Formwork A guide to _ good practice iN N concrete society EBX TGFormwork A guide to good practice 2nd Edition 1995 The First Edition was prepared by a joint committee of the Concrete Society and the Institution of Structural Engineers The Second Edition was prepared by a Working Party of the Society’s Construction Group which is one of the specialist technical groups within the Technical Development Centre. The membership of the Working Party is shown on pages iii and iv.Acknowledgements ‘The Concrete Society gratefully acknowledges the contribution made by members of the ‘Technical Group for Construction and in particular Eur Ing PF Pallett in the preparation of this edition ‘The Concrete Society also wishes to express its gratitude to all those participating organisations and individuals who have assisted in the preparation of the guide, and in particular to The West Midlands Region of the Conctete Society, The Institution of Structural Engineers, Mr IR, Hart, Mr D.E, Creasy, Rapid Metal Developments, Tony Gee and Partners, Tarmac Construction Holdings Ltd., GKN Kwikform Ltd, Expamet Building Products Ltd ‘Alfted McAlpine Construction South Region Lid, the National Association of Scaffolding Contractors, and the University of Birmingham. ‘The Committee also thank all those who supplied the photographs included in this guide, ‘Many organisations have taken advertising space in Appendix H and The Concrete Society ‘expresses its gratitude for the support given to the guide by the inclusion of these advertisements, ‘The Data Sheet in Appendix E is reproduced from CIRIA Report 108, Concrete Pressure on Formwork, by permission of the Director of CIRIA. I is also available from CIRIA in laminated sheet format as Special Publication 39. Concrete Society Special Publication CS030 ISBN 0946691 525 © The Concrete Society 1998 ‘The Concrete Society No.3, Batongate 112 Windsor Road. Slough, Berkshire SL1 JA United Kingdom Further copies may be obtained from Publication Sales, The Concrete Society All rights reserved. Except as permitted under current legislation no patt of this work may be photocopied, stored in a retneval system, published, performed in public, adapted, broadcast, transmitted, recorded or reproduced in any form or by any means, without the pror permission of the copyright owner. Enquiries should be addressed to The Concrete Society Although the Concrete Society (limited by guarantee) does its best to ensure that any advice, recommendations or information it may give either in this publication or elsewhere is accurate, no liability or responsibity of any kind (including liability for negligence) howsoever and from ‘whatsoever cause atising, is accepted in this respect by the Society its servants or agents Note on photographs: The Committee recognise that some photographs may show breaches of current safety regulations but the photographs have been retained in the guide to illustrate particular items of interest, Readers should also note that all Concrete Society publications referenced in Section 9 are ‘subject to revision from time to time and should therefore ensure that they are in possession of the latest version, Graphic design by Keating Industrial Design, 3 Courtside Road, Coolhurst Road, London NB EW ‘Typeset and printed by The Chameleon Press Limited, 5. wis 4sc Burr Road, Wandsworth, London w concrete societyMembers Chairman and Convener for ‘nd Edition: Secretary Ist Edition: 2nd Edition: Editing: ‘2nd Edition Section (st Edition) Members: (st Edition) Corresponding (st Edition) Eur Ing PF. Pallet, BSc, CEng, FICE, FCS ‘Temporary Works Consultant RI Ward ‘Tarmac Construction Engineering Services MJ. Walker, JP, CEng, MICE, FIHT, FCS ‘The Concrete Society K. Croft BSc(Eng) DW. Levering (Sections Two and Three) Rapid