ICI Souvenir

IAStructE
Workshop on
Innovations in Enabling Works,

Formwork & Scaffolding Systems
11-12 September, 2015
Convention Centre, SCOPE Complex,
Lodhi Road, New Delhi - 110003
Sponsors
Exhibitors
Workshop on
Innovations in Enabling Works, Formwork & Scaffolding Systems
Table of Contents
About ICI
06
About the Workshop
06
Committees
07
ICI Governing Council Members
08
ICI NDC, Executive Committee Members
09
Programme
10
Abstracts / Articles
11 - 33
1. Formwork Selection & Economics The Success Key to Your Construction
12 - 17
2. Allround Scaffold: Ideal for High Rise Industrial Structures
18 - 19
3. MFS Aluminium Formwork System
20 - 21
4. Modern Formwork Systems An Overview
22 - 23
5. Scaffolding & Formwork Types, Materials and Usage
24 - 33
Workshop on
About ICI
Indian Concrete Institute (ICI) is the premier professional body for concrete technology with above
10,000 members with 31 centres spread across India. It has on its fold the captains of Construction
Industry, Building material manufacturers, Leading Consultants & Civil Engineers, Contractors, Academicians and Educational Institutions. ICI was founded in 1982 with its headquarter at Chennai. The objectives of ICI are to promote growth of concrete construction and its sub-specialisations, to disseminate
knowledge and to train personnel, to collaborate with national and International agencies in creating
better understanding of concrete construction technology, to identify R&D issues, encourage outstanding achievements in concrete construction technology through its institutional awards etc. ICI organises
periodical seminars, conferences, workshops and exhibitions on the subject and arrange lecture series
on selected topics of relevance to concrete construction.
ICI has collaborations with American Concrete Institute, Asia Concrete Federation, Singapore Concrete
Institute, and Concrete Institute of Australia etc. ICI publishes a quarterly Journal containing peer-reviewed technical papers, technical abstracts from about 40 journals. ICI has also brought out a number
of publication and monographs on various related topics.
About the Workshop

Enabling works, formwork & scaffolding are essential parts of construction. Not only concrete, even
steel construction often requires temporary structures and scaffolding. Elaborate temporary works are
involved in the making of precast concrete for buildings and bridges. Precast segmental bridge requires
carefully designed launching girder. Specialised pre casting yards are required for precast segmental
box girder and precast pretensioned girder bridges. Transportation of precast/prefabricated members
necessitates special tools, tackles, and special trailers. Specialised cranes, gantries and launching girders
are required to erect these prefabricated elements. Special purpose derricks are used to lift and erect
large span structures. Use of resin coated ply has given new dimensions to aesthetics of architectural
fair faced concrete. Similarly use of high quality rubber form liner for the precast segments can provide
excellent aesthetics. Tunnel form in aluminum is used for construction of prestressed floors in order to
further enhance the speed of construction. Tall piers and chimneys employ slip forming / jump forming
as an efficient means of construction.
Formwork and scaffolding system contribute to a substantial share of cost in concrete constructions.
Speed of erection and ease of stripping contribute immensely towards the speed of construction. Number of reuses influence the cost of construction. A flexible system allows for easy adaptability to handle
complicated site requirements in practical applications. It should be safe to make it accident free, at
the same time results in aesthetics and desired architectural finishing. Finally a good shuttering system
ensures durability of concrete construction.
Considering the requirement of cost effectiveness, speed, safety and durability of the structure, it is
essential that right system of enabling works, formworks and scaffolding system are selected for a
particular application. With technological advancement and availability of a large no of systems, it is
imperative that a practicing engineer should identify project requirements and analyze the formwork
options to ensure best results.
With the objective of improving concrete construction in India, Indian Concrete Institute New Delhi
Centre (ICI - NDC) is organising a two day Workshop to familiarise and enrich the Stake holders in the
construction industry.
Workshop on
Organising Committee
Chairman:
Abraham, K P, Chairman, ICI-New Delhi Centre
Organising Secretary:
Bansal, Shishir, DTTDC, Delhi
Members:
Agrawal, Shailesh, BMTPC
Anchuri, S P, ICI
Bhachech H, Virag, Hi-Lite Aluminium Formwork
Byapari, Amitab, Mahindra Real Life Spaces
Chauhan, Kishore Singh, UltraTech Cement Ltd
Das, Supradip, Consultant
Gaggar, Shashi, UltraTech Cement Limited
Ghanti, Rudrabir, Durabuild
Heggade, V N, Gammon India Ltd
Jairam P, Afcons Infrastructure Ltd
Joshi, Mukund, PWD, Delhi
Kataria, Rajan, DMRC
Khandelwal, Pradeep, EDMC
Kumar, Arun, UP Housing Board
Kumar, Mithilesh, Layher Scaffolding Systems
Kumar, Rajeeb, UltraTech RMC
Kurian, Jose, ICI
Lakhani, Raj, PERI India Pvt Ltd
Manjunatha, L R, JSW Cement
Mehta, Rahul, L&T

Mishra, Santhanu, Pranav Constructions
Mittal, Vikas, Nova Plasmold
Niranjana, P, L&T
Pradeep, K P, Master Builder
Rawal, Mayank, Asian Laboratories
Robinson, Jim, MFE Formwork Technology
Roy, Debashish, Vollert
Sahai, Paramjit Singh, EPA Construction
Saraf, Sunil, Simplex Infrastructure Ltd
Saraswati, S, President, ICI
Sarkar, Amitendra, Doka
Seth, P K, NBCC
Shanmugam, Muralidharan, Lhita Engineering
Services Pvt Ltd
Sharma, Rohit, Maini Scaffolds and Formwork
System Pvt. Ltd
Singh, D P, DDA
Technical Committee
Chairman:
Gupta, Vinay, TCPL
Co-chairman:
Garg, B D, Northern Railway
Members:
Bhattacharjee, B, IIT Delhi
Fassler, Andreas, Bridge Lab
Grover, S K, Slipco
Gupta, R K, Bridgecon
Kalgal, M R, UltraTech Cement Ltd.
Krishnamurthy, P, McAlloy
Kumar, Jayesh, PWD, Delhi
Lakshmy, P, CRRI
Mahajan, S L, BM & Associates
Maiti, S C, UltraTech Cement Ltd.

Manjure, P Y, Freyssinet
Meyer Max, VSL
Miranda, Mario, Studio Miranda
Pal, Kamalika, Hilti India Pvt. Ltd.
Patanker, V L, IAHE
Sharma, A K, CPWD
Tandon, Mahesh, TCPL
Workshop on
ICI Governing Council Members

Saraswati, S. Dr., President
Gangopadhyay, Partha Er., Vice-President (E)
Gupta, Vinay Er., Vice - President (N)
Kalgal, M.R. Dr., Vice - President (S)
Tayade, K. C. Er., Vice President (W)
Radhakrishnan, R. Er., Secretary General
Chaudhury, Ganesh. P. Er., GC Member
Chaudhary, Subrato Dr., GC Member
Jain, S.K. Er., GC Member
Jain, Ish Er., GC Member
Jayasankar, K.Er., GC Member
Kurian, Jose Er., Immediate Past President
Kulkarni, V.R. Er., Past President
Manjunatha, L.R. Er., GC Member
Moorthy, K.G.K. Mr., GC Member
Naik, Vivek Er., GC Member
Pofale, A.D. Dr., GC Member
Pradeep, K.P. Mr., GC Member
Srinivasan, Prakash. Er., GC. Member
Workshop on
ICI NDC, Executive Committee Members

Abraham, K.P. Er., Chairman-NDC, Chief Engineer, CPWD, India
Chauhan, K.S. Er., Hony. Secretary-NDC, Ultra Tech Cement Ltd., India
Mehta, Rahul Er., Joint Secretary-NDC, L&T Ltd.
Bansal, Vivek Er., Hony. Treasurer-NDC, Suptdg. Engineer, DTTDC, India
Bansal, Shishir Er., Chief Project Manager, DTTDC, Delhi
Bhattacharjee, B. Prof., Professor, Civil Engeering Department, IIT, Delhi
Bhowmick, Alok Er., Managing Director, B&S Engg. Consultants Pvt. Ltd.
Das, Supradip Mr., Consultant, Buildtech Product I. Pvt. Ltd
Ghanti, Rudrabir Er., Management & Engineering Consultant, Dura Build Care Pvt. Ltd
Gupta, U.K Er., Vice President, Jaiprakash Associates Ltd, Former Dir. (Tech.) SCOPE
Gupta, Vinay Er., Vice President- North, CEO, TCPL
Kumar, Rajeeb Er., DGM, Zonal Head - Technical UltraTech Concrete, India
Kurian, Jose Er., Honorary Member, Immediate Past President,Chief Engineer, DTTDC, Delhi
Maiti, S.C. Dr., Former Joint Director, NCCBM
Rawal, Mayank Er., Director (Technical), Asian Laboratory
Workshop on
Programme
DAY 1: 11th September, 2015 (Friday)
Registration
0845 hrs - 0945 hrs
Inauguration
0945 hrs - 1030 hrs

Chief Guest: Er. Mangu Singh, MD, DMRC
Key Note Address: Jim Robinson
Theme : Lifting, Transportation, Handling and

