IFNIT 4 PRINCIPLES OF DESIGN AND

DETAILING OF FORMWORK AND

1~ SCAFFOLDING

ructure
4.1 Introduction
()hjectives

4.2 Necessity of Formwork and Scafloldings

4.3 Materials of Forinwork and Scaffoldings
4.3.1 Necess~tyof Formwork iuld Scaffoldlng*
4.3.2 Materials of Formwork : Tlrnher
4.3.3 Plywood
4.3.4 Steel
4.3.5 Alunuruum
4.3.6 Glass Flhrr Kelllforced Plnctlc*
4.3.7 Form L ~ n ~ nMatrr~al~
g
4.4 Allowable Stresses in Material of various Forn~worksand Scaffolds
4.5 Design and Detailing of Formwork and Staging
4.6 Inspection and Testing of Form Materials
4.7 Supervision of Formwork and Staging
4.8 Summary
4.9 Key Words
4.10 Answers to SAQs

4lh INTRODUCTION
aware that freshly mixed concrete is a semiliquid-solid mass and needs
setting, hardening and achieving strength. Till such number of days, it is
shape and position by certain separate supporting system. The system

i) Formwork in which the concrete is poured to have its internal faces exactly
matching with the external faces of the member under consideration. In case
of beams of rectangular section 300 x 600 mm the internal dimension of the
formwork having sheets on two vertical sides and one bottom side leaving
top face open for lowering down the designed steel-reinforcement cage and
pouring the concrete. In the case of R.C.C. dome construction, there will be
two forms of dornical shape one to match on the lowerhottom surface of
concrete dome and another form to suit the top surface of the dome making
arrangement to hold them so that the clear gap equal to thickness of the
dome remains constant even after pouring the concrete between the two parts.
ii) Staging and Centering are meant to provide supports from a rigid ground
(or previousIy cast R.C.C. members which have already gained strength) to
the formwork so that formwork is able to withstand both vertical and
horizontal forces.
objectives
going thr9ugh this unit, you will be acquainted with basic information of

I various materials that are used in formwork and staging.

design procedure for formwork,
Detailing of Reinfomed detailing of formwork and staging,
Concrete Constructloo
methods of inspection, testing of formwork, and
the work involved in supervision and checking of salient features.

4.2 NECESSITY OF FORMWORK AND SCAFFOLDINGS

You already know that we mix cement, sand, aggregates, water and possibly some
plasticisers (admixture) in a mechanical mixer to produce a uniform colloidal mass called
concrete. This green concrete is poured into forms to form
a) llorizontal members, like tloor-slabs, floor beam, rafts,
b) vertical members like columns, walls, shafts,
c) inclined members like ramps, staircases, or
d) planar and non-planar shapes like pyramids, hopper bottoms, folded plates or
spiral stairs, cylindrical shells etc.
Thus you would notice that the green concrete needs some outside confinenlent to give it a
desired shape as finally intended by the designer, and it needs vertical as well as horizontal
supports to give the desired spatial elevations. Thus we must have formwork and
shuttering to receive green concrete and we must support these forms by strong
scaffoldings and falsework till concrete can support its own load and other incidental
loads like construction loads (labour, forms, pumps/vibrators etc.) likely to be placed on it.
As the green concrete poured to fornl beams, columns or walls are vibrated, we lilust
remember that the form-work must be strong enough to resist lateral forces on account of
lateral pressures generated due to liquid nature of green concrete and vibration in addition
to vertical loads'. Thus the formwork can be looked upon as temporary structures and
designed adequately. Construction-collapses take place due to improper design of
formworks and scaffoldings, improper fixing of forms, displacements of props, \
overloading due to rapid placements or sudden stoppages of concrete-carrying bugkies etc.
Thus proper formwork design/executiotl is as important as that of the actual structure itself.

4.3 MATERIALS OF FORMWORK AND SCAFFOLDINGS

Before getting on to the materials used for formworks and scaffoldings, let us lock at the
basic elements and parts of the same.
4.3.1 Necessity of Formwork and Scaffoldings
The part of formwork which receives the concrete directly is called the sheeting, sheathing
or boarding (Figure 4.1 (a) (b) (e) & (g)).
The sheeting transmits the load to the joists or beams or yokes or bearer, as shown in
Figure 4.1 (a) and (b).
The load from joists is ultimately carried down to ground or the concrete structure by the
props. For ordinary and small structures, the props are provided with nominal lateral ties
and bracings as shown in Figure 4.1 (f), but if the height of the props is large, say more
than 6 m, an elaborate system of braces, lateral ties and platforms may have to be provided
as in bridges, for auditorium gallery beams etc.
4.3.2 Materials of Formwork: Timber
Practically all formwork jobs, regardless of the varied or exotic form of materials that may
be used, require some timber in one way or the other and timber forms are one of the most
popular material in India. India produces a large variety of structural timber in different
parts and generally locally available timber is used as sheeting material, joists or as props
and bracing materials.
 Principles of Desim and Detailing
of Formwork and ScPffddin~

(Sheeting

Span -

[, Span I Sheefing

Pr@ssure

(a) (b) Sheeting of timber or plywood on joists (continuous in Fig (b))

(e) (d) Joists spenning over props (continuous in Fig (d))
(e) Sheeting and yokes for walVcolumn aud pressurn on the same

Figure 41 :Basic Elements

Detailing of Reinforred
Concrete Construction Sheeting 7

sleeper commcted

Span of beam or joist

-I
Ihl
(0Sheeting,joist, pmps, ties and braces
(g) Sheeting of MS plates on telescopic adjustable steel beam
(h) Telescopic open type steel beams on adjustable spans
Figure 4.1 :Basic Elements

i) Any timber that is straight and structurally strong and soupd may be used for
formwork, although the wide distribution and abundance of softwoods make
them generally most economical for all types of formwork,. The softwtmds
are usually lighter in weighter and are generally easier to work. Hardwood
caps and wedges may be introduced where additional strength cross grain is
needed.
ii) Partially seasoned stock is preferred for formwork, since fully dried timber
swells excessively when it becomes wet and green timber will dry out and
warp during hot weather, causing difficulties of alignment and uneveu
surface. (:)Id and new sheeting or boards should not be used together in the
same panel if uniform form finish is important.
iii) Refer Table 4.1 for some typical species of structural timber, m d e names,
availability etc, as per 15883, Table 4.1. Timber which has been surfaced to
attain smoothness of surface and uniformity of size is called "dressed"
timber. The surfacing may he on one side 6 1 s ) . two sides (S2S). two edges
(S2E). Dressed timber is generally used for formwork because it is easier to
handle and work, but roughsawl1boards and timbers may be used in bracing
and shoring, or as a form surface material to secure a special texture effect
in the f i s h e d concrete.
 iv) Tongue and groove boards are to be used for sheathing where smnt~>lhness of
surface is an important consideration. "Matching" of the boards, that is
fitting the tongue into the groove of the adjacent board improves alignment
of the sheathing and also prevents loss of mortar through the joints.
v) Refer I.S.4891 for preferred sizes of timber which are reproduced in
Tables 4.2,4.3 & 4.4 (these are sawn sizes).

Table 4.2 :Referred Cut Sizes of Structural Timbers for Roof Trusses from 3 to 20 m

Thickness (mm) Depth (mm)

20 40 SO 60 80 - - -

25 40 SO 60 80 100 120 140 160

30 40 SO 60 80 100 120 140 160

40 - - 60 80 100 120 140 160

Table 4.3 :Prefeired Cut Sizes of Structural Timbers for Purlins, Rafters, Heams etc.

Table 4.4 :Preferred Cut Sizes of Structural Tlmbers for Partition Framing and
Covering
Depth (mm)

Preferred length of Timber 0.5. 1. 1.5 and 2 m

&
 4
4. 3 Plywood
widely used for job-built forms and prefabricated form panel systems.
arge sheets of plywood save labour in form-building and correspondingly large
Principles of Design and Derailing
of Forniwork and Scaffdding

t-free concrete reduce the cost of finishing and rubbing exposed surfaces. Also
exceptionally high strength/stiffness to weight ratio; it is easy to handle, cut
; it can be bent ru~dc a be
~ for~ned
~ into curves and has good thermal
properties. When bonded with phenol fornlalclehyde synthetic resin and treated
preservatives, plywood becomes highly water-pnmf m d durable against

cwd is a reconstituted sheet nlaterial n~adcfrom wood. It is made up of thin layers of

of wotxl called "veneers" bonded togather using a synthetic resin adhesive, with the
of grains of adjacent layers ru~lnulgat right angles to each other thus possessing
i) high strength in two principal directions,
ii) high resistance to splitting particularly while nailing close to edges, and
iii) dimensional stability
Besides, being an article of wtn)d, plywood possesses all the superior
features of wood like high strenglh/stil'li~eosto weight ratio, thermal and

+
electrical insulation properties ax1 easy workability using hand tools.

