Formwork refers to the mold used in construction, specifically the casing into which casting material, typically concrete, is poured to achieve the desired structural shape.

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In the construction industry, formwork functions like a mold to cast concrete members into various shapes and sizes using different materials such as timber, steel, aluminum, and plastic. Shuttering is a synonymous term used for formwork. Formwork must possess sufficient strength to support both dead loads and live loads during the casting operation and subsequently, until the concrete hardens and achieves a percentage of its design strength.

Formwork serves as a system to support the plastic state of concrete, maintaining its shape until it gains sufficient strength to support its own weight.

Some modern techniques involve not removing formwork, referred to as stay-in-place formwork or lost-in-place formwork.

Definition of Formwork

According to standards, formwork is 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.”

Thus, formwork serves as a temporary mold into which concrete is poured and formed. It can be arranged either vertically or horizontally to maintain concrete in position until it gains sufficient strength and desired shape. Additionally, formwork is a system comprising props, staging, and shuttering components.

Functional Requirements of Formwork

1. Erection and Release

Formwork must be designed and constructed to allow for removal in parts or a planned sequence without damaging the concrete surface or disturbing adjacent sections, preventing the collapse of the formwork system. The connections between various formwork components should facilitate easy removal during formwork stripping.

2. Ease of Inspection

Once the formwork is ready, inspection is the next step. Typically, the site supervisor calls the site engineer to inspect the completed formwork.

Thus, the formwork system should provide adequate and safe access to all areas for easy inspection.

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3. Shape and Size

The formwork must be erected to ensure that the shape and dimensions of the concrete structures conform to the drawings, specifications, and tolerances. Chamfers and beveled edges, if specified, should be included in the forms. For instance, if planning to construct a curved wall, the shuttering material should be flexible enough to achieve the required curvature.

4. Finish

The formwork must be robust enough to withstand activities such as reinforcement fixing, pouring and vibrating of concrete, and the removal of forms without sustaining damage. Additionally, the sheathing materials used must provide the desired finish to the concrete structure.

5. Reuse and Number of Repetitions

Formwork should be designed and planned to allow for maximum reuse and repetitions, thereby reducing the costs of concrete and labor. When using plywood as sheathing/shuttering material, proper usage is crucial to ensure higher repetitions.

Summary

The essential requirements of formwork include:

1. It should have the strength to handle dead loads, live loads, incidental loads, and other expected loads during construction until the concrete reaches its strength.
2. The joints in the formwork must be rigid to prevent bulging, twisting, or sagging under load.
3. The construction lines in the formwork must be true and the surface plane as flat as possible to minimize finishing costs.
4. The formwork should be easily removable without causing damage to itself or the concrete.
5. Ease of inspection must be provided.

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