Erection & Formwork Materials
Tea Break : 1030 hrs - 1100 hrs

Session 1: 1100 hrs - 1300 hrs
Chairperson - Dr. A K Mullick
Co- Chairperson - Shashi Gaggar
Monolithic Formwork Technology
Er. Rohitt Sharma
Topic
Most Modern Methods of Construction:

Tunnel form
Er. Jignasu Mehta / Er Thierry Geoffroy
Author
Topic
Author
Climbing Formwork Systems and Modular

Scaffolding
Er. Raj Lakhani / Mr. Anibrata Routh
Topic
Author
Controlled Permeability Formwork Liner

Prof. B. Bhattacharjee
Topic
Precasting and Launching of Full Span Precast Pre-tensioned Box Girders

Er. R. K. Gupta
Author
Slip Forming of Deep Under Ground

Structures
Er. S. K. Grover
Topic
Author
Tunnel Formwork
Dr. Rajiv Dua
Chairperson - A K Sharma
Co-Chairperson - Shishir Bansal
Theme : Codal Provisions & Safety
Theme : Enabling Temporary Works & Architectural Fair

Faced Concrete
Author
Topic
Chairperson - Er. Raj Lakhani

Co-Chairperson - Dr. S. C. Maiti
Topic
Plastic Formwork System

Er. Vikas Mittal
DAY 2: 12th September, 2015 (Saturday)
Author
Topic
Author
Topic
Lunch Break : 1300 hrs - 1400 hrs
Topic
Issues related to Slipform in Chimneys

Er. Ravindra Shah
Author
Theme : Modern Formwork Systems

Topic
Author
Topic
Author
Topic
Author
Codal Provisions and Importance of Design

Er. Vinay Gupta
Topic
Author
Temporary Works- Basic Approach According

to British Code
Er. K. B. Rajoria
Topic
Author
Enabling Works of Signature Bridge

Er. Sanjib Konar
Tea Break : 10.30 hrs - 1100 hrs
Smart Dynamic Concrete for Monolithic

Formwork Construction
Er. Nilotpol Kar / Er. Amol Patil

Chairperson - Er. Mario De Miranda
Co-Chairperson - Rajeeb Kumar
Optimising Project Schedule Through Innovative Construction Method - A Case Study

Er. P. Niranjana
Theme : Scaffolding Systems & Formwork Failures: Case

Studies
Topic
Author
Formwork Issues in Multi-storeyed BuildingShoring and Reshoring

Dr. Neeraj Jha
Author
Innovative Methods & Equipment in the Constructions of Cable Stayed Bridges

Er. Mario De Miranda
Topic
Author
Industrial Application of Scaffolding

Er. Mithilesh Kumar
Topic
Author
Erection & Launching Systems

Er. Vinay Gupta
Topic
Lean Digital Construction Project Management: The new way of delivering Projects
Cheaper, Faster & Better
Er. Subhash Rastogi
Topic
Author
Steel Bridges of Jammu- Udhampur

Er. B. D. Garg
Topic
Author
System Formwork & Shoring

Er. Suraj Pal Singh
Author
Tea Break : 1530 hrs - 1600 hrs
Valedictory Session : 1300 hrs - 1400 hrs
Lunch
Chairperson - Uday Vartak

Co-Chairperson - Mayank Rawal
10
ARTICLES
Workshop on
Formwork Selection & Economics

The Success Key to Your Construction
Sameer S Malvankar, Deputy Manager-Engineering, Gammon India Ltd., Mumbai
ppropriate selection of a formwork system is a

crucial factor in successfully completing most
building projects. However, in practice, selection
of an appropriate formwork system has traditionally
depended mainly on the intuitive and subjective opinion of
practitioners with limited experience. This article discusses
the guidelines on how to choose formwork, factors
affecting the selection, economics involved in formwork
and the present scenario of formwork in India. This can
assist engineers to determine the appropriate formwork
system at the inception of future projects.
Introduction
Formwork is a die or a mould, including all supporting
structures, used to shape and support fresh concrete until it
attains sufficient strength to carry its own weight. It should
be capable of carrying all imposed dead and live loads apart
from its own weight. A formwork system is defined as the
total system of support for freshly placed concrete including
the mould or sheathing which contacts the concrete as well
as supporting members, hardware and necessary bracing.
However, System implies a fully compatible arrangement
of formwork with a minimum of individual components
with reusable elements intended to solve each forming
task thereby rationalizing the forming work.
misalignment, misplacement, deflective concrete or holding

up other works causing serious interruption can result.
The basic parameters of formwork are:
-
Quality: in terms of strength, rigidity, position, and

dimensions of the forms
Safety: of both workers and the concrete structure
Efficiency: in operation, the ease of handling, erection

and dismantling, number of repetitions within the
optimal limits
Economy: the least cost, consistent with quality and

safety
Percentage Of Formwork Cost In Total Construction

Cost
In a typical multi-storey reinforced concrete building,
formwork cost is the largest cost component. Formwork
cost accounts for nearly 20-40% of cost of concrete and
involves more than 60% cost of time. Overall formwork
related cost have significant share i.e., 10% in the total
construction cost. A large proportion of the cost of
formwork is related to formwork labour cost. Significant
cost savings could be achieved by reducing labour cost. An
exemplary comparison reveals that the additional concrete
use of up to 15% is economical than the handling of
angular forming areas, since their assembly is rather timeconsuming and the cost per square metre is higher than
that for a straight surface.
An Integrated Formwork/Concrete Life Cycle
The process of providing formwork and concrete is
highly integrated. In Figure 2, the left circle represents
the formwork life cycle, while the right circle represents
Figure 1 - Main cost type in a typical building project
Formwork system is among the key factors determining

the success of a construction project in terms of speed,
quality, cost and safety of works. Nowadays, most projects
are required by the client to complete in the shortest
possible time as a means to minimise costs. For high-rise
buildings, the most effective way to speed up works is
to achieve a very short floor cycle - to have the structure
of a typical floor completed in the shortest time. On the
other hand, aiming purely at speed often contradicts the
achievement of other quality standards. Problems such as
12
Figure 2 - Integrated formwork/concrete lifecycle
Workshop on
the concrete construction life cycle. The two intersection

points represent the beginning and the end of concrete
construction life cycle. It should be noted that the
phases cure concrete and stripping of formwork are
interchangeable depending on the type of structural
element. For example, columns and walls are cured after
stripping the forms while slabs and beams are cured before
and then stripped.
- Wall, Column - Girder form, Frame panel form, climb

form or jump form
Various Formwork Systems
- Core walls, shells- Climbing formwork, Jump form and

slip-form
Formwork can be classified according to a variety of

categories as follows:
- Slab - Conventional timber form, Modular slab

formwork, primary-and-secondary-beam method, Panel
form, Drop head-beam-panel system, table form
- Repeated regular section - tunnel form, modular
aluminium form
- Precast structure- steel /aluminium mould forms

Classification according to materials of construction
Timber : most popular formwork material - low initial
cost - high adaptability to complicated shape - labour
intensive and environmental unfriendly
Steel: hot-rolled or cold-formed sections-heavy weight
- suitable for large-sized panels
Aluminium: stiff and light weight - higher material and
labour cost - excellent finish
Plastic: recyclable, tough, light weight
- Sacrificial concrete panels - Left in place formwork
Classification according to nature of operation
Crane independent Manually handled formwork
Figure 3 - Categories of formwork classification
Self-climbing formwork
Classification according to size
Crane-dependent formwork
Small-sized formwork
Gantry, travelling and tunnel type formwork system
Operation by workers manually
Classification according to brand name of the product
Wooden and aluminium formwork

Large-sized formwork

Crane facilities are required in the operation
Reduce the number of joints and to minimize the

number of lifts
Stiffening components -studs and soldiers
Some companies in the market that are specialised in

formwork manufacturing are DOKA, PERI, MEVA RMD,
ULMA, TABLA, TITAN, MIVAN, HARSCO etc. Each has a
different system for various structures.,
Classification according to location of use

Various elements in the structure have specific design
and performance requirements in the use of formwork.
Some systems are more adaptive for specific location of
use, such as
- Irregular frame structure - Conventional traditional
timber form
Figure 4 - Parties involved in formwork selection process
13
Workshop on
Evaluation/Selection Criteria For Formwork System

Earlier formwork was once built in-place, used once, and
subsequently wrecked. The trend today, however, is towards
increasing prefabrication, assembly in large units, erection
form or steel form, may be quite difficult to use in such

situations; frequent adjustments of the form to meet the
changes in dimensions may eventually result in incurring
extra cost and time.
Headroom
Higher headroom increases the amount (height) of
staging required and can also create accessibility and
safety problems. It can also make the erection of formwork,
ensuring formwork stability and the placing of concrete
more difficult.
Building Span
Figure 5 - Process cycle for formwork selection
by mechanical means, and repetitive use of forms. These

developments are in tune with the increasing mechanisation
of production in construction sites and other fields.
Formwork planning includes detailed layouts, cycle
plans, calculation of optimum amount of material for the
site, observance of fixed schedules and selection of the most
appropriate and the most economic formwork system to
be used at the construction site.
Formwork Selection Criteria