Metal Developments Limited Eur Ing BF Pallet (Sections Four and Five) ‘Temporary Works Consultant PR. Luckett, CEng, MIMechE (Sections Six and Seven) (Retired) Chant Formwork Limited Dr JE, Ash, BSc, PRD, CEng, MICE ‘University of Birmingham Bur Ing D.A. Biddlecombe, CEng, MICE GKN Kwikdorm Limited IN. Clatke, BSo(Tech) E & EN. Spon Limited Eur Ing DK. Doran, BSc, DIC, CEng, FICE, FiStructE, MSocIS Private Consultant AB. Hall, BSo(Eng), FIWSe Finnish Plywood International LR. Hart, Eng, MIET, FISMM, FCS Consultant DJ. Irvine, BSe, CEng, FICE ‘Tilbury Douglas ple Rev. M, James, CEng, MiswuctE, MICE Health and Safety Executive FOL Lane Sir Robert McAlpine & Sons Limited LDG. Lee, BSc, FIWSc (Retited) Chipboard Promotion Association BH, North, CEng, FICE, FisuructE, FIT, FWeld! Kennedy Henderson Limited LA. Partridge, CBE, ARA, FRIBA Howell, Kilick, Partridge & Amis GW. Richards, BSc, CEng, MICE, MistructE (‘etired) Alired McAlpine Construction Limited 1G. Richardson, FIMt, FICT Precast Concrete & Quality Consultant HW. Skeemer Primepiot Limited GE True, HNC Mech Eng, MICT TBY. Stangers D.A. Warrior, BA(Dunelm) Pilkington Reinforcements Limited AS. White (Retired) Scaffolding Great Britain Limited IR. White, BA (Oxon) Cordek Limited MA, Williams, BSo(Eng), CEng, MICE, MIHT, MIOSH Health and Safety Consultant CJ. Wilshere, OBE, BA, BAI, CEng, FICE ‘Consultant LE Withers, CEng, MIMechE (Retired) Timber Research & Development Association Dr TA. Harrison, PhD, BSc, CEng, MICE, FICT British Ready Mixed Concrete Association J. Melville, BSc, CEng, MICE (Deceased) Baliour Beatty Scotland Limited. D, Maher QR Systems Limited RE Roberts, BSc, CEng, MICE, FCS ‘The Concrete Society Advisory Service concrete society ui)Corresponding DE. Creasy, MA, CEng, MICE Members: (@nd Edition) ‘Consultant IRE. Comish, CEng, MistuctE SGB Youngman RW. Dunkley, BSc, CEng, MICE Laing Civil Engineering AB. Hall, BSc, FIWSe Finnish Plywood International Dr C. Hampton, BSc, PhD Richard Lees Steel Decking Limited Dr TA. Harrison, PRD, BSc, CEng, MICE, FICT British Ready Mixed Concrete Association LR Han, IEng, MIET, FISMM, FCS Consultant PM. Hesford, BSc, CEng, MICE Balfour Beatty Construction Northern Limited. Rev. M. James, CEng, MistructE, MICE Health and Safety Executive MN. Jones, BSc, MBA, CEng, MICE, CDipA(F) Rapid Metal Developrients Limited RJ. Lucas ‘Amec Civil Engineering Limited A.L, Neviton, MCS ‘Newton Formwork Design Limited MCL. Owen Hammond Concrete Testing Services G.Rabbitts, CEng, MIMechE Expamet Bullding Products Limited J, Rendle, BSc(Eng), CEng, MICE ‘Construction Consultant 1G. Richardson, FIMt, FICT Precast Concrete & Quality Consultant EN. Rowley, FICE, FCIArb, MConsE, ‘Tony Gee and Partners DE. Thorley Consultant RI Ward ‘Tarmac Construction Engineering Services DJ. Wilson, BSc, CEng, MICE CIS Construction Products Limited ww) concrete societySummary ‘his guide has been prepared to promote good practice in the design, specification, construction and safe use of formwork for both insitu and precast concrete. It contains information for the economic and safe design of wall fomwork used in both building and civil engineering construction. When used for the design of soft Jonmwork the guide is intended to bbe read in conjunction with BS 8975, Code of Practice for Falsework The guide assumes that formwork will be designed by persons with the relevant design and practical experience. The guide gives information for the building design team, the planning supervisor, for the contractor as well as for the sub-contractor and supplier. Wall formwork for a motorway pier at a railway crossing on the M42 motorway concrete societyContents Section One - General LL Introduction 1 12 Scope a 13° References a 14 Definitions and Abbreviations a 18 Symbols 5 16 Eoonomics of Formwork and Falsework 6 161 General 1.62 Influence of the Permanent Works Designer (PWD) 1.63 Influence of the Temporary Works Designer (TWD) Section Two- Preamble to Design 21 General 8 22 Parties tothe Design. 