Andhra Pradesh State Highways Project

Formwork
1500
Formwork

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1501. DESCRIPTION

Formwork shall include all temporary or permanent forms required for forming
the concrete of the shape, dimensions and surface finish as shown on the drawing or as
directed by the Engineer, together with all props, staging, centering, scaffolding and
temporary construction required for their support. The design, erection and removal of
formwork shall conform to IRC : 87 “Guidelines for Design and Erection of Falsework
for Road Bridges” and these specifications.

1502. MATERIALS

All materials shall comply with the requirements of IRC : 87. Materials and
components used for formwork shall be examined for damage or excessive deterioration
before use/re-use and shall be used only if found suitable after necessary repairs. In case
of timber formwork, the inspection shall not only cover physical damages but also signs
of attacks by decay, rot or insect attack or the development of splits.

Forms shall be constructed with metal or timber. The metal used for forms shall
be of such thickness that the forms remain true to shape. All bolts should be countersunk.
The use of approved internal steel ties or steel or plastic spacers shall be permitted.
Structural steel tubes used as support for forms shall have a minimum wall thickness of 4
mm. Other materials conforming to the requirements of IRC : 87 may also be used if
approved by the Engineer.

1503. DESIGN OF FORMWORK

1503.1. The Contractor shall furnish the design and drawing of complete
formwork (i.e. the forms as well as their supports) for approval of the Engineer before
any erection is taken up. If proprietary system of formwork is used, the Contractor shall
furnish detailed information as per Appendix 1500/I to the Engineer for approval.

Notwithstanding any approval or review of drawing and design by the Engineer,

the Contractor shall be entirely responsible for the adequacy and safety for formwork.

1503.2. The design of the formwork shall conform to provisions of IRC : 87. It
shall ensure that the forms can be conveniently removed without disturbing the concrete.
The design shall facilitate proper and safe access to all parts of formwork for inspection.

1503.3. In the case of prestressed concrete superstructure, careful consideration

shall be given to redistribution of loads on props due to prestressing.

1504. WORKMANSHIP

1504.1. The formwork shall be robust and strong and the joints shall be leak-
proof.

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Balli shall not be used as staging. Staging must have cross bracings and diagonal
bracings in both directions. Staging shall be provided with an appropriately designed base
plate resting on firm strata.

1504.2. The number of joints in the formwork shall be kept to a minimum by

using large size panels. The design shall provide for proper “soldiers” to facilitate
alignment. All joints shall be leak proof and must be properly sealed. Use of PVC JOINT
sealing tapes, foam rubber or PVC T-section is essential to prevent leakage of grout.

1504.3. As far as practicable, clamps shall be used to hold the forms together.
Where use of nails is unavoidable minimum number of nails shall be used and these shall
be left projecting so that they can be withdrawn easily. Use of double headed nails shall
be preferred.

1504.4. Use of ties shall be restricted, as far as practicable. Wherever ties are used
shall be used with HDPE sheathing so that the ties can easily be removed. No parts prone
to corrosion shall be left projecting or near the surface. The sheathing shall be grouted
with cement mortar of the same strength as that of the structure.

1504.5. Unless otherwise specified, or directed, chamfers or fillets of sizes 25 mm

x 25 mm shall be provided at all angles of the formwork to avoid sharp corners. The
chamfers, bevelled edges and mouldings shall be made in the formwork itself. Opening
for fixtures and other fittings shall be provided in the shuttering as directed by the
Engineer.

1504.6. Shuttering for walls, sloping members and thin sections of considerable
height shall be provided with temporary openings to permit inspection and cleaning out
before placing of concrete.

1504.7. The formwork shall be constructed with precamber to the soffit to allow
for deflection of the formwork. Pre-camber to allow for deflection of formwork shall be
in addition to that indicated for the permanent structure in the drawings.

1504.8. Where centering trusses or launching trusses are adopted for casting of
superstructure, the joints of the centering trusses, whether welded, riveted or bolted
should be thoroughly checked periodically. Also, various members of the centering
trusses should be periodically examined for proper alignment and unintended
deformation before proceeding with the concreting. They shall also be periodically
checked for any deterioration in quality due to steel corrosion.