Internal Layout
Some buildings may have very simple layouts with a few
in-situ walls and floor plates framed with regularly spaced
columns, as seen in many commercial and office buildings.
However, some developments feature very complicated
load-bearing internal walls that can make the casting
process difficult.
Structural Forms
Large building spans also create problems similar to

those with high headroom situations. In addition, longspan structures generally have larger beam sections, heavier
reinforcement provisions, or accompany post-tension
works. This will further complicate the formworks design
and erection process.
Repetitive Nature
High-rise block-shaped structures usually require
highly repetitive cycles and this is favourable to the
use of formwork. However, the degree of repetition in
building with very large construction area like a podium or
underground structures such as basements is limited and
the use of formwork, as an expensive resource, becomes
very critical.
Project Planning/Speed Of Work
The over-all construction sequence must be planned
to use formwork in efficient manner and to permit the
optimum investment in formwork to meet schedule
requirements. Contractor should plan formwork and job
sequence at the time of making a bid. Project planning
such as the phasing or sectioning arrangement, integration
Like internal layout, the structural form of buildings also

affects the formwork options. For example, buildings with
a structural core in the form of a vertical shaft limit the use
of formwork systems other than those of a self-climbing
nature. Buildings in flat slab design make table forms or
flying forms the most obvious choice. For buildings with
regularly arranged shear wall designs, the best selection is
large-panel type steel forms or other types of gang forms.
Consistency In Building Dimensions
Some buildings may have non-standardised dimensions
due to the architectural design and layout or to fulfill other
structural requirements. These include the reduction of
sizes for beams, columns and walls in high-rise buildings
as the structure ascends. Formwork systems like the climb-
14
Workshop on
of the structure, site layout and set-up arrangements

or hoisting provisions and concrete placing facilities are
influencing factors when considering formwork selection
and application.
When working with buildings with large construction
areas and horizontal spread, projects can be expedited by
the introduction of additional sets of formwork, to create
more independent work fronts. This will, of course, increase
the cost of construction. For high-rise buildings, increasing
the number of formwork used cannot always expedite
the project, for the critical path still depends on the floor
cycle. However, a properly selected, designed and arranged
formwork system will increase work efficacy for each typical
cycle. In some cases, adding half or a full set of formwork,
especially for the floor forms, may help to speed up the cycle
as the additional set can provide more flexibility when the
form is struck at an earlier time.
Another factor that affects the economy of the selected

system is the effect of stopping formwork activity and
concreting because of extreme weather conditions. In
the case of a slip-form, the work is usually continuous,
round the clock. If the slip-form stops because of weather
conditions, it may impact structure as well as cost.
Labour Efficiency
Considering the availability and qualification of the work
force, improving labour cost efficiency is a major factor,
especially in markets experiencing a building boom. Here,
the qualification of workers tends to be low in relation to
ever higher demands posed by construction methods.
Construction Process, Methods

For selecting formwork one must know the sequence
of construction activities and methods to be followed.
Construction method will always give idea about
interdependency of the activities, specifications and
additional requirements in pour. This will enable us to
workout appropriate system which fulfills the construction
needs.
Site Logistics
Exceptionally small or very large sites, sloped or very
crowded sites, proximity to sensitive structures, sites where
other major activities are underway, or sites with many
physical or contractual restrictions will increase the difficulty
of working with formwork. There is no specific solution to
improve the situation in general and problems are tackled
according to individual circumstances.
Accessibility to work during the course of construction
is also important. Accessibility problems may be created
through segregation, temporary discontinuation, or
blocking of the layout by the partially completed building,
or, in cases of constructing a shaft-type core wall, the shaft
may stand independently for a long period of time before
it is connected to the horizontal elements. Proper access
to all components should be considered while planning a
site layout.
Climate Condition
Formwork systems are sensitive to weather conditions.
Typically, in vertical forming systems, the newly placed
concrete is supported by the wall already cast below it. The
lower wall section must get sufficient strength to support
the fresh concrete above. The rate of strength gain of lower
wall is influenced by the ambient temperature, moisture
content, and the freezing and thawing cycles.
Cost of Formwork System

This is a vital factor for deciding formwork system as
one must know the capital provision for formwork in the
project. It is always beneficial to work out these details at
the time of bidding.
Cost is Influenced By Three Components:Initial Cost or Make-Up Cost: Includes cost of
transportation, materials, assembly and erection
Reuse Cost of Formwork System: The formwork system
cost goes on reducing as we increase reuse of the same.
A careful balance between cost, speed, performance and
the quality of output should be properly considered when
making the selection.
Maintenance & Storage Cost: It includes cost of
stripping, repair, storage, etc. Formwork materials are a
valuable asset of company, If proper care is taken during
handling and storage, much return is obtained on the
investment. Formwork needs to be handled correctly,
maintained, repaired if necessary and finally, cleaned
regularly. Avoiding damage reduces costs incurred. Proper
storage of formwork materials gives easy reconciliation,
faster retrieval of material, better space management and
helps avoid unnecessary expenditures, improve safety at
work place.
15
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Availability Of Lifting Devices (Crane time)
Provision Of Construction Joints In Structures
These include considerations of whether there will be

lifting appliances provided for the erection of formwork;
whether these appliances will be able to access the work
spot to assist in the operation as the structural works
proceed; whether any special equipment will be required
for striking the forms; and how the removed formwork
panels can be transported to other spot to continue work.
Many a times a large number of construction joints are

inevitable in a large structure because of the subdivision
of works into effectively workable sizes. The provision of
construction joints can challenge the output and affect the
quality of the concrete. Careful selection should be made
to ensure a particular formwork system can satisfactorily
allow such arrangements.
Characteristic to high rise building sites is the confined

and congested space availability for working. Crane time
and space is regularly limited. In general, reinforcing (rebar)
activities are most critical, since lifting the reinforcement
to building level is the most crane-time consuming job of
all. Thus, the capability of formwork to rely less on or be
used independently of crane time is critical in high rise
construction.
Inventory - The Fewer, The Better
Simple Logic Of The System

Formwork system ought to be self-explanatory to
use, this automatically eases the usage for the engineers/
supervisor and also the labourers who are end users of
the system.
Working Safety
Formwork should be self-securing with safe access
and working platforms. Thus, it is not left to the end user
whether they take safety measures or not. Creating a safe
work environment for the entire work force involved in
the construction process, has become the pivotal issue in
emerging construction markets.
The most frequent time & cost consuming activity of

formwork assembly is the loose and small components/
accessories. The lesser inventories will help to reduce risk
of losing parts and provide ease in construction.
The Indian Scenario
In the past, India had been lagging behind over the other
advanced countries in applying advanced and safe concepts
for formwork in reinforced concrete construction resulting
in a poor surface quality, wastage and low productivity
of the people involved in concrete construction. This
unfortunate situation continued for a long time because of
availability and use of very cheap unskilled labour and very
few skilled personnel who have had professional training
for formwork jobs.
With increasing demand and competition and reducing
project completion times, there have been significant
developments in the construction industry in terms of
experience and mastering of the required managerial,
construction or engineering skills for handling very large
Special Requirements On Concrete Surface/Finish

Fair-faced concrete demands very high quality formwork
in terms of surface treatment of the panels, tightness of the
formwork joints and in dimensional accuracy. Requirements
are slightly relaxed where the concrete surface is to be
finished at a later stage.
Area or volume of cast per pour
The optimum volume of cast per pour depends on the
types of formwork used, the particular elements of structure
to be placed, the actual scale of work, and different levels
of provisions of plant facilities.
Involvement of other construction techniques
Tensioning and prefabrication activities are often
involved in construction. This may create certain impacts
on the use of formwork, especially where precast elements
are to be incorporated during the casting process. Provision
should be made for temporary supports or slot spaces and
box out positions in the formwork for the precast elements,
or extra working space for placing stressing tendons and
onward jacking.
16
Workshop on
and complex projects. At the same time, the motivating

factors highlighted above have created an eagerness and
readiness within the industry to advance. From the building
construction point of view, the use of better formwork
systems is no doubt a very direct way for introducing
innovative methods in the construction of buildings.
Conclusions
1. Selection of formwork system is highly dependent on
individual site/project environment
2. Economy of formwork can be achieved with seamless
collaboration between owner, architect, designer teams
and contractor. And it can aid in the effective use of
advanced formwork systems
3. The structural form of the building is one of the critical
factors to determine the choice of formwork
4. System products contribute much in the success of
formwork application
References
1. ACI 347-04, Guide to formwork for concrete,
American concrete institute, 2005
2. Hanna A. S. & Sanvido V.E. , An interactive knowledge
based on formwork selection system for building,
Computer integrated construction, 1989
- Formwork labour cost is so immense that any innovative

system resulting in a labour cost reduction is highly
lucrative.
- Fulfilment of fast track construction schedule provides
fewer choices, one of which is to adopt more innovative
formwork systems.
3. Hurd M. K., Formwork for concrete, American

concrete institute, 1915, 6th edition
4. Raymond W. W. M. , Application of formwork for high
rise and complex building structures- Hong Kong cases,
Division of building science & technology, city university
of Hong Kong.
- Traditional systems can hardly satisfy the tight quality

standard that is required nowadays.
- Similarly, traditional systems can hardly satisfy current
safety and environmental standards.
- The accumulation of experienced crews makes the
application of more sophisticated formwork systems
more reliable and economical.
- Many developers view the application of innovative
technology in the construction process as a positive
image-building factor. Major systems dominate
todays state-of-the-art formwork approach in high rise
construction.
- Slab edge protection by screens, providing a safe
working environment on the construction levels
- Modular slab formwork, operated independently of
the crane time, adapted flexibly to different building
geometries and floor layouts
- Undisturbed shoring for slab with drop beam systems
- Frame formwork for columns and walls
- Crane dependent climbing formwork for shear walls/
mega columns
- Crane independent climbing formwork for core
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Workshop on
Allround Scaffold: Ideal for High Rise

