9.

1 FORM WORK

9.1.1 Introduction
The formwork or shuttering is a temporary ancillary construction used as a mould for the structure, in
which concrete is placed and in which it hardens and matures. The construction of formwork involves
considerable expenditure of time and material. The cost of formwork may be upto 20 to 25% of the cost
of structure in building work, and even higher in bridges. In order to reduce this expenditure, it is
necessary to design economical types of formwork and to mechanize its construction. When the concrete
has reached a certain required strength, the form is no longer needed and is removed. The operation of
removing the formwork is commonly known as stripping. When stripping takes place, the components of
formwork are removed and then reused for the forms of another part of the structure. Such forms, whose
components can be reused several times are known as panel forms.
Forms are classified as wooden, plywood, steel, combined wood-steel, reinforced concrete and plain
concrete. Timber is the most common material used for form work. The disadvantage of wooden form
work is the possibility of warping, swelling and shrinkage of the timber. However, those defects can be
overcome by applying to the shuttering water impermeable coatings. This coating also prevents the
shuttering from adhering to concrete and hence makes the stripping easier. Steel shuttering is used for
major work where everything is mechanized.

Steel form work has many advantages, such as follows:

i. It can be put to high number of uses, iv. It possesses greater rigidity,
ii.It provides ease of stripping, v. It is not liable to shrinkage or distortion.
iii.It ensures an even and smooth concrete surface,
However, steel form work is comparatively more costly.

9.1.2 Requirements

A good form work should satisfy the following requirements:

 The material of the form work should be cheap and it should be suitable for re-use several times.

 It should be practically water proof so that it does not absorb water from concrete. Also, its
shrinkage and swelling should be minimum.

 It should be strong enough to withstand all loads coming on it, such as dead load of concrete and
live load during its pouring, compaction and curing.

 It should be stiff enough so that deflection is minimum.

 It should be as light as possible.

 The surface of the form work should be smooth, and it should afford easy stripping.

 All joints of the form work should be stiff so that lateral deformation under loads is minimum.
Also, these joints should be leak proof.

 The form work should rest on non-yielding supports.

9.1.3 Indian Standard on Form Work (IS: 456-2000)

1. General: the form work shall conform to the shape, lines and dimensions, as shown on the plans and
be so constructed as to remain sufficiently rigid during the placing and compacting of the concrete, and
shall be sufficiently tight to prevent loss of liquid from the concrete.

2. Cleaning and treatment of forms: All rubbish, particularly chippings, shavings and sawdust, shall be
removed from the interior of the forms before the concrete is placed and the form work in contact with
the concrete shall be cleaned and thoroughly wetted or treated with an approved composition. Care shall
be taken that such approved composition is kept out of contact with the reinforcement.

3. Stripping time: In no circumstances forms shall be struck until the concrete reaches a strength of at
least twice the stress to which the concrete may be subjected at the time of striking.

The strength referred to shall be that of concrete using the same cement and aggregate, with the same
proportions, and cured under condition of temperature and moisture similar to those existing on the work.
Where possible, the form work should be left longer, as it would assist the curing.

In normal circumstances (generally where temperature are above 20° C), and where ordinary cement is
used, forms may be struck after expiry of following periods:

Sl. No. Description of structural member Period of time

a Walls, Columns and vertical sides of beams 24 to 48 hours as may be decided by engineer-
in-charge.

b Slab soffits (props left under) 3days

c beams soffits (props left under) 7days

d Removal of props to slabs:

i. Spanning upto 4.5m 7days

ii. Spanning over 4.5m 14days

e Removal of props to beams and arches:

i. Spanning upto 6m 14days

ii. Spanning over 6m 21days

Note: the number of props, their sizes and disposition, shall be such as to be able to safely carry the full
load of the slabs, beam or arch as the case may be.
4. Procedure when removing the form work: All form work shall be removed without such shock or
vibration as would damage the reinforced concrete. Before the soffit and struts are removed, the concrete
surface shall be exposed, where necessary in order to ascertain that the concrete has sufficiently
hardened. Proper precautions shall be taken to allow for the decrease in the rate of hardening that occurs
with all cements in, the cold water.

5. Camber: It is generally desirable to give forms an upward camber to ensure that the beams do not
have a sag when they have taken up their deflection, but this should not be done unless allowed for in
design calculations of the beams

6. Tolerances: Form work shall be so constructed that the internal dimensions are within the permissible
tolerances specified by the designer.

9.1.4 Shuttering for Columns

Column forms

Shuttering for a column is probably the simplest. It consists of the following main components:

i) sheeting all round the column periphery, ii) side yokes and end yokes, iii) wedges, and iv) bolts with
washers. Figure shows the form work for a square column. The side yokes and end yokes consist of two
numbers each, and are suitably spaced along the height of the column. The two-side yokes are
comparatively of heavier section, and are connected together by two long bolts of 16mm dia. Four
wedges, one at each corner, are inserted between the bolts and the end yokes. The sheathing is nailed to
the yokes.

Figure shows shuttering for octagonal and round columns.

9.1.5 Shuttering for Beam and Slab Floor

Beam form and supports

Figure shows the form work for beam and slab floor. The slab is continuous over a number of beams. The
slab is supported on 2.5cm thick sheathing laid parallel to the main beams. The sheathing is supported on
wooden battens which are laid between the beams, at some suitable spacing. In order to reduce the
deflection, the battens may be propped at middle of the span through joists. The side forms of the beam
consist of 3cm thick sheathing. The bottom sheathing of the beam form may be 5 to 7 cm thick. The ends
of the battens are supported on the ledger which is fixed to the cleats throughout the length. Cleats
10cmx2cm to 3 cm are fixed to the side forms at the same spacing as that of battens, so that battens may
be fixed to them. The beam form is supported on a head tree. The shore or post is connected to head tree
through cleats. At the bottom of shore, two wedges of hard wood are provided over a sole piece.