Design of Formwork and Scaffolding (BCV613B)

Module-5
TOPICS:

Formwork building and erection, Formwork Failures, Formwork assembly for Wall &
Column Panels, Equipment and Layout, Plant and Machinery, Formwork erection and safety,
Inspection and Corrections, Plant and Machinery, Code and Contractual Requirements.
Formwork Failures: Causes, design deficiency, safety in formwork, prevention of formwork
failures.

Introduction to Formwork building and erection

Formwork building and erection refers to the process of creating temporary moulds into
which concrete is poured to form structural elements like slabs, beams, columns, and walls. It
plays a critical role in shaping and supporting concrete until it gains sufficient strength to
support itself. Formwork is a temporary or permanent mould used to hold wet concrete in
place until it hardens. It must be strong enough to bear the load of the concrete and any

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additional loads (like workers, equipment, etc.).

Types of Formwork
C
 Timber Formwork: Traditional, flexible, and easy to work with; suitable for small
projects.
N
 Plywood Formwork: Used with timber frames for a smooth finish.
 Steel Formwork: Durable and reusable; often used in large-scale projects.
SY

 Aluminium Formwork: Lightweight, durable, and suitable for repetitive tasks like in
housing schemes.
 Plastic Formwork: Modular, reusable, and ideal for simple, repetitive structures.
U

Components of Formwork
VT

 Sheathing: The surface that comes in direct contact with the concrete.
 Bearers and Joists: Horizontal supports.
 Props/Shoring: Vertical supports that hold the formwork in position.
 Bracing: Prevents movement or collapse.
 Ties and Anchors: Hold the formwork together and resist concrete pressure.

Steps in Formwork Erection

1. Planning and Design: Based on the structural drawings and concrete pressure.
2. Material Selection and Preparation: Choosing appropriate formwork materials and
components.
3. Setting Out: Marking the layout on the construction site.
4. Assembly: Erecting the formwork according to design, ensuring correct dimensions
and alignment.
5. Inspection and Safety Check: Ensuring stability and conformity to safety standards.
6. Application of Release Agent: Prevents concrete from sticking to formwork.
7. Concrete Pouring: Done after final checks.
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 Design of Formwork and Scaffolding (BCV613B)

8. Stripping/Dismantling: Done after the concrete gains adequate strength.

Best Practices

 Use proper bracing to prevent collapse.

 Ensure all joints are tight to avoid leakage.
 Remove formwork only after the concrete has gained enough strength.
 Regularly inspect for wear and damage, especially for reusable formwork.

Introduction to Formwork failures

Formwork failures refer to the collapse or malfunction of the temporary structures used to
support freshly poured concrete. These failures can be catastrophic, leading to injury, loss of
materials, construction delays, and significant financial loss.

Common Causes of Formwork Failure

1. Inadequate Design

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o Improper calculation of loads (dead load of concrete, live loads from workers
or equipment).
o Overlooking lateral pressure exerted by fresh concrete.
2. Poor Construction Practices
C
o Incorrect assembly of formwork components.
o Use of damaged or substandard materials.
N
o Insufficient bracing or support.
3. Premature Removal of Formwork
SY

o Removing formwork before the concrete has reached sufficient strength can
cause collapse.
4. Improper Vibration or Overloading
o Excessive or poorly applied concrete vibration can shift formwork.
U

o Pouring too much concrete too quickly increases lateral pressure.

5. Foundation Settlement
VT

o Uneven or weak ground beneath the formwork can lead to tilting or collapse.
6. Environmental Conditions
o High winds, heavy rain, or freezing conditions can weaken supports or
misalign structures.

Signs of Potential Failure

 Excessive deflection or bending of formwork components.

 Creaking or popping sounds during concrete pour.
 Movement or shifting of the form during pouring.
 Cracks or leaks appearing in the form.

Preventive Measures

 Use qualified engineers to design formwork systems.

 Conduct regular inspections before and during pours.
 Use only materials in good condition and of suitable strength.

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 Design of Formwork and Scaffolding (BCV613B)

 Train workers on correct assembly and load limits.

 Monitor concrete pressure during pouring, especially for tall walls and columns.
 Never remove formwork without structural approval.

Case Study Examples

 Willow Island Disaster (1978): Cooling tower formwork collapsed during

construction in West Virginia, killing 51 workers. Cause: premature removal of
formwork and inadequate support during concrete curing.
 Generic Slab Collapse: Common in high-rise buildings where slab formwork is
stripped too early or bracing fails under concrete load.

