JBLDG – Spring 2011 [HORIZONTAL FORMWORK] ‐ Outlines

Outlines:

1. Introduction
1. Definition of concrete formwork
2. Definition of horizontal formwork
2. Horizontal formwork categories
1. Hand­set
2. Crane­set
3. Joist slab system
4. Dome forming system
3. Slab form design
1. Design steps
4. Criteria for choice of horizontal formwork
1. Building design (slab type)
2. Building shape
3. Speed of construction
4. Local conditions
5. Supporting organization

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 JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – Introduction

Introduction
Throughout this report we are going to
define horizontal formwork, its
categories, how to design it, and the
criteria based on it we choose the
formwork.

Definition of Concrete Formwork

The construction of a concrete building

requires formwork to support the slabs
(horizontal formwork) as well as columns
and walls (vertical formwork).
Formwork is defined as a temporary
structure whose purpose is to provide
support and containment for fresh
concrete until it can support itself. It
molds the concrete to the desired shape
and size, and controls its position and
alignment.
Concrete forms are engineered structures
that are required to support loads such as fresh concrete, construction materials, equipment,
workers, various impacts, and sometimes wind. The forms must support all the applied loads
without collapse or excessive deflection.

Formwork System

A formwork system is structural

defined as ‘‘the total system of
support for freshly placed
concrete including the mold or
sheathing which contacts the
concrete as well as supporting
members, hardware, and
necessary bracing.’’

As concrete has come of age and

been assigned increasingly
significant tasks, formwork
builders have had to keep pace.
Form designers and builders are
becoming increasingly aware of
the need to keep abreast of
technological advancements in
other materials fields in order to develop creative innovations that are required to maintain
quality and economy in the face of new formwork challenges.

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 JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – Introduction

Formwork was once built in place, used once, and subsequently wrecked. The trend today,
however, is toward increasing prefabrication, assembly in large units, erection by mechanical
means, and continuing reuse of forms. These developments are in keeping with the increasing
mechanization of production in construction sites and other fields.

Definition of Horizontal Formwork

Horizontal formwork systems are used to temporarily support horizontal concrete work such as
concrete slabs. There are seven horizontal forming systems that can be used to support
different slab types:
(1) Conventional wood system (stick form).
(2) Conventional metal (aluminium) system (improved stick form).
(3) Flying formwork system.
(4) Column‐mounted shoring system.
(5) Tunnel forming system.
(6) Joist‐slab forming system.
(7) Dome forming system. Joist‐slab and dome forms are steel or fibreglass pans usually
placed above the plywood sheathing and thus can be used with any of the first five
horizontal formwork systems. As a result, they will not be considered in this book as
separate systems.

Formwork systems for horizontal concrete work can be also classified into two main categories:
hand‐set systems and crane set systems. Conventional wood systems and conventional metal
systems are classified as hand‐set systems. In hand‐set systems, different formwork elements
can be handled by one or two labourers.

Flying formwork systems, column‐mounted shoring systems, and tunnel formwork are
classified under crane‐set systems. In crane‐set systems, adequate crane services must be
available to handle formwork components.

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 JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – Horizontal Formwork Categories

Horizontal Formwork Categories

Conventional Wood Formwork System: (stick form or hand‐over‐hand method)

It includes formwork for slabs, beams, and foundations. The system is usually made of lumber and
plywood. They are made in situ, may be cut into small pieces and may be used as it is. They can be
reused several times.

a)Formwork for Concrete Slabs

Plywood is preferred over lumber sheathing

because it provides a smooth concrete surface that
requires minimum finishing effort. The use of
plywood for decking is also productive because of
its large panel size. Sheathing is supported by
horizontal members called joists. Joists are
supported by another set of horizontal members
perpendicular to the joists, called stringers. The
stringers are supported by vertical members
called shores. Shores are rested on heavy timbers,
called mudsills, to transfer the vertical loads to the
ground.

The thickness of plywood or lumber is determined by structural analysis and is a function of the
applied loads, type of wood or plywood, and the spacing between sheathing supporting elements.

b) Formwork for Concrete Beams

Formwork for beams consists of a bottom and two

sides in addition to their supporting elements. The
plywood and lumber used are usually of thickness of
0.75 in. (19.0 mm) or 1 in. (25.4 mm).

First, the bottom of the beam is constructed, then

one side of the beam is erected with holes to install
tie steel rods; which are used to hold the two sides
together and resist the horizontal pressure resulting
from placing fresh concrete, after that, the
reinforcement is placed inside the beam, and finally,
the other side is erected. Additional temporary
spreaders may be used, to further support the two
sides of the beam, at the top of the beam sides at
regular distances.

