constructed
with materials that can be reused many times. Their initial
cost is generally high but it is offset by the potential for
more reuse cycles, increase productivity in erecting and
stripping of forms and speed of work. They are available
in standard design or can be tailored made for a particular
project. They can also be designed for larger spans.

Advantages of Proprietary formwork system

·
Ideal for large scale projects which has sufficient
standardization in design and has repetitive use where
speed and quality are governing criteria.
·
Easy to erect with less skill workforce and can save on
labor cost
·
Stiffeners are generally build into the panel, therefore
alignment of the panel is very easy.
·
Well planed assembly and stripping design make it
convenient and fast to erect and dismantle
·
Practically no wastage with very high number of reuse.
·
The factory precision on assembly results in perfect
dimensional accuracy of the finished concrete.
·
Is available for any and all requirement and also in
large spans.

Disadvantages of Proprietary formwork system

·
High initial investment.
·
Less flexibility with respect to form variation compare
to conventional form.
·
May need mechanical equipment to handle if the
panel sizes are big.
·
Require user to keep minimum stock of couplers,
anchor nut and other required accessories of the
system since the same may not be available at all
places.

9
 Form Materials
Form Materials
Some commonly used Form Ferro-cement and wire mesh forms : This is
Materials: another very effective, relatively low cost
system adopted to create unique curved
Timber and Plywood are the most common surfaces like concrete shell. In this system,
material used largely on most small wire mesh is used to develop basic shape as
conventional works. They are widely required. Once the shape is created, the
available and impart flexibility of creating bottom surface is plastered with rich
any shape as desired. cement mortar of proportion 1:2 or 1:3. This
gives a basic form surface to then carry out
Steel forms : For general repetitive concreting on the top. Ferrocement system
construction, all steel formwork is better will work as lost form. If design correctly and
than any other forming material. It is also used advantageously, it can work out
most widely used material by most establish cheaper in creating special shapes since can
builders and contractors. Some of the either eliminate the need for support
general advantages of steel forms are : system completely or partially.
· Steel forms can be easily designed to give
required rigidity, strength, good surface Forms for aesthetic concrete : Range of
finish and can provide better alignment. building material including timber, stone,
· Larger number of reuse will help to clay tile, asbestos cement sheet, rubber
achieve economy. boards etc are used as special form lining so
· Ease of fabrication and centering on site. as to capture their patterns or grains on the
· Since all the properties of steel are well concrete improving the aesthetic. These are
known and easily available in readily generally used only in exposed concrete.
usable format, it provides ease and Range of products have been tried by
comfort for formwork designers to various innovators so as to impart different
design system accurately and surface taxtures to the concrete. It is
confidently. important that the material used satisfies
the basic requirement of being non-
Fiber forms : Use of fiber based form absorbent and non reactive (inert) with
material is increasing day by day in the concrete. Many time they are left in place
formwork system. They are used for creating becoming a facia element. Based on the kind
variety of multi-dimensional and free of material used, the backing formwork
flowing shapes especially for architectural material which will actually impart strength
concrete. Also, they can be used as a lost- and stability of the form is decided. Also, the
form, left in place after concreting as the joinery is worked out so as to keep the lining
exposed face to improve acoustical, material in place during concreting. It is very
insulating and architectural appearance of important to work out neat joinery in such
the concrete. Fiber board manufacturer's cases since any signs of nails or nail heads
recommendation should be followed in will reflect in the exposed concrete.
setting up and working out spacing of
supports for form-boards.

10
 Design
Design
Formwork shall be designed to meet the be assumed as 500 N/sqm for the purpose of initial
requirements of the permanent structure using calculations.
relevant Indian Standards for materials selected
(B) Imposed Loads : Loads during construction
for formwork. The design should take into account
operation shall constitute the imposed loads (see
the actual condition of the materials to be used for
IS : 875 (Part2): 1987. Such loads may occur due to
the falsework, work environment and site
construction personnel, plant and equipments,
conditions. Before actual design is done all the
vibration and impact of machine delivered
relevant information like site data, expected
concrete, lateral pressure of fresh concrete,
loading scheme of load transfer, sequence of
unsymmetrical placement of concrete,
erection and releasing, procedure of concreting
concentrated load and storage of construction
and time frame, should be procured.
materials.
Formwork system shall preferably be so designed (C) Environmental loads: These included loads
that the vertical members are subjected to due to wind or seismic loads, earth pressure,
compressive force only under the action of water pressure, snow and thermal load, etc. It
combined horizontal and vertical loads. should be calculated in accordance with IS : 875
(part 3 and 4): 1987
· Timber user for formwork shall confirm to IS (D) Permissible Stresses : Shall not exceed the
3629:1966. values specified in the relevant Indian Standards
· Modulus of elasticity of a clear specimen of for permanent structures. Timber - IS: 399: 1963,
timber tested in bending should not be less IS 3629: 1976, Plywood - IS: 4990: 1993, Steel - IS:
than 5600 MPa 800: 2007 and IS: 2750: 1964, Tubular Section - IS:
· Seasoned timber with moisture content 806: 1968 and IS 1161: 1998.
ranging from 12 to 20% should be preferred.
· Timber used shall be checked for cracks or Deflection limit
knots kind of defects. The formwork shall be designed so as to remain
· Preferable thickness of timber to avoid sufficiently rigid during placing and compaction of
warping should be as below : concrete. Total calculated deflection (d ) of
¨ For vertical sides (walls/beam sides, etc) falsework including the initial imperfection in the
25 mm members shall not exceed the following :
¨ For bottom (floors, beams, etc) 30 mm (A) for beam span < 3000 mm, deflection (d )>3
Note: Size of the timber member should be mm
selected based on prescribed permissible (B) for beam span > 3000 mm, deflection (d ) is the
stresses. The above thicknesses are for general least of 1) 30mm or 2) L/1000
reference only so as to avoid warping.
Stability : A factor of safety of 1.5 may be used in
design against overturning and sliding.
Falsework shall be designed to resist the
expected In addition to obvious structure requirements
formwork designer's should also give due
(A) Dead load - Weight of falsework structure, self attention to points such as inserts, water stops,
weight of formwork and any ancillary temporary holes through concrete, surface finish of concrete
work connected or supported by formwork desired, tolerances for plumb and level, details of
including weight of freshly placed concrete will be construction joints, expansion joints, dowels, etc.
part of dead load. In absence of the data, load may