Ty c of Plywood Used in Formwork

i) Plain shuttering plywood :This is a boiling water proof type plywood

nlanufactured from veneers of selectetl hart1 woods using phenol
fornlaldehyde synlhetic resin as adhesive. It is further treated with fixed type
preservative chemicals by a vacuum pressure impregnation process. After
the treatment, the panels are dried to a moisture content of 10 to 12 5%. The
salient features of gcnxl quality plain shuttering plywood are as follows :
I it can be reused several times as the bond can withstand alternate
a)
wetting and drying,
I b) it is durable against attacks by wood fungi and termites,
it has a smooth and hard surface Lhat can withstand the normal
c)
pressures and abrasion from concrete,
d) the surface has slight permeability and after absorbing some moisture
from fresh concrete, it leaves the fine cement particles to form a
smooth and even surface,
e) being strong in both directions, sheeting thicknesses can be reduced
compared to timber,
t') it insulates fresh concrete from extreme temperatures, and
g) it is easy to transport, handle fix, trim and maintain.
ii) Plastic film face plywood :This shuttering plywood is manufactured from
selected hard woods, bonded with phenol formaldehyde synthetic resin and
further overlaid with 6 reinforced phenolic film. The surface film is
prtxluced by impregnating a layer of kraft paper with phenol formaldehyde
synthetic resin. Additional advantages of this plywotd are
a) more reuses (50% more) of forms as the film overlays are wear
1
resistant,
b) it has exceedingly smtnXll and glossy surface which gives a cleaner
and smoother finish to concrete surface, and
I c) this phenolic film overlay is resistant to the alkaline constituents of

+
Foll
cement concrete and acts as barrier against wtnd extractives.
ing are d e generally available sizes and thickness of plywood.
Detailing dReinforced Table 4.5
Concrete Construction
Plywood Size m x m Thickness (mm)
2.44 X 1.22

The density of ply~loodnlny ht. taka,) as 6.8 k W m 3

4.3.4 Steel
Steel has long been an irrlportant material for the fabrication of special purpose fornu, all
steel panel systems for ger~eralbuilding construction have been succt:sst~,illyfabricated
and used; and steel framing and bracing are Important in ths ccins&uc:tion of mrulj, wc.n>d
and plywood panel systems; horiaelal and vertical sheres of ssec'! are wldcly ?!xi:rl today.
Standard and lightweight ut~u:::ural steel rnernbers coaslsting of channel), mgies. I
beams, open telescopic trusf bcalal? a!lrl oti~ers,car1 be used to support !hc stieathnng. With
proper inalntenance they Inst nnu~fllor~ycrluld therebq may prove econonmcal even
though their initial cost is high. It I \ very colmnon to use circular steel plpes for staging
work as they have the best structur;~llyefficient cross-sectional shape for carrying 'axial
compressive loads. For durability these can also be galvanised.
Prefabricated forms and forming system9 have become increasingly popular as they save
both material and labour cost. They are built for durability even after repeated uses. Some
of these proprietary system are described below:
i) Panel Forms
There are two types commordy in use - all steel panels and plywood panels
set in steel metal frame. They are light and are manufactured in standard
modular sizes of 600 rnrn wide and 1150, 1000,900 & 800 mn long.
Generally all steel panels are 2 mm thick with pressed flanges and stifher
(Ref Figure 4.2 (a), (b)). 9 to 12 mrn thick plywood panel forms are fixed
onto metal frame by sunk carriage bolts or slipped into metal frame as
shown in Figure 4.1. (c), (d). They are 900 x 1200 & 1500 in plan.
ii) Wall Panels
Wall panels are also similar in design and construction as referred in floor
panels above.
iii) Adjustable Spans
They are basically telescopic lattice type horizontal beams. They are used
for supporting the sheathing or floor panels and can be used for spans
varying from 2 to 5 m (Refer Figure 4.2 (e), (0,(g)).
iv) Vertical Props
There are several types of adjustable individual props. Some of them have
provisions for adjustment both at the top and bottom. Figure 4.2 (b) shows a
prop with tripod base for stability and hence can stand independently. There
is also a provision for height adjustment at tripod and in the mop. The
adjustable two way head helps in holding the longitudinal beam in both
directions.
v) Staging Frames
Refer Figure 4.3 (a) & (b) for staginglshoring frames and Figure 4.3 (c) for
heavy duty tower frames which can be used upto 10 m heights.
 /.Carriage nut Principles d Design and Detailing
of Formwork and Scsffddinp:
( a ) Section- floor panel
-
( c 1 Section- floor panel

]:I L
-- - - - ------
-- - ,,- - - - - - ,I 1
(

I
I
) Plan - floor panel

I d l Plan - floor panel

( e l Telescopic beam -outer

Tapered Section A -A

( f 1 Telescopic benm - inner

-did
Sec 10

I ( g l Telescopic beam assembled

Transverse beam -. --1

~ondtudiml
beam

Floor prop
Removable
folding tr ;pop

q*)
Spreader

(a)(b) All Metal Steel Floor-Panel Form

(c) (d) Plywood Panel on Metal Frame
(e) (f) (g) Telescopic Beam (Outer. Inner, Assembled)
(h) Propping Arrangement
Figure A2 :Proprietary Systems
Detailing of Reinforced
Concrete Construction
vii)
viii) Accessories for Steel Scat'folding
vi) Ties
A variety of concrete form ties are available for securing the formwork
against lateral pressure of unhardened fresh concrete as show11 in Figure 4.4.
In Figure 4.5, continuous single member and a specially designed holding
device is added for engaging the tensile unit against the exterior of the form.
These ties may be md or flats and may be cut to length on the job site or
completely pre-fabricated. Internal disconnecting type, in which tlla tensile
unit has an inner part with threaded connections to removable external
members and have devices for holding them against the outside form.
Figure 4.4 (b), 4.5 (c) for leak proof ties for water retaining structures.
Figure 4.6 for various types of form anchor used to secure forn~workto
previously placed concrete of adequate strength.
Dropheads
These are the uilits fixed on the liead of staging arid they help in removing
slab forms without disturbing the supporting prop unit 111 position (Ref.
Figure 4.7)
Figure 4.8 (a) to (0shows various accessories for steel scaffolds iis follows :
a) Adjustable Stirrup Head
These are generally used with 100 mm timber rulmers. :uld designed
for fine adjustment of height hetween 80 to 200 nun.

Screw jack
U head

(a) Bracing (BR

Figure 4.3 :Stapjnp; Systems (a,b a d c)

 Primiplor d I>erign and Detailing
of Formu,ork and Srafldding

I (a) Snap 'fie with Sn~ullCone Spwader

n
u - U -
-Water seal (optional )

"
n

I (h) Washer Sprcuder, Crimped kbr Hrrnk Hnck

S~)rCudcr
(c) COIIC

(dl No Spreader, May he IBullcdor May Iw l ! ! u i l q ~ dwith Rreok Point

(e) Taper Tie to hc Withdmwn

I
(0 Strap Tie Use with Panel

U (g) h p End Tie Used with Panels

(h) Straight Tie with AUarhed Elastic Tube (Suggested Load Capacity 20 to 224 W)
Dccallinp: of Reinforced
C o n c ~ i Construction
e

(i) Thlreded Rzu with Unatta~chedI'lstic Sleeve (Suggested 1,t)ad Ca~pneily20 111220 kN)

(j) S p w r d r r (Suggested I ACnpnait~

CtJI Type Tic wit11 trr without Co~tt* B ~ 20 t o IfhbkN)

( k ) P l d n Coil Type, Coil'l'ypes are also available with 4 Struts (Suggmted I,oud C:npacily 20 10 ILO kN)

(I) Water Senl Coil Type (Suggested I,od Cnpueity 20 10 160 k N )

Wedge shaped holder

.s
l a
v
n
y
-
(m) Crinlped 'Tic with I)iscw~nectingEI~N (Suggcstrd Load Capacity 14 10 42 k N )

Nu) washer or other Ma haw hole h r

locking unit f notng
J to stud

(nl Plain Tie with Sl~e-RollI)iscon~wctinp.Ends may have Water Stop (Suggested Imrrd Capacity I4 to 2tW)kN)
-
Figure 4.4 (n to 11) : Fomt Ties (Suggested Working Load Approximately 9 to 22 k N (:e~~o.r;~lly
;md for Taper
Ties 20 to 220 kN)

Figure 4.5 (n) :Representative of the Mnny Special Purpose Tying Devices are these Two for Altachmmt t o
Reinforcing Steel. The Lower Single-end Coil Tie can be Welded in the Field, while the u p p r r one is Suitable for
lnstulation whew Welding to the Reinforcing Bar is not Permittrd
 Principles rbf I)csign und Detailing
rpf Fnrmw~~rk and Scdolding

~ i , , ~4s
, . (c)
~ :plws Designed to fill Tie Cone Holm are avnilable in Mortar or Plastic: with folours e w e r
matc.iw or wi(h surrounding concreie. Various types of Epoxies be used to assure a Positive
Sed. H u p may be sized for Flwh Irwtollntion if desired

b) Double Couplers
These s e used to assemble scaffold tubes finilly at right atlgles.
c) Screw Type Adjustable Base
This is a Screw Type Adjustable Base used for adjustment of
base-height in the range of 80 to 200 mrn from ground level. This is
provided with a robust threaded rod and a 150 mnl square base- plate.
d) Tubular Type Adjustable Base
This is telescopie tubular arrangement used for coarse adjustment of
height in steps between 600 mrn to 1000 mm.
e) Swivel Coupler
Swivel couplers are used to assemhle two tubes at any angle.
f) Expanding Joint Pin
These are special bars or pins used for intercomecrhg scaffold tubes
end to end. When tiUed, the pin expwds, internally to apply grip
against the wall of the tubes to make r firm joint.
ix) Slip fonn Shuttedng is a special type of device in which formwork for
concrete tanks/vessles can be made to move or dip upward as the concrete in
" ~ e rrinb wrtiw is set. The conar(ins cpo go ~on~uousIy.
"" ae h e = h a a i ~ system ofjacks,
p'affom md
jacw.
rods, ~o&~ieg~,
Figure 4.9

s l i ~ ~ @ - f ~ m w oover
r*
R,C. wdl,
Detailing ot Reir~lomed
Concrete Construction