Formwork Assembly for Wall and Column Panels

Formwork Assembly for Wall and Column Panels involves setting up modular or custom
systems to mould and support vertical concrete elements. These systems must be strong,
aligned, and leak-proof to ensure safety and achieve a good concrete finish.

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1. Formwork Assembly for Wall Panels

Key Components:
C
 Formface (Sheathing): Plywood, steel, or plastic sheets in contact with concrete.
N
 Studs and Walers: Horizontal and vertical members for rigidity.
 Ties and Tie Rods: Hold opposite panels together to resist lateral pressure.

SY

Bracing and Supports: External elements to maintain position and plumb.

Assembly Steps:
U

1. Mark Layout: Mark the wall line and formwork position.

2. Position First Panel: Place the first panel and plumb it with supports.
3. Install Additional Panels: Place subsequent panels, joining them with clamps or bolts.
VT

4. Install Tie Rods: Through-wall ties prevent panels from spreading under concrete
pressure.
5. Check Plumb and Alignment: Use levels and string lines.
6. Install Bracing: External bracing for stability during pour.
7. Apply Release Agent: Ensure concrete does not stick.
8. Final Inspection: Before concrete pouring.

2. Formwork Assembly for Column Panels

Key Components:

 Column Forms (Panel or Box Types): Usually steel, timber, or plastic.

 Corner and Closure Panels: Ensure tight fit at edges.
 Tie Bolts or Clamps: Hold sides together.
 Base Plate/Form Stopper: At the bottom to prevent leakage.
 Bracing/Supports: To maintain plumb position.

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 Design of Formwork and Scaffolding (BCV613B)

Assembly Steps:

1. Install Base Form or Stopper: Ensures accurate column base and prevents leakage.
2. Assemble Panels Around Rebar Cage: Place two or three sides, insert rebar, then
close with final panel.
3. Tighten Tie Rods or Clamps: Ensure no spreading during pour.
4. Check Plumb and Verticality: With spirit level or plumb bob.
5. Install External Bracing: Against overturning forces.
6. Apply Release Agent: Before pouring concrete.
7. Inspect for Gaps or Weak Spots.

Best Practices

 Use modular systems for repeatability and speed.

 Preassemble panels offsite if possible.
 Check all tie and bracing systems are secure.
 Use proper access scaffolding for safe work at height.

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Formwork Equipment and Layout
The equipment and layout used for formwork must ensure safety, efficiency, and precision in
placing concrete for walls and columns. Proper planning helps minimize labor, material
C
waste, and delays.
N
1. Equipment for Formwork
SY

A. Formwork Panels and Systems

 Timber panels: For custom shapes, small projects.

 Steel or Aluminium panels: Reusable, suitable for high-rise and repetitive structures.
U

 Plastic modular systems: Lightweight, for simple structures.

 Plywood sheathing: Used with frames.
VT

B. Supporting and Fastening Equipment

 Props/Shoring: To support vertical loads.

 H-Frames/Scaffolding: Provide working platforms and stability.
 Tie rods and wing nuts: Hold panels in position against concrete pressure.
 Bracing and struts: Prevent lateral movement.
 Walers and soldiers: Distribute pressure and hold panels aligned.
 Turnbuckles: Fine adjustment for plumb and alignment.
 Release agents: Prevent concrete from sticking to the form.

C. Lifting and Handling Tools

 Cranes or hoists: For large/heavy panels.

 Panel trolleys or forklifts: For site movement.
 Hand tools: Hammers, wrenches, crowbars, levels, and screw guns.

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 Design of Formwork and Scaffolding (BCV613B)

2. Formwork Layout Planning

Goals:

 Efficient workflow.
 Minimized lifting and handling.
 Safe access and working zones.

Key Layout Considerations:

 Access Routes: Clear paths for workers and equipment (hoists, wheelbarrows).
 Storage Areas: Nearby but out of the way—separate for used/unused formwork.
 Assembly Zone: Flat, level area to assemble and pre-check formwork panels.
 Crane or Lifting Access: Ensure room for equipment to move panels into position.
 Safety Zones: Marked areas around formwork for bracing and fall protection.
 Working Platforms: Scaffolds or walkways to allow safe work at heights (especially
for columns).