Industrial Structures
Mithilesh Kumar, Director, Layher Scaffolding Systems Pvt Ltd
ayher, the German Company, produces high-quality

scaffolding systems in Germany. Layher has worldwide presence with more than 40 sales subsidiaries.
The products are being used by industries like Construction, Cement Plant, chemical plants, power plants, at shipyards and offshore.
More Possibilities - Layher Products and Services
Layhers present product characteristics and services
help customers achieve long-term success and increase
the profitability of their companies. The Layher Allround
Scaffolding has been established as a synonym for modular
scaffolds on the market. The Allround Scaffolding offers
unsurpassed versatility to be used in construction sites,
chemical industry, power plants, aircraft, shipyards, event
sector, theatres and arenas.
Application of Layher Allround Scaffold in Cement
Industries
Cement silos are either part of the production process
in integrated cement plants or they can also be the key
part of distribution terminals. For the cement industry
the cement industry are built with diameters up to 30

m while typical silos for the storage of 20000 t cement
are typically 4 to 30 m in diameter and 20 to 72 m in
height. It is clear that such silos require an efficient and
trouble-free emptying. Accordingly highest requirements
are given to overall plant reliability and practically 100%
availability. To achieve a high availability flow problems
have to be strictly eliminated. From the theory of flow
in silos it is well-known, that this can only be achieved
with mass-flow. For cement silos, the central cone
version has become the predominant design. On the one
hand, the central cone has a displacement function for
the material in the silo; and on the other hand several
designs especially for multi-compartment designs become
possible. Multi-compartment silos are used for producing
special cements from a number of main and secondary
cement components.
Not only has the shape of the building reminded of
a crystal, but also the surface of the faade. To attach
the Local Scaffolder solved this task technically with the
Layher Scaffolding and Technical team: section by section
they adapted the scaffold to the slope of the building with
various brackets on the inside and then shifted it inwards
by one scaffold width. Scaffold was anchored with the help
of Layher Anchoring equipment, even the increased wind
loads could be transferred without putting unnecessary
strain on the structure.
The construction of Scaffolding for maintenance of
Silo is a challenging task due to wind pressure. It includes
selection of support systems (scaffolding with permanent
structure) and avoiding obstructions by bracket or cable
tray around the silo. Layher Allround Scaffolding systems
provide unique, bolt-less connection technique, the
patented Allround joint has replaced the conventional
scaffold technique especially in construction of Scaffold
for Silo up to 72 metre height. Allround Scaffolding can
accommodate all types of high loads and is the ideal
system for all kinds of support scaffolding. Allround
scaffolding has an efficient solution to deal with all
challenges, regardless of whether they involve false work
at great height or round inner scaffolding.
these storage silos are very important because this allows

a continuous production, while the cement dispatch
can be discontinuous. Largest cement storage silos in
It needs to be built in a modular scaffolding system

for maintenance of Silo and high rise Industrial structure.
Cement Plant situated near the sea shore necessitates to
take care of wind force.
18
Anchoring, essential for the stability of the scaffolding
Workshop on
must be continually installed as scaffolding assembly

progresses. Only provide anchoring on sufficiently can
be tested strong components, if necessary, the anchoring
surface by pull out tests. A check can be dispensed with
if sufficient load- bearing capacity can be assessed on the
basis of professional experience and the service e value of
the anchoring force does not exceed 1.5 KN or in the case
of reinforced concrete.
Connect Horizontal Ledger with two standard couplers
with very wide scaffolding structures, it must be necessary
to anchor with the aid of a horizontal ledger. The selection
of anchoring configuration depends on the bay width,
the load on the scaffolding, live load, wind load and
the structural height of the scaffolding. As the load on
the scaffold increase, the anchoring configuration must
become denser in order to pass the force safely into the
anchoring surface. The dense anchoring configuration
shall lower the force on the individual wall ties.
Landing Type Aluminium Stair Access up to 72 Metre
Height
With Layher Modular stair tower, access possibilities
that always fit and that match the system. With the
landing type Aluminium stair tower, it is simple to
construct a 4-standard stairway tower, either integrated
into the scaffolding or as a free-standing access structure
anchored onto the building. There is no hindrance to work

on scaffolding by using Aluminium landing type stairway.
Furthermore, a distinction is made between independent
access structures that are anchored to the silo and access
structures that are integrated into the Scaffolding. The
maximum permissible load bearing capacity of Aluminium
stair tower is 2.5 kN/m2. It is easy to construct up to 72
m height due to light weight components. Attach the
necessary anchoring continually in accordance with
structural requirements. Unlike external platform stairway
access, the platform stair tower has the advantage that
work being done inside the scaffolding is not hindered by
people ascending or descending.
With allround Scaffolding, thanks to 8 different
connections possible at the Allround connector and
the variable choice of angles, it is a simple task to erect
scaffolding around curved surfaces. Possible connections
and variable angle selection, curved surface can be
enclosed with scaffolding without any problem. To
build economical large-diameter scaffolding, the largest
possible bay widths must be planned. In systems solutions
using Allround equipment, two variants have proven their
worth in practice: in the first variant, only system bays are
used, while the second variant uses intermediate bays. In
both cases, it is recommended that at least the last bay be
selected as an equalizing bay.
Workshop on
MFS Aluminium Formwork System

Rohitt Sharma, Director, Maini Scaffolds & Formwork Systems Pvt. Ltd
ndia being the second most populous country in the

world with a growing population of 1.28 billion, is
facing huge shortage of housing units. Requirement of
housing units due to urbanization is increasing day by day.
Different government bodies launch various schemes to ful
fil this demand, but due to delay in the delivering of these
units, the gap between demand and supply is increasing
rapidly. Use of conventional methods of construction
consumes more time, which leads to delay in completion
of any project. Desired quality is not achieved and safety
of workers is compromised. It is therefore obligatory to
work out a method or a scheme, where speed and quality
of construction are controlled automatically by a systematic
approach.
The Construction Industry in a growing economy like
India has reached a stage where mechanization is essential
for survival. The shortage of skilled labour and spiralling cost
of labour is indeed disturbing. Capital is in short supply and
hence expensive. Interest rates for construction industry is
one of the highest in the world, which means the period
for which capital is deployed is very critical. Therefore, it
is imperative that our esteemed customers choose right
service partner and systems, which will eventually lead to
financial and business viability.
MFS Aluminium Formwork is a unique system,
which ensures monolithic concreting that eliminates one
stage of concreting. Entire forms for Vertical (Shear Walls
/ Columns) and Horizontals (Beams and Slab) including
staircases, balconies, window hoods, storage lofts etc. are
set at one stage for single pour, resulting in accurate finish
with consistent quality.
MFS Aluminium Formwork System is an advanced
formwork technology highly suitable for mass housing
construction, where quality and speed can be maintained
at a reasonably high level. Speedy construction, consistency
in architectural dimensions, excellent finish, and less

dependency on skilled workers and simplicity in erection
and de-shuttering makes MFS Aluminium Formwork
System more viable and preferred formwork technology
for construction of mass housing projects. Following are
some unique advantages:
Shortens construction period (7 - 8 days slab to slab
cycle is achieved)
Reduces construction cost
Greater strength and durability of structure
Monolithic crack free structure
Environment friendly
Eliminates entire plastering
Seismic earthquake resistant structure
Civilized method of construction
20
Workshop on
MFS provides end-to-end solutions viz. designing,

manufacturing and professional after sales services
(consisting of training & education for proper usage of MFS
Aluminium Formwork System) ensuring more productivity
at economic prices.
Designing of MFS Aluminium Formwork System is
done with in-built Software. A Rotating 3D Model of entire
unit along with individual panels is viewed for accuracy. Any
overlaps or clashes are identified and removed at design
stage prior to the generation and release of shop drawings,
assuring flawless manufacturing drawings based on which
entire system is manufactured.
MFS Aluminium Formwork System is the front line

product of MAINI Scaffolds & Formwork Systems Pvt.
Ltd. - Faridabad and is being successfully used by reputed
developers / contractors across India.
With annual manufacturing capacity of approximately
6 lakh square metre and implementation of latest and
advanced techniques we always endeavour to be at
the forefront of advancing formwork technologies and
continue to bring our valued customer, the highest quality,
best services and unsurpassed value. With the focus of core
engineering skills and decades of experience towards taking
an innovated approach to continually upgrade the system,
we are continually adapting to rapidly changing demands
of our valued customer.
Make in India
Our competent and experienced team of design

engineers ensures maximum repetitions of formwork
in particular project for better viability, which ensures
economy along with quality and safety.MFS Aluminium
Formwork System is designed with maximum standard
size inventory so that 60 - 65% of inventory can be reused
in other projects. However, if floor-to-floor height is
controlled, 70 75% of inventory can be reused making
our system versatile and more economic.
We also provide technical design assistance for optimum
usage of MFS Aluminium Formwork Systems enabling the
customers to re-use maximum number of components in
their future projects.
MFS Aluminium Formwork System is most suited
formwork system for residential projects. Designed and
manufactured as per Indian conditions, it ensures faster
completion of project at optimum cost while maintaining
high quality standards. Unlike the myth that Aluminium
formwork can be used for structure with shear walls only,
our system is designed for shear wall and column - beam
structures as well. We firmly believe that Formwork System
should be designed as per the structure and not Vice
Versa.
Make in India is a major national initiative, which