Fknre 46 (a)to (h) :Smple screw -or (left) she* the Two Pnrta of the Unit Assembled in Concrete
Embedded Ao&omge Unit only is shown for aeved other tgpw of Fonn-l)sehor. Some of these require abon
shorn on the I d t . The Crbnped Anchor q a f r o s an lntcrually Threaded Bolt Canneetion, and the H ~ ~ c - P ~ U
 ..
...
- . .. .- .- . . . Principles nf Design and llrtililing
of Formwork iuwl S c a d d i n g
-. ...- HOLES ORLLLE

....
--.....
..
...
....
. -. . THREAOEO ROD
.. .. .. . . . . . . .
..,.. . . . . . . - * . .. .. ... .. -. .. . .: .. TO CONNECT TO

:One t l t h e several available Anchons lor Ofl-rock Tying. The Anchor Unit b placed in a h d e
r e k . When (he BoH o r External Fmtener is inserld it expands thc Anchors. Thus tightening it
VII~ the rock .%me Rock Anchors are domiu~cdto he surrnunded hy grnut i n Ute rock cavity

(a) Rabcd-Pmition with Fonns in Pmition (b) Struck-Position for Removd of Fonns
Figure 4 7 :Dr~phends

I
(a) Adjuntable Stirrup Head (h) Double Coupler

( c ) Screw Type Adjustable Bane ( d l Tube Type Adjustable Base

Detailing d Reinforeed
Concmte Construction

Swivel Coupler (f) Expnndi~rg.loin1 I'in

Figure 4.8 (n to f) :Accwnories of Steel Scallddin):

R e W t Template

Woter
Shutt

Figure 4.9 :Slip Fonn Shuttering

4.3.5 Aluminium
Density of aluminium is 33 8 that of steel. Use of aluminium alloys for fortning and
shoring applications can be, therefore, useful where cost of transport and hatxllinp is a
major consideration. Alunlinium is very light. Aluminium is ;ul ideal strucmr;ll malerial to
be used in launching heavy precast concrete girders of bridges etc. However. pure
aluminium is attacked chemically by wet concrete and special treatme~~ts to alu~lli~lium
forms are required. However. as use of aluminium is not that comnon we woultl not
proceed further with this topic. The main aspect is that its basic cost is too hipll.
 b
4. .6 Glass Fibre Reinforced Plastics
G or FRP forms are strong and light and'are capable of producing high quality
ete surfaces and generally last through numirous re-uses with nominal touch-ups.
can he readily fabricated to complex shapes. FRPIGRP coatings can also be applied
Prineiiplcr ot Design and &tailing:
of Formwork and Scadding

er f(xming material such as plywood or steel to get high quality finished surfaces or
re-uses. Again these being uncomnlon usages we would not proceed further with
FRP.
4.317 Form Lining Materials

1
The following are die special purpose form liners:
a) Rubber Liners
Neoprene arid other types of r h h e r lnals 11lay be used as baseliners in
repetitive factory precasting work.
1 b) Vacuum Liners
Vacuum treatment removes water aid air bubbles from surface layer of
iieshly placed concrete thus iolpn,vinp ils durability and strength. The
vacuum treatment is achieved (specially of mads, factory floors, run-ways)
on fonned surfaces using two-layer o i screen or wire mesh covered by a
layer of cloth.The liner is sealed witli rubher or caulking material around the
edges of the form panel. A series of opcnings in the form panel backing is
connected to a vacuum pump and as s m n as concrete is placed the liner is
covered over the fresh axicrete and vacuum is applied.

As more water than that required for chenlical hydration is invariably used in
concretes, the concrete produced lnay have internal voids and less strength.
llie form liner incorporating textile fabrics helps in draining of excess waer
thus reducing voids and producing strong and durable surface and body
concrete. These can be used in heavy slabs, beams, columns, walls, piers,
1 dal~isetc.
) Insulation Form Llners
These can he used to keep concrete at such temperatures during casting that
it does not dry out in hot weather or does not freeze in cold weather so that
concrete lnay gain strength without loss of heat of hydration. These liners
liuy consist of insulated sandwitched panels or foamed polystyrene plastic
boards.

Indicate the basic element of fonn-work arid scaffolding. Draw neat sketches
of the same.
Enumerate at least five different nlaterials which can be used as for m-work.
i()
"In the case of timber, a partially seasoned stock is preferred for
formwork". Is the slatement correct. Give suitable explanation.
Indicate the density (X L,llowing wood-varieties referrills to I.S.88:1
it)

1 c ) Eucalyptus
I d ) Indian Oak
y el Teak
V) I11dicate briefly howplywood is manufactured and explain its important
properties including its density a i d approximate modulus of nlpture (Refer
Taple 4.7).
Indicate salient feature of tlle plain shuttering wood? What ruie the general
available sizes.
D v i n g crt ReinfcA'r.ner( .....;:
'>.
I 3._
~i~~;:~_i?;t?~i:.'~;r'a~:,~:j.i-i;;?iiionssteeliscc~>~o~cforfomwork:'Draw
Concrete Ctmsts-r ctv,n- ni::r: -:.lici:i:i.t i:f ?*::~.ii.\:prr; [231;4 arid the adjustable tubulx prop.
j R; 'rh<ig:i 'f:? (f;>-:!ivtjr&ftr; ~ t a i ~ c a in s c() (VI) above us~llpplywood sheets.
J i) 3!!) 11.; ntv, o:k ir, r.fyw:'nd sheeting, timbrr-heams, aid steel props
f d i r

f,~: a cci~;::tca,: l ~ (4CO ~ mm m wide x 2000 mm dcep), soffit being at 4

mclircs vcl Assnnke Emperat'lrc of 20 "C at the time ot co1lcrctlng. slunip
i c

ol ic'.t r.,:.. ?nri *A!:: o~p!asc:rncnt of conzreie as 2 tiletref per hour.

59.:

-9' Di ,r;D !bc 3 , r ,* icib, in c;r:rx.i ti;r a rrti~intnpwall, 2 m helow groutid level
: "i, F ~ C ' J-r;si , ~ 1;ri !:\t<:j, 25 nietres long amd 200 illin unitornl tNck11css.
?l:r* it,: t.. : 3iictre ,!la heel-slab 1s 2 nlctres. Assiarnr: the concrete with
c-!t.,,~

ia) tst!;y;,'f,n:~i~,. n J 15 'V (b) slump of 50 mm,ad ( c ) rate ot p1;iccnient o f

r. ;I, I t*lr , ., : : l , i l : ~ ~ ~ f i l ( ? Ass~llie
,.~~. W l d pressure to hi: 1.s k ~ l l n ' .

$.,.Ih!,I .O!*$'t1:31,E STRESSES IN MAI'EWIAIAS OF

VAMf OUS Tt20RhllFVORKS AND SC!\IE'FOI,DS
Eva! tlln::f.l! itr;. Rarc,iu c i l Imlim St;li~tiar.iishas not spr:citicaily !;lid dowrr critcri;l ['or
rnalcri;:is. ri!iin~;!hie si~~.c.c.es aird deflecricms for fnrmworks and sc;iffc)ld~,dlc criteria
' : i d i.!t)!i : jil r:c:!'~~::j?cli;i?ili~ .slr~cI~ralcodes Inay he used with incri?:rsetl SlreSSeS ill ltrrlll
:vii!-ri :<I$: cc~:m?iri~i'tiori Ic,acls are taken as "short tcrm" or "erectioii loads".
q,..
giqlher
2

tteier 'Thblc 4 6 for vaiues of modulus of elasticity. allowable stresses in hcudinp. shsar &
ct)mprt:asiari rcproducetl iiom IS : 883 for common t~n~hers.

RtnCerTahEz 4 7 r.: :' . XS3 forproperties of proprietary plywood (comlercially available)

Ordinary Str-aac.tut-nESteel
Rekr Table 4.6 tix summary of inportant design stresses when using ordienry structurikl
steel as.per IS : 800 Cirade I+ 250 and Table 4.7 summarises stresses for welcls (IS : X I h)
Structural Steel Tubes
Table 4.8 suanrmarises basic design stresses for structural steel tubes as per IS : 806 Lor
grade YSt 22.
Table 4.6 :Summary of Design Stresses for Fe 250 Steel
Axial Tensile Stress. 4, = 150 Nfnlnl2 (C'lause 4.1.1).

A x ~ a('on~presslvc
l Stressas, on,III Nln1m2 (Clause 5 1 . 1 ) .