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Layout Tips for Walls & Columns

 Wall Formwork: Layout panels linearly along the wall path, with storage for tie rods
and bracing nearby.
C
 Column Formwork: Centralized setup around rebar cages with 360° access, especially
for crane placement.
N
 Sequencing: Arrange formwork in order of use to minimize movement and handling.
SY

Plant and Machinery Used in Formwork Construction

U

In formwork construction—especially for walls and columns—plant and machinery are

essential for handling, lifting, assembling, and pouring concrete efficiently and safely. The
VT

choice of equipment depends on project size, height, and formwork system used.

1. Lifting and Handling Equipment

A. Tower Cranes

 Used to lift and position heavy formwork panels, rebar cages, and concrete buckets.
 Ideal for high-rise or large-scale projects.

B. Mobile Cranes

 Flexible and quick to set up.

 Useful for lifting wall and column formwork on mid-sized sites.

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 Design of Formwork and Scaffolding (BCV613B)

C. Forklifts / Telehandlers

 Transport formwork panels and materials around site.

 Useful in both assembly and dismantling stages.

D. Hoists (Material or Passenger)

 Used to lift equipment and workers vertically.

 Essential in multi-story construction for wall and column formwork.

2. Concrete Placement Equipment

A. Concrete Pumps

 Boom Pumps: For tall or hard-to-reach columns and walls.

 Line Pumps: Suitable for smaller jobs or horizontal pumping.

B. Concrete Buckets

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 Lifted by crane to pour concrete directly into formwork.
 Common for columns or remote parts of the site.
C
3. Formwork Assembly Tools & Machinery
N
A. Vibrators
SY

 Needle Vibrators: Ensure proper compaction of concrete in wall and column forms.
 Prevents voids and honeycombing.

B. Power Tools
U

 Drills, screw guns, spanners, torque wrenches: For assembling and tightening
VT

formwork connections.
 Grinders and saws: For cutting timber or plywood when custom sizes are needed.

C. Scaffolding Systems

 Provides working platforms for formwork erection, adjustment, and concrete pouring.

4. Miscellaneous Equipment

 Mixers: For onsite concrete mixing (small projects).

 Generators: To power tools and lights in remote or incomplete buildings.
 Compressors: For pneumatic tools if used in the formwork system.

Selection Factors

 Project size and height.

 Formwork material (steel vs. timber panels).
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 Design of Formwork and Scaffolding (BCV613B)

 Speed of construction needed.

 Site constraints (space, access).
 Safety and regulatory requirements.

Formwork Erection and Safety

Formwork erection involves assembling temporary molds to hold freshly poured concrete
until it gains sufficient strength. Safety during formwork erection is critical due to the high
risk of collapse, falling materials, or instability under load.

1. Formwork Erection Procedure

A. Pre-Erection Preparation

 Review drawings and load requirements.

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 Check materials: Ensure panels, props, ties, and braces are in good condition.
 Site layout: Ensure clear, level ground for stable erection and storage.

B. Erection Process
C
1. Set Base Plates and Supports: Ensure stable ground or shoring foundation.
N
2. Assemble Panels: Start from one corner or edge and progressively align.
3. Install Ties and Bracing: Ensure panels are securely connected and plumb.
SY

4. Check Alignment: Use levels, plumb bobs, and measuring tapes.

5. Install Working Platforms: Provide safe access for high walls or columns.
6. Apply Release Agent: Before concrete is poured.
7. Final Inspection: Structural and safety inspection before concrete placement.
U

2. Safety Measures During Formwork Erection

VT

A. General Safety

 Trained personnel only: Erection must be done by experienced workers.

 Use PPE: Hard hats, gloves, safety boots, harnesses, etc.
 Fall protection: Guardrails, harnesses, and working platforms for elevated work.

B. Structural Safety

 Proper bracing: Prevents collapse due to wind or load shifting.

 Tight connections: Ties, clamps, and bolts must be secure.
 Safe load handling: Cranes and hoists must be operated within rated capacity.
 Avoid overloading: Do not exceed designed concrete pressure.

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 Design of Formwork and Scaffolding (BCV613B)

C. Inspection and Maintenance

 Inspect formwork before, during, and after pouring concrete.

 Check for shifting, bulging, or leaking during concrete placement.
 Never remove formwork until concrete has reached specified strength (as per
engineer's instruction).

3. Common Hazards

 Collapse due to poor bracing or premature removal.

 Injury from falling materials or shifting panels.
 Trips and falls on uneven or cluttered work areas.
 Struck-by hazards from crane or hoist operations.

