Formwork 101 - MEVA USA

What is Formwork?

In a nutshell, formwork is the mold wherein fresh concrete is poured and formed. The mold, which can be permanent or temporary, holds the poured concrete and shapes it until it solidifies and becomes strong enough to support itself and other loads.

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Formwork is also known as “shuttering.” However, in certain parts of the world, shuttering refers to using plywood or timber to create the mold.

Formwork systems can be classified according to the following parameters:

• Types of material used to create the mold (plastic, steel, timber, aluminum)
• Types of concrete structure it supports (slab, column, wall)

Construction costs usually consist of building materials (ca. 45%), labor (ca. 45%), and operating expenses (ca. 10%). Formwork material comprises 15% of the total building material and contributes roughly 44% of the total labor. Meanwhile, formwork construction accounts for up to 25% of the total cost of building the structure. For this reason, many builders and construction companies prefer reusable forms (panel forms). The process of removing formwork is called “stripping.”

2. Column

As the name suggests, column formwork is used in the construction of circular or rectangular columns. Columns have formwork sections with a “closed load transmission,” which is supported by the formwork’s design and the guaranteed tensile strength rather than by using ties.

Steel formwork is often used to form circular columns as it is economical and available in incremental dimensions. Single-use forms, which are destroyed and disposed of during stripping, can be used as an alternative. However, using single-use formwork is not advisable if you need to construct multiple circular columns.

Meanwhile, rectangular columns are formed using three systems depending on their specifications. For instance, classic timber girders with steel walers and a plywood facing are often used when builders need to construct a significant number of columns with special dimensions. The windmill system, which is composed of columns or multipurpose panels of frame formwork systems, is suitable for building single columns with a standard dimension.

Finally, a foldable column formwork is highly suitable for columns with great heights. Because all the essential components (panels, connecting devices, ladders, and access platforms) are integrated into this type of column formwork, it helps builders reduce their construction time and costs.

3. Wall

Wall formwork comes in different types and classifications, as outlined below.

Conventional
Conventional wall formwork consists of boards or sheets and squared timber. It is flexible, but it can be costly and time-consuming as each component must be assembled on-site. In addition, all of its parts should be made according to the project’s specifications, and they must be nailed together and dismantled again after concreting.

Girder

This is a better version of the conventional formwork. Its components, which usually consist of dimensionally stable girders with two chords and one web, have been standardized to facilitate the assembly of identical and ready-to-use panels. The connection of the panels has also been systematized.

Frame
This type of wall formwork helps reduce labor time since its essential components (forming face, support for forming face, and steel walers) are assembled as one panel. The profile nose of the frames protects the edges of the forming face, thereby extending its lifespan. Connecting devices are used when assembling the frame panels to large-sized units, which are then usually transported by crane.

Crane-independent (hand-set)

This type of formwork can be moved by hand. Because of weight considerations, it is usually made of aluminum or plastic. It can take less concrete pressure than crane-dependent formwork, and is often used in housing and municipal construction projects.

Crane-dependent 

Crane-dependent formwork systems feature a large frame and formwork panels, usually made of steel. As a result, they cannot be moved manually. Since they can resist more fresh concrete pressures than crane-independent forms, they are suitable for the construction of commercial buildings and other extensive infrastructure projects.

Two-sided
As the name implies, two-sided formwork is erected on both sides of the wall. Its formwork ties, which are usually sleeved by spacing plastic tubes so they can be reused, take up the fresh concrete pressure. Push-pull props or large heavy-duty braces are attached to the formwork to align and secure it against wind loads during operation.

Single-sided
Single-sided formwork is used when the concrete has to be poured against existing structures or when builders need to do concreting against a hill or soil. This is why it is most suitable for reconstruction jobs. With this type of formwork system, concrete pressure is transferred from the formwork to the base plates through a support structure. 

Prefabricated
This formwork consists of two prefabricated concrete panels which are assembled in advance, and then transported and filled with concrete on-site. Braces and push-pull props are often used to secure the walls, while working and safety scaffolds are installed with the help of special adapters to make the construction process more cost-effective. Prefabricated formwork helps minimize project duration and labor costs. However, pre-planning is required to ensure that it is transported safely to the site.

Circular
Circular formwork is designed for the construction of curved and polygonal walls. It is also quite useful in the construction of specific concrete structures, such as septic tanks and car park ramps. This formwork system comes in three different types:  

• Round girder – timber spacers are added between the timber girders and steel walers so the formwork can be adjusted to the required radius. 
• Flexible girder – ideal for the construction of curved walls with different radii. It comprises timber/steel girders and a spindle, which allows builders to adjust the formwork to the required radius without having to reassemble the panels.
• Polygonal – existing “flat” frame formwork panels can be refurbished as polygonal formwork by adding supplementary radius panels and rails, allowing builders to minimize their project costs.

Climbing
Climbing formwork is quite useful in the construction of high-rise concrete structures, such as control towers and skyscrapers, because it climbs with the wall. It comprises large wall formwork mounted to a climbing scaffold. There are three different types of climbing formwork:

• Crane-dependent – the climbing unit (scaffold and formwork) requires the use of a crane to reach the next cycle.
• Self-climbing – an automatic climbing system that does not require the use of a crane to reach the next suspension point. Hydraulic rams/pumps lift the scaffold, secondary platform, and formwork to the next pouring cycle. It is ideal for the construction of very tall concrete structures.
• Slipform – a two-sided formwork that slides upwards along the structure being built at a rate of 20–25cm per hour. A system of pipe rods, which is integrated into the already-set concrete, supports the slipform.
   