I
Slenderness 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
Ratio

150 148 145 139 132 122 112 101 90 80 72 64 57 51 45* 41 37 33

Bending Tension (ubr)

or Compression (oh)= 165 Nlmm2 (Clause 6.2.1)

= 187.5 NImm2 (Clause 6.3)

Bearing Stress. o,,

Shear Stress, c, = 112.5 Nfmm2 (Clause 6.4.1)

Allowable Stresces In Bolts (Clause 8.9.4.1)Nfmnl?

 r(~lr-\nl I ) e d ~ nand Detailing
.. F r t r r i w ~ r kand ScdTolding

f s :Aifi~t S h a r = 40 .V/mm2 (Clause 5.4)

ii:;".:'~

Proprietar., Pruducts and Sgsterns

Lot of standxdi>?l! propric.tary produ.cts along with their accessories are available and can
be ordered off t l : ~shelf. Table 4.9 summarises the load carrying capacities of some of the
products includiiig slab fonr~sshown in Figure 4.10 and adjustable props as shown in
Figure 4.1 1. (Refer Charts 4. I to 4.6for quick design guide for timber members.)

Table 4.9 (a) : Floor/Slab Forms Capaclty

1

Size Span M d m u m Slab

(mm) (mm) Thickness

1150x600
900 X 600
1150
900
(mm)
300
400
"
d
/'q
M.S. 16.9

800 x 600 800 400 (2 mm)

110 r Slab-Form
Detailing: of Reinforced
Concrete Canstrucaion 4 -- 4.9 (b) : Capacities of Open Telescopic Beams
Table
Slab, Total load Includimg 1.8
Thickness
(mm)
k ~ l r n *for Shuttering and
Construction Live Load
Gtn
( k ~ / m ')
100 4.20
125 4.80
150 5.40
180 6.12
200 6.60
250 7.80
300 9.00

Max. BM = 10.4 kNm

Max. L o d = 27 kN

Figure 411 :Props &Adjustable Heights

Chart 4.1 :Tim ber Planks

Design C3atts tor Formwork (slab.sheeting)

1) Safe shearing stress = 1.4 ~ l m m '!
2) Safe bending stress = 7.0 Nlmm2
3) Assumed E (Young's Modulus) = 8.5 x lo3 ~ l m m '
4) Deflection, not exceeding 3 mm a id i not exceeding spad360
Values allow fatimber being 3 m m 1, .ss than nominal sizes
 Chart 4.2 : Timber Props I'rinciples of 1)esiyn .uld Detailing
of Formwork arid Scaffolding

Heiaht between braces/bmadth of s,hul

~ & i Charts
~ n for Formwork (Struts)

I ) Safe shearing stress = 1.4 ~ / l n I n '

2 ) Safe bzncling stress = 7.0 N1111rn-
3 ) A s s u ~ ~El d(Young's Modulus) = 8.5 x 10? P4ln1ln2
4 ) 1)etlection. not exceeding 3 111111 ilnd not excercling span/2hO
5) Values dlow for till~brrk i l g 3 111111 ICSS than nciminal sizes
Chart 4.2 (a) :Timber Props

Height IBreadth ( S l d or L l d )

Design Charts for Formwork (Struts)

1) Safe shearing stress = 1.4 ~ l m n ~ ~

2) Safe bending stress = 7.0 ~ l r n n l ~
3) Assumed E (Young's Modulus) = 8.5 x lo3 ~ l m n l ~
4) Deflection, not ex&ing 3 m m and not e x d i n g spann60
5) Values allow for timbtx M n g 3 mnl less than nominal sizes
Detail* of Reinforced
Concrete Construction

is':' I It&!
ts ,<,I.l*or~li\vc~rk
(Wall and Colunlns Sheeting)

!) S.!!L. ::h.:.lnrlg .;tress = 1.4 NIIII~II-

21 c strcqs = 7.0 NIIIIIII-
S ~ l I,c,~i~ling
3 3
Assnil~i.~l ti (Y(:ung's Mo~lulus)= 8.5 x 10' NIIIIIII'
.&I I )cllic!ion. 11t't rxcce~lir~g 3 111111 ant1 not excet.~lil~g
spi111i360
5) i';.iluqs .~lluwt'crl- ril~lhcrIxing 3 111111 ICSS than nti~l~inalsiz1.s
Chart 4.4 :'Timber Heoms

. - -
Span (metre 1
IJesignChortq fur Furmwnrk t.ldsts, Yokes & Bearers37 nun Wido)
2
I ) Safe shann; .?as = I .4 Nlmtli
1
2) Safe bending stress = 7.0 N/~iiai'
3
3 ) Assu~iirtlE (Young's Modulus) = 8.5 x 10. ~ / m m ?
4 ) Ileflection. not rxcwtling 3 111nland not a x d i n g span1360
5 ) Vduls dlow for tinibex bring 3 111111less than no~ninalsizes
 SPCBF{ mat re )
Ilt CitagbZ, for Rwn~wurk(.loists, Yokrs A Isenrer\ fs2 liuzr 12'idr I
i) S:\ft- sh~rrillgstrcss = 1.4 Nirntn2
2) S,~ii:irnding srl.css = 7.11 ~ i l n r n '
.i) ,\::stiillwl f; (Y1,ung's Modul~s)= 8.5 x 103 N / I ~ I I I ~
-I ; t)ellcclion, not excaalinp 3 nrtn ;~nclnot c x ~ e u l i l ~spanlZh0
g
5) Vi~luei dl,*w fcr tiniher being 3 111111 lrss than notllind si~rs

Chart 4.6 :Timber Ream

Design Charts for Formwork (Joists, Yokes & Rearers 75 mm Wide)

7
I ) Safe sharing stress = 1.4 N/IIIIII-
2 ) +fe bending stress = 7.0 N/tllrn-
3 ) Assu~iirclE (Young's Modulus) = 8.5 x ld N/~~!II'
4) 1)eflcction. not excrtttling .Z IIIIII ant1 not excer~lingspan1360
5) Values illlow for tiillber k ~ n 3g 111111 less than nc)r~rindsizes
Detailing of Reinforced
Concrete Construction
4.5 DESIGN AND DETAILING OF FORMWORK AND
STAGING
Formwork for concrete must support all vertical and lateral loads that inay bt: applied
until such time as these loads can be carried by the concrete structure itself. Loads on the
forms are:
1) weight of reinforcing steel and fresh concrete,
2) self weight of forms, and
3) -various live loads imposed during the construction such as labour and
equipments like pumps, vibrators, buggies, etc.
Dumping of concrete, movement of construction equipments and action of wind inay
produce lateral forces for which also the formwork must be designed. Formwork design
must also consider unsymmetrical placement of concrete, uplift, (the other end of
unloaded beam in a continuous beam form) and concentrated load produced by storing
supplies on the freshly placed slab.
a) Vertical Loads
Generally unit weight of R.C. construction can be taken as 25 kN/m3and
weight of formworks for ordinary structures may be taken between 0.5 to 0.7
kN/m2.Construction live load for ordinary structures may be taken at 2.5
kN/m2 which may be increased to 3.75 kN/m2when using mnotorised
buggies
b) Lateral Pressures of Concrete
The effect of high frequency vibration on freshly placed concrete with~nthe
formwork is to keep it in a tluid state producing a hydrostatic pressure that
acts laterally on vertical forms. However, full hydrostatic pressure may or
may not be developed depending on whether stiffening or archillg of
concrete occurs before the lift is finished. For structural concrete placed at
controlled rates Amercian Concrete Institute's Committee 347 has developed
the formulae below for maximum lateral pressure on the form for
prescribed condition of temperature, rate of placement, vibration, weight of
concrete and slump. They are all empirical formulae based on experiments,
and should not be considered theoretically precise.
If p = lateral pressure in psf,
R = rate of concrete placement (ft/hr),
T = Temperature in ( O F ) of concrete in the forms;
h = height of fresh concrete above point of consideration in ft, then
i) For Columns
R I
p = 150 + 9000 - (Maximum of 3000 psf or 150 ,h whichever is less
T
ii) For walls, rate of placement not exceeding 7 fthour
R
p = 150 + 9000 - (maximum of 3000 psf or 150 h whichever is
T
smaller)
iii) For walls with rate of placement between 7 and 10 fthr

+- R
p = 150 43400+ 2800 - (maximum of 2000 psf for 150 h
T T
whichever is smaller)
iv) For walls with rate of placement greater than 10 f t . h
p=150h
v) For slipform
 All these formulae are for concrete made with OPC with unit weight of 25 Principles ofDesip;n and Detailing
k ~ l d c o n t a i n i n gno admixtures, with sluii~pless than 100 mm and placed of Fonnwork and Scaffolding
with normal internal vibration. Concrete pressure on form work can also be
based on CIRIA Report, refer Tables 4.10.. 4.1 1,4.12, for design pressures
p, (height lirnit).pr (arching limit) and y , (st~ffeninglimit) respectively.
(
i \ c) Horizontal Loads
Bracings and props should be designed for all the possible horizontal loads
due to wind, inclined supports, dumping of concrete and equipments.
However, in no case, this horizontal load acting in any direction at each
floor line should be less than 1.5 kN/m of 11oor edge or 2% (of total dead
load on the form distributed as a unifornl load/nl of slab edge whichever is
greater. Wallforms also should be designed to meet wind load requirements

1b) of Indian Standards Code of Practice. Bracing for wallfortns should he

designed for a horizontal load of atlert I S kN/m of wall applied at top.
Special Equipment Loads
If special methods of placing concrete using equipmerits like pumps ace
adopted, the form work including staging should be designed for additional
load in the case of pumping, if the transport pipes are anchored onto the
stagings, the bendings in the pipes will transmit very high lateral and
vertical loads to the staging. Hence the staging should be adequately
designed and braced. It is alsci necessary to take into account the effects of
starting and stopping of heavy equipments on the deck, these can he
estimated using the expression.