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c) Formwork for foundation:

The plywood used is supported by vertical stakes driven

into the ground. The top of the vertical stake is supported
by a diagonal brace driven into the ground. On small
footings, steel straps are used. It is common practice to
construct the forms higher than necessary and place the
straps in the inner sides of the form at a height equal to the
concrete level.

Large footings are similar to the small and continuous

footings except that the sides are supported by studs and
Wales. In the sides of the forms, we make holes to pass tie wire to the studs. Lumber are used to
provide extra support.

Limitations of conventional wood system:

There are five major problems with use of all‐wood conventional formwork systems.

• High labour cost: Labour costs range from 30 to 40 percent of the total cost of concrete
slabs.
• High waste: It is estimated that 5 percent waste is generated from a single use of formwork;
breaking of edges and small pieces.
• Limited number of reuses: Typically, conventional formwork is limited to five to six reuses. A
limited number of reuses forces the contractor to use several sets of formwork
• Higher quality of labour force and supervision: In areas with an unskilled or semiskilled
labour force and minimal supervision, more sophisticated formwork systems are more
appropriate.
• Limited spans. Since dimension wood is low strength it has limited use in applications where
long spans are desired.

Advantages of Conventional Wood System

• Flexibility: A complicated architectural design can be formed only by this system, as it can be
cut into pieces.

• Economy: The system has the advantage of low makeup cost or initial cost. This system is
not economical in terms of labour productivity and material waste. However, the system
may be economical for small projects with limited potential reuses.

• Availability: Wood is an available construction material everywhere.

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Conventional Metal systems:

In the conventional metal system, joists and stringers are made of aluminium or steel supported by
aluminium or steel shoring.

Types of Conventional Metal Systems:

Conventional metal systems include different combinations of wood, aluminium, and steel for joists
and stringers. There are two systems:

• Plywood sheathing for decking supported by dimensional

wood or laminated wood for joists and standard steel
sections for stringers.
• Plywood sheathing for decking supported by standard steel
sections for joists and stringers.
¾ A movable aluminium or steel scaffolding system is used
for shoring for both systems.
In these two systems, steel joists and stringers have the advantage of
supporting greater spans, resulting less shores, joists, and stringers
to be used. The main problem is its heavy weight in forming concrete
slabs; it is difficult for a person to handle it. A standard steel W‐
section is used because its wide flange makes it easy to connect
stringers with shore legs.

Conventional aluminium system description:

This system is a hand‐set system that consists of a deck surface made
of plywood or wood supported by aluminium ‘‘nailer type’’ joists and
stringers. it is sometimes referred to as ‘‘an improved stick system.’’

Plywood Sheathing: Plywood and plyform can be used as sheathing.

Plywood is available in two types, interior and exterior. Exterior
plywood is made of waterproof glue that resists absorption of
concrete‐mix water.

Extruded Aluminium Joist: it is the first component in the

conventional metal. The extruded aluminium joist takes the shape of a
modified I beam with a formed channel in the top flange.

Aluminium Beams (Stringers): The purpose of stringers is to transfer the loads to the scaffold
Extruded aluminium joists can be also used as stringers unless the loading is too excessive.

Aluminium Scaffold Shoring: The system consists of several frames connected together by cross
bracing. Aluminium shoring is light and has the advantage that its load‐carrying capacity equal to or
greater than steel shoring.

Post Shore: A post shore is a single member made of steel or aluminium and support stringers. Post
shores can be used to replace, or in combination with, scaffold shoring.

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ntal Formwo

ges of Conve
Advantag entional Alu
uminium Systems

• Liight weight: Aluminium joists and stringers

s hav
ve a strength
h‐to‐weight ratio better than
th
hat of steel jo
oists and stringers.
• E
Economy: it saves 20 to 30 percent for the labo our cost com
mpared to coonventional wood
w
fo
orm.
• H
High reuse: Alluminium secctions have higher
h reused
d more timess than wood..

ons of Conve
Limitatio entional Aluuminium Sysstems
• Fabrication, erection, and stripping are done piecee by piece, ressulting
¾ Low labour productiv vity
¾ High waste of plywoo od
• Seections are exposed
e to ro
ough handlinng on site
• Chemical reacction between aluminium m and spilled concrete

Crane
e­Set Systtems
Crane‐sett formwork systems
s are typically con
nstructed and assembled d as one largee unit that caan be
moved ho orizontally or
o vertically from
f floor to
o floor by craanes. As a reesult, adequaate crane serrvices
are required for handdling these sy
ystems.

ormwork Sysstem
Flying Fo

Flying foormwork is a relatively new formw work

system thhat was deveeloped to red duce labour cost
associateed with erecting
e an
nd dismanttling
formwork k. The namee ‘‘flying formwork’’ is used
u
because forms
f are flo
own from sto ory to story by a
crane. Flyying form syystems are best
b utilized
d for
high‐rise multi‐story buildings suuch as hotels and
apartmen nt buildingss, where many reuses are
needed.