focuses on maximum usage of equipment, which are
manufactured in India. This comes, as a great opportunity
for Indian manufacturers to compete with global agencies
but at the same time it also requires quality deliverables
as per global standards. We are fully geared to cater to
Indian Construction Industry with best quality products,
in-time deliveries and best technical services as we have
firm belief in our team and its capability to face any
challenge with positive attitude. It would be refreshing to
see Indian formwork industry to grow to new heights. At
MFS Aluminium Formwork System we encourage this
great initiative and shall contribute to make it successful.
We are determined for changing the mindset by
delivering better quality products than any of the global
players.The success of any business is gauged by the capability
of an organization to complete the job on time with
budgeted resources. Time waits for no one. Aspirations
cant wait and ambition does not know tomorrow. We, at
MFS Aluminium Formwork System believe that tomorrow
is a day too late. We continuously strive to provide value
for money to our clients enabling them to achieve the most
cost effective solutions for their projects with high safety
standards, excellent quality and unparalleled services. With
excellent team work, we aim to turn our vision into reality
NOT TOMORROW BUT TODAY
We look forward to take MFS Aluminium Formwork
System, to the next level with market goodwill of our
satisfied customers. We welcome any suggestions from
our esteemed readers for betterment of our products and
services.
21
Workshop on
Modern Formwork Systems An Overview

Kamalika Pal, Assistant Manager - C & A, Hilti India Pvt. Ltd.
he formwork industry has evolved significantly

in the past few decades to keep pace with the
changing requirements of the construction industry.
Traditionally, a formwork was considered to be good if
it was able to withstand the construction load and was
rigid enough to retain its shape. With time, this definition
has also changed to accommodate aspects like flexibility,
ease of use, cost effectiveness, etc. This definition of
good formwork varies from project to project. In some
projects, a light-weight and flexible formwork system
capable of delivering a superior surface finish like fabric
formwork system may be required and in other a more
rigid system may be required. Different aspects like
strength, stiffness, water tightness, robustness, ease of
removal, standardization and safety may be considered
while defining the required formwork system. Some of
the common types of formwork for modern concrete
construction are:-
Slipforms
Slipform systems comprise of moving formwork. It
may be used both for horizontal and vertical construction.
For vertical construction, hydraulic jacks may be used to
move the form after the concrete has gained adequate
stiffness. The rate of slip forming may vary from 300400
mm per hour for vertical construction and 300500 m per
day for horizontal construction. This type of formwork
allows speedy construction with less area of formwork.
Gang Forms
Gang forms comprise of large panels which are
moved as a complete unit using cranes. Modular panels
are often used for gang forms. This system also allows
speedy construction. Though these systems are expensive,
the cost of formwork is often offset by multiple re-uses
and the time saved. Some types of gang forms are listed
below:
- Table Forms: Large sections of soffit form along with
propping and bracing elements are fabricated into a
single unit. These units are moved using cranes.
- Jump / Climb Forms: These systems are used for
casting vertical elements. These systems are not labour
intensive. These systems do not require cranes for
handling as they comprise of simple mechanical means
for handling. After striping the form, it is shifted to a
new position and then re-aligned using its own in built
jacking system.
Permanent Forms
Modular Formwork
These systems comprise of modular panels which can
be reused on a wide variety of jobs. Steel frame with
plywood is commonly used to form the modular panels.
The support and fixing required for modular formwork are
simple.
Permanent forms are left in place to become part of the

finished structure. The use of these systems minimizes the
need for subsequent finishing operations. These systems
sometimes also assist in taking some of the structural
load.
22
Workshop on
Fabric Formwork
The material used for fabric formwork is usually highly
flexible. A variety of shapes can be cast using fabric
formwork.
Conclusion
Each system has its own set of advantages and
disadvantages. It is very important to select the right
formwork system based on the project requirement. But,
the desired results depend not only on the selection of the
formwork itself but also on the tools used to ensure proper
erection, support, aligning and levelling. If the concrete is
not levelled properly, it could lead to non-conformance in
casting tolerance, improper form operation, and difficulty
in stripping, damage to the casting or form components
and wastage. For example, the use of a rotating laser like
Hilti PR3 when used for erection of modular formwork
might result in better quality and cost saving compared
to use of traditional levelling tools. Consider a 10 storied
residential jobsite of 5000 metre-square area per floor.
The deviations during pouring of concrete for casting
of slab are generally around 10mm using traditional
methods, which results in extra concreting of 50 metre-
cube. This will result in wastage of 350 cement bags for

5000 meter-square area per floor. With the help of PR3
the deviations can be controlled to 0.75mm. Hence,
a contractor can save up to 350 cement bags per floor
with an added advantage that only one labour is required
to check the levels and cover large areas with a range of
300m (diameter). In summary, formwork should not be
considered just as means casting for but as an integral
part of concrete construction. All stages from selection
of the correct formwork system to execution are equally
important.
Workshop on
Scaffolding & Formwork Types, Materials

and Usage
Dr. R Kuberan, Senior Editor (Technical), Civil Engineering & Construction Review
Scaffolding
Evolution
Scaffolding, also called scaffold or staging, is a temporary

structure used to support a work crew and materials
to aid in the construction, maintenance and repair of
buildings, bridges and all other man-made structures.
Scaffolding is also used in adapted forms for formwork
and shoring, grandstand seating, concert stages, access/
viewing towers, exhibition stands, ski ramps, half pipes
and art projects.
There are four main types of scaffolding used worldwide
today. These are Tube and Coupler (fitting) components,
prefabricated modular system scaffold components,
H-frame / facade modular system scaffolds, and timber
scaffolds. Each type is made from several components
which often include:
A base jack or plate which is a load bearing base for
the scaffold.
The standard, which is the upright component with
connector joins.
The ledger (horizontal brace).
The transom, which is a horizontal cross section load
bearing component which holds the batten, board or
decking unit.
Brace diagonal
component.
and/or
cross
section
Sockets in the walls around the paleolithic cave paintings

at Lascaux, suggest that a scaffold system was used for
painting the ceiling, over 17,000 years ago.
The Greek historian Herodotus thus wrote of scaffold:
At first, it (the pyramid) was built with steps, like a
staircase. The stones intended for use in constructing the
pyramids were lifted by means of a short wooden scaffold.
In this way they were raised from the earth to the first step
of the staircase; there they were laid on another scaffold,
by means of which they were raised to the second step.
Lifting devices were provided for each step, in case these
devices were not light enough to be easily moved upward
from step to step once the stone had been removed from
them. I have been told that both methods were used, and
so I mention them both here. The finishing-off was begun
at the top, and continued downward to the lowest level.
The Berlin Foundry Cup depicts scaffolding in ancient
Greece (early 5th century BC). Egyptians, Nubians and
Chinese are also recorded as having used scaffolding-like
structures to build tall buildings. Early scaffolding was
made of wood and secured with rope knots.
bracing
Batten or board decking component used to make

the working platform.
Coupler a fitting used to join components together.
Scaffold tie used to tie in the scaffold to structures.
Brackets used to extend the width of working
platforms.
Specialized components used to aid in their use as
a temporary structure often include heavy duty load
bearing transoms, ladders or stairway units for the ingress
and egress of the scaffold, beams ladder/unit types used
to span obstacles and rubbish chutes used to remove
unwanted materials from the scaffold or construction
project.
24
Repair work on Buckingham Palace in 1913, under the scaffolding of

Patent Rapid
Workshop on
Modern Era
In days gone by scaffolding was erect by individual
firms, with wildly varying standards and sizes. Scaffolding
was revolutionised by Daniel Palmer Jones and David
Henry Jones. Modern day scaffolding standards, practices
and processes can be attributed to these men and their
companies. With Daniel being the better known and patent
applicant and holder for many scaffold components still in
use today, he is considered the grandfather of Scaffolding.
The history of scaffolding being that of the Jones brothers
and there companys Patent Rapid Scaffold Tie Company
Ltd, Tubular Scaffolding Company and Scaffolding Great
Britain Ltd (SGB).
and general design for access and working scaffolds.