\I where,
F = the average force,
w = weight of the equipment, and
u = acceleration or deceleration.
ncrete buckets are used, it may be necessary to ullload the concrete at one
bution. This can cause impact due to dropping and utibalanced loading on

-
Table 4.10 :Horizont~lPressurep1 Helght Llrnlt

Table 4.11 :Horizontal Pressurep, -Arching Llmit

 Table 412:Horizontal Pressurep, -Stiffening Effect

4.5.1 Design Criteria

Although there is a need for greater accuracy than is frequently used in forinwork design,
too much refinement is also riot called for. Absolute precision is unwarranted when so
many assumptions have to be made as to loads, lateral pressures, quality of mateirals,
workmanship at site etc. Hence the following simplifications can be done for calculation
of moments, shears and deflections.
All loads are assumed as uniformly distributed.
Beam supported over three or more spans are regarded as continuous and approximate
formulae used. The stresses induced in every member of formwork, in bending, shear and
bearing should be wihin the permissible working stress for that material. Forills must be so
designed that the various parts will not deflect beyond prescribed limits as per
specifications (or 1.6 im for sheathing, 3 rmn for beams upto 1.5 m span and spanl3W for
larger spans)
Example 4.1
Design the sheeting and beams for R.C.flat slab 200 mm thick on 5 x Sin module:
height 3 m. Assume 25 mm planks are available. Group B (Table 4.6)
Solution
Dead load of R.C. slab = 25 x 0.2 = 5 kN/m2
Load of forms + Liveload = 2.5 k ~ / m ~
Total load = 7.5 kN/m2
a) Sheetlng Deslgn :Assume I m wide sheet for design purpose with 25 mrn
sawn size reduced to 20 mm.
Allowable bending stress (n. = 1.25 x 10.2 = 12.8 N / i m 2 (IS :8a.7-
Tablc Ci)
Allowable shear = 1.25 x 0.9 = 9.73 N/rmii2
 'w l2 *iples of Design and Detailing
M, (continuous section) = - = JZ of Fo~mworkand Scaffdding
10

.. P = 1.138, and I = lm(approx.)

Check for deflection :

1
As deflection is 6 > -
360
(= 2.8 mm) or 1.6 mm, change span

New span = @ 7.8

xlWO=67Omm

Check shear stress = Oe9 0'67 7500 = 0.23 N/-2

lo00 x 20
Thus you will notice, deflection is the governing criteria. As the module is
5000 mm, we adopt spacingof joists as 500 rnm. (Refer Figure 4.12)
Joists :Try 50 x 100 (40 x 90)
Span from de'nection criteria

1=1240 i f 6 9 3 mm
Assume 1= 1.30 m
Check bending stress
0.5 x 7500 x 1 . 3 x~ 1000
M = Nmm = 6.34 x l d Nmm
10

Assume span = 1250

1
Check shear stress, H. Since, - = 1250 and D = 90;
2

:. Design shear = 0.6 x -

3750 (1250
1000
- 2 x 90) = 2407.5 N

Beam Design : Assume size of 50 x 160 (50 x 150) and span 1.25 m.
(Refer T d l e 6 of IS :883 )
Total Load = 7.5 x 1.25 x 1.25 = 11.7 kN
Detailing of Reinforced
Concrtte Construction

Bending stress = 1.4hx l o b x 6 = 7.8 NImm2

50 x (150)~

Shear stress = (o'hx lrnO) = 0.94 N/mm2 % 1.13

50 x 150
d) Load on Prop = 7.5 x 1.25 x 1.25 = 11.7 kN, height = 3 111

Try @ 100 wooden prop,A = 78.54 x lo2 mm2 = 8g2 = tP

Allowable load = 2.4 x - 7854 - 18.8 kN and this may be increased by

1000
1.25. (RqferChurt 4.2 )
Check as per IS : 883 CI 6.5 : 1.3

0.329E 0.329~10~
Compressive stress = - = = 2.85 N/mn2 compared to
(sW2 . 342
2.4 N/mm2 from Chart 4.2.
STRtSS 25 T H I C K PLANKS
PERM~SSIBLE
198B JCL 6.5

T ( 5 0 k 100)
O N SO0 o ~ c
1.25 SPAN

(a) Elevation (b) Section at YiYl

Flgure 4.12 r Fonnwork for RC. Flat Slab

e) Check Bearing Stresses

i ) Beam resting on the prop : bearinc, area = 250 x 50 mm2

11700 - 0.94 N/mm2

Bearing stress = -
12500
:. OK

ii) Joist bearing on beam

7500 x 1.25 x 0.5
Bearing Stress =
40 x 50

for bearing of 50 mm,

Example 4.2
Design sheeting (in plywood), telescopic steel beams and formwork for concrete
beams 200 x 800 on 6 m span with slab 200 rnm on 6 m x 6 m module.
 Principles of Design and Detailing
of Formwork and Scaffolding
Slab sheeting
Load : Concrete 0.2 x 25 = 5 kN/m2
Live load (forms) = 2.5 kN/m2
Total = 7.5 k ~ l r n ~
Section XX of Figure 4.13 shows a three span continuous sheet
with L = 400 mm.
Panel 1.2 x 0.9 m ; E = 9000 N/mm2

0.12~10~x6
Bending stress.f = = N1mm2
144000

Refer Figure 4.13 to note the panel arrangement.

I Y-l
Section y 3,

Section X-k ;O

?
F'lgrue 413 I Lnyoat Plan of Panel

Design of member (m)

Load on frame member (m)on 1.2 m span

1 Permissible stress = 165

Hence provide angle 60 x 40 x 5 mm,Z = 4200 mm3

Detailing of Reinforced
Cot~creteConstruction

Hence use steel angle of 60 x 40 x 5 mm for framing.

B1-TELESCOPING BEAM

Figare 4.14 :Bern Layout

c) Telescopic beam
Approximate span 5.7 m.
Refer Figure 4.15 showing prop on the centre-line of symmetry.
Load = 1.2 x 7.5 = 9.0 kNlm
Refer Table 4.9 B for a total load of 7.8 kN/m2 and spacing of 1.2 m the
beam span % 2840 mm, hence provide two beams on 5.7 m with one central
52
row of props of capacity - = 26 kN each.
2
d) Formwork for main beam
Assume depth of beam = 600 mm,
Slab thickness = 200 mm.
Refer Figure 4.25 for details
i) Bottom sheetlng
Load of Concrete = 0.8 x 25 = 20 kN/m2
Live load + Self weight = 2.5 kN/m2
Total Load = 22.5 kN/rn2

M = 22.5 (Oe2)' = 0.1 13 *m/m

B.M.,
8
Bending stress in 12 mm plywood
 Principles &Design and Detailing
of Formwork m d Scaffolding

ii) Side sheetlng

Depth of side-plank upto mid-height of spreader = 0.4 m
Consider a surcharge of 0.1 m.
Design for lateral pressure of concrete of height of 0.5 m (approx.)

Assume vertical spacers at 0.5 m cr/cr (indicated as blocking in the

Figure 4.15)

Bending stress, J = Oe2 l o h X 6 = 4.7 ~ / , ~ 2

loo0 x 256
I (for 10 mm sheeting)

Figure 4.15 (a) :Hnrizontr,l Pmrure

Oirtrihutirn

1 However, use 19 rnrn thick plywood.

Use spreader pieces 50 x 25 x 400 rnm at suitable spacing to maintain
uniform gap of 400 mrn between vertical.

Prop on 1.2 c l c

Head plate 100 x 8.0

Detailing d Reinforced iii) Kkkers
Coocrete Construction
There are two kickers for the bottom sheeting.
L = 1.2 m. (Refer Figure 4.15 (a) indicating horizontal pressure
distribution.)
Pressure at bottom = 25 x 0.6 = 15.0 kN.
1 -
Reaction at base = - x W = 3 kN/m
3

Vertical load per kicker = 22'5 Oa2 = 2.25 kNlm

Hdzontal load = 3 kN/m at base (as computed above).

M,, =
w P --
- 2.25 x (1.2)' = 0.32 lrNm
10 10

M -- x 0.32 = 0.43 kNm (proportional with M,)

- 2.25
Try section 80 x 100 (70 x 100 timber)

Bending stress,f,, = o.32 (lo)" = 3.9 N/mm2

100 x (70)~

0.43 X 106x 6 = 3l Nlmm2

Bending stress,fbH =
70 x (100)~

.: x~, = 7.6 N/mm2 d 1.25 x 6.3

2.25 x 1.2 x 0.6 x (10)' = 0.23 Nmur

Shear stress due to vertical load =
100x70
3
Shear stress due to horizontal load = -
2.25
x 0.23 = 0.3 1 ~ / n l m ~

These values are quite low.

iv) Blocking :Transmits only telescopic beam reaction on the head-plate.