Flying Fo
ormwork Components

Flyin
ng formwork tables with alumin
nium and timbe
er joists;
Sheathingg Panels the tables are supp
ported by shoes attached to pre
eviously
Flying foorms usually y consist of large sheeathing poured columns and walls.
panels thhat are typiccally made of
o plywood oro ply‐
form. Ply
ywood with standard sizee of 4*8 feet (1.22*2.44
( m allows few
m) wer joints and d produces a high
quality off concrete.

Aluminium m Joist
Sheathingg panels are supported by b aluminium m ‘‘nailer‐typ pe’’ joists. Eaach joist is a standard I‐b
beam
with a wiide top flangee that allowss a wood nailler to be inseerted to provvide a wider nailing
n surfacce for
the sheatthing panels.

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ntal Formwo

Aluminium m Trusses
Sheathingg panels and d joists are su
upported byy aluminium trusses. Alum minium trusses and joistts are
always used
u becausee of their ligght weight. However,
H steeel trusses and joists aree used for lo
onger
spans an nd heavier lo oads. Alumin nium trussess are braced d in pairs at the ground d level to provide
lateral staability in thee direction peerpendicularr to the trussees

Telescopiing Extensionn Legs

Adjustablle vertical telescoping exxtension legs are an integgral part of th
he
trusses; they
t are usedd to support the aluminiu um trusses and to transfeer
the load vertically
v to the ground oro to subsequ uent floors th
hat have beeen
already cast.
c Telescopping extensioon legs are made
m of squaare or circulaar
hollow stteel sections braced togetther by tabular steel struuts. These leggs
can be adjusted
a upp and down n to achievee the exact level of th he
formwork k. Extensionn legs are typpically rested on woodeen planks thaat
distributee the loads to
o a larger areea and also prevent
p the extension
e leggs
from slid
ding, particullarly in the winter
w seaso
on. For strippping, after th
he
concrete has gained enough
e strenngth, the system can be lowered
l awaay
from the slab by turn ning down th he jacks. Thee truss moun nted forms arre
then mov ved by crane from one cassting position to the nextt.
Telescoping Extension Le
egs

Flying Fo
ormwork Cyccle

1. Flying to a New Position

Fl
2. owering and Stripping
Lo
3. R
Rolling Out
4. Fl
Flying to a New Position

ormwork Usage and Ben

Flying Fo nefits

Flying fo ormwork has h proved to be an

efficient system in achieving a shorter
constructtion cycle of initial fabrication,
erection, stripping, and re‐erecction. Other
visible benefits of flying
fl formwwork are as
follows:
1. Fabrication off the flying formwork
f is
normally performed on the t ground,
w
which yields higher
h produ
uctivity.
2. Loads are tran nsformed by y telescoping
exxtension leggs located underneath Flying Formwork cyccle
th
he aluminiu um trusses and thus
giiving enough h working sppace below the
t formworkk to allow otther construction activitiies to
be performed d.
3. Costs of flyinng formwork k are lower than for con
nventional horizontal
h fo
ormwork sysstems
w
when 10 or more
m reuses are
a available.

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4. Lightweight aluminium trusses and joists allow average capacity construction cranes to
handle the flying tables.
5. A shorter floor cycle can be achieved
6. A large‐size flying table results in a smaller number of deck joints which produces high‐
quality smooth concrete.
7. Fibreglass or steel pans used to form joist or waffle slabs can be placed on the flying tables
and become an integral part of the flying table.

Flying Formwork Limitations

1. In windy weather conditions, large flying formwork panels are difficult to handle.
2. Flying formwork should not be used for flat slab with drop panels around the columns.
3. The building must have an open facade through which the flying tables can be passed.