1504.9. The formwork shall be so made as to produce a finished concrete true to

shape, line and levels and dimensions as shown on the drawings, subject to the tolerances
specified in respective sections of these specifications, or as directed by the Engineer.

1504.10. Where metal forms are used, all bolts and rivets shall be countersunk
and well ground to provide a smooth, plane surface. Where timber is used it shall be well

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seasoned, free from loose knots, projecting nails, splits or other defects that may mar the
surface of concrete.

1504.11. Forms shall be made sufficiently rigid by the use of ties and bracings to
prevent any displacement or sagging between supports. They shall be strong enough to
withstand all pressure, ramming and vibration during and after placing the concrete.
Screw jacks or hard wood wedges where required shall be provided to make up any
settlement in the formwork either before or during the placing of concrete.

1504.12. The formwork shall take due account of the calculated amount of
positive or negative camber so as to ensure the correct final shape of the structures,
having regard to the deformation of false work, scaffolding or propping and the
instantaneous or deferred deformation due to various causes affecting prestressed
structures.

1504.13. Suitable camber shall be provided to horizontal members of structure,

specially in long spans to counteract the effects of deflection. The formwork shall be so
fixed as to provide for such camber.

1504.14. The formwork shall be coated with an approved release agent that will
effectively prevent sticking and will not stain the concrete surface. Lubricating (machine
oils) shall be prohibited for use as coating.

1505. FORMED SURFACE AND FINISH

The formwork shall be lined with material approved by the Engineer so as to

provided a smooth finish of uniform texture and appearance. This material shall leave no
stain on the concrete and so fixed to its backing as not to impart any blemishes. It shall be
of the same type and obtained from only one source throughout for the construction of
any one structure. The contractor shall make good any imperfections in the resulting
finish as required by the Engineer. Internal ties and embedded metals parts shall be
carefully detailed and their use shall be subject to the approval of the Engineer.

1506. PRECAUTIONS

(i) Special measures in the design of formwork shall be taken to ensure that it
does not hinder the shrinkage of concrete. The soffit of the formwork shall
be so designed as to ensure that the formwork does not restrain the
shortening and/or hogging of beams during prestressing. The forms may
be removed at the earliest opportunity to the minimum time for removal of
forms with props retained in position.

(ii) Where necessary, formwork shall be so arranged that the soffit form,
properly supported on props only can be retained in position for such
period as may be required by maturing conditions.

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(iii) Any cut-outs or openings provided in any structural member to facilitate

erection of formwork shall be closed with the same grade of concrete as
the adjoining structure immediately after removal of formwork ensuring
watertight joints.

(iv) Provision shall be made for safe access on, to and about the formwork at
the levels as required.

(v) Close watch shall be maintained to check for settlement of formwork

during concreting. Any settlement of formwork during concreting shall be
promptly rectified.

(v) Water used for curing should not be allowed to stagnate near the base
plates supporting the staging and should be properly drained.

1507. PREPARATION OF FORMWORK BEFORE CONCRETING

The inside surfaces of forms shall, except in the case of permanent form work or
where otherwise agreed to by Engineer be coated with a release agent supplied by
approved manufacturer or of an approved material to prevent adhesion of concrete to the
formwork. Release agents shall be applied strictly in accordance with the manufacturer’s
instructions and shall not allowed to come into contract with any reinforcement or
prestressing tendons and anchorages. Different release agents shall not be used in
formwork for exposed concrete.

Before re-use of forms, the following actions shall be taken:

(i) The contact surfaces of the forms shall be cleaned carefully and
dried before applying a release agent.

(ii) It should be ensured that the release agent is appropriate to the surface to
be coated. The same type and make of release agent shall be used
throughout on similar formwork materials and different types should not
be mixed.

(iii) The form surfaces shall be evenly and thinly coated with release agent.
The vertical surface shall be treated before horizontal surface and any
excess wiped out.

(iv) The release agent shall not come in contact with reinforcement or the
hardened concrete.

All forms shall be thoroughly cleaned immediately before concreting.

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The Contractor shall give the Engineer due notice before placing any concrete in
the forms to permit him to inspect and approve the formwork, but such inspection shall
not relieve the contractor of his responsibility for safety of formwork, men, machinery,
materials and finish or tolerances of concrete.