11
 Formwork shall be properly designed for self such information, the camber for beams and
weight, weight of reinforcement, weight of slabs can be taken as 4mm/meter (1 to 250)
fresh concrete, and in addition, the various and for cantilever the camber at free end can
live loads likely to be imposed during the be 1/50th of the projected length.
construction process (such as workmen,
materials and equipments). Also designer Tolerance in formwork
must consider loads due to unsymmetrical The formwork is the one which defines the
placement of concrete. This will cause partial shape of the final concrete. Hence formwork
uplift forces on formwork system. should be made strictly as per the size and
shape specified in the drawings. The
In case the height of centering exceeds 3.50 tolerances on the shape, lines and
meters, the prop may be provided in dimensions shown in the drawing shall be
multistages. A typical detail of multistage within the specified limits given in IS 456:
shuttering is given in fig below: 2000 which is as below:

Suspended Floor/ Slab to be Cast

a) Deviation from specified +12 mm

dimensions of cross-section - 6
Shutteting

Centring

Height of columns and beams

Steel

Beam
£3.5M
Head b) Deviation from dimensions
of footings
1. Dimensions in plan + 50 mm

Props./ - 12
Height
Verticals £3.5M 2. Eccentricity 0.02 times the
width of the
footing in the
direction of
Sole Plate
Suspended Floor - Multi stage shuttering (Vertical Section)
deviation but
not more than
Camber : Suitable camber shall be provided in 50 mm
horizontal members of structure, especially in 3. Thickness ± 0.05 times the
the cantilever spans to counteract the effect specified
of deflection. The formwork shall be thickness
assembled with the provision of camber
These tolerances apply to concrete dimension only, and
provided by Designer or EIC. In absence of not to positioning vertical reinforcing steel or dovels.
Adjustable steel props and Forkheads
Removal of shores from multi-storey
building requires special consideration The following limiting factors are appropriate
because a given floor/slab may be required to adjustable steel props:
to support one or two stories of · Props should be undamaged and not
construction live and dead loads for the visibly bent.
work going on above. The total load of the · Props should be plumb within 1.5° of
upper structure, including freshly placed vertical (that is, not exceeding 25mm out
concrete, formwork, workmen, placing of vertical over a height of 1m)
equipment, etc must not exceed the live · Props should be placed centrally under the
load which the lower structure is capable of member to be supported and over any
carrying at the strength then available. member supporting the prop, with no
eccentricity in excess of 25mm.

12
 Stripping
Stripping
Stripping of Formwork restraint imposed. Needed precautions and
measures be adopted to ensure the safety and
Generally soffit formwork shall not be quality of concrete. When formwork to
released until the concrete has achieved a vertical surfaces of columns, beam and wall is
strength of at least twice the stress to which removed at early stage, the
the concrete may be subjected, at the time of care should be taken so as to protect concrete
removal. While the above criteria of strength from any damage arising due to impact or
shall be the guiding factor for removal of extreme climatic conditions.
formwork, in normal circumstances, as per IS :
456 the following minimum stripping time Column forms should be made so that they
may be observed. can be stripped without disturbing adjacent
beam/girder forms. Similarly Beam and Girder
Vertical formwork to column, vertical faces may be made to come out
walls, beams 16-24h before slab soffits and their own bottom form.
Soffit formwork to slabs (props to
be re-fixed immediately after Formwork coatings and Releasing agent:
removal of formwork) 3 days For longer service life of the shuttering
Soffit formwork to beams (props material and ease in release of forms, it should
to be re-fixed immediately after be coated with suitable coating or releasing
removal of formwork) 7 days agent of approved composition. The form
Props to slabs: release agent are temporary coatings
(A) Spanning upto 4.5 m 7 days consisting of fatty acids which react with the
(B) Spanning over 4.5 m 14 days alkali in cement and leave behind a soap like
Props to beams and arches substance on the contact surface. This helps
(A) Spanning upto 6 m 14 days release of the form. These may be oils,
(B) Spanning over 6 m 21 days emulsified wax, oil based emulsions with
water globules, petroleum based products,
For cements other than OPC and lower catalysed polyurethane foam, etc.
temperature, the stripping time
recommended above may be suitably Careful consideration should be given to the
modified. choice of release agent taking account of the
type of surface to which it is to be applied, the
The number of props left under, their sizes and conditions under which it is to be used, the
disposition shall be such as to be able to safely type of concrete, the quality of finish, the area
carry the full dead load of the slab, beam or of form and the ease of application. The
arch as the case may be together with any live conventional use of waste oil as release agent
load likely to occur during curing or further should not be encouraged since it does not
construction. contain fatty acids.

Where the shape of the element is such that

the formwork has re-entrant angles, the
formwork shall be removed as soon as
possible after the concrete has set, to avoid
shrinkage cracking occuring due to the

13
 General
General
Formwork
Formwork
Details
Details
Footings : Slopped footings will normally it; various marks are made for the slab
require formwork for vertical sides only. If thickness, floor sheathing, beam bottom,
the slope of the top faces exceeds angle of yoke spacing and other accessories so as to
repose of the vertical concrete, formwork get all the form levels correct and accurate.
may be required for the top face. The In many cases the column head is
column if made of rectangular footing then specifically designed so as to straightway
the form can be as shown in the sketch. accommodate the beam formwork. This will
further enhance the speed of erection.
Plywood sheathing
Once the reinforcement work is completed
and cover is installed on the reinforcement
bar, the column formwork panels are shifted
around the column. If the starter is
concreted then, that itself work as a base of
2.5 x 5 cm bracing the column erection using which the panels
are aligned around the column and then
bolted. Generally, the exterior columns are
aligned first ( in case of multi-storey
building). Once they are aligned and
erected, other interior columns are taken
up. It is very important to ensure correct
Top form alignment of column as an individual
5 x 10 cm bracing column and also with reference to all other
columns.
Deep footing if is made of two or three steps
then in that case either the lower form is Chamfer Strip
concreted first and then allowed to rest a Plywood Column
little before next lift is concreted. Sides

Alternatively one can use the method of

sheathing the top of the lower form to Adjustable Column
prevent the concrete from overflowing. Clamps

Columns : A column formwork can be made

using timber, plywood or steel sheathing. It Clean Out
is generally designed as a unit which is Doot

erected in two parts or more parts but each

side of the column acting as one panel. The
height of the panel is generally floor to floor
clear height less the floor sheathing
Template for
arrangement, less the beam depth. When Positioning Form
there is repetitive use, to make a column
panel, a measuring stick is used. This stick is Clean-Out Detail
cut to the full height of floor to floor and on Typical Construction of Heavier Column

14
Walls: Concrete wall will have generally Wall Reinforcement
formwork on both the sides of the wall. In Timber tie
case of a concrete wall construction, (50 x 25)
generally the reinforcement work is Concrete
finished before the form-panels are starter Wall
erected. It is very important for concrete Thickness
wall to have good inclined braces to impart 75 x 75
it needed stability during the course of timber
concreting.