Modular and Design Factors for Selecting Flying Formwork

There are many factors that affect the selection of the flying formwork system for a concrete
building. Some of these factors are related to economy, site condition, architectural, and structural
considerations.
1. Standard modular flying tables are available for contractors to rent or purchase. Flying table
width ranges from 15 to 30 FT (4.6 to 9.1 m), with the most economical width for flying
tables being 22 FT (6.7 m).
2. Column size and location perpendicular to the flying table (i.e., the bay width) should be the
same from floor to floor to avoid changing the formwork dimension by adding filler panels.
3. Beam sizes and location should be the same from floor to floor on a modular building grid.

Column­Mounted Shoring Systems

Column­mounted shoring system is the term used for formwork panels supported by an up‐and‐
down adjustable bracket jack system attached to already‐cast concrete bearing walls or columns. In
contrast to traditional formwork systems, this formwork for slabs is supported by several levels of
shores and re‐shores or the ground. In multi‐story concrete buildings, the conventional
construction method is to build formwork and place concrete for columns, then strip formwork for
concrete columns after 12 to 24 hours.
Erection of formwork and placing of concrete for slabs proceed after column forms are stripped.
Though the newly placed columns have enough strength to support slab loads, they have a limited
role in supporting the newly placed concrete slabs. The newly placed concrete slab is typically
supported by several levels of shores and re‐shores. Those levels of shores delay or block the
progress of any other construction activities underneath those concrete slabs. As a result, column‐
mounted shoring systems were developed to employ concrete columns to support formwork for
concrete slabs and thus eliminate any need for shoring and re‐shoring that may ultimately reduce
the overall construction schedule.

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Componeents of Colum
mn­Mounted
d Shoring Syystems

The systeem consists of

o two majorr
componeents, a deck panel and a
column‐ or wall‐mounted
w d
bracket jack system m. The deck k
panel co onsists of a plywood d
sheathingg supported by a system m
of wood joists (head ders), and a
pe open‐weeb stringerr
nailer‐typ
that allow
ws a 2*4 in. (50.8*101.6 6
mm) woo od section to
o be insertedd
into thee open web. A trusss
system supports
s botth the joistss
and stringers.
The seco ond component of the Components off column‐mountted shoring systtems – courtesy of Formwork Exxchange Ltd
column‐m mounted shoring system is the brackeet jack systemm. The function of the brracket jack sy ystem
is to supp
port the deckk panel. The weight of th
he freshly placed concrette and the dead weight of o the
deck panel are transfferred from the
t deck thro ough the braacket jack sysstem and theen to the con ncrete
column or
o wall; thus no
n shores are required too support thee deck panel..

Column­M
Mounted Sho
oring System
m Cycle

Column‐m mounted sho oring systems are either assembled

a att the job sitee or preassemmbled in a loccal or
regional yard facility and delivered to the job b site. Deck panels are flown
f from floor
f to floorr by a
crane in a manner sim milar to whatt is done in the
t flying truss system. Ty ypically, the column‐mou unted
shoring system
s cycle starts from the
t ground flloor, whether or not slabs on grade exxist.
The column‐mounted d shoring syystem cycle is described d below. How wever, somee minor tech hnical
details arre different frrom one mannufacturer too another.
1. Assembling the deck panel.
2. Positioning off the deck pan nel.
3. Sttripping of thhe deck panell.

Advantag
ges, Usage, and
a Limitatiions of the Column­Mou
C nted Shoring
g Systems

1. H
Height­indepeendent System ms. This is particularly
p important in n the first few
f floors, where
w
sttory height can reach 25 to 30 FT (7.6 6 to 9.1 m).
2. Construction workers
w arenn’t at risk because they are
a not forming slabs at high
h elevation
n.
3. Because the system requ uires no sho oring or re‐sshoring, otheer constructtion activitiees are
alllowed to pro oceed simulttaneously with the constrruction of concrete slabs..
4. Cost of the sy ystem is commpetitive with traditionaal systems iff 8 to 10 reu uses or morre are
avvailable.
5. The system requires largee capital inv vestment (iniitial cost). However, if enough reusees are
avvailable, the final cost peer square fooot or square meter of con ntact area is competitivee with
trraditional forrmwork systtems.
6. The system reequires adequate crane service
7. The deck pan nel has an indefinite num mber of reusees as long ass the plywoo od sheathingg is of
high quality and the panell is handled with
w care.

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8. Electrical and plumbing connections can be installed on the ground on the deck panels. This
results in substantial productivity improvement because there is no need for scaffolding or
work performed at high elevations.