1508. REMOVAL OF FORMWORK

The scheme for removal of formwork (i.e. de-shuttering and de-centering) shall
be planned in advance and furnished to the Engineer for scrutiny and approval. No
formwork or any part thereof shall be removed without prior approval of the Engineer.

The formwork shall be so removed as not to cause any damage to concrete.

Centering shall be gradually uniformly lowered in such a manner as to permit the
concrete to take stresses due to its own weight uniformly and gradually to avoid any
shock or vibration.

Where not specifically approved, the time of removal of formwork (when

ordinary Portland Cement is used without any admixtures at an ambient temperatures
exceeding 10 degrees Celsius) shall be as under:

a) Walls, piers, abutments, : 12 to 48 hours as may be

columns and vertical faces decided by the Engineer
of structural members

b) Soffits of Slabs : 3 days

(with props left under)

c) Props (left under slabs) : 14 days

d) Soffit of Girders : 7 days

(with props left under)

e) Props (left under girders) : 21 days

Where there are re-entrant angles in the concrete sections, the formwork should
be removed at these sections as soon as possible after the concrete has set, in order to
avoid cracking due to shrinkage of concrete.

1509. RE-USE OF FORMWORK

When formwork is dismantled, its individual components shall be examined for

damage and damaged pieces shall be removed for rectification. Such examination shall
always be carried out before being used again. Before re-use all components shall be
cleaned of deposits of soil, concrete or other unwanted materials. Threaded parts shall be
oiled after cleaning.

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All bent steel props shall be straightened before re-use. The maximum deviation
from straightness is 1/600 of the length. The maximum permissible axial loads in used
props shall be suitably reduced depending upon their condition. The condition of the
timber components, plywood and steel shuttering plates shall be examined closely for
distortion and defects before re-use.

1510. SPECIALISED FORMWORK

Specialised formwork may be required in the case of slipform work, underwater

concreting, segmental construction etc. Such specialised formwork shall be designed and
detailed by competent agencies and a set of complete working drawings and installation
instructions shall be supplied to the Engineer. The site personnel shall be trained in the
erection and dismantling as well as operation of such specialised formwork. In case
proprietary equipment is used, the supplier shall supply drawings, details, installation
instructions, etc., in the form of manuals along with the formwork. Where specialised
formwork is used, close co-ordination with the design of permanent structure is
necessary.

For slipform the rate of slipping the formwork shall be designed for each
individual case taking into account various parameters including the grade of concrete,
concrete strength, concrete temperature, ambient temperature, concrete admixtures, etc.
In the case of segmental construction, the concrete mix shall be normally designed for
developing high early strength so the formwork is released as early as possible.

In order to verify the time and sequence of striking/removal of specialised

formwork, routine field tests for the consistency of concrete and strength development
are mandatory and shall be carried out before adoption.

For specialised formwork, the form lining material may be either plywood or steel
sheet of appropriate thickness. Plywood is preferred where superior quality of surface is
desired, whereas steel sheeting is normally used where large number of repetitions are
involved.

1511. TEST AND STANDARDS OF ACCEPTANCE

The materials shall be tested in accordance with these Specifications and shall
meet the prescribed criteria.

The work shall conform to these Specifications and shall meet the prescribed
standards of acceptance.

1512. MEASUREMENTS FOR PAYMENT

Unless stated otherwise the rate for concrete in Plain Concrete or Reinforced
Concrete or Prestressed Concrete shall be deemed to include all formwork required in
accordance with this section and shall not be measured separately.

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Where it is specifically stipulated in the Contract that the formwork shall be paid
for separately, measurement of formwork shall be taken in square metres of the surface
area of concrete which is in contact with formwork.

1513. RATE

The unit rate of the Plain Concrete or Reinforced Concrete or Prestressed Concrete
as defined in respective sections shall be deemed to cover the costs of all formwork,
including cost of all materials, labour, tools and plant required for design, construction
and removal of formwork and supervision as described in this section including properly
supporting the members until the concrete is cured, set and hardened as required.

Where the contract unit rate for formwork is specifically provided as a separate
item, it shall include the cost of all materials, labour, tools and plant required for design,
construction and removal of formwork and supervision as described in this Section
including properly supporting the members until the concrete is cured, set and hardened
as required.

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