One can use the system of starter for Wall Footing

concrete wall as shown in the sketch. This
will make things easy for the erection of
heavy wall forms with speed and accuracy. Sketch showing starter formwork for concrete wall

A typical sketch of concrete formwork is

5 x 10 Studs shown. It has various elements like studs,
wales, braces, spreaders and ties. Its is
very important to have both spreaders and
tie wire to ensure correct alignment of the
wall. If the bolts are used to keep the forms
19mm
Plywood together, which is the case in most places
Sheathing then bolts should be greased for easy
Wire removal from the concrete.

2.5x4 cm
Spacer outside shutter, formply
adjustable steel
floor centers at deck formply nailed on 75 x 35 battens
400 ctrs. at edges only 75 x 50 soldiers
at say 800 ctrs.
stitch nailed to
concrete side shutter
Wall Formwork With Wallings edge beam brace nailed
to soldier and
kicker
o
25x25x45
fillets

Beams and floor slabs : Once the columns are

concreted, the formwork for slab and beam is done 75 x 25 brace
nailed to kicker 75 x 35 kickers,
continuous. Typ.
jointly. From the column head, the beam bottoms are and beam side
shutter
75 x 50 on edge
first installed and leveled. On the beam bottom then the for bottom or
this side shutter carrying soffit shutter
beam sides are installed. To aligned to this sides, then weight from slab, provide
verticals between battens,
the slab formwork is installed. It is very important to shutter sits on top of "cross".

Formwork for beam on external face of the building

15
 install all the beam sides in such a way
that they can be removed/de-
Slab Sheathing
shuttered before the beam bottom or Beam Side
slab bottom.

Generally the slab formwork is done Wire Tie

using steel forms or plywood

sheathing. Once the beam and slab
Stringer or
fo r m w o r k i s c o m p l e t e d , t h e Joint
reinforcement work is started above Leadger
Blocking
it. On completion of reinforcement
work, the slab is concreted. Kicker

Chamfer Strip

T-Head
Beam Bottom Sheet Metal
Shores
Bevel Strip Closure

Typical components of Beam Formwork with

Slab framing in as per IS 14687:1999
Alternate Details At 'A'

Stairs : Formwork for concrete stairs is generally done using

either timber, plywood or steel forms. First the formwork for 5x10 cm
the sloping slab of the staircase is done as per line and level. It is 5 cm
Planks 10x10 cm
supported using varying height of props from bottom. It will be Brace
important to mention that due to varying height of props,
many times, contractor puts too little props or doesn't anchor
or support props properly, leaving them loosely on ground.
Also to avoid cutting of props to smaller size, they install props,
heavily inclined; which is of no use and should not be done.
Also, as the staircase rises, near the first floor slab, the height of
the prop from out side is about 13 to 15 feet, which mostly they
raise by patching up two props, over each other, loosely. The
same should be
Floor Landing avoided.

2.5x10 cm
Brace

Between Walls
25 Tread

5cm Plank In case of staircase, once the

Bevel
bottom sloping staircase is
Stringer laid, the reinforcement is
7.5cm placed and then, the riser's
Clearance 10x10cm
are installed. Also, many
7.5x10cm times, to avoid riser concrete,
contractor tends to make
10x10cm about
80cm C/C
hybrid stair by making risers
Floor
in brickwork, as shown in the
2.5cm Sheathing
photo.
Between Landings or Floors
16
 Photographs
Photographs and
and
Good
Good Details
Details
In conventional practice, as seen in A typical detail for footing concrete
the photo, generally; carpenter given by CPWD so as to ensure
tends to avoid placing vertical alignment and correct slope. With
sides for the footing concrete. This the above arrangement, one need
is not a good practice since, this not use nails for fixing of footing in
will give poor and honeycomb position, and fixing and releasing is
concrete, footing dimensions will very easy without damaging the
vary, increase wastage, in case if corners.
the footing is a sloped footing, will
hamper slope formation and that
will directly affect the structural 75x50mm Reapers to join
Bolt planks & also fix the bolts
stability of the column. Side A 12mm
Hole Bolts &
Nuts
Side B

1.50 m
75x50
Better example of footing where mm
1.50 m Reapers
side planks are used for footing Side B for
38 mm thick joining
concrete. Even in this case, as seen, Kail II planks planks
the side planks are not secured 38mm
systematically. This may lead to thick
Kali II
dimensional variation and should be Side A Planks
75mm x 50mm
avoided. reapers
Formwork for RCC Footing
Photographs

As seen in the photo, the perpendicular Steel plate is extended

inside the cross section of the beam. This will lead to serious
error because, once the beam is concreted, to remove the
plate the carpenter will have to break the section of the beam.
This will lead to serious structural consequences and should
not be allowed what so ever. In such cases it is advisable to use,
hybrid formwork and introduce a small section of plywood cut
to exact size and replaced with the steel plate in that section.
The plywood piece will need special attention during fitting
and should not leave any leaking / loose joints.

Above photo is a typical photo of Grade beam

concrete from conventional practice. Timber
is a common material used by local contactor
for Grade beam sides. The timber is generally
warped and wavy and hence the resulting
grade beam too becomes wavy. It is not
advisable to use such wavy timber as a
shuttering material.

17
 Photographs
In Grade beam formwork concrete will exert pressure on
sides and hence it is very important that sides are secured
with proper lateral support and tie members as shown in
the photograph. This will help in maintaining correct
alignment.

As seen in the photo above, mostly, carpenter tends to put the sides
of plinth beam directly on the uneven stone work. This leaves large
voids for concrete slurry to flow out; leaving the concrete weak and
full of voids. This practice should not be followed. For small individual
To ensure correct alignment of the timber or work, in case if such method is followed, all voids should be sealed
plywood formwork, it is must that they are with lean mortar before concreting.
nailed tightly with a runner as shown in the
photo. If the timber board or plywood is left
free, then it will warp and resulting concrete
too will be wavy.
Photographs

To ensure and maintain correct width of Grade beam it is

In the above photo, for concreting of 230 mm
grade beam, carpenter has used, a brick as a
must to install a spacer or a tie rod at the top surface as seen in
spacer. This is very crude practice and should not the photo. This will hold the two sides of shuttering in place
be followed. Spacer should be of correct size and and prevent them from bulging.
dimension and also should be of non
absorbing/reacting material.