Modular and Design Factors Affecting Selection of Column­Mounted Shoring Systems

An important criterion when using a modularized formwork system is the maximization of

the number of reuses. As a result, modification to the deck panels should be kept to a
minimum. Modifications to deck panels are caused by changes in building design from floor
to floor. The following are some modular limitations that should be considered to achieve
maximum profitability of the column‐mounted shoring system.

1. Optimum size of a column‐mounted shoring systems deck is 16 to 20 ft. (4.9 to 6.1

m) in width and 30 to 40 ft. (9.1 to 12.2 m) in length. Maximum dimensions should
not exceed 30 ft. (9.1 m) in width and 70 ft. (21.3 m) in length. If bay length is more
than 70 ft. (21.3 m), two deck panels can be bolted together.
2. Bay sizes should not vary from floor to floor, so as to avoid modification of the
forms. In high‐rise buildings where bay sizes changes are inevitable, bay widths
should remain constant for at least 6 to 8 floors.
3. Columns and/or walls should be aligned to avoid adding shims. The addition of
shims reduces the carrying capacity and adds more time for installing and removing
of the jack bracket system.
4. Cross beams between intermediate columns should be avoided.
Tunnel Formwork System

The use of tunnel forms in North America is a relatively new process, but has been seen in several
cities in Europe for a number of years. The growing popularity of the tunnel forms can be attributed
to the high productivity that results in constructing buildings that have repetitive concrete rooms
using tunnel forms. With the walls and slabs being cast monolithically, separate vertical and
horizontal formwork systems are not required.

System Description

Tunnel forms come basically in two

different shapes: full and half. Full‐
tunnel systems are all‐steel
formwork used for rooms that are
relatively square in shape. Half
tunnel is an L‐shaped all‐steel
formwork system that is set by crane,
then another half‐tunnel form set
separately adjacent to the previous
half. The two halves are then Tunnel formwork system – Courtesy of Symons Corp
connected together to form an
inverted U‐shaped tunnel form. The half‐tunnel system allows for greater flexibility in room sizes
by simple addition or replacement of centre fill panels. Half tunnels are simpler, lighter and faster in
use than full tunnels.

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The tunnel formwork system consists of:

• Deck panel. The thick steel skin used to form the ceiling and floor of each module
• Wall panel. Also made of a thick steel skin, used to form the walls between two adjacent
modules
• Waler and waler splices. Stiffer deck and wall panels to minimize deflection due to concrete
lateral pressure
• Diagonal strut assembly. Used to provide additional support for the floor slab and keep walls
and floors perpendicular
• Taper tie. Wall tie between forms of two adjacent tunnel, keeps forms in place while
concrete is being placed
• Wheel jack assembly. Allows labourers to move tunnel forms over short distances, and also
allows cranes to pull out a collapsed form after concrete has cured

Typical Work Cycle

1. Starter Slab and Wall

2. First Cycle
3. Steel Reinforcement Placement
4. Form Placement
5. Concrete Pour
6. Stripping

7. Second Cycle Raising the tunnel form

Advantages of Tunnel Formwork

Cost: The initial cost for a formwork

system may be deceiving when one is
controlling the cost of the forming
process. The initial cost for purchasing a
set of five or six tunnel forms is be much
higher than the cost of conventional
forms, the all‐steel formwork construction
allows the number of reuses to be
anywhere from 500 to a 1000. This allows
the contractor to reuse the forms on
similar projects, thus reducing the costs
for each use of the forms. Once the forms Typical two‐way cycle
begin to wear and deteriorate,
rehabilitation of the forms can be accomplished.

Construction Time

Labour Force: an experienced foreman can quickly turn relatively unskilled labour into skilled
tunnel operators. This allows less expensive labourers to be used for other construction activities
and can greatly reduce cost without sacrificing quality.

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Flexibility

• The forms can be designed for

different sized rooms.
• The preassembled forms require no
make‐up area.
• The all‐steel forms with fewer joints
and ties provide an excellent
concrete finish with little deflection.
• The tunnel forms can be reused 500
to 1000 times.
Typical two‐day cycle with an end wall
• Windows and doors can be easily
moved from floor to floor.

High Quality

Safety

• Since they are preassembled in a factory setting, the system should have predictable strengths
and quality assurance.
• The forms are not dismantled between lifts, and thus remain the same as when first used.
• Guard rails are provided at the slab edges.
• Supervised craning operations provide safety below.
• Workers positioning or stripping forms underneath are secure due to the all‐steel and rigid
tunnel form system.