Requirements given are for scaffold structures that rely
on the adjacent structures for stability. In general, these
requirements also apply to other types of working
scaffolds.
The purpose of a working scaffold is to provide a safe
working platform and access suitable for work crews to
carry out their work. The European Standard sets out
performance requirements for working scaffolds. These
are substantially independent of the materials of which
the scaffold is made. The standard is intended to be used
as the basis for enquiry and design.
Materials
David Palmer-Jones patented the Scaffixer, a coupling

device far more robust than rope, which revolutionised
scaffolding construction. In 1913, his company was
commissioned for the reconstruction of Buckingham
Palace, during which his Scaffixer gained much publicity.
Palmer-Jones followed this up with the improved Universal
Coupler in 1919 - this soon became the industry standard
coupling and has remained so to this day.
The basic components of scaffolding are tubes, couplers

and boards. The basic lightweight tube scaffolding that
became the standard and revolutionised scaffolding,
becoming the baseline for decades, was invented and
marketed in the mid-1950s. With one basic 24 pound unit
a scaffold of various sizes and heights could be assembled
easily by a couple of labourers without the nuts or bolts
previously needed.
The advancements in metallurgy throughout the

early 20th century saw the introduction of tubular steel
water pipes (instead of timber poles) with standardised
dimensions, allowing for the industrial interchangeability
of parts and improving the structural stability of the
scaffold. The use of diagonal bracings also helped to
improve stability, especially on tall buildings. The first
frame system was brought to market by SGB in 1944 and
was used extensively for the post-war reconstruction.
Tubes are usually made either of steel or aluminium,

although there is composite scaffolding, which uses
filament-wound tubes of glass fibre in a nylon or polyester
matrix, because of the high cost of composite tube, it
is usually only used when there is a risk from overhead
electric cables that cannot be isolated. If steel, they are
either black or galvanised. The tubes come in a variety
of lengths and a standard diameter of 48.3 mm. The chief
difference between the two types of metal tubes is the
lower weight of aluminium tubes (1.7 kg/m as opposed
to 4.4 kg/m). However they are more flexible and have a
lower resistance to stress. Tubes are generally bought in
6.3 m lengths and can then be cut down to certain typical
sizes. Most large companies will brand their tubes with
their name and address in order to deter theft.
Extensive scaffolding on a building in downtown Cincinnati, Ohio.

This type of scaffolding is called pipe staging
Scaffolding Today
The European Standard, BS EN 12811-1, specifies
performance requirements and methods of structural
25
Assembly of bamboo scaffolding cantileveredover a Hong Kong

street
Workshop on
Boards provide a working surface for scaffold users.

They are seasoned wood and come in three thicknesses
(38 mm (usual), 50 mm and 63 mm) are a standard
width (225 mm) and are a maximum of 3.9 m long. The
board ends are protected either by metal plates called
hoop irons or sometimes nail plates, which often have
the company name stamped into them. Timber scaffold
boards in the UK should comply with the requirements
of BS 2482. Timber, steel or aluminium decking as well
as laminate boards are used. In addition to the boards
for the working platform, there are sole boards, which
are placed beneath the scaffolding if the surface is soft or
otherwise suspect, although ordinary boards can also be
used. Another solution, called a scaffpad, is made from
a rubber base with a base plate moulded inside; these
are desirable for use on uneven ground since they adapt,
whereas sole boards may split and have to be replaced.
Couplers are the fittings, which hold the tubes together.
The most common are called scaffold couplers, and there
are three basic types: right-angle couplers, putlog couplers
and swivel couplers. To join tubes end-to-end joint pins
(also called spigots) or sleeve couplers are used. Only right
angle couplers and swivel couplers can be used to fix tube
in a load-bearing connection. Single couplers are not
load-bearing couplers and have no design capacity.
Bamboo scaffolding is widely used in Hong Kong, with

nylon straps tied into knots as couplers. In India, bamboo
or other wooden scaffolding is also mostly used, with
poles being lashed together using ropes made from
coconut hair (coir).
Basic Scaffolding
The key elements of the scaffolding are the standard,
ledger and transoms. The standards, also called uprights,
are the vertical tubes that transfer the entire mass of the
structure to the ground where they rest on a square base
plate to spread the load. The base plate has a shank in
its centre to hold the tube and is sometimes pinned to a
sole board. Ledgers are horizontal tubes, which connect
between the standards. Transoms rest upon the ledgers
at right angles. Main transoms are placed next to the
standards, they hold the standards in place and provide
support for boards; intermediate transoms are those
placed between the main transoms to provide extra
support for boards. In Canada this style is referred to as
English. American has the transoms attached to the
standards and is used less but has certain advantages in
some situations. Since scaffolding is a physical structure,
it is possible to go in and come out of scaffolding.
As well as the tubes at right angles there are cross
braces to increase rigidity, these are placed diagonally
from ledger to ledger, next to the standards to which they
are fitted. If the braces are fitted to the ledgers they are
called ledger braces. To limit sway a facade brace is fitted
to the face of the scaffold every 30 metres or so at an
angle of 35-55 running right from the base to the top of
the scaffold and fixed at every level.
Of the couplers previously mentioned, right-angle
couplers join ledgers or transoms to standards, putlog
or single couplers join board bearing transoms to ledgers
- Non-board bearing transoms should be fixed using a
right-angle coupler. Swivel couplers are to connect tubes
at any other angle. The actual joints are staggered to avoid
occurring at the same level in neighbouring standards.
Basic scaffold dimensioning terms. No boards, bracing or couplers

shown
Other common scaffolding components include base

plates, ladders, ropes, anchor ties, reveal ties, gin wheels,
sheeting, etc. Most companies will adopt a specific colour
to paint the scaffolding with, in order that quick visual
identification can be made in case of theft. All components
that are made from metal can be painted but items that
are wooden should never be painted as this could hide
defects. Despite the metric measurements given, many
scaffolders measure tubes and boards in imperial units,
with tubes from 21 feet down and boards from 13 ft
down.
The spacing of the basic elements in the scaffold

are fairly standard. For a general purpose scaffold the
maximum bay length is 2.1 m, for heavier work the bay
size is reduced to 2m or even 1.8 m while for inspection a
bay width of up to 2.7 m is allowed.
The scaffolding width is determined by the width of
the boards, the minimum width allowed is 600 mm but a
more typical four-board scaffold would be 870 mm wide
from standard to standard. More heavy-duty scaffolding
can require 5, 6 or even up to 8 board width. Often an
inside board is added to reduce the gap between the
inner standard and the structure.
26
Workshop on
The lift height, the spacing between ledgers, is 2 m,

although the base lift can be up to 2.7 m. The diagram
above also shows a kicker lift, which is just 150 mm or so
above the ground.
Transom spacing is determined by the thickness of
the boards supported, 38 mm boards require a transom
spacing of no more than 1.2 m while a 50 mm board can
stand a transom spacing of 2.6 m and 63 mm boards can
have a maximum span of 3.25 m. The minimum overhang
for all boards is 50 mm and the maximum overhang is no
more than 4x the thickness of the board.
Foundations
Good foundations are essential. Often scaffold
frameworks will require more than simple base plates
to safely carry and spread the load. Scaffolding can be
used without base plates on concrete or similar hard
surfaces, although base plates are always recommended.
For surfaces like pavements or tarmac base plates are
necessary.
- ie.2-3m centres (tie patterns must be provided by the

System manufacturer/supplier). The ties are coupled
to the scaffold as close to the junction of standard and
ledger (node point) as possible. Due to recent regulation
changes, scaffolding ties must support +/- loads (tie/butt
loads) and lateral (shear) loads.
Due to the different nature of structures there is a variety
of different ties to take advantage of the opportunities.
Through ties are put through structure openings such
as windows. A vertical inside tube crossing the opening
is attached to the scaffold by a transom and a crossing
horizontal tube on the outside called a bridle tube. The
gaps between the tubes and the structure surfaces are
packed or wedged with timber sections to ensure a solid
fit.
Box ties are used to attach the scaffold to suitable pillars
or comparable features. Two additional transoms are put
across from the lift on each side of the feature and are
joined on both sides with shorter tubes called tie tubes.
When a complete box tie is impossible an l-shaped lip tie
can be used to hook the scaffold to the structure, to limit
inward movement an additional transom, a butt transom,
is place hard against the outside face of the structure.
Sometimes it is possible to use anchor ties (also called
bolt ties), these are ties fitted into holes drilled in the
structure. A common type is a ring bolt with an expanding
wedge which is then tied to a node point.
Scaffolding showing required protection of a working platform with

maximum dimensions. Butt-board not visible. No couplers shown
For softer or more doubtful surfaces sole boards must

be used, beneath a single standard a sole board should be
at least 1,000 cm with no dimension less than 220 mm,
the thickness must be at least 35 mm. For heavier duty
scaffold much more substantial baulks set in concrete can
be required. On uneven ground steps must be cut for the
base plates, a minimum step size of around 450 mm is
recommended. A working platform requires certain other
elements to be safe. They must be close-boarded, have
double guard rails and toe and stop boards. Safe and
secure access must also be provided.
The least invasive tie is a reveal tie. These use an opening

in the structure but use a tube wedged horizontally in the
opening. The reveal tube is usually held in place by a reveal
screw pin (an adjustable threaded bar) and protective
packing at either end. A transom tie tube links the reveal
tube to the scaffold. Reveal ties are not well regarded,
they rely solely on friction and need regular checking so
it is not recommended that more than half of all ties be
reveal ties.
Ties
Scaffolds are only rarely independent structures. To
provide stability for a scaffolding framework ties are
generally fixed to the adjacent building/fabric/steelwork.
General practice is to attach a tie every 4m on alternate
lifts (traditional scaffolding). Prefabricated System
scaffolds require structural connections at all frames
27
Workshop on
If it is not possible to use a safe number of ties rakers