9 221 Permanent Works Designer (PWD) 222 Contractor 223° Sub-contractor 224 Supplier of Specialist or Proprietary Equipment 23 Safety 10 24 Formwork Specification 12 241 General 242 Specification by Method or Performance 28 Finishes 13 251 General 252 Classesof Finish 283 Class, Basic or Rough’Board Form Finish 254 Class F2, Plain and Normal Finish 285 Class F3, High Class Finish without Ties 286 Class F4, Fine/Iigh Class Finish 237 — Class FS, Fine/High Class Finish 238 Fair Worked Finish 289 Spacial Surface Finishes 2510 Enhanced Durability Finishes 26 Tolerances % 261 General 262 Wall Formwork 263 Soffit Formwork 264 Column Formwork 27 Deflection Limits and Cambers 8 28 © Sampleand Trial Panels 6 29 Formwork Designer's Brief 6 Section Three ~ Materials and Equipmer 31 General 2 31.1 Permissible Stresses 312 — Materialsas Form Facing 32 Timberand Wood: based Materials 0 321 Timber 32.1.1 General 32.1.2 Permissible Stresses for Solid Timber 32.13 Structural Properties for Solid Timber 322 Wood-based Face Contact Materials M4 322.1 Sawn Board Formwork 322.2 Plywood and other Sheet Materials 3223 Structural Properties of Sheet Materials 3224 Design Factors concrete PREVIOUS PAGE IS BLANK ) society (wi)33 Metals 331 Steel 332 Expanded Metal 333° Aluminium 34 Plastic, Rubber and Fabric a7 341 General 342 Foamed and Expanded Plastic 343 Glass Fibre Reinforced Plastic (GRP) 344 Polypropylene 348 Rubber 348 Plastic Sheet 347 Fabric 348 — Contolled Permeability Materials 38 Cement-based Materials C7 381 Concrete 352 Glass Fibre Reinforced Cement (GRO) 353 Fibre-reinforced Cement Sheet 354 — Wood Wool 36 Proprietary Equipment 85 361 General 362 Basic Panel Systems 363 Road Forms 364 — Tableforms and Flying Forms 365 Apartment Formwork Systems 366 Slab Support Systems 367 — Waffleand Trough Moulds 368 Adjustable Floor Centres 369 Adjustable Telescopic Steel Props 3610 Soldiersand Walings 3611 Columnand Beam Clamps 37 Permanent Formwork Co 371 General 372 — Materials 31.3 Composite Floors with Steel Decking 38 FormTies B 381 General 382 Assessment of Loads 383 Load Capacity of Recoverable and Non-Recoverable Components 384 Load Transmission 388 Safety Precautions 386 Elongation of Ties 387 — Anchor Ties 388 Hanger ‘Ties 39 Reinforcement Spacer Systems 6 310 Surface Treatments ® 3101 General 3102 Release Agents 31021 Selection and Uses 310.22 Classification 31023 Face Contact Materials 31024 Ste Work 3103 Surface Retarders 3104 Other Associated Treatments, 311 Ancillary Materials and Items a 3111 Void Formers 3112 Hole Formers 3113 Grout Checks, Sealing Grooves and Feature Strips 3114 Box-outs| 3118 Chamfersand Fillets 3116 Formwork Tapes and Foam Strips 3117 Castin Components 312 FormLiners 8 3121 General 3122 Materials 3123 Controlled Permeability Formwork itt) concrete societySection Four-Loadings 41 General % 42 Self-weight of Formwork 3 42.1 Materials 422 WallForms 423 Sofft Forms 43° Imposed Loads 4 431 Permanent Works Loads 432 Construction Operations Loads 44° Concrete Pressures, 8 441 General 442 Parallel Sided Forms 443° Nor-parallel Sided Forms 444 Underwater Concreting 445 Expanded Metal Formwork 48 Environmental Loads 103 481 Wind Loads 452 Snowand lee Loads 46 Horizontal Loads 105, 461 General 462 — Minimum Stability Force - Walls Section Five - Design 5.1 General Design Considerations 107 5.11 Responsibility of Formwork Design Organisations 512 Checking of Formwork Design 813 Deformations 5.131 Deflection by Elastic Movement 8132 Creep 5.133 Moisture Movement 3134 Thermal Movement 5.185 _Stressing Movement 