Modular Consideration for Tunnel Formwork

Before the work cycle begins, the formwork designer must select the appropriate size and
type of tunnel form. The overall dimensions of any tunnel form can be modified by simply adding
fit‐in sections (fillers). To increase the height, fit‐in sections are added to the lower section of the
walls, allowing the height to vary anywhere from 7.5 to 10 ft. (2.29 to 3.04 m). The span of the
tunnel form can also be varied by adding a fit‐in section in the centre of the deck, allowing the span
to vary from 13 to 24 ft. (3.96 to 7.32 m). As for the length, the standard dimension is 8 ft. (2.44 m),
but tunnels can be coupled to form varying lengths.
A majority of the reduction in construction cost and duration can be attributed to the
standardization of building modules. The design begins by selecting a bay size that will be repeated
time and time again. Because the design will dictate whether the tunnel forming method can be
used, the construction process must be closely analysed, organized, and coordinated from start to
finish. This will ensure that construction can proceed with a minimum of labour, and over the
shortest duration.
Consistency and simplicity are the easiest ways a designer can substantially reduce
construction costs. Maintaining constant dimensions for the different structural elements unifies
the project and allows for tunnel forming systems to be adapted. The repetitive room layout
assures that the workers can increase productivity based on their learning

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Limitations

The use of tunnel formwork is limited by specific design requirements. During the design phase of a
project, the type of formwork should be determined. Without early consideration for a standard
repetitive design and planning, the economic benefits of tunnel formwork cannot be achieved.
There are also additional limitations that must be considered.

• High initial make‐up cost.

• Requires extensive crane time.
• Requires high degree of engineering supervision.
• Takes workers a couple of cycles to become familiar with system.
• Used mainly for buildings with repetitive rooms.
• Large and different shaped rooms may be difficult.
• Site must be accessible since forms are large.
• To make the initial costs worthwhile, there should be at least 100 rooms.
• Can be used only on rooms with flat plate construction.

Joist Slab Formwork System

Joist slab system was developed to reduce dead weight and reinforcement of an RC slab compared
to designing it as a solid slab. As desired spans increase, the efficiency of solid slab construction is
rapidly offset by the increase in the dead load, hence, the joist slab system replaces the solid slab
with a monolithic combination of regularly spaced ribs and a top slab arranged to span in one
direction or two orthogonal directions. This enables the engineer to provide the depth required for
adequate stiffness and efficient utilization of the reinforcement without excessively high dead load.

The formwork for a joist slab system is mainly composed of standard size reusable forms which are
placed above the sheathing of the conventional formwork to
shape the ribs.

For one way joist slabs, the one way steel pan (Lap pan)
system is probably the most efficient. The typical lap pan is a
16‐gauge or a 14‐gauge piece of sheet metal, 3 feet long, bent
into one of three traditional shapes with varying flange widths
dependent on style and supplier, with both ends open.
One Way Joist Slab System

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To install the lap pan system, the following general steps are followed:

• A chalk line on the sheathing of the conventional form should be used to align the pans.
• End caps are placed first and work proceeds toward the center of the member from both
ends
• Pans are overlapped until proper closure is achieved.
• Flanged pans are nailed into position.
• After the pans are tightly in place, they should be oiled before other trades proceed with
their work.

Typical Pan Shapes

The normal procedure for setting pans is to set the end caps first, nailed to the deck form on the line
where the coffer begins. A long section of pan is first placed over the end cap. Then, through pre‐
punched matching holes in the top flange of the end cap and the top surface of the pan section, nails
are dropped in to form a bond between the form sections. This connecting procedure assists in
preventing the end cap from collapsing inward under the pressure of concrete placing. The pan
section is then nailed in place and a free standing steel or wood diaphragm (internal brace) is
inserted into the form and nailed in place. The next pan section is then installed, reasonably lapping
(1 to 5 inches) the previous section and the previous procedure is repeated until the coffer is
completely formed. It should be noted that all pans may require diaphragms to resist lateral
pressures. The soffits of all steel pans should be strengthened with some type of permanently
attached internal brace, the most common of which is a welded sheet metal angle at least of the
same gauge as the body of the pan.

Procedure for setting pans

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 JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – Horizontal Formwork Categories

Layout for Joist Slab Formwork

Dome Forming System

For two‐way joist slabs (Waffle Slabs) another type of reusable units is used rather than the metal
pans for one‐way system. The same principle of creating voids in the concrete slab to shape the ribs
applies, however, since the ribs here span in two perpendicular directions, the used units are in the
shape of domes which are placed at equal spacing (equal to the thickness of the ribs) in both
directions. The material for the dome can be plastic or fibreglass.

