5 Must-Have Features in a Formwork Material

What is Formwork?

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

Goto Trico to know more.

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

Formwork systems can be classified according to the following parameters:

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

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

2. Column

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

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

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

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

3. Wall

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

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

Girder

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

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

Crane-independent (hand-set)

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

Crane-dependent 

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

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

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

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

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

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

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

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

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

If you are looking for more details, kindly visit Formwork Material.

In the construction industry, formwork systems play a pivotal role in shaping and supporting concrete until it achieves sufficient strength to bear its own weight. Choosing the right formwork system is essential for ensuring structural integrity, safety, efficiency, and cost-effectiveness in a project. With numerous options available, understanding the key features of a high-quality formwork system is crucial for construction professionals. This blog explores the essential aspects to consider when selecting a formwork system.

1. Durability and Material Quality

A high-quality formwork system must be durable and constructed from premium materials. The durability of formwork not only determines its lifespan but also its ability to maintain structural integrity over multiple uses. Common materials include:

• Steel: Offers high strength, reusability, and resistance to deformation, making it ideal for large-scale projects.
• Aluminium: Lightweight, corrosion-resistant, and easy to handle, aluminium formwork is widely used for repetitive construction tasks.
• Timber: Suitable for intricate shapes, though less durable compared to metal options.
• Plastic or Fiberglass: Lightweight and reusable, often used for smaller or specialized projects.

The choice of material should align with project requirements, expected load conditions, and environmental factors.

2. Ease of Assembly and Dismantling

Time is a critical factor in construction projects. A high-quality formwork system should be easy to assemble and dismantle, reducing labor costs and project timelines. Modular systems with interlocking components or pre-assembled panels enhance efficiency, allowing workers to set up and remove the system with minimal effort and specialized tools.

Look for systems that provide detailed assembly manuals, standardized components, and integrated safety features to simplify the process further.

3. Load-Bearing Capacity

The formwork must be designed to withstand the weight of wet concrete, construction loads, and any additional forces such as wind or vibration. A system with inadequate load-bearing capacity can lead to deformation or failure, compromising the structure’s safety and quality.

Key considerations for load-bearing capacity include:

• Compatibility with the specific concrete mix and its density.
• Resistance to lateral pressure exerted by fresh concrete.
• Reinforcement to handle heavy loads without sagging or collapsing.

4. Reusability

Reusability is an essential feature of a cost-effective formwork system. High-quality systems should withstand multiple uses without significant wear and tear. Reusability depends on the material, maintenance, and handling practices. For example:

• Aluminium and steel formwork: Can be reused dozens of times with proper care.
• Plastic formwork: Often designed for a high number of reuse cycles due to its resistance to moisture and chemicals.

A reusable system not only reduces material costs but also contributes to sustainable construction practices by minimizing waste.

5. Surface Finish Quality

The formwork’s design and material influence the surface finish of the hardened concrete. A smooth, defect-free finish minimizes the need for post-casting treatments like plastering or rendering, saving time and costs. High-quality formwork systems:

• Ensure tight joints to prevent grout leakage.
• Have smooth surfaces to produce a uniform finish.
• Use non-stick coatings or release agents for easy removal.

6. Adaptability and Versatility

Construction projects often involve complex designs and unique architectural features. A high-quality formwork system should be adaptable to various shapes, sizes, and configurations. Modular systems that can be easily adjusted or expanded are ideal for:

• Irregular shapes like curved walls or domes.
• Multi-story structures requiring repetitive setups.
• Customized applications without compromising precision or safety.

7. Lightweight Design

A lightweight formwork system enhances handling and reduces the labor required for transportation, assembly, and dismantling. Aluminium and plastic formworks are excellent choices for their lightweight nature without compromising strength. This feature is particularly advantageous for high-rise construction or sites with limited access to heavy machinery.

8. Cost-Effectiveness

While high-quality formwork may have a higher upfront cost, it should offer long-term cost benefits through reusability, reduced labor, and minimal maintenance. Evaluate the overall cost-effectiveness by considering:

• Durability and lifecycle costs.
• Savings in labor and time.
• Potential reductions in finishing and repair costs due to superior surface quality.

9. Safety Features

Safety is paramount in any construction project. A high-quality formwork system should comply with safety standards and include features like:

• Secure connections to prevent accidental disassembly.
• Non-slip surfaces for workers’ safety.
• Stability under varying loads and environmental conditions.

Additionally, consider systems that offer integrated scaffolding or platforms for ease of access during concrete pouring and inspection.

10. Resistance to Environmental Conditions

Formwork systems should withstand the environmental conditions of the construction site. This includes resistance to:

• Moisture and corrosion for projects in humid or coastal areas.
• Extreme temperatures without deformation.
• Chemicals or aggressive agents used in certain construction processes.

Materials like aluminium and plastic are particularly suited for challenging environments due to their resistance to rust and chemical reactions.

11. Ease of Maintenance

A high-quality formwork system should require minimal maintenance while remaining functional and efficient over its lifecycle. Features like anti-corrosion coatings, non-stick surfaces, and replaceable parts can significantly reduce maintenance efforts.

Regular inspection and proper cleaning after each use can further extend the formwork’s lifespan and ensure consistent performance.

Conclusion

Choosing the right formwork system is a strategic decision that impacts the quality, safety, and efficiency of your construction project. By focusing on key features like durability, ease of assembly, load-bearing capacity, reusability, and adaptability, you can select a system that meets your project’s unique requirements while offering long-term benefits.

Investing in a high-quality formwork system may require a higher initial outlay, but the advantages in terms of cost savings, sustainability, and superior construction outcomes make it a worthwhile choice. Whether you are working on residential buildings, commercial complexes, or large infrastructure projects, selecting the right formwork solution is an essential step toward achieving success.

For more insights and expert guidance on scaffolding and formwork solutions, feel free to contact us. We’re here to help you build smarter, safer, and faster!

For more Aluminum Concrete Forminformation, please contact us. We will provide professional answers.