Best Practices

 Follow manufacturer guidelines for proprietary formwork systems.

 Conduct toolbox talks and safety briefings regularly.

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 Use tagging systems to identify inspected and safe-to-use formwork.
 Keep area clear of unauthorized personnel during erection and pour.
C
Formwork Inspection and Corrections
N
Inspection and correction are critical to ensure the safety, stability, and quality of formwork
SY

before, during, and after concrete placement. Proper inspection helps prevent formwork
failure, ensures design compliance, and delivers high-quality concrete surfaces.
U

1. Stages of Formwork Inspection

A. Pre-Erection Inspection
VT

 Material condition: Check formwork panels, ties, props, and braces for damage, rust,
warping, or cracks.
 Design conformity: Ensure formwork matches structural drawings and load
requirements.
 Base and foundation: Confirm the ground or support base is level, compacted, and
stable.
 Release agents: Check for correct type and even application to prevent sticking.

B. During Erection

 Alignment: Use spirit levels and plumb bobs to confirm verticality and squareness.
 Joint sealing: Ensure all joints are tight and sealed to prevent concrete leakage.
 Support spacing: Verify props, walers, and bracing are at correct intervals.
 Tie rod placement: Check for correct installation and tensioning of form ties.

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 Design of Formwork and Scaffolding (BCV613B)

C. Pre-Pour Inspection

 Final checks: Confirm tightness of all bolts/clamps, plumb alignment, and that all
supports are locked.
 Working platforms: Inspect scaffoldings and access areas for safe use.
 Cleanliness: Remove debris, water, or contaminants from inside the form.
 Access points: Ensure clear space for pouring and vibrating equipment.

D. During Concrete Placement

 Monitor for movement: Watch for bulging, leaking, shifting, or unusual sounds.
 Check pour rate: Ensure controlled concrete placement to avoid pressure spikes.
 Monitor props and ties: Re-check load-bearing supports under live loads.

E. Post-Pour / Stripping Inspection

 Formwork condition: Inspect for signs of damage or stuck concrete.

 Concrete quality: Check surface finish, alignment, honeycombing, or cold joints.

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 Safe removal: Ensure concrete has achieved required strength before striking.
 Recover and repair: Clean and repair formwork materials for reuse.

2. Common Defects and Corrections

C
Defect Cause Correction
N
Use sealing tape, rubber gaskets, or
Leakage at joints Poor sealing or gaps
foam fillers
SY

Improper bracing or shifting Re-align panels, install adjustable

Misalignment
during pour props
U

Inadequate support or Add more bracing, reduce pour

Bulging
VT

overpressure height/speed

Poor compaction or form

Honeycombing Improve vibration, seal form joints
leakage

Surface Use correct release agents and

No or improper release agent
marks/sticking reapply evenly

3. Formwork Inspection Checklist (Key Items)

 Is the formwork built to the approved design and dimensions?

 Are all joints tight and sealed?
 Are all props and supports properly placed and secured?
 Are access platforms and ladders in place and safe?

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 Design of Formwork and Scaffolding (BCV613B)

 Has a release agent been applied uniformly?

 Has the system been checked for plumb, level, and square?
 Are tie rods and braces tight and undamaged?
 Has the form been cleaned internally?
 Are warning signs and exclusion zones set up?

Code and Contractual Requirements for Formwork

Formwork construction must adhere to national codes, international standards, and
contractual specifications to ensure structural safety, quality, and compliance with the law
and project agreements.

1. Applicable Codes and Standards

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Depending on your region and project type, formwork work is governed by the following
codes:

A. International and Regional Codes

C
Standard/Code Region Coverage
N
ACI 347 – "Guide to USA (American Design, construction, and removal of
SY

Formwork for Concrete" Concrete Institute) formwork

Safety standards for concrete and

OSHA 1926 Subpart Q USA
U

masonry construction

Execution of concrete structures

VT

EN 13670 Europe
(includes formwork requirements)

Falsework and formwork safety and

IS 14687 – Indian Standard India
performance

Formwork design and surface finish

AS 3610 Australia
requirements

B. Typical Areas Covered in Codes

 Formwork design loads (dead loads, live loads, lateral pressure from concrete)
 Material strength and quality

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 Design of Formwork and Scaffolding (BCV613B)

 Safety provisions: bracing, shoring, fall protection

 Tolerances for plumb, level, and dimensions
 Formwork removal timing
 Inspection and maintenance procedures

2. Contractual Requirements in Projects

Contract documents (drawings, specifications, BOQs, etc.) typically include:

A. Technical Specifications

 Type and quality of formwork materials (e.g., plywood, steel).