Bearing stress on blocking = - -

13'00 - 4.7 N/mm2
50 x 55
Example 4.3
Formwork for a column 600 x 600mm by 5 m high is to be designed for a rate of

nr
placement of 15 m/hr, slump of concrete 100 mm,and temperature -10%. Design
the forms.
Solutlon
Evaluate the design lateral pressures as per Tables 4.10.4.11.4.12.
Since h = 5 m, thickness, d = 600 mrn and R = 15 m/hr for columns.
p, = height limit = 125 kN/m2 (Table 4.10)
p, = arching limit = 110 kNlm2 (Table 4.1 1)
p, = stiffening effect = 150 kNlm2 a able 4.12j
:. Adopt design pressure = 110 kN/m2.
a) Let ids use timber sheathing and timber yokes.
i) Use 40 mm thick planks with yokes at 500 nunc/c

Bending moment in sheeting, M = 'lo

x("'5)2 = 2.75 k N m h
10
Flgure A16 :Lateral Pressure on
Planks d RC Colaqm
Bending stress,f = 2.75 'Obx = 10.3 N h m 2 d 1.25 x 10.2
lo00 x 1600
 a=-- W P -
145 EI
'x '
145
lo ' '
(0.5)4 lo'' l2
loo00 x 1000 x 64000
= 0.9 mm s 1.6 mm :. OK
Principles of Design and Detailing
or T O I I I I Wrind
O ~ ~scaffolding

40 mm timber jdnnking 200 wide sheeting.

ii) Consider yokes (1) and (2) at 500 nun c/c at base of 5 m high column.
Lateral pressure is shown in Figure 4.16.

.: Total load = 53.5 x 0.6 = 32 kN

Load on yoke (2) = 9.8 x 0.5 = 49 k N / n ~

.. Total load on yoke = 29 kN/m

Bending moment in yoke ( 1) = 32 x0.6 = 2.4 m m .

8

72
Direct tension in yoke ( I) = - = 16 kN.
2
Design size of yoke (Refer Figure 4.17).

(a)SECTIONAL ELEVATION

Figure 4.17 (a) (b) (c) :Sectional Elevation of Wooden Fonn

I Detailing of Reinforced
Concrete Construction
Try size 60 x 160 (50 x 1hO),

Direct tension = -
1*00 - 2 N/mm2, (allowable 1.25 N/mm2)
8000
244 lo6
Bending tension = = 11.3 N/mm2, (allowable 12.8 N/-~)
1.7 x lo7
Maximum tensile stress = 2 + 11.3 = 13.3 N/rnm2 > 12.8 N I ~ ~ I I ~ '
This is only marginally exceeded (within 5%) and hence car1 be accepted.
If required change section to 80 x 160 mm
Direct tension to be transmitted at the comers of yokes through bolts. Using
16 mm diameter two bolts to have shear capacity (considering threaded bolts)
=2 ~2~0.7~80~1.25=28000N=28kN.
Load on the bolt is simultaneously along two directions each being 16 kN.
.: Resultant load = 16 fi=
24 kN < 28 kN.
Note .: As we proceed upwards, the lateral load reduces and hence yoke spacing
could be increased in which case plank would need deflection check.
b) Let us use plywood,sheuthing timber yokes and adjustable nnd dcmountuble
steel column clumps (Refer Figure 4.18 (a) ( b ) )
Assume c/c distance between clamp (1) and (2) as 400 mm and a total load
on clamp (1) as (53 kN x 0.6) = 32 kN.
For 25 mm plywood, where E = 7000 ~ l m m ~

We may accept this thickness as actual span is less than 400 mm

-
(i.e. 400 60 = 340 mm is the clear span). The yoke size chosen as before
(60 x 160) (and not (80 x 160)) as only bending is taken by yoke and clamp
takes the tension. Again yoke spacing may be changed as we go up.

Stwl clamp member

I
Plywood
25 thick
PLAN
(a) Plan
 Principles d Design and Detailing
of Formwork and Scaffdding
Steel clamp momber
( 5mm .x 50mm 1

(b) Adjustable Stccl Clmtp

Figure 4.18 :~dju~tab~elDemounhhIc
Steel Clasnp

As shown in the perspective view Figure 4.18 (a), a series of rectangular

notches are pmvided on the clamp inenlher (CM)so that clamp plate can be
inserted to tighten the clamp against tile yoke.
~mple4.4
Design wall forms For structure in Bombay (Basic wind velocity 15 kN/m2) with the
following data :
height = 5 m, length = 15 In, thickness = 400 nml,
rate of concrete placement = 1.0 nmr, slump = 150 mm, temperature = 20°C.
ution
Design lateral pressures from Tables 4.10.4.1 1.4.12 ( i s . p, = 25 kN/m2,
p2 = 60 kN/m2, p, = 35 kN/m2 ) is taken as 25 kN/m2
i) Use 40 mm timber planking 240 mm wide on 600 mm.

OaY lo''
Bending stress = = 3.4 N/-2
1000 x 402

Refer Figure 4.19 showing formwork for the wall.

ii) Assume wales at 1.9 m c/c for design of studs: size 80 x 200 (70 x 200).
Load = 0.6 x 25 = 15 kN/m, assumed uniformly distributed.

5'42 (lo)'
Bending stress =
70 x (20012
= I 1.6 N / m 2 :. O.K.

iii) A h m e ties on 0.6 x 1.9 m grid

Load on tie = 25 x 0.6 x 1.9 = 28.5 kN
25 $ has capacity of 0.7854 x 625 x 0.7 x 1.25 x 80 N '= 34.5 kN.
Detailing of Reinforced
Coocrete Construction iv) Try wale size 140 x 100 mm, I = 140 x(100)3 = 1.17 ~ ( 1 0 ) ' nun4
12
Z = 2.33 x lo5 mm"
Load = 1.9 x 25 = 47.5 kN/m

47.5 x (0.6)~/ 10
Bending suess = x lo6 = 7.3 N I I I I ~ ~:. ~ o .~.
2.33 x (10)"
(Alter~lativelyuse two 60 x 100 nun wales for better detailing.)
V) Rearing: Joist or stud on wale
Load = 15 x 1.9 = 28.5 kN
A = 70 x 140 = 9800 nun'

28500
Bearing stress = -= 2.9 N/nmi2
9800
Try wales 60 x 100 mm, A = 2 x 60 x 70 = 8400 run*
Bearing suess = - - 3.4 ~1-2
28500 - > 1.25 x 1.8x 1.17
MOO
Hence use bearing plate between stud 'and wales 25 mil thick.
28500
Area required = = 12670 mm2 i.e. 150 x 100 ~iirii.
1.25 x 1.8

I
Q!

Figure 419 :Fonnwork for Wdl

vi) Bracing.for Walls
Refer Figure 4.20 showing struts 5.1 m long.
The wall is designed for a wind load on face of 0.75 x 1.5 = 1.13 k ~ l m '
5
(IS : 875) i.e. 1.13 x- = 2.81 kN/m at top and if top of shrut is 0.6 m below
Figure 420 :Horizontal Load on 2
strut top, this load may be taken as
 '
5 -0.6
x 2.81 = 3.2 kN/m
Principles of Design and Delpiling
of Fonnw?rk and Scaffddhg

Force in strut (compressionltension) = = 6.5 kNlm of wall

2.5
If shruts are provided on 1.8 m clc
Loadonstrut= 1.8x6.5= 11.5kN

s 5100-42
Try 120 x 140 timber, - = - -
d 120
Compression capaclty = 1.82 x 1.25 x 120 x 140 = 38 kN.

4.6 INSPECTION AND TESTING OF FORM MATERIALS

Be~ngused to prtduce an engineered structure, Ihe lorn1 materials must have the
specified properties and sizes assumed for deslgn purposes. Timber bclng a natural
product ruld with different clilnatic cond~t~ons, ra~nl'alls,altitude ot the place, nature of
soils etc., the availability and properties of a gven categorylrpecies of wood vary very
much. WIUI proper treatment processes and beasonitlg, un~forn~ity 01 srles ar~dproperties,
for example, a glven moisture content could be achlcvetl WIwrisas 111the case ol plywood,
mldsteel, GKPIFRP etc, bemg man-made prcducts and ~nanufi~cturetl In factories ,and
nulls, their englnccrlng properties could eas~lybe colitrollcd and protlucrs could he
accepted as they are.

1) For group "B" Timber, the modulus ot elast~c~ty in beocirng shall be at

least 10000 ~ / m m ' ,allowable belld~ngslress ot 1 0.2 ~lrnrn',allnu able
beam shear of 0.9 ~ 1 m . m and
~ these musl be confirmed by testing m the
laboratory on samples as per Indian Standards IS: 1141, 1331,883,287, etc,.
2) Timber with loose grain, splits, compression wotd in coniferous structural
timber, heartwood, rot, saprot and warp 6i worm holeb made by powder
postbeetles and pltch pockets shall not be used.
Timber to be given preservative treatments at site and during storage arid shall be stored
above gmund level.