Dome unit Setup

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JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – Horizontal Formwork Categories

Pouring Concrete Stripping Formwork

Waffle Slab

17
 J
JBLDG – Sprin
ng 2011 [HO
ORIZONTAL FORMWOR
RK] – Slab Fo
orm Design

Slab Form
F Desiign
The basicc elements foor an elevated d slab formwwork are:
ƒ Sheathing
S
ƒ Joists
J
ƒ Stringers
S
ƒ Shores
S
ƒ Wedges
W
ƒ Mudsills
M
Joists an
nd stringers are designed as a systeem of main
and seco ondary beam ms, as the jo oists rest onn stringers.
Design ussually starts by first seleccting a cross section for
the elemeent sand then n calculatingg a correspon nding span.
An integger or modu ular value is usually seelected for
spacing.

D
Design Loads

Vertical Loads Horizontal Loads

L

Such as:
Deaad Loads Live lo
oads Sesmicc
Wind

Design Steps
The stepss in the desiggn of forms too support concrete slabs include the following:
f
1. Determmine the total unit load on n the floor deecking, includding the effect of impact, if any.
2. Select the
t type of floor decking, along with its i net thickn ness.
3. Determmine the safee spacing of floor
f joists, based
b on thee strength orr permissiblee deflection of
o the
decking.
4. Select the
t floor joists, considering the load, type,
t size, an
nd length of joists.
5. Select the
t type, sizee, and lengths of stringerss, if required d to support the
t joist.
6. Select the type, size, length, an
nd safe spacin ng of shores, consideringg the load, thhe strength of
o the
stringers, and the safee capacity off the shores.

18
 JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – Slab Form Design

Size, Length, and Spacing of Joists

The selection of the size, length, and spacing of the joists will involve one of the following:
1. Given the total load on the decking, the spacing of the joists, and the size and grade of the joists,
determine the maximum span for the joists.
2. Given the total load of the decking, the size and grade of the joists, determine the maximum
spacing of the joists.
3. Given the total load on the decking, and the size and the span of the decking, determine the
minimum size joists required.
For practical purposes, the selected span is rounded down to the next lower integer or modular
value.

Stringers and Shores

The joist span selected will be based on the spacing of the stringers. We can follow the same
procedure that is used for analyzing joists. Again, an integer or modular value is selected for
stringer spacing. After calculating the stringer spacing, the span of the stringer is checked against
the capacity of the shore. The load on each shore is equal to the shore spacing multiplied by the load
per unit foot of the stringer. The maximum shore spacing will be the lower of these two values
(based on joists loading or shore spacing). In calculating the design load of stringers, we do not
consider the effect of joists on stringers. Instead, as a good approximation, we calculate load
transmitted directly from sheathing to stringers.
Hence, it is necessary to check for crushing at the point where the joists rest on stringers. Finally,
shores are designed as columns (compression member). In checking the capacity of the different
elements of the form, we use the same equations that will be used in the analysis of the wall form
design. These equations are shown in the following table:

Type One Span Two Span Three Span

Bending Moment M=WL2/96 M=WL2/96 M=WL2/120
(in.­lb)
Shear (lb) V=WL/24 V=5WL/96 V=WL/20
Deflection (in) ∆=5WL4/4608 EI ∆=WL4/2220 EI ∆=WL4/1740 EI
Notation: L= length of span (in.); w = uniform load per foot of span (lb/ft); E =modules of elasticity (psi);
I=moment of inertia (in.4).

Usually the most economical design of forms results when the joists are spaced for the maximum
safe span of the decking. Likewise, reasonably large joists, which permit long spans, thus requiring
fewer stringers, will be economical in the cost of materials and in the cost of labor for erecting and
removing the forms.
The use of reasonably large stringers will permit the shores to be spaced greater distances apart,
subject to the safe capacities of the shores, thus requiring fewer shores and reducing the labor cost
of erecting and removing them.

19
 JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – Criteria for Choosing Hz Formwork

Criteria For Choice of Horizontal Formwork

Selecting the formwork system for cast‐in‐place reinforced concrete slabs is a critical decision that
can affect cost, safety, quality, and speed of construction. Many factors must be considered for the
proper selection of the formwork system. Among these are:

1. Factors related to building architectural and structural design, which include slab type
and building shape and size
2. Factors related to project (job) specification, and schedule, which includes the speed of
construction
3. Factors related to local conditions, which include area practices, weather conditions, and
site characteristics
4. Factors related to the supporting organizations, which include available capital, hoisting
equipment, home‐office support, and availability of local or regional yard supporting
facilities

Building Design(Slab Type)

The construction cost of slabs is often more than half the cost of structural framing systems, except
in extremely tall buildings. Therefore, selection of the slab formwork system deserves considerable
attention to minimize cost. The selection of a formwork system should be made on the basis of the
selected floor system that satisfies the structural loading conditions. Types of Floor slabs mainly
divided into two main categories, one way slab and two way slab.