18
 Photographs
If the grade beam work is not done ensuring proper line and
level, it is likely that bottom of the Grade beam is caved in as
seen in the photo. This is one of the most commonly occurring
error found on site. This happens because, there is a
conventional mis-understanding that bottom of the grade
beam should be kept slanting towards inside; so that under the
pore pressure it can bulge. This is completely a wrong practice
and should not be allowed. The formwork should always be
installed as per proper line and level following design drawings
& secured strongly.

Concrete finish level marked

clearly on the formwork to
ensure correct line and level
of finish concrte

All the columns should be marked as a group and then

formwork should be done. As seen in the photo, the string
should be stretched across in both directions to check both
The top level of the finished concrete of the
individual and group alignment of the column before final
Grade beam should be at one level. To ensure securing the forms. Alignment of column is very important for
Photographs

the same, before starting of the concrete required structural performance.

operation, using level tube, a concreting level
should be marked on the sides of the shuttering
plate and on the column reinforcement as well.
The concreting should be done till this filling
level. This will help ensure the correct alignment
of the grade beam top.

Though timber is used as one of the most

common formwork material, it's use needs due
attention and precautions. photo is a close up
of a finished column, in which sides have caved
in because timber formwork used for column
sides had warped. This will lead to reduce
column cross-section and will hamper the
strength and stability of the column.

19
 Photographs

Starter concrete helps in ensuring correct

alignment of the column. As seen in above
photo, 3” section of the column is
concreted first. This will help ensure Above is a photo of starter concrete done with negligence. To
correct alignment and also, work as ensure quality, starter concrete should be done along with
support and reference for erection of the Grade beam. If it is done separately, it creates multiple
column formwork. cold joints within a very small cross section of column. Also,
scale of starter concrete is so small that if the activity is not
schedule consciously with other column concrete, then
generally field team tends to do it without any supervision or
equipment using just hand mix concrete. This will lead to
result as seen in the photo above. This should not be
permitted what so ever.

Above photograph displays column which

Photographs

is skew in its plan. It is very important that

columns are checked from alignment Column once aligned and plumbed; should be secured in all
apart from verticality or plumb. Also, four direction so as to ensure stability during concreting.
twisting of reinforcement is not at all
allowed while installing formwork or
cover. This will seriously hamper the load
carrying capacity of the column.

Column formwork should be designed leak

tight so as to allow proper compaction of
concrete.

20
 Photographs
Column formwork should be secured properly on all sides.
There should not be any leakage of cement slurry. It is
commonly seen that the carpenter ensure that there is no
leakage from formwork sides but overlooks the leakage
from the bottom of the formwork as seen in the above
photo. The same occurs if there is no starter or mis-
alignment of column. If needed the joint could also be
packed using lean cement mortar.

Above photo shows a

column which is out
of plumb by more
then an inch due to
negligence during
formwork alignment.
This will lead to
serious structural
instability and should
not be permitted.

To achieve speed in execution, at many places,

carpenter tends to remove column forms
prematurely or exactly by 16 to 24 hrs. In such
cases, if the concrete has not gain sufficient
strength or reinforcement bars are not secured
properly then due to the swaying of reinforcement
bars of column, a fine crack develops as seen in the
photo. This can seriously affect the strength and
durability of the member. All care should be taken
that the formwork is not released prematurely
and reinforcement bars are secured properly
Photographs

against any lateral swaying effect.

When column is casted in two lift; it is very important and
critical to ensure the alignment during formwork. In many
places it is seen that during second lift, since work is to be
done at particular height, negligence crops. The result is the
above photo, where one can see column out of plumb and
shifted in second lift. This will pose serious threat to the
structural stability of the building. Also, the joint between
the two lift is very important and proper precautions should
be taken to avoid cold joint and segregation.

To avoid weak joint between two lifts of column,

precautions like the one shown in photo of putting
additional aggregate pieces will help.
 In small works, as seen in the photo above, the contractor tends to use
brickwork as two sides of column formwork. They raise the brickwork
on both the sides of the column, and then just place two planks on
remaining two sides. This is a very crude method of column concrete
and should not be allowed. In such method, most of the time, it is
difficult to maintain the column cross section and it can become
smaller or bigger then specified. Also, brick being a porous material,
will absorb, lot of water from the concrete, leaving the concrete
section in touch with the brickwork porous and non-durable.

As seen in the photograph, the practice of using

brickwork as column formwork is more commonly
seen for the column section between lintel and slab.
In most cases the length of this section is about half
a meter; hence people generally tend to overlook it
and manage it using brickwork as formwork. This
results in the same concerns as elaborated in above
point and should not be followed.
Photographs

Photograph shows a typical example of

column concreted using brickwork as
formwork. One can clearly see the variation
in the cross section across the column A photograph showing separate box formwork
length. This will what generally happens installed for the column section above lintel so as to
ensure correct quality.
when brickwork is used as column formwork
and hence it should be avoided.

Photographs shows a peculiar example of using

proper infrastructure i.e. using separate small size
column box to avoid problems discuss earlier. But
while using the same, if care is not taken, it can too
lead to disastrous results of mis-alignment, leakages
or twist as seen in the photo.

22
 Photographs

In most cases, for lintel formwork to save time and

material, carpenter tends to avoid giving lateral
supports. They nail the planks directly to the wall as
shown in the photo above. This is not a good practice,
as it will not secure the forms correctly and leakages
will happen from the bottom of the forms as seen in
the photo. A better detail will be to install a runner
plate at the bottom of the form and then nail the Lintel formwork can be done either in timber, plywood
forms with it. Also, provision of sufficient inclined or or steel. As in case of grade beam and column, the use of
ground support so as to ensure lateral stability is timber may lead to warping and hence wavy final finish
must. or concrete. But conventionally contractor tend to use
the same due to low initial investment and ease in
Photographs

workmanship.

For lintel bottom, conventionally carpenter tends to Above photograph clearly shown the sagging of lintel
rest the bottom at two places i.e. Just nail a piece of log concrete, due to settlement of forms which were not
on the wall and support the bottom as shown in the secured properly.
photo above. Additionally just a prop is placed and
naied through top. The above method of lintel
formwork is very crude method and it will lead to
bending of lintel.

Use of Props with ‘T’ head as shown in the photo will

help provide better support to lintel bottom.

23
 Photographs

T headed props can also be made using wooden ballies as

seen in the photo above.
Photographs

When such unseasoned and fresh quality of timber,

as seen in the photo, is used, it will tend to absorb lot
of moisture from the concrete and will lead to honey
combs. The approved quality of de-shuttering agent
if applied on such forms, it will not only reduce water
absorption by shuttering material but also help in
quick release of forms.