1) Plywood used shall not be delaminated and all edges shall be properly
sealed.
2) Manufacturers' certificate indicating all important engineering properties be
available at site.
3) Ul~loadingof plywood at site shall be by lifting and not sliding to avoid
edge damages.
4) It shall be stacked on raised level with proper ventilahon and protected
fro111strong sunlight.
5) Coat all the form panels wlth mould oil.
Structural Steel
1) A manufacturers' certificate indicating all Important engineering properties
1s to be insisted.
2) Collfirmatory tests to be done in laboratories for all mportant properties.
3) All steel to be stored above ground lcvel platform.
4) The steel to be cleaned and painted with antirust paints to avoid stainlng
concrete.
5) ,411 accessories illust be as per proprietary systelxls w ~ t hthreads. bolts, nuts
etc. 111 order.
Detailing d ReMomed
concrete cwstmction
4.7 SUPERVISION OF FORMWORK AND STAGING
Let us make a list of sonie of the deficiencies in relation to formwork so that you will
know importance of supervision better: .
1) Inadequate lateral and diagonal bracings for vertical props and stagings,
2) Inadequate area of the vertical props to cater to the loading,
3) Poor splicing of timber props,
4) Inadequate details when in double stages props are one over the other,
5) Lack of bracings at joints in props,
6) Props not in plumb,
7) Locking devices on steel props not locked, in operative or defective,
8) Unstable or l m e soil under the props,
9) Improper packings under props to make up the height,
10) Insufficient connectors at joints i.e. nails, bolts etc:,
11) Inadequate forms for lateral pressures of concrete,
12) Inadequately tightened or secured form ties,
13) Inadequately securedwedges for form and scaffoldings,
14) Failure to check tightness of props on floors below,
15) Failure ti) inspect ru~dtl~oroughlycheck cleanliness, tightness o f joints.
rusting etc.,
16) Failure to co~ltrolvertical rate of placement of concrete md consequent
increased lateral loads,
17) Uneven placement of concrete imposing unbalanced load on forills and
props,
18) Vibrations and shock arising from external and internal vibrators,
equipn~entslike buggies and lifts with loose joineries,
19) Premature removal of props specially under cantilevers,
20) Overloading of phyrietory standard systems and thdr ;~ccessories,
21) Use of defective .ind substmdard wood,
22) Improper sequence of stripping of forms,
23) Lack of wettingof timber forms before concreting, thereby absorbing water
from fresh concrete and swelling, that causes warping and htwleyconlbing,
ruld
24) Failure to seal edges of cut plywood results in blemishes in concrete.
Check List for Formwork Supervision
1) The formwork drawing be made available well in advance nf construction
schedule.
2) All form materid (be it timber, plywood or steel) as indicated on drawings
along with all accessories such as wedges, blockings, headplates, couplers.
at site along with all the tools etc.

or specitications.

4) The forms to come in contact with concrete must be freefrom g r e w dirt,

staills etc.
5) Timber sheetings, if used, must be moistened before concreting to prevent it.
absorbing water and creating distortions and honeycombing.
Release agents and sealers be applied to get blemishless surfaces and easy Principles oCDesign a d Detailing
stripping. of Formwork and ScatYolding

The following may be used.

i Woodforms : Most of the comnlercial oils, chemically active release
agents, light coloured petroleum oils, oil emulsions, etc. sometimes
might retard settings of concrete, in which case treating wood with
whitewash or limewash is a must.
ii) Plywood : Plywcwd should be treated with linseed oil cut with
kerosene,,oilemulsions, most commercial oils. If plywood is already
mill-oiled, it should be used once without oiling and then coated
lightly for each reuse and sealing the cut edges with aluminium
paints, rubber -based paints, mastic, urethane coatings protect
glue-line from absorbing moisture.
iii) Steel : Paraffin base form oils and blended oils consisting of a
petroleum base along with synthetic castor oil, silicones, graphite.
Rough surfaces nmy be conditioned by rubbing in a liquid solution of
paraffin in kerosene or deaned and oiled with non-drying oil, then
exposed to sun for a day or two to get nonstick tinish.
All holes in wood and plywc~dmust be filled and sealed Drill timber
forlnwork from,the face to avoid splintering this surface.
All joints in sheeting placed in position must be sealed. On u p p r lifts, make
sure the lower edge of the panel is tight against the hardened concrete of the
previous lift. With concrete exposed to view, use a foamed plastics strip at
panel joints, stop-ends, returns and construction joints, to prevent grout
leagage.
Use each panel in its correct location by numbering the same.
Make sure props, shores, walings, bearers, clamps & wal-ties are at designed
locations.
Slab form shall be in corret level so also beam forms and verticality of
forms in beams sides, walls and columns shall be maintained. Refer Table
4: 15 for recommended tolerances.
After repeated usages the ends of wood props resting on ground as also steel
props may get damaged, deteriorated or get corroded in case of steel, hence
the ends need special inspection, from time to time, and protective
treatments beapplied/provided.
In weak soils and areas where water is likely to get accumulated, it is better
to provide props on solid wooden sleepers.
Wooden props resting on sleepers or runners be provided with double
wedges for proper tightness and easy de-propping. Steel props having
adjustable base must be checked for proper functioning of their threads and
jack.
Table 4.13 :Refer IS :4891 on Timber
Tolerances Cut Shes
a) Width and thickness
i) Upto lo0 mm

ii) Above 100 nun

bngth

Tapered section due to sawing, variation for

i) 25 to 50mm I Thicknessb 6 nun

I1 ( ii) 60 to 90 nun I ThicknessS 10 mm

II
1 iii) 100 and above 1 Thickness 6 15 nun
Detailing of Reinforced Table 4.14
Concrete Constructiun
Recommended 'Tolerances Plywood 5'I Z ~ S
I
1 a) Width and Length I + O m to - 1.Smn (
b) Thickness 0.5 mm
1
Table 4.15 : Recommended Tolerances In Forms as laid

Fa)lanbs
i) Elevation of formed soffit before removal of 2 20 mm
props.

ii) Variation in thickness - slab < 300 mm

-
iii) Variation of size of upelling

b) Beams
i j Variation of lcvel of formed soffit before
removal of props.
I -
i~ I Devisltio~~
from speoified size I ) upto 300 mm -6mm
2)300to900mm +12mm
- -
Columns and Walls

I
I
i) Var~ationfrom specified size I ) upto 300 mm
-
2)300to900mm
- 6 rnm
t10mm
ii! Out of plumbness in completed structure -25m
30 mm high
-
I iij) Variation in the size of wall openings - 6 m
+ 25 mm
d) Footings
i) Dimensions in plan -12mm
+ 50 mm
ii) Thickness k 5%

I iii) 'Zbe Misplacement 2% of size

15) No steel prop shall be used if the tube has a bend or crease in it or corrosion
has reduced the area of section or its head or base plate is bent or the pin is
damaged.
16) Props should not be off-centre by more than 25 rnnl and should be generally
in plumb and not out of plumb by more than 1 in 40.
17) All props and shores must be braced as per designs and the design loild shall
not be exceeded.
18) When using double staging, the props must he in one line in vertical plane
and shall be braced in plane of staging as also in vertical planes as per
design/manufacturers' requirement.
19) All accessories after every reuse shall be checked for their size shape,
threads, pins, or any damage etc. to maintain integrity of the system.
20) All formwork must be checked for the rigidity so that internal and external
vibrators;equipments etc. do not affect the form joints or dislodge props. A
separate team of . work force be assigned this task of supervision and
corrective actions must be taken immediately.
21) Ties, separators, form blockouts must be inspected before and during
consttuction. The ties or tie bolts in beams columns and walls be properly
tightened to avoid diqprtions in cross- sections.
 Principles of 'Designm d Detailing
22) Before concreting beams, columns and walls, all dirt, shavings, tie-wire, of Formwork and Scaffolding
clippings, nails, etc. shall be removed from within the formwork. Also
ensure that all the inserts, embedments, cutout blanks are in correct locations.
Ensure further that these are secured firmly in its position against
displacements caused due to pouring of concrete and due to vibrations.
23) The rate of placement of concrete shall conform to the design requirements
so that excess horizontal pressures do not develop on forms. Also dumping
or uneven loading of concrete shall be avoided, and vibrators shall not be
used to spread the concrete.
24) Enough working platforms and adequate accesses are to be provided so also
safely nets and belts.
25) Premature removal of forms and props shall be guarded against instruction
for deshuttering & removal of forms be taken from structural consultants.
Refer Table 4.16 for IS 456 guidelines for form strippings in ordinary normal
circunlstances and using O.P.C.
26) Sloping or horizontal top forms are subjected to upward pressures from the
fresh concrete and need to be firmly restrained and tied down.
27) Special care need be exercised at the base of props that support ramps,
staircase slabs, arches, shells as they also induce in addition to vertical load a
horizontal load as well. These structures need bracings and raker for better
stability.
28) Forms must be given enough camber so that after their removal the
structures do not exhibit pronounced sag.
29) Stripping sequence or order and rate is also very important so that Ule load
shall be gradually be transferred to the structure without jerks and impact
ties and clamps should be loosened gradually and the same to be collected
systematically. Props under simply supported or continuous slabs and beams
be removed from centre to both supports evenly and props under cantilever
beam be removed from free end to the support and earlier than the beam at
the back.
Table 4.17 : Form Stripping Time as per IS 456
Items Stripping Time
a) Walls, colurm~sand vertical faces of all 24 tn 48 11rs after casting
structural members is completed
C 1
b) Slabs (props left under) 3 days (i.e. 72 hours)
C) --- --
Beam soffits (props left urrder) 7 days
Removal of props under slab-
1) Spanning upto 4.5 m 7 days
2) Spanning over 4.5 m . -- -- 14 days
Removal of props undel 1,-.1:136 md arches
14 days
2) Spanning over 6 m 2 1 days

I Note :Fomq shall not be muck untll the ii~Tetehas reached a strength at l a s t twlce the stress to which the concrete
may be ~ubjectedat the t ~ of
m removal c b t formwork.

i) Referring to chart 4.1 &tennine the suitable thickness of timber plank for
slab sheeting considering load of 7.5 kN/m2over a span of 1.2 metres.