can be used. These are single tubes attached to a ledger
extending out from the scaffold at an angle of less than
75 and securely founded. A transom at the base then
completes a triangle back to the base of the main scaffold.
Specialty Scaffolding
Types of scaffolding covered by the Occupational Health
and Safety Administration in the United States include the
following categories: Pole; tube and coupler; fabricated
frame (tubular welded frame scaffolds); plasterers,
decorators, and large area scaffolds; bricklayers (pipe);
horse; form scaffolds and carpenters bracket scaffolds;
roof brackets; outrigger; pump jacks; ladder jacks; window
jacks; crawling boards (chicken ladders); step, platform,
and trestle ladder scaffolds; single-point adjustable
suspension; two-point adjustable suspension (swing
stages); multipoint adjustable suspension; stone setters
multipoint adjustable suspension scaffolds, and masons
multipoint adjustable suspension scaffolds; catenary; float
(ship); interior hung; needle beam; multilevel suspended;
mobile; repair bracket scaffolds; and stilts.
It is still used extensively where the labour costs are

lower than the costs for procuring reusable formwork. It
is also the most flexible type of formwork, so even where
other systems are in use, complicated sections may use it.
- Engineered Formwork System. This formwork is built
out of prefabricated modules with a metal frame (usually
steel oraluminium) and covered on the application
(concrete) side with material having the wanted surface
structure (steel, aluminium, timber, etc.). The two major
advantages of formwork systems, compared to traditional
timber formwork, are speed of construction (modular
systems pin, clip, or screw together quickly) and lower
life-cycle costs (barring major force, the frame is almost
indestructible, while the covering if made of wood; may
have to be replaced after a few - or a few dozen - uses, but
if the covering is made with steel or aluminium the form
can achieve up to two thousand uses depending on care
and the applications).
Formwork
Formwork is the term given to either temporary or
permanent moulds into which concrete or similar materials
are poured. In the context of concrete construction, the
false work supports the shuttering moulds.
Formwork and concrete form types

Formwork comes in several types:
- Traditional timber formwork. The formwork is built
on site out of timber and plywood or moisture-resistant
particleboard. It is easy to produce but time-consuming for
larger structures, and the plywood facing has a relatively
short lifespan.
Modular steel frame formwork for a foundation
- Re-usable plastic formwork. These interlocking

and modular systems are used to build widely variable,
but relatively simple, concrete structures. The panels are
lightweight and very robust. They are especially suited for
low-cost, mass housing schemes.
Re-usable plastic-formwork for mass housing irs

Timber formwork for a concrete column
28
Workshop on
- Permanent Insulated Formwork. This formwork

is assembled on site, usually out of insulating concrete
forms (ICF). The formwork stays in place after the concrete
has cured, and may provide advantages in terms of speed,
strength, superior thermal and acoustic insulation, space
to run utilities within the EPS layer, and integrated furring
strip for cladding finishes.
- Coffor is a structural stay-in-place formwork
system to build constructions in concrete. It is
composed of two filtering grids reinforced by vertical
stiffeners and linked by articulated connectors that can
be folded for transport. A standard panel 1.10 m x 2.70
m (3 8 x 9) weighs 32.7 kg and can be carried by hand or
by any means of machine. After Coffor is placed, concrete
is poured between the grids: excess water of concrete is
eliminated by gravity and air is also eliminated. Coffor
remains in the construction after concrete is poured and
acts as reinforcement. Any type of construction can be
built with Coffor: individual houses, multi-story buildings
including high-rise buildings, industrial, commercial or
administrative buildings. Several types of civil works
can be done with Coffor. Coffor is delivered completely
assembled from the factory. No assembly is necessary on
the construction site.
Sketch of the side view of traditional timber formwork used to form

a flight of stairs
- Stay-In-Place structural formwork systems. This

formwork is assembled on site, usually out of prefabricated
fibre-reinforced plastic forms.
These are in the shape of hollow tubes, and are usually

used for columns and piers. The formwork stays in place
after the concrete has cured and acts as axial and shear
reinforcement, as well as serving to confine the concrete
and prevent against environmental effects, such as
corrosion and freeze-thaw cycles.
- Flexible formwork. In contrast to the rigid moulds
described above, flexible formwork is a system that
uses lightweight, high strength sheets of fabric to take
advantage of the fluidity of concrete and create highly
optimised, architecturally interesting, building forms.
Using flexible formwork it is possible to cast optimised
structures that use significantly less concrete than an
equivalent strength prismatic section, thereby offering
the potential for significant embodied energy savings in
new concrete structures.
Slab Formwork (deck formwork)

Some of the earliest examples of concrete slabs were
built by Roman engineers. Because concrete is quite
strong in resisting compressive loads, but has relatively
poor tensile or torsional strength, these early structures
consisted of arches, vaults and domes. The most notable
concrete structure from this period is the Pantheon in
Rome. To mould this structure, temporary scaffolding and
formwork or false work was built in the future shape of
the structure. These building techniques were not isolated
to pouring concrete, but were and are widely used in
masonry. Because of the complexity and the limited
production capacity of the building material, concretes
rise as a favoured building material did not occur until
the invention of Portland cement (and developments by
the Edison Portland Cement Company) and reinforced
concrete.
Timber beam slab formwork
Similar to the traditional method, but stringers and joist
are replaced with engineered wood beams and supports
are replaced with metal props. This makes this method
more systematic and reusable.
Placing a formwork component
Pantheon dome
29
Workshop on
Traditional slab formwork
Modular slab formwork

These systems consist of prefabricated timber, steel or
aluminium beams and formwork modules. Modules are
often no larger than 3 to 6 feet or 1 to 2 metres in size.
The beams and formwork are typically set by hand and
pinned, clipped, or screwed together. The advantages of
a modular system are: this does not require a crane to
place the formwork, faster construction with unskilled
labour, formwork modules can be removed after concrete
sets leaving only beams in place prior to achieving design
strength.
Table or flying form systems
Schematic sketch of traditional formwork
On the dawn of the rival of concrete in slab structures,

building techniques for the temporary structures were
derived again from masonry and carpentry. The traditional
slab formwork technique consists of supports out of
lumber or young tree trunks that support rows of stringers
assembled roughly 3 to 6 feet or 1 to 2 metres apart,
depending on thickness of slab. Between these stringers,
joists are positioned roughly 30 centimetres apart upon
which boards or plywood are placed. The stringers and
joists are usually 4 by 4 inch or 4 by 6 inch lumber. The
most common imperial plywood thickness is inch and
the most common metric thickness is 18 mm.
Steel and plywood formwork

for poured in place concrete
foundation
These systems consist of slab formwork tables that

are reused on multiple stories of a building without being
dismantled. The assembled sections are either lifted per
elevator or flown by crane from one story to the next.
Once in position the gaps between the tables or table and
wall are filled with fillers. They vary in shape and size as
well as their building material. The use of these systems
can greatly reduce the time and manual labour involved
in setting and striking the formwork. Their advantages are
best utilized by large area and simple structures. It is also
common for architects and engineers to design building
around one of these systems.
Structure: A table is built pretty much the same way
as a beam formwork but the single parts of this system
are connected together in a way that makes them
transportable. The most common sheathing is plywood,
but steel and fiberglass are also in use. The joists are either
made from timber, wood I-beams, aluminium or steel.
The stringers are sometimes made of wood I-beams but
usually from steel channels. These are fastened together
(screwed, weld or bolted) to become a deck. These decks
are usually rectangular but can also be other shapes.
Traditional timber formwork

on a jetty in Bangkok
Metal beam slab formwork

Similar to the traditional method, but stringers and joist
are replaced with aluminium forming systems or steel
beams and supports are replaced with metal props. This
also makes this method more systematic and reusable.
Aluminium beams are fabricated as telescoping units,
which allows them to span supports that are located at
varying distances apart. Telescoping aluminium beams
can be used and reused in the construction of structures
of varying size.
30
Modular formwork with deck for housing project in Chile
Workshop on
Support: All support systems have to be height

adjustable to allow the formwork to be placed at the
correct height and to be removed after the concrete is
cured. Normally adjustable metal props similar to (or the
same as) those used by beam slab formwork are used to
support these systems. Some systems combine stringers
and supports into steel or aluminium trusses. Yet other
systems use metal frame shoring towers, which the decks
are attached to. Another common method is to attach
the formwork decks to previously cast walls or columns,
thus eradicating the use of vertical props altogether. In
this method, adjustable support shoes are bolted through
holes (sometimes tie holes) or attached to cast anchors.
Size: The size of these tables can vary from 70 to 1,500
square feet (6.5 to 139.4 m2). There are two general
approaches in this system:
1. Crane Handled: this approach consists of
assembling or producing the tables with a large formwork
area that can only be moved up a level by crane. Typical
widths can be 15, 18 or 20 ft. or 5 to 7 metres but their
width can be limited, so that it is possible to transport
them assembled, without having to pay for an oversize
load. The length might vary and can be up to 100 ft. (or
more) depending on the crane capacity. After the concrete
is cured, the decks are lowered and moved with rollers
or trolleys to the edge of the building. From then on the
protruding side of the table is lifted by crane while the rest
of the table is rolled out of the building. After the centre
of gravity is outside of the building the table is attached
to another crane and flown to the next level or position.
necessary high lifting capacity of building site cranes,