Weathershed or Chajja formwork is generally done along

with lintel as shown in the photo. In general practice,
carpenter tends to use timber as shuttering material for
this purpose due to ease in workability and also due to
low initial investment. The same could be made in ply or
steel shuttering plate. The finish quality will be better in
case of steel or ply shuttering.

When timber shuttering is used, there are large gaps,

and one of the most economical or common system
people use is put waste cardboards as packing over
the gaps. The system is not a recommended practice.

As seen in photo when using timber forms, there are

all possibilities that the ends of forms are not
straignt. In such conditions, it is important ot ensure
that: a) the form is intact till the minimum concrete
pore height and b) there are no leakages while
concreting.

24
 A photograph shows peculiar way of concreting of slab used by
contractors in general. The wooden piece highlighted in figure is
a guide piece used by many for establishing filling level of
concrete. Reference piece is made of 4” or as per the design
thickness of slab and then putting it as reference level slab is
concreted till its top. This method is a very crude method since
instead of getting a universal level what one gets is a 4” level with
respect to formwork. Now if there are any variation in the level
of the formwork, the same will be reflected in the slab making
slab wavey or of varying thickness.
Photographs

Generally to achieve varying height in single pore,

All inserts and conduits of concealed work should be carpenter tend to use brick as a stopper. A better
installed after formwork and before concreting. Breaking of practice will be to have a shuttering material with a
concrete to install conduits should not be allowed. gap below but in cae if the bricks are used then they
should be fully soaked in water so that they don't
absorb any water from concrete.

Forms should be applied with approved quality of

de-shuttering agent so as to ensure easy release of
form without affecting the quality of concrete. The
deshuttering agent will also help protect the forms
Photo above is a typical example of what happens when giving it larger usable life. All needed precautions
slab is concreted using timber planks. As highlighted in should be taken to ensure the deshuttering agent
photo, due to multiple joints in planks, the cement slurry does not come in contact with the reinforcement
leaks leaving concrete with honeycombs. and affect its bonding capacity.

Photographs
25
 Photographs
It is important to wet the forms before
actual concreting is started. This is very
important in case when timber and
plywood shuttering are used. Also once the
formwork operation is complete after
reinforcement laying and before concreting
As seen in the photo, in certain part all concealed wiring and inserts should be
of India, people use timber planks as fixed correctly as shown in the drawing.
bottom shuttering and lay GI sheets
over it. The system does solve the
problem of leakages, but the system
Alternatively, certain contractor
is very cumbersome. Also, due to
tend to use, low grade plastic like
waveyness of the sheet, the concrete
the one shown in the photo
too is wavey.
above, which is preferable for
small individual projects. Such
plastic will give good leak proof
surface but the surface will not
be plane. It will be wavey in
nature and hence will consume
more plaster in finishing the
same. Also, smoothness of
plastic will tend to reduce the
effective bond between
concrete and plaster.

When steel plates are used as forms, due to modular

sizes of the readily available steel plate, the system will
be generally hybrid system. Contractor will use the
timber plank for the residue as seen in the photo above.
Care should be taken, to ensure correct matching of
levels between the two materials. Also, joints should be
made leak proof.

The photo above shows a better arrangement of supporting

structure. All the props are vertical and are ‘T’ headed. Also,
they are supported on the firm ground with a base plate,
eliminating any chances of settlement or collapse.

The photo crearly shows the status of the supporting

structure in most conventional works. The ballies are spaced
apart much larger then they should be. Also, most of them
are inclined. Such supporting structure will be very unsafe
and may lead to collapse.

26
 Photographs
A typical photograph showing the implication if
proper filling level is not marked on the slab
formwork. One can see the top reinforcement bars
exposed indicating lower filling level. This could lead
to structural implication and should not be allowed.

In the above photo a person is observing

leakages of cement slurry through
timber sides. This is one of the common
concerns faced by most carpenter since
sides are being done by timber which is
difficult to make water tight. A best
solution will be to either use ready
made PVC fillets available in the market
at the junction to make it water tight or
seal the same using cement mortar
from inside.

Timber is largely used as

sides for the slab

A photograph
showing sagging in
the slab reflecting a
very clear example
of settlement of
support props
during concreting.

Photo beside is a classic example of

what happens when props are not
secured properly. one can see the
concreting is going on for the way slab
of the staircase and a carpenter is re-
adjusting the props below. All the
As seen in the photo above, carpenter
supports should be checked for
generally tend to secure side planks of
stability before the actual concreting
slab by tying it to reinforcement using
is started.
binding wire. Such practice, will not
secure forms properly and will also
facilitate corrosion of steel in the future.
The same should not be permitted.

Photographs
27
 Good Details

Finished
A Concrete
Concrete
B When timber planks are used for wall or
Fines
vertical formwork, they should be
staggered in a pattern for better look.
It will be important to ensure that formwork is erected in such a way
Also, staggering should be in line with
that there is no possibilities of concrete leakages in joints and
the post support, for better rigidity and
inserts causing formation of fins as shown above. The detail similar
clear finish of concrete
to the B should be evolved to avoid such cases.

It is very basic and important

point that when ever nailing is
done in formwork erection, it
is not done perpendicular but
slightly inclined for better
holding capacity. Also, for
easy removal of nails; without
damage to the formwork, the
nail heads shall be left slightly Similarly; it is advisable to stagger joint
protruding. between vertical and soffit member of
formwork.

It is advisable to
have additional
support to the post
when load carrying
members are
directly nailed to
the props.

Similarly installation of additional

stiffener plate will impart better
stability to the joint.

As seen in the photo above, make shift arrangement to obtain

the required height for props should be avoided. This is the
reason for most of the formwork failures.