I iii)
ii) Referring to chart 4.3 determine the suitable thickness of timber plank for
wall-sheeting considering load of 7.5 kN& over a span of 1.2 metres.
Referrirlg to chart 4.5 for Timber Beams de'termine the
of the 62
wide beam to support a U.D.L. of 7.5 m/m over a span of 1.2 metre.
'Vj "'"g chm4.2 (a) for timber prop &tennine ~e sde compessive aid
S'ess
(1' '' prop of height 3 metres and diameter (a) 50 mm (b) 65 mm
& (d) 100 nun. State also Ule a i a l load capacity in
Detailing of Reinforced
Concrete Construction
v) Write clearly the functions of the following:
a) Tie Bolt;
b) Wedge;
c ) Sleeper;
d) Raker prop;
e) Joint sealers;
vi) Design a suitable formwork and scaffolding for a staircare 1.5 ll~etrewide,
having midlanding at 3 metres, has 20 risers each of 150 mm and 19 treads
each of 300 mnm and a waist slab of 200 mm thickness in R.C.C. Use all
timber members. Check the base of prop when safe load hexing capacity
of compacted ground is 20 kN/m2.
vii) Redesign the formwork for staircase in (vi) above using plywood sheets.
viii) Design the formwork in plywood sheeting, timber-beams ruld steel-props for
a concrete beam (400 mm wide x 2000 mm deep) soffit being at 4 nletres
level. Assume temperature of 20°C at the time of concreting, slulnp of 100
mm and the rate of placement of concrete as 2 metres per hour.
ix) Design the formwork in wood for a retaining-wall, (2 m) below ground level
'md (3 m) above ground 25 metres long and 300 mrn uniform thickness. The
clear toe is !metre and heel-slab is 2 metres. Assurne the concrete with
(a) temperature of 15°C (b) s l u q of 50 mm and (c) rate of placement of
concrete is ? metreshour. Assunie w~ndpressure to be 1.S kN/11i3.

- - -----
4.8 SUMMARY
In this unit you have been given basic ideas as to the funcuons of formwork In
consuuction of R.C. concrete structures, various materials. their engmeeri~lgproperties
and inspection of form materials and supervision of the same. It is hoped tllar you now
realise the Importance of formwork desiin and execution and supervisit~nat site. It is to
be noted that for t~mberforn~workthe properties should be verified by conducting
laboratory tests whenever there are doubts. Care should be taken in scaffr)lding by
providing bracing (diagonal) and l..ieral ties.
In c g e of use of structural steel and steel plates, it is a l l y necessary to check against
corrosion. Note the reduction in Ule area of sections. Making neat joints both it] case of
timber scaffolding or steel scaffolding IS of utmost inlpr)rtance and needs to be supervised.

4.9 KEY WORDS

Beam : The main load bearing element in flexure.
Bearer : Load transmjtting run11er beam supporting stringer
Bracklng A member connecting vertical props or horizontal
beams to tie up the structure.
Formwork or False Work : A temporary structure designed for support of permanent
structure.
Joist : A subsidiary flexural member supporting sheeting of
slab.
Lift Form : Formwork used for tall structures and is lifted up in
jumps at a time.
Plywood : Series of thin wooden sheets glued together.
pro^ or Shore : Verticd member to support fdsework.
 I
Sh etinp :

:
Menlber of formwork nearest and in contact with
~ollcrete.
Mernher resting on ground nearest tobase in formwork
01'walls, colunuls etc.
PrinciyIes of I)r'iixn :~tidL)et;lilinr:
of Forn~work;~ndScaffolding

t
Sle per :

:
A menlber under tlle ba:.%of prop for spreading the load
011 larger
area in poor ground.
k temporary member keeping oppoite sheeting at
correct distance.
: A systetn of vertical, Ilorizontal and inclined members
of fonr~work.
~!!#~,rrn : -4 coniinuousi:~clllnbinp formwork for tall structures.

stribpr : A flexura! 111einIyrsupporting joists in siab for~ns

5tui : A flrxu! 1: ~licili'ncrstlpportlog wall Iorms.

4 ANSWERS TO SAQs

j !-I !i!10 jvi! art. availat~lein the text of this unit in pc>rtion4.7 md 3.4 svnle
prmicrl cf sii::tea'i~j are ~ ~ n i l i i b ?later
i : in rhe Tables or Charts
VII) Sled f(~rinu'n$k hag an advanl'lgc that lighler rnemher$ are possible since
rabncated 110i10w ~nenlhers;Ire made with adequate del>th T~mber
scctltn IS dlw,iyb bo/~dmd 11t'ncc heailer Tlle ntilrihrr ot reuse of steel
form 1s much Inore thiul number i ~ usages
f of I I ' * plywood. Hence in a
peritxl of 10 years. for prolects where I'ornls ( , i\ed repeatedly steel
formworks will be cheaper. rile thickness ot dr, 2nlent of 5 to 6 Inn1 is

sAQr
acceptable.

Answer for i) is (5Q nml)

1 Answer for ii) is (37 rnm)
1 Answer for iii) is ( 1 50 rnm)
1iv) ? 1 .h5: (c) 2 nld (d) 3.5 N/aun2
(a) 1 N / ~ I (h)
v) Now h a t you have go~letluough the basic design proceclures, and the text,
it is not difficult to write down the functions of the following;
I) Tie-bolts in the beams and wall fonns:
2) Wedges at the base of wotxlen prop
3) Sleeper or spreader under props in poor ground conditions
4) Raker props iurder ramp slah
5) J o i ~ sealers
~t
Tie bolts :Concrete being a ~rlixtureof cement, sand, metal md water is
like semiliquid and he~lceproduces lateral pressures. It is the function of lie
bolts to take up this liorizont;~lload.
Wedge :A wedge between prop base and sleeper not only helps hl
riglltening the prop but also helps in depropping by tr'msferring load from
prop to thc structure gradually.
Sleeper under props :When props are supported on groundlearth the
sleeper increases the loaded area of gcwnd a~itlthereby reduce the soil
1
pressure, and thus nlini~nisesscttlcment or movement cot prop (2) and
distortions a1 top of prop.

i
Detailing of Reinforced
Concrete Construction
Raker under ramps :any inclined rne~nherwould have lo,ul conlponcllls
in vertical and horizontal directions giving resultant 111 inl'linctl tlirectr )n and
the inclined raker prop is the best suited to resist the SiIIIX.
5) Joint sealers : These help in preventing loss of n~olsturcliom uuihsr
sheetinglplywood at their cut-edges.

vi)

End plate1 20 thk 1

LO x 160 on 600 c/c ( Joist I

100 x 200 Main barn timber
CROSS -SECTION

SPLICE

(iil 6 :0.87mm for L x500mm

Figure 421 :Timber Formwork & Scaffolding lor S h i m

vii)

k
J
(a) Elevation (b)Cms-section
Figure 4.22 :Fonnwork lor RC Beam
viii)
Principles vf Ilrsign and Detailing
of hrmu.clrk and S e m d i n p ,

Figure 4.21
FURTHER READING --- .-- . - -- --

1) Concrete Technology by Neville

2) Concrete Technology by M.S.Sheny
3) IS 45611978 : Plain & Reinforced Concrere
4) IS 87511987 : Parts (1 to 5 ) : Loading Standorit
5) IS 189311984 :Earthquake Design of Struclures
6) IS 1392011993 : Detailing of R.C. Structures
7) Reinforced Concrete Designer's Handbook by C. E. Reynolk
8) Indian Practical Civil Engineers HandBook by P. N. Khanna
9) IS 178611985 : High Strength Deformed Bars.
10) IS 269 I 1976 : Ordinary and Low Hear Portland Cement
11) IS Handbook on Concrete Design - Mixes.
12) IS - 45611978 : Plain and Reinforced Concrefe
13) IS - 189311984 :Earthq;ia.ke Dexign qf\'tr~:ctrrms
14) IS - Handbook - SP-16 (Design A!.d to I .;' 456-197bj
15) Reinforced Cornrere I)e.signur',~fi;)ndhvnk B y C E, Reysuids
16) Reinforced Concrete by H. J. Shah
17) Reinforced Concrete by A. K. Jaiz
18) Foundation ofStructures by C. W . Dm;ham
19) Foundution Desigtz Manual by N. V . Nayak
20) Foundation Desigrr and Constructionby M . J . Tomlinson
21) I.S. Handbook on Concrete Reinforcement and Detailing (SP734)S6tT11987.
22) I.S. 1392011993 : Ductile Detailing of Reinforced Concrete Structures subjected to
Seismic Forces.
A large number of IS Code reference is already given in the text. Reference to additional
IS Codes on various other materials and their testing is given in Text Book at Sl. No. (2).