MEVA is an industry leader offering a wide variety of wall formwork systems that provide highly efficient shuttering, flexibility, and reliability. Our products are lightweight and easy to assemble, and therefore will facilitate the rapid completion of your construction projects. Click here to learn more.

Steel Formwork – The Comprehensive FAQ Guide

Steel formwork, in case you aren’t familiar, is one of the few types of formwork that is considered the most common because of how it’s structured and because they are used in most projects and in the majority of construction work.

We here at Total Contec offer steel formwork, as well as a few other types and to help you in identifying whether steel formwork is the type you need or not, here are the most commonly asked questions and concerns raised by people about it.

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What is Steel Formwork?

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Figure 1 – An image of what steel formwork looks like

From its term alone, steel formwork is one of the many different types of formwork that makes use of steel. To be more accurate, steel formwork utilizes medium to large-sized steel plates that are coupled and fused together using bars – also commonly referred to as falsework.

Imagine a temporary mold of a building or a structure that’s made out of steel? That’s something else – you might as well just use it! Moreover, steel is an excellent choice because it does not bend, warp, get deformed, and break easily, especially during the curing process.

What Are the Different Types of Formwork?

Figure 2 – Timber Beam Formwork, one of the most common types of formwork structures

Out of all the different types and categories of formwork in the industry, there are a few that standout because of the frequency of usage. To help you with it, here are the different types of formwork you can choose from for your construction project:

• Timber Formwork
• Steel Formwork
• Aluminum Formwork
• Plastic Formwork
• Fiberglass Formwork

NOTE: These formworks are almost always similar to one another. Differences that they have often revolve around the materials used – for timber formwork, timber (strengthened wood is used) whereas for steel (galvanized or reinforced steel is what’s used), etc.

How Do You Select Formworks To Use?

Figure 3 – Choose your formworks by how strong, durable, and long-lasting they are

Selecting or choosing the type of formwork to use does not necessarily need you to be an expert about it. In fact, your choices can simply depend on how you want the formwork to function – how you want it to flow through.

We can offer little help, and that is by making sure that the quality of the formwork you will be getting is on point. So, here are a few key considerations you can make in choosing or selecting a formwork you can take advantage of:

1. Finalize the type of material you want to use. There are instances where concrete is good, but there are situations where using aluminum will be extremely better.
2. Check the overall cost of the project. Would the formwork you’re planning to get fit the budget properly?
3. Assess and deliberate on the strength, durability, and overall sturdiness of the formwork.
4. Identify the timeline and the length of the project.
5. How safe would the formwork be? Check and assess the safety and security of the formwork.

These are among the top considerations you can have when it comes to your steel formwork.

What Are the Differences Between Steel Formwork and Aluminum Formwork

Figure 4 – An example of what an aluminum formwork component looks like

The most common misconception people have with steel formwork is that they confuse it with aluminum formwork, when, in fact, they are two (2) completely different materials and types of formwork.

To help you with it completely, though, here’s how they are different:

Steel formwork is a category of formwork where still is used, while aluminum formwork is the type of formwork where aluminum is used. Both are great products and types of aluminum, but they have different usages.

Steel is great for big building and construction projects, and the main advantage it has over aluminum formwork is its reusability. It can be reused multiple times in similar structures. It’s conventional, used by many businesses, and the steel is stronger, more rigid, and more durable than aluminum.

Aluminum, on the other hand, is a category of formwork where it’s strong and durable, too, Compared to steel formwork, aluminum formwork is lighter in weight, which means it is extremely easier to carry and transport. It’s also less durable and weaker than steel. Overall, due to these circumstances, aluminum formwork is cheaper and more affordable than steel formwork.

What Are the Advantages of Steel Formwork?

Some of the most known advantages and pros of steel formwork include:

• They’re durable and strong to the extent that they wouldn’t be worn out and taken down easily
• Steel is sturdy and would not tip over by light to medium winds
• The surface finish is smooth
• Highly reusable
• It can be fixed, moved, removed, and changed

These advantages are what make up the entirety of why steel formwork is commonly used and purchased. But if you think it’s all rainbows and butterflies, think again!

What Are the Disadvantages of Steel Formwork?

A few of the disadvantages and cons of steel formwork include the following:

• The shapes and sizes you can purchase them for are limited
• The loss of heat is excessive
• They’re heavier and more difficult to carry and transport
• The extreme smoothness can give problems when it’s time for finishing

These are some of the considerations you need to factor in when choosing steel formwork. By now, you should know that not all steel formwork are made equally.

Is Steel Formwork Stronger Than Cement Formwork?

Figure 5 – Workers setting up concrete formwork

Yes, steel formwork is stronger, a lot more durable, and extremely longer-lasting than cement formwork. The simple fact that they’re steel is more than enough to say that they are stronger and will be better performing than cement formwork.

Where Can You Get High-Quality Steel Formwork?

If you’re on the market and you’re trying to look for superior quality steel formwork, Total Contec is the key! For 12+ years of dominating the market, we have produced many different types of steel formwork that provided assistance to various construction projects like buildings, residential, commercial, and even industrial infrastructure.

All our experts here at Total Contec have produced some of the world’s most significant and most important types of formwork wherever you are, and whatever business you might be in!

Other than steel formwork, Total Contec is also known in the industry because of high-quality frame scaffolding, steel planks and ladders, aluminum scaffolding, construction tools and safety equipment, and many more!

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