28
 Mould
Mould
“MOULD” Design and economic consideration for precast elements
·
Mould cost forms major component of total cost stripping of mould completely is the best
of Precast element. The mould cost depends on solution.
number of moulds shape, repetition of mould, ·
Generally, the minimum positive draft that will
time required for assembling and dissembling of allow the unit to be stripped from the mould
the mould and complexities in terms of reveals easily is 1:12, but 1:8 is preferred. This draft
and rustication. should be increased for narrow or delicate units
·
Precast element may require typical shapes, where the suction between the unit and the
particularly at the corners, edges or mould becomes a major factor in both strength
architecturally, while changing the details at the requirements and reinforcement of unit. The
same time keeping the over all language same. draft should be increased to 1:6 for units pierced
The design should accommodate these shapes to with many openings, for narrow ribbed panels
be produced from the same basic (master) mould and for smooth concrete and delicate units.
rather than all together different mould. (Ref fig) ·
Drafts for ribbed panels should be related to the
·
The mould material selected typically depends depth, width and spacing of the ribs.
on a project's schedule. A project with a long lead ·
At areas where negative draft is required, it may
time should permit fewer moulds to be built, but be necessary to incorporate slip blocks (i.e.,
it also may require more expensive, longer- removable plugs) to aid in stripping the precast
lasting moulds. concrete panel from the mould.
·
Wood and fiberglass moulds will last for about 20 ·
Regardless of material used an individual mould
to 30 castings before they must be completely complexities determines its cost. Reveals and
refurbished or replaced. Where as steel mould rustication must be placed in repetitive pattern
gives repetitions of about 100 times, with minor to minimize modification throughout mould life.
maintenance. Reveals, like all other form features, must be
·
For minimising the time required to dissemble design with small draft (by creating bevel) so the
the mould and reassemble it for manufacturing panel can be stripped without damaging the
of next piece; removing the element without form feature.

MASTER MOULD CONCEPT is based upon fabricating one master mould (with appropriate additional
tooling) which allows a maximum number of casts per project. Units cast in the mould need not be identical
provided changes in the units can be accomplished as pre-engineered mould modifications.

Intermediate panel

Surface of panel is trowelled

flat Timber Mould
Panel with left and return Panel with right
hand return

29
 Safety
Safety
·
Do a through inspection of all the ·
Erection should be done in such a way so as
scaffolding material before use so as to to provide access to all parts of the
check for any damages or weakness. scaffolding and formwork system any time
before, during and after concrete.
·
No material should be stress beyond its
Additional staircase may be provided if the
permissible stress level.
inspection is not possible as a part of
·
Props should be rested vertical on a farm scaffolding system.
ground using base plate.
·
There should be always extra support
·
Preferably timber member should not be members and other scaffolding / form
spliced between supports. material available so as to be used in case
of any unforeseen event of settlement.
·
All splices should be secured properly.
·
It is advisable to keep a watch on the
·
Fasten all braces securely. movement of the scaffolding elements for
·
Take special precautions when shoring to any unforeseen movement or upliftment
and from slope surfaces. by experience form watchers.

·
All erection work should be done as per the ·
If pump concrete is to be used, ensure that
design and specifications. No alteration lateral loads, vibration and other forces
should be done in the field without the have been considered and adequate
permission of EIC. precautions taken to assure stability.

·
If the load is to be transferred on newly ·
Plan concrete pouring methods and
build structure, ensure that it has gain sequence to ensure against unbalance
sufficient strength to take the live and dead loading. Take all necessary precautions to
load of the scaffolding system along with avoid uplift of shoring components and
wet concrete and concreting loads. formwork.

·
Ensure that the spanning members of the ·
Erection should be done under the
scaffold have proper bearing and are supervision of the competent engineer
secured properly for any up-liftment. and should be approved formally by EIC for
concreting. Safeguard or accident
·
Provide guardrail systems on all open sides prevention measures be taken where
and openings in formwork and slabs. Also, necessary or advisable.
as per the requirement of site; workforce
should be provided with Personal ·
Stripping of formwork should never be
Protection Equipment (PPE) like helmet, done before the stipulated time as
safety gloves, safety footwear, eye recommended in IS 456: 2000.
protection, masks, safety belts, etc. ·
It is advisable that based on the site
·
Do not place additional loads on the conditions, a “safe working method and
scaffold system such as brick or rebar sequence” is worked out on site and the
bundle. If kept check for stability and load workforce is trained in operating the same
carrying capacity of scaffold system. Also way. This will help ensure quality and also
ensure uniform distribution of any such safety of the formwork system as well as
additional loads. the workforce implementing the same.

30
·
Special attention should be given to the ·
In case structural elements such as
partial erected or dismantled formwork, cantilever beams/slabs, where
since in such cases the formwork is not overturning is an important parameter,
completely secured at all point of time. stripping of formwork should only be done
Also, if the work is left half done(at the end after full restraining forces are ensured.
of the shift) then the stage at which it
should be left should be decided by
competent authorities and any additional
provisions needed to secure the half done
work should be installed before closing of
the work.

Common Mistakes and Malpractices

·
Overlooking formwork activity as “not so critical” activity.
·
Un availability of formwork drawings on site.
·
Inadequate on site training and supervision.
·
Erection of formwork system on unstable base support or ground.
·
Poor installation of bracing and ties.
·
Last minute unauthorized changes in the formwork.
·
Use of substandard formwork materials and tools.
·
Overestimating the strength of the existing structure or newly build permanent structure and
erecting formwork with its support.
·
Overloading of formwork or improper placement of concrete.
·
Inadequate anchorage against uplift due to battered form faces.
·
Failure to observe "minimum stripping time" requirement clause.
·
Not planning for stripping sequence correctly.

31
 Formwork Maintenance
Formwork Maintenance
·
Formwork components should be sorted and stored in stable position so as to avoid any undue
stress on any component or member. Storage should be carried out on load carrying and flat
areas.

·
If plywood formwork is to be stored for long time after use, the panels should be dried
completely by stacking in free circulation area and then stored using suitable spacers.

·
Timber formwork should not be stored in direct contact with ground or wall and should never
be stored in damp atmosphere.

·
All nails and projecting elements should be removed from formwork material before shifting
them to the storage site. This will ensure proper safe stacking of forms.

·
If to be stored for longer duration, bolts, couplers and other similar components, should be
oiled or greased to avoid rusting.

·
All form material which will come in direct contact with concrete should be coated with
suitable form release agents.

·
When placing heavy items, such as re-bar bundles suitable support and protection must be
used so that the form lining is not damaged.

·
During concreting, unused tie holes and drill holes should be sealed using suitable material.
This will keep formwork material clean and will prevent the need of additional cleaning and
repair works.

·
All tie-holes plugged with concrete or any other material should be cleaned carefully.

·
Concrete surplus should be removed after each de-shuttering operation. This will ensure
longer service life of the forms.

·
Any formwork material should not be span more then its permissible carrying capacity. This
will ensure its alignment and avoid any deformations.

·
Striking of formwork should be done appropriately using correct tools. Also, formwork
material should never be thrown from height but lowered to the ground using ropes or other
suitable materials.

·
Any repair work to be carried out on the formwork system should be done by qualified persons
under the instruction of Engineer.