814 Formbiners 818 Stability 818 — Factorsof Safety 517 Design Concept 82 Wall Formwork 13 821 General 522 Double Face Formwork 5221 General 5222 Parallel Sided Formwork 5223. Non-parallel Sided Formwork 523 Single Face Formwork ut 5231 General 5232 Externally Strutted Formwork 8233 Cantilevered Formwork 8234 Dam Formwork 824 — Curved Wall Formwork 528 Striking Vertical Formwork 53 Sofftand Beam Formwork ee 831 General 532 — Nominally Level Sofits 833 Inclined Sofits 128 8331 General 8332 Inclined Sofit without Top Form. 5333 Inclined Sofit with Top Form 534 Cantilever Sofits 133 838 Beam Formwork 536 Striking Beam and Sofft Formwork 137 5361 General 5362 Striking Procedure 5363 Quantifying Concrete Strength 8364 Accelerated Curing concrete society @®54 Backproppingand Repropping 541 General 542 Backpropping 543° Repropping 88 Column Formwork 581 General 562 Erection 58 Special Applications 861 Arch Formwork 562 Domes, Shells and Folded Plate Formwork. 863 — Underwater Formwork 87 Construction Joints S11 Getieral 812 Vertical Stopends to Walls and Beams 513 Vertical Siopends to Slabs 514 Horizontal Joints in Walls, Beams and Thick Slabs 518 Construction joint Positions 5316 — Movement joints 58 Watertight Construction 881 General 582 — Water Bars and Waterstops 59 Mechanical Handling of Formwork on Site 891 General 582 Lifting Beamy/Spreader Beams 893 Slings 894 Hooks 588 Shackles 898 Chain 587 — Eyebolts 588 C'Hooks Section Six~ Special Formwork 61 General 62 Travellers 63 Formwork for Tunnels 631 General 622 Telescopic Tunnel Formwork 64 Incremental Launch Construction 63 Slip Forms 66 Moulds for Precast Concrete 861 General 662 Tiltup Moulds 663 Gangand Battery Moulds 664 — Moulds for Prestressed Concrete 664.1 Posttensioned Concrete 8642 _Pre-tensioned Concrete 665 Heated Moulds 67 Stairs and Staircases 68 Titup Construction Section Seven - Work on site 1 General 12 Workmanship 13 Supervision 14 inspection and Checking 18 Salety 781 General 752 Accessand Working Platforms 3 a 48 180 183 134 189 160 182 184 168 167 m m 173 13 173 174 18 wo concrete society76 Vibration of Concrete 161 General 762 — Intemal Vibration 163 External Vibration 11 Sariking Procedures Section Eight - Recommendations 81 Further Research 82 Training Section Nine References Section Ten - Bibliography Appendix A - Common Failures of Formwork ‘Appendix B - Typical Loading Cases Part One ~ Single Span Members Part Two - Continuous Members on Multiple Spans Appendix C- Worked Examples of Formwork Design Cl Double-faced wall formwork: C2 Square column formwork C3 Bridge deck soffit formwork CA Inclined double-faced wall formwork Appendix D- Worked Examples of Backpropping DI Four storey car park slab backpropped through to foundations D2 Mult-siorey car park slab backpropped three storeys D3. Office slab backpropped one storey D4 Flat slab structure, flying form, backpropped two storeys D3_—_Flatslab structure, as D4, backpropping two storeys, Appendix E- CIRIA Concrete Pressure: Data Sheet (Repnin of CIRIA Special Publication 39) Appendix F - Organisations and Addresses 118 178 179 180 181 191 198 194 197 209 210 221 231 231 281 252 283 284 255 288 280 262 ‘Appendix G-- Structural properties of Trade Associations’ and Suppliers’ Sheet Materials 255 ‘Appendix H- Advertisements for Specialist Formwork Materials, Equipment and Services 28 Index al concrete society cx)List of Figures Figure No. Page Wall formwork for a motorway pier at a railway crossing on the M42 Frontispiece’ motonray. 