 Required surface finish (e.g., smooth, textured).
 Reusability limits for formwork panels.
 Specific removal times or concrete curing requirements.
 Tolerances for dimensions and alignment.

B. Method Statements and Approvals

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 Contractors must submit formwork method statements for approval.
 Shop drawings for complex formwork assemblies (especially curved or cantilevered
structures).
C
 Inspection and test plans (ITPs) for formwork checks.
N
C. Safety Compliance
SY

 Must meet local labor laws and safety regulations (e.g., PPE, fall protection, scaffold
safety).
 Formwork systems must include engineer's design certification for complex or
proprietary systems.
U

3. Key Responsibilities Defined in Contract

VT

Party Responsibility

Designer/Engineer Specifies structural and formwork design loads and requirements

Contractor Builds, maintains, and safely removes formwork per code/spec

Supervisor/Inspector Verifies compliance with design, code, and safety procedures

Client/Consultant Approves materials, method statements, and inspection reports

✅Best Practices for Compliance

 Always reference the project specifications alongside national/international codes.

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 Design of Formwork and Scaffolding (BCV613B)

 Keep formwork designs stamped and approved by a qualified engineer.

 Document all inspections, corrections, and approvals.
 Use only certified workers and supervisors for high-risk formwork operations.

Formwork Failures
Formwork failures can lead to catastrophic accidents, loss of life, material damage, and major
construction delays. Understanding the root causes and implementing robust design, safety,
and prevention practices is critical for safe and successful concrete construction.

1. Common Causes of Formwork Failures

Cause Explanation

Incorrect load calculations, failure to consider concrete pressure,

Design errors
dynamic loads, or wind forces.

Inadequate
support/bracing
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Weak or missing shoring and bracing leads to instability or
collapse.
C
Damaged, warped, or under-strength formwork panels, ties, or
Poor quality materials
N
props.
SY

Improper construction
Incorrect assembly, loose joints, or missing components.
practices

Premature removal Stripping formwork before the concrete gains sufficient strength.
U

Overloading Excessive concrete pour rate or additional load on formwork.

VT

Foundation failure Uneven settlement or soft ground under formwork supports.

Lack of inspection No routine checks to catch early signs of stress or failure.

2. Design Deficiencies in Formwork

 Incorrect load assumptions: Underestimating fresh concrete pressure (especially for

tall walls or columns).
 Omission of live loads: Failing to account for workers, tools, or equipment weight.
 Insufficient lateral support: Leading to sway or bulging.
 Improper spacing of supports: Excessive span between props or walers.
 Lack of robustness: No redundancy in load paths; one failure triggers collapse.

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 Design of Formwork and Scaffolding (BCV613B)

Designs should follow standards like ACI 347, IS 14687, EN 13670, or local building codes,
and be certified by qualified engineers.

3. Safety in Formwork Operations

Key Safety Practices:

 Qualified Personnel: Only trained workers should erect, inspect, or dismantle

formwork.
 Use of PPE: Helmets, gloves, boots, harnesses, and eye protection.
 Scaffold Safety: Ensure proper access platforms and fall protection at heights.
 Secure Zones: Establish exclusion zones during erection and concrete pouring.
 Pre-pour Checks: Confirm bracing, alignment, tie tightness, and form integrity.
 Weather Precautions: Extra bracing in windy or rainy conditions.

Inspection Focus:

 Joint tightness, support strength, form alignment, tie placement, release agent

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application, debris inside forms.

4. Prevention of Formwork Failures

C
A. During Design
N
 Engage qualified structural/formwork engineers.
 Calculate all loads, including environmental and dynamic effects.
SY

 Include sufficient bracing, anchoring, and load redundancy.

B. During Construction
U

 Follow approved formwork method statements and drawings.

 Use high-quality, undamaged formwork materials.
VT

 Install props, ties, and braces as per design spacing.

 Apply release agent uniformly to prevent sticking and damage.

C. During Pouring

 Monitor formwork for movement or leakage.

 Control concrete pour rate to limit pressure buildup.
 Ensure proper vibration without disturbing formwork.

D. During Stripping

 Wait until concrete reaches required strength (verified by test).

 Strip gradually and symmetrically to avoid stress concentrations.

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