32
 Formwork
Measurements
Formwork
Measurements
Formwork : Methods of Measurement as per SP 27-1987

Formwork is generally measured in sq.m as the actual surfaces in contact with the concrete or any
other material requiring formwork. Description of formwork, unless specified otherwise will
generally include:

nSplayed edges, notchings, allowance for overlaps and passings at angles, sheathing
battens, strutting, bolting, nailing, wedging, casing, striking and removal;

nAll supports, struts, braces, wedges as well as mud sills, piles or other suitable
arrangements to support the formwork;

nBolts, wire ties, clamps, spreaders, nails or any other items to hold the sheathing
together;

nWorking scaffolds, ladder, gangways, and similar items;

nFilleting to form stop-chamfered edge or splayed external angles not exceeding 20 mm

wide to beams, columns and the like;

nIf required, temporary opening in the forms for pouring concrete, inserting vibrators, and
clearing holes for moving rubbish from the interior of the sheathing before pouring of
concrete;

nDressing with oil to prevent adhesion; and

nRaking of circular cutting.

·
Where formwork is required to be lined with lining or to be coated with mould liquid or lime
white; such formwork shall be so described and measured separately.

·
Where lining of wallboard, asbestos, cork slab and the like is of a permanent character and is
to be left in, such lining shall be measured separately; the description shall include any
necessary fixing to the concrete.

·
No deductions shall be made for opening up to 0.4 sq. m. No deduction shall be made for any
opening /cutouts when slip form techniques is used.

·
Raking of circular cutting and rounded or moulded edges shall be measured in running meters.
Moulded stoppings shall be enumerated.

·
Formwork to secondary beam shall be measured up to the sides of main beams, but the
deduction shall be made from the formwork of the main beam where the secondary beam
intersects it. Formwork to beam shall be measured up to sides of column, but no deduction
shall be made from the formwork to stanchion or column casings at the intersections of beam.

33
 Table showing shuttering materials that can be conveniently used for
different items
Sr.
Item Type of Centering Material Reason
No.
1. Sides and Pedastal 30 to 40 mm thick timber planks Normally the side depth where
of RCC footing or plywood. shuttering for a footing is to be provided
is 150mm to 300 mm and thus only
shuttering with timber planks is most
suitable. Adjustments due to change of
size can always be made without much
effort.

2. Plinth Beams, D.P.C. 30 to 40 mm thick timber planks As the depth of member where
and Window Sills, or plywood. shuttering is to be provided would be
etc. considerably small, use of timber
shutters would be suitable.

3. RCC walls circular or (i) For small works ply wood with For small works repetitions will be less
straight timber backing. and altering timber shutters is easy.
(ii) For large works only steel
shuttering.

4. Suspended floor, (i) Bottoms : Preferably steel or Regardless of quantity of work involved,
Roofs, Landings and ply wood with timber backing. steel shuttering for bottom face is most
Balconies (ii) Slab edges : Only timber suitable. Even in small towns one can get
planks are used conveniently. the steel shutters on hire. The use of
(iii) Supports and Bracings : For planks for bottom will leave lot of gaps
small works ballies can be between the planks, and it will be almost
useful regardless of span. impossible to control the leakage of
However, for slabs at a height slurry. As edge thickness is generally
of more than 3.5 m steel props within 150mm only timber planks would
or steel pipes should be be most suitable. For slabs at a height less
preferred. than 3.5m the bottom shutters can rest
on timber runner of size 50mm x 75mm
which is supported by ballies.
For slabs at a height of more than 3.5m
the bottom shutters can rest on steel
channels supported by either steel props
or pipes.

5. Chajjas -do- -do-

6. Lintels (i) for small works : Bottom, sides As the bottoms are to fixed on both sides
and ends all with timber planks of the frame and the heights of sides are
or playwood less only timber planks are suitably used.
(ii) For large repetitive work :
For large repetitive work (like mass
Bottom, sides and ends with
housing), modular shuttering made using
ply or steel forms.
ply or steel will help increase speed and
improve productivity.

34
Sr.
Item Type of Centering Material Reason
No.
8. RCC Beams (i) Bottoms : Timber planks or ply For smaller widths timber planks are
wood with timber backing. most suitable. However for wider
Steel shutters can be used if bottoms, plates with shuttering ply
the quantity is more and the and timber backing are manufactured
sizes of members is same. and used. Depending upon the
quantity of work, and sizes, steel
(ii) Beam Sides bottoms are used. For small height
a) Sides for Beams within beams, the use of timber planks is
300mm height : Timber planks. more convenient.
b) Sides for Beams more than
300 mm height : Preferably Regardless of the height of the beam
shutters with ply backed with above floor, the beam side shutters
timber or even steel shutters manufactured with ply backed with
are used. timber are used very conveniently.
Only if the quantities are large and the
(iii) Supports and Bracings: heights of beams are same steel
a) Beams within 3.5m height shutters are used.
above floor : Medium size
Ballies (100mm or so) Normally ballies are preferred for all
b) Beams above 3.5 m height small and medium works. If available
from floor : steel props and steel props are pipes are used, which
pipes. is preferable to Ballies.

As per general safety norms, only steel

props or pipes must be used if the
height is more then 3.5m.

Normally ply backed with timber When compared to the investment

9. RCC Columns shutters are used but if the and return between ply backed with
quantity of work is more and sizes timber shutters, and steel shutters. It
are same, steel shuttering is used. is only the former, that is preferred.
However only if quantity is more steel
shutters are preferred.

10. Stair-Case (i) Risers and Edges/Sides. Only As the height of shuttering is generally
timber planks. 150mm or less only timber planks are
(ii) Landing slab. Waist slab, etc. used. It is very convenient to use steel
Mostly steel plates or ply plates too. These days steel plats are
(iii) Supports : Ballies or props. generally available on hire in even
medium towns. As the heights are less
and varying in case of waist slab only
ballies are used using steel props or
pipes will not be easy.

35
 Sr.
Item Type of Centering Material Reason
No.
10. Arches and Domes Dome/Arch bottoms : (mixed type) For all types of domes timber planks are
Most common method is Timber shaped to size and fixed and on top
planks cladded with thin steel either thin steel sheet or ply is fixed.
sheets or ply. Alternatively steel This method is suitable for all size
sheets are fixed to angle iron domes. There is absolutely no necessity
runners bent to shape. to insist on doing steel shuttering for
this item. However some times instead
Staging for Dome or Arch : Mostly of wooden runners angle iron is bent to
the staging of wooden ballies is shape and the iron sheet is cladded on
used. top.

It is most convenient to use balli staging

for both dome or arch so that all small
supports can be given easily. Staging
with steel it is most convenient to use
balli staging for both dome or arch so
that all small supports can be given
easily. Staging with steel pipes is a
cumbersome job and shall require more
effort and labour and ultimately
become very costly.