1, Example of an Fi finish toa caisson under construction on a Boating pontoon 16 2. Bxample of an F2 finish on a retaining wall using a proprietary panel system 16 3. Bxample of an F2 finish to the soffit of a bridge with an F3 sloping side and 7 precast parapet 4. Bxample of an F3 finish to the edge of @ highway bridge ila 8. Example of an F4 finish to a sample wail cast af the Cement and Concrete 18 Association in 1972 using plywood with a chemical release agent Photographed in 1976 6 Finish obtained from plain unsealed douglas-fir plywood with a chemical 1B release agent after weathering for twelve years 7. Finish obtained using @ proprietary rubber liner on a wall 19 8 Finish obtained using a GRP form liner with a chemical release agent, 19 (Subway to Gateshead elevated road) 9. Finish obtained using a proprietary high density polystyrene form liner with 20 Lactory applied special release coating ‘Special surface finish to a large wall atea with vertical and horizontal a profiling, (Carlsberg Brewery Northampton; Commendation in 1960 Concrete Society Awards) 1, Finish obtained using vertical grooving with edges subsequently hammered a 'o expose the aggregate 12, Finish obtained using vertical grooving with light bush-hammering to ribs al 18. Finish obtained using rough sawn’ boards with polyurethane sealer and 2 ‘chemical release agent 1M. Finish obtained from precast sculptured panel (cast face down) with insita a white cement concrete and Sawn board’ formwork. (Cathedral Church of SS Peter and Paul, Chifon Winner of 1974 Concrete Society Awards) 18, Finish obtained on insitu wal with a deeply point-tcoled finish 2 16. Composite sample or tril panel (hypothetical) we 1. Complex timber formwork for the spiral volute of a power station turbine Ey ‘block (photographed during the tral erection) ‘Shear stress diagram for a rectangular solid section 2 Direction of face grain (FO) either parallel or perpendicular to span for fat 4 ‘and curved sheet materials to Tables 9.10.11, 3 and G-W 20, Steel faced formwork (Sill walls to Thames Barrier) 6 21. Expanded metal typical details for use as siopends to slab formwork 6 22. “Aluminium walings in use on wall formivork 6 23. Gass fibre reinforced plastic formwork and the 32mm deep profiled finish 8 obtained Glass fibre reinforced plastic form liner used for the wall in Figure 8 8 Rubber form liner in use 0 Fabric material in use on repair of bridge pier 5 21. Open grid plastic material in use as @ contaminant material for concrete 31 surround t@ a manbale 28. Gass fibre reinforced cement permanent formwork between precast beams 54 (on roof of motorway tunnel on M28 motorway (Holmesdale tunnel) 29, Gass fibre reinforced cement permanent formwork as facade formwork to 4 sloping wall/sleb of a building 30, Typical proprietary steel panel formwork system 87 ‘Typical proprietary plywood faced panel formwork system 87 A tabieform system being moved using aC hook 9 A fying form system being moved 9 ‘An apartment formwork system in use ca Proprietary ‘quick strip’ sofit system of formwork with plywood face contact 61 material to fat slab 36. Proprietary slab support system incorporating a plywood panel system @ 32. Example of the FI finish obtained on the soft ofa car park using wafle forms 3 38. ‘Moulds in position on sofft formwork before concrete placing. Left showing 8 trough moulds, right with waffle moulds 38. Adjustable floor centres as soft support fo fat slab between downstand a ‘beam supports 40, Safe working loads of UK props «6 41. Proprietary soldiers on a tall wall with timber walings and plywood face. An eo ‘elastomeric form liner is used on the top part of the formwork 42, Proprietary soldiers and timber walings on a scmall wall 6 43. Timber formwork to column using column clamps 63 44. Precast concrete units as permanent formwork on a composite slab a 45. Stee! profile sheeting as permanent soft formwork 2 48. Examples of proprietary profile steel decking systems % 47, __Typical methods of restraining void formers fo soffit formwork 85 (ai) concrete sociely