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 JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – Criteria for Choosing Hz Formwork

Building Shape
Special buildings such as industrial buildings and power plants usually have extensive
electrical and mechanical requirements which do not lend themselves to any sophisticated
formwork system.
As a result, they should be constructed using the traditional formwork method.
Some of the factors that enable the contractor to decide whether to use a formwork system or a
traditional forming method are:
1. Variation of column and wall location
2. Variation of beam depth and location
3. Variation of story height
4. Existence of blockouts and openings for windows and doors
5. Extensive HVAC requirements

Speed of Construction
The most important advantage of using a formwork system is the speed of construction. The
speed of construction affects cost because it determines the time when the building will be
available for use and also reduces the financial charges. The major factor that determines the speed
of construction is the floor cycle time.

Local Conditions
The nature of the job, including local conditions, is one of the primary factors in formwork
selection. Some of the factors that should be considered are explained below.

Area Practice
In geographic areas where the labor force is expensive and unskilled, the use of formwork
‘‘systems’’ can substantially reduce the cost. In areas where the labor force is inexpensive and
skilled, a conventional formwork system is an economical alternative even if the building features
are compatible with a sophisticated formwork system. As a result, some geographic areas use
preassembled formwork systems because of the lack of inexpensive skilled labor force.

Site Characteristics
The building site itself may influence the selection of a suitable forming system, because of
site limitations and accessibility for construction operations. The feasibility of using flying forms,
for instance, is influenced by site characteristics, which include:
1. Accessibility to the site.
2. Availability of a fabrication area.
3. Surrounding area restrictions such as property lines, adjacent buildings, power lines, and
busy streets. In open and unrestricted suburban sites, all forming systems are practical and
some other considerations should be evaluated to determine the most efficient and cost‐
effective system. In downtown restricted sites, the only possible system may be ganged
units that can be transferred from floor to floor.

21
 JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – Criteria for Choosing Hz Formwork

Supporting Organization
Most of the crane‐set formwork systems (i.e., flying form, column mounted shoring system, and
tunnel), require high initial investment and intensive crane involvement. The major resource
requirements that should be carefully evaluated when deciding upon a forming system are
discussed below.

Available Capital (Cost)

The cost of concrete formwork is influenced by three factors:
1. Initial cost or fabrication cost, which includes the cost of transportation, materials,
assembly, and erection.
2. Potential reuse, which decreases the final total cost per square foot (or per square meter)
of contact area.
3. Stripping cost, which also includes the cost of cleaning and repair. This item tends to
remain constant for each reuse up to a certain point, at which the total cost of repairing and
cleaning start rising rapidly.
In deciding to use a specific formwork system, the initial cost should be evaluated versus the
available capital allocated for formwork cost. Some formwork systems tend to have a high initial
cost, but through repetitive reuse, they become economical. For example, slipforms have a high
initial cost, but the average potential reuse (usually over 100) reduces the final cost per square foot
(or per square meter) of contact area of this alternative. In the case of rented formwork systems,
the period of time in which the formwork is in use has a great effect on the cost of formwork.

Hoisting Equipment (Cranes)

Some formwork systems require special handling techniques, which can include a good
crane service. The flying truss system is a good example of crane influence on the selected system.
The size of the flying modules may be limited by the crane carrying capacity and its maximum and
minimum lift radii.

Supporting Yard Facility

The feasibility of using prefabricated forms such as flying formwork is largely influenced by the
availability of a local or central (regional) yard facility. When a local or central yard facility is
available, the standard formwork elements can be manufactured and assembled under efficient
working conditions. However, the cost of transporting form sections to the site may influence the
economy of the selected system.

22
 JBLDG – Spring 2011 [HORIZONTAL FORMWORK] – References

References

1. [Link]
md_100_63%5Bd16d3fabed64d156b173e48fe9de40b4%[Link]

2. [Link]

3. [Link]
Pg/s1600/IMG_6648_2.jpg

4. [Link]

5. [Link]
scaffold-shanghai-aluminum-scaffolding-amp-shoring-co-ltd_B1557164-
[Link]

23