Formwork is a simple tool whose prime role is to hold the wet concrete together during the curing process and ensure all the structure looks perfect and uniform.
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Formworks are an essential component that can greatly influence a construction project's efficiency, cost, and final quality. Without it, making a single pillar would be difficult—let alone constructing an entire structure. Formworks can be classified into two types: one is traditional forms, which have been used for centuries, and the other is modern ones, which are more advanced and offer additional features compared to conventional methods. Different materials used for formwork in construction plays a vital role in determining the speed and efficiency of the project.
Some years ago, timber and plywood were the two popular formwork materials that, in fact, were widely adopted on construction sites; they became almost the first chosen option for many contractors due to their availability practically all over the place and ease of use during the centuries. However, due to progress, the original drawbacks of those two materials have become so irreparable that this fact has forced manufacturers to look for better substitutes.
This guide dives deep into the different materials used for formwork and their advantages to better clarify the best form materials.
There are a diverse range of formwork materials that can be found in today's world. Here is some of the formwork that most contractors use.
Timber forms: This form material is made using wooden boards and planks. And have been used for centuries. They are easy to use and easy to cut, shape, and assemble. Furthermore, in comparison to other forms, they are comparatively cheaper and are usually used in small scale projects.
Plywood forms: Plywood is another form that has been used for centuries. This formwork material is made by gluing the thin layer of wood together. Moreover, this formwork material is very strong and can handle heavy loads with ease. Hence, it can be used in large-scale projects with moderate load-bearing requirements.
Steel forms: This form material is made by using steel panels, which is the reason why steel formworks are the most robust and durable formwork you could ever find. Besides, they can easily support heavy loads and are less likely to deform than wood or plastic. In addition, steel forms can be reused many times without losing their strength, thus making it a good long-term investment.
Aluminum forms: This formwork material is just like steel but much lighter. Just like steel formwork, aluminum forms are made using lightweight aluminum panels. Because of this they are easy to handle and assemble. Furthermore, they, too, are very robust and can carry the weight of concrete with ease.
Plastic forms: One of the modern formwork innovations is that this formwork material can last long and can be reused multiple times; if used in proper and moderate conditions, plastic formwork can last for a while. The best part about plastic formworks is that they do not absorb moisture and are less prone to damage caused by moisture.
When deciding which formwork material is best for your project, several essential factors must be taken into account. Comparing these aspects will help you make an informed decision. Below are some critical considerations when selecting formwork materials:
Initial cost: The first factor when evaluating the different formworks material is the cost. For instance, certain form materials like timber and plywood are cheaper and offer average durability. In contrast, other forms like steel, plastic and aluminum offer high reusability but may require a higher investment. Depending on the requirement, decide which formworks fit the budget.
Long-term cost: One is the initial cost while deciding on the formwork. Many often focus on the initial cost, thinking low-cost formwork would be cost-effective for them. However, if we talk about long-term use, it's important to go for something that would last for quite a time. Some formwork, though, may be expensive at first but provide additional benefits and may require lesser replacement, which may offset their higher initial costs.
Strength and load bearing: However, strength and load-bearing capacity are also big factors, apart from cost. Some materials, for instance, steel and aluminum, can withstand heavy loads without distortions. On the contrary, even though plastic formwork can be reused, it is still an option with limited load capacity.
Ease of handling and installation: Formwork timbers such as timber and aluminum are lighter, therefore, they are easier to assemble and to use, thus, saving time and labor costs at a construction site. Nonetheless, steel formwork results in the unmatched level of durability; although, it is more time and labor-intensive to install.
Apart from the above considerations, other aspects to keep in mind include:
Durability – How long the formwork will last under different conditions.
Resistance to Fire and Moisture – Ensuring safety and longevity.
Surface Finish – The quality of the finish left on the concrete after removal.
Brand Reputation – Choosing a reliable supplier with proven quality standards.
Choosing the right formwork material is crucial for the success of any construction project. Regardless of timber being one of the most widely chosen choices because of the cost and the ease of use, other materials such as steel, aluminum, and plastic provide their unique advantages for particular needs. Overall, it is up to you to make the most suitable decision according to your project requirements and the budget.
In a nutshell, formwork is the mold wherein fresh concrete is poured and formed. The mold, which can be permanent or temporary, holds the poured concrete and shapes it until it solidifies and becomes strong enough to support itself and other loads.
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Formwork is also known as “shuttering.” However, in certain parts of the world, shuttering refers to using plywood or timber to create the mold.
Formwork systems can be classified according to the following parameters:
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.”
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.
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:
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:
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