11. RCC shafts Shaft walls : Normally shutters with Normally for all small and medium
ply backed with timber is used. jobs only timber shutters with ply facing
However, if the quantity is preferred. These shuttes can easily be
is more, steel shuttering is used changed for required size etc. however
steel shutters are mostly used on big
projects.

12. Vertical and Only timber shuttering or plywood As these are small sections only timber
Horizontal fins planks or plywood are used to these
items.

13. Bands, coping, -do- -do-

Moulding etc.

36
 Annexure
Information to be supplied by the manufacturers of properietry falsework system
The manufacturer should give the information in such details so as to assist the user and to
obviate unsafe use of the material due to absence of information or due to wrong assumptions
made on the part of the user.

The user may refer unusual problems or problems of erection or assembly, which the
manufacturer should clarify with all technical details.

The manufacturer of proprietary falsework systems or its parts shall supply the information
necessary for the design, erection, use, dismantling and maintenance of the components. The
information should relate to the properties of the individual components, their use in expected
assemblies, any specific requirements for inspection and maintenance; and should include the
following:

Identification, description and the intended use of the components, their dimensions and
weights.
·
Drawings of major components giving dimensions, extensibility, weight, locating and fixing
arrangements. Locations of holes and cleats, etc, and any other details, of interest or use to
designer or site engineers.
·
Details and specifications of the materials used and reference to relevant standards.
·
Modifications for extended or additional uses and limitations for every use should be given.

Strength details of the component and assemblies, as given below:

·
Characteristic (that is assured) failure loads;
·
Maximum working loads for different conditions of use and extensions;
·
Maximum eccentricities related to above conditions;
·
Deflections and cambers at maximum working loads;
·
Conditions of limiting deflection;
·
Assumed working stresses and material properties, for example, yield stresses;
·
Section properties;
·
Information on design of sway bracing against lateral loads;

37
 References
·
IS 456 : 2000 Plain and Reinforced Concrete - Code of Practice

·
IS 2750 : 1964 Specification for Steel Scaffoldings

·
IS 4014 (Part 1) : 1967 Code of practice for steel tubular scaffolding Part 1 Definitions and
materials

·
IS 4014 (Part 2) : 1967 Code of Practice for Steel Tubular Scaffolding - Part II : Safety
Regulations for Scaffolding

·
IS 4990 : 1993 Plywood for Concrete Shuttering work Specification

·
IS 6461 (Part 5) : 1992 Glossary of terms relating to cement concrete: Part V Formwork for
concrete

·
IS 10421 : 1983 Proforma for analysis of unit rate of shuttering/formwork for
concrete items

·
IS 14687 : 1999 Falsework for Concrete structures - Guidelines

38
A typical format for form Watchers Report as per IS Code

Job location _________________ Date : ___________________

Placement Description : Floor______________________________

General Contactor_______________________________________

Placement number ______________________________________

General contractor supervisor______________________________

Column line references___________________________________

Starting time of placement ________________________________

Completion time of placement _____________________________

Concrete placing equipment _______________________________

Concrete conveying equipment _____________________________

Scope of sub-contractor's work_____________________________

Type of formwork or structure to which sub-contractor's work is framed___________________

Comments on general contractor's framing ___________________

List of points to check out before and during concrete placement

Form details for job ______________________________________

All shores in place _______________________________________

Wedges under shores tight and nailed________________________

Shoring hardware secured _________________________________

Sills solid on ground or slab________________________________

Lacing installed, when required _____________________________

Pans nailed _____________________________________________

Check for spreaders when required in joist pans ______________________________________

39
 Plywood joints flush ______________________________

X bracing installed where lateral movement could occur ______________________________

Beam spreader in place____________________________

Form hardware tight ______________________________

Tighten wedges under shores along construction joint of previous pour__________________

Check shores for plumb____________________________

Telltales in place and marked where required _______________________________________

Camber Installed _________________________________

Clean out holes patched___________________________

Chamfer and grade strips in place____________________
Equipment available in case of need for adjustment or strengthening
Extra jacks______________________________________
Extra lacing _____________________________________
Extra shores_____________________________________
Wedges ________________________________________
Pre-arranged signal with concrete foreman to stop pour in emergency ___________________
Check for possible exit routes in case of trouble have atleast two such routes available,
wherever possible________________________________
Know placing crews' sequence of pour, check for placing deep
beams or drops before main deck ___________________
For walls; know rate of placement for which forms designed and
protest, if exceeded _______________________________

40
Disclaimer
It is always advisable to seek professional advice for Formwork. The Manual is only intended to provide general assistance and
guidance for formwork. While all care has been taken to make this manual self-explanatory, Indian Standards be referred to if any
difficulty arises in interpretation. The Manual does not replace any rules, regulation or code of practice in force. Therefore, any
loss or damage arising due to reliance on this Manual can not be accepted.

A joint publication of

Building Material and Technology Promotion Council (BMTPC)

Ministry of Housing & Urban Poverty Alleviation, Government of India
Core-5A, First Floor, India Habitat Centre, Lodhi Road, New Delhi - 110003
Phone: +91-11-24638096, 24636705; Fax: +91-11-24642849
E-mail: bmtpc@del2.vsnl.net.in; Website: www.bmtpc.org

and

Society for Environment Protection (SEP)

6-A, Kalamwadi Society, Nr. Shreyas Crossing, Paldi,
Ahmedabad-380 007 (Gujarat)
Phone: 91-79-65137987, Mobile: 9327201215
E mail : admin@sepindia.org, Website: www.sepindia.org

Prepared by Mr. Dipan Shah with the support from SEP Team.
Design by Mr. Rajesh Patel
Photo credits: Society for Environment Protection (SEP)
© 2012, All rights reserved
For further details contact:

Building Material & Technology Promotion Council

Ministry of Housing & Urban Poverty Alleviation, Government of India Manual on Basics of
Formwork
Core 5 -A, First Floor , India Habitat Centre, Lodi Road,
New Delhi- 110 003, India
Phone: 91-11-24638096, 24638097, 24636705 Fax: 91-11-24642849
E-mail: bmtpc@del2.vsnl.net.in, Website: www.bmtpc.org

Building Materials & Technology Promotion Council

Society for Environment Protection (SEP) Ministry of Housing & Urban Poverty Alleviation
6-A, Kalamwadi Society, Nr. Shreyas Crossing, Paldi, Government of India
Ahmedabad-380 007 (Gujarat)
Phone: 91-79-65137987, Mobile: 9327201215
E mail : admin@sepindia.org, Website: www.sepindia.org