additional expensive crane time, higher material costs and
little flexibility.
2. Crane fork or elevator handled: By this approach
the tables are limited in size and weight. Typical widths
are between 6 and 10 ft or 2 and 3 metres, typical lengths
are between 12 and 20 ft or 4 and 7 metres, though table
sizes may vary in size and form. The major distinction of
this approach is that the tables are lifted either with a crane
transport fork or by material platform elevators attached
to the side of the building. They are usually transported
horizontally to the elevator or crane lifting platform single
handedly with shifting trolleys depending on their size
and construction. Final positioning adjustments can be
made by trolley.
This technique enjoys popularity in the US, Europe and
generally in high labour cost countries. The advantages
of this approach in comparison to beam formwork or
modular formwork is a further reduction of labour time
and cost. Smaller tables are generally easier to customize
around geometrically complicated buildings, (round or
non-rectangular) or to form around columns in comparison
to their large counterparts. The disadvantages of this
approach are the higher material costs and increased
crane time (if lifted with crane fork).
Tunnel Forms
Tunnel forms are large, room size forms that allows
walls and floors to be cast in a single pour. With multiple
forms, the entire floor of a building can be done in a
single pour. Tunnel forms require sufficient space exterior
to the building for the entire form to be slipped out and
hoisted up to the next level. A section of the walls is left
uncasted to remove the forms. Typically castings are done
with a frequency of 4 days. Tunnel forms are most suited
for buildings that have the same or similar cells to allow
re-use of the forms within the floor and from one floor to
the next, in regions which have high labour prices.
Flexible Formwork
Hand setting modular aluminium deck formwork
This technique is fairly common in the United States

and East Asian countries. The advantages of this approach
are the further reduction of manual labour time and cost
per unit area of slab and a simple and systematic building
technique. The disadvantages of this approach are the
There is an increasing focus on sustainability in design,

backed up by carbon dioxide emissions reduction targets.
The low embodied energy of concrete by volume is offset
by its rate of consumption which make the manufacture of
cement accountable for some 5% of global CO2 emissions.
Concrete is a fluid that offers the opportunity to
economically create structures of almost any geometry we can pour concrete into a mould of almost any shape.
31
Workshop on
This fluidity is seldom utilised, with concrete instead being

poured into rigid moulds to create high material use
structures with large carbon footprints. The ubiquitous
use of orthogonal moulds as concrete formwork has
resulted in a well-established vocabulary of prismatic
forms for concrete structures, yet such rigid formwork
systems must resist considerable pressures and consume
significant amounts of material. Moreover, the resulting
member requires more material and has a greater selfweight than one cast with a variable cross section.
held in a system of false work before reinforcement and

concrete are added. By varying the geometry of the fabric
mould with distance along the beam, the optimised shape
is created. Flexible formwork therefore has the potential
to facilitate the change in design and construction
philosophy that will be required for a move towards a
less material intensive, more sustainable, construction
industry.
Handset modular aluminium formwork
Formwork tables in use at a building site with more complicated
Simple optimisation methods may be used to design a

variable cross section member in which the flexural and
shear capacity at any point along the element length
reflects the requirements of the loading envelope applied
to it.
By replacing conventional moulds with a flexible
system composed primarily of low cost fabric sheets,
flexible formwork takes advantage of the fluidity of
concrete to create highly optimised, architecturally
interesting, building forms. Significant material savings
can be achieved. The optimised section provides ultimate
limit state capacity while reducing embodied carbon,
thus improving the life cycle performance of the entire
structure.
Control of the
flexibly
formed
beam cross section
is key to achieving
low-material
use
design. The basic
assumption is that
a sheet of flexible,
permeable fabric is
Flying formwork tables with aluminium
and timber joists.
structural features
Climbing Formwork
Climbing formwork is a special type of formwork for
vertical concrete structures that rises with the building
process. While relatively complicated and costly, it can
be an effective solution for buildings that are either very
repetitive in form (such as towers or skyscrapers) or that
require a seamless wall structure (using gliding formwork,
a special type of climbing formwork).
Various types of climbing formwork exist, which are
either relocated from time to time, or can even move on
their own (usually on hydraulic jacks, required for selfclimbing and gliding formworks).
Climbing formwork (crane-climbing): In this type of
climbing formwork, the formwork around the structure
is displaced upwards with the help of one or more cranes
once the hardening of the concrete has proceeded far
enough. This may entail lifting the whole section, or be
achieved segmentally.
Climbing formwork (self-climbing): In this type of
formwork, the structure elevates itself with the help of
mechanic leverage equipment (usually hydraulic). To do
this, it is usually fixed to sacrificial cones or rails emplaced
in the previously cast concrete.
32
Workshop on
Gliding formwork: This type of formwork is similar

to the self-climbing type above. However, the climbing
process is continuous instead of intermittent, and is usually
only interrupted for a very short time (for example to fix
the mounting mechanisms to new anchoring points). The
advantage is that it will produce seamless structures, but it
requires a continuous, uninterrupted process throughout,
with serious potential quality and stability problems if the
pour has to be stopped.
Usage of Formwork
For removable forms, once the concrete has been poured
into formwork and has set (or cured), the formwork is struck
or stripped (removed) to expose the finished concrete. The
time between pouring and formwork stripping depends
on the job specifications, the cure required, and whether
the form is supporting any weight, but is usually at least
24 hours after the pour is completed. For example, the
California Department of Transportation requires the
forms to be in place for 17 days after pouring, while the
Washington State Department of Transportation requires
the forms to stay in place for 3 days with a damp blanket
on the outside.
Spectacular accidents have occurred when the forms

were either removed too soon or had been under-designed
to carry the load imposed by the weight of the uncured
concrete. Less critical and much more common (though
no less embarrassing and often costly) are those cases in
which under-designed formwork bends or breaks during
the filling process (especially if filled with a high-pressure
concrete pump). This then results in fresh concrete
escaping out of the formwork in a form blowout, often in
large quantities.
Concrete exerts less pressure against the forms as it
hardens, so forms are usually designed to withstand a
number of feet per hour of pour rate to give the concrete
at the bottom time to firm up. For example, wall or column
forms are commonly designed for a pour rate between 48
ft/hr. The hardening is an asymptotic process, meaning
that most of the final strength will be achieved after a
short time, though some further hardening can occur
depending on the cement type and admixtures.
Wet concrete also applies hydrostatic pressure to
formwork. The pressure at the bottom of the form is
therefore greater than at the top.
K. R. Anand
C-57 & 59, Ground Floor, Ramesh Nagar (Double Storey),
Opp. Metro Station, New Delhi - 110015
Phone : 011-25459680, Fax : 26459660
E-mail : kranand.com@gmail.com
33
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ICI Souvenir

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IAStructE

Innovations in Enabling Works,

Innovations in Enabling Works, Formwork & Scaffolding Systems

About the Workshop

ICI Governing Council Members

ICI NDC, Executive Committee Members

1. Formwork Selection & Economics The Success Key to Your Construction

2. Allround Scaffold: Ideal for High Rise Industrial Structures

3. MFS Aluminium Formwork System

4. Modern Formwork Systems An Overview

5. Scaffolding & Formwork Types, Materials and Usage

Innovations in Enabling Works, Formwork & Scaffolding Systems

About the Workshop

Innovations in Enabling Works, Formwork & Scaffolding Systems

Mehta, Rahul, L&T

Maiti, S C, UltraTech Cement Ltd.

Innovations in Enabling Works, Formwork & Scaffolding Systems

ICI Governing Council Members

Innovations in Enabling Works, Formwork & Scaffolding Systems

ICI NDC, Executive Committee Members

Innovations in Enabling Works, Formwork & Scaffolding Systems

0845 hrs - 0945 hrs

0945 hrs - 1030 hrs

Theme : Lifting, Transportation, Handling and

Tea Break : 1030 hrs - 1100 hrs

Most Modern Methods of Construction:

Climbing Formwork Systems and Modular

Controlled Permeability Formwork Liner

Precasting and Launching of Full Span Precast Pre-tensioned Box Girders

Slip Forming of Deep Under Ground

Theme : Enabling Temporary Works & Architectural Fair

Session 4: 0930 hrs - 1030 hrs

Chairperson - Er. Raj Lakhani

Plastic Formwork System

DAY 2: 12th September, 2015 (Saturday)

Session 2: 1400 hrs - 1530 hrs

Lunch Break : 1300 hrs - 1400 hrs

Issues related to Slipform in Chimneys

Theme : Modern Formwork Systems

Codal Provisions and Importance of Design

Temporary Works- Basic Approach According

Enabling Works of Signature Bridge

Tea Break : 10.30 hrs - 1100 hrs

Smart Dynamic Concrete for Monolithic

Session 5: 1100 hrs - 1300 hrs

Optimising Project Schedule Through Innovative Construction Method - A Case Study

Theme : Scaffolding Systems & Formwork Failures: Case

Formwork Issues in Multi-storeyed BuildingShoring and Reshoring

Innovative Methods & Equipment in the Constructions of Cable Stayed Bridges

Industrial Application of Scaffolding

Erection & Launching Systems

Steel Bridges of Jammu- Udhampur

System Formwork & Shoring

Tea Break : 1530 hrs - 1600 hrs

Valedictory Session : 1300 hrs - 1400 hrs

Session 3: 1600 hrs - 1800 hrs

Chairperson - Uday Vartak

Innovations in Enabling Works, Formwork & Scaffolding Systems

Formwork Selection & Economics

ppropriate selection of a formwork system is a

misalignment, misplacement, deflective concrete or holding

Quality: in terms of strength, rigidity, position, and

Safety: of both workers and the concrete structure

Efficiency: in operation, the ease of handling, erection