1

INTRODUCTION
Formwork is a mould or die used to shape and support the concrete
until it attains sufficient strength to carry its own weight. The formwork is a
kind of baking tin, which holds the concrete until it hardens to attain the
required shape and size.
SIGNIFICANCE
Formwork constitutes 30% of the cost and 60% of the time in concrete
construction.
Quality of concrete finish and soundness of concrete depends very
much on the formwork system.
Formwork should be properly designed, fabricated, and erected to
receive fresh concrete.
If formwork is not done properly the desired shape of concrete is not
possible.
When concrete is compacted, it exerts pressure and the formwork
must be strong and stable to take this pressure. The form should be
leak proof to retain the concrete & slurry.
Accidents happen because of faulty formwork and scaffolding/staging.
Proper care and attention to be paid at all stages of form work in
construction
TRADITIONAL APPROACH
The traditional practice is to use ballies as supports for shuttering. This
practice is labour intensive, many times unsafe and unreliable. It does not
produce good quality of concrete surface necessitating plastering and
rendering. The reuse value of these materials is also very low.
The choice of the right formwork system depends primarily on the
geometry of the structure, the frequency with which the components are

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likely to be used and the desired type of concrete surface. In addition, the
weight of the formwork is very important and it is to be set up without the
use of a crane.
SAFETY IN USING FORMWORK
Safety is ensured if
Components are light in weight for manual handling.
Loose or dangling / hanging components are minimal.
Minimum operations are involved in each reuse.
Individual components are self standing.
System facilitates fixing and removal at each location without the use
of sophisticated tools and tackles.
Usage of appropriate of tools
Erection and dismantling is done as per the procedure or methodology
Proper house keeping and stacking of materials
Inspection of materials condition before usage
Usage of appropriate PPEs
Training to new comers
TYPES OF PROPRIETARY SYSTEMS BASED ON COMPONENT
MATERIALS
All steel formwork
Generally lightweight structural steel sections or sheet bent profiles
are used as framework and steel sheets are used as sheathing. They are
strong and durable if prevented from rusting. They can prove economical

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since more reuses can be derived. However, as they are heavy, manual
handling and frequent shifting may consume excessive labour.
Steel and plywood formwork
Framework uses steel and plywood that acts as sheathing. Normally,
they are in the form of panels of standard sizes with provisions for fixing
with adjacent ones. These panels are supported by steel flexural members
(walers or soldiers), which are supported by form ties in wall formwork, slab
staging and beam formwork. By using some suitable rigid clamping
accessories among panels in wall formwork systems heavy steel supporting
flexural members can be eliminated.
Steel, plywood and timber beams
Plywood is used as sheathing. It is supported at regular intervals by
timber beams, which are further supported by steel flexural and axial
members. Plywood with timber beams as their immediate supporting
members have ample flexibility to suit a wide range of form geometry.
Timber beams are light in weight and more in number, whereas steel is used
where higher strength is required. Systems, in which the timber beams are
engineered, produce good cost effectiveness. L&T uses glue laminated
timber beams called H-beams, in most of its applications.
All Aluminium formwork
Panels use Aluminium in both sheathing and framework. If compared
with steel, investment cost is higher and strength is less, but it is lighter and
avoids rusting. However, it is susceptible to other corrosive attacks and
requires careful handling to prevent from mechanical deformations.
RELEASE AGENT
A release agent is required to prevent adhesion between concrete and
formwork.

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Release agent is coated on the form surfaces by brush, roller or spray
equipment before use.
Release agents are more commonly known as mould oils or soap oils.
As name implies, a release agents main purpose is to act as a parting
agent and permit the forms to be easily removed away from the
concrete during striking. This helps prevent damage occurring at both
form and concrete surfaces; a very important fact in concrete
construction. Certain release agents provide further additional benefits
such as sealing effect on absorbent timber or ply forms, which produce
more uniformly colored concrete. When smooth impermeable forms
are used they can help prevent the formation of blow holes on the
concrete face.
There are several types of release agents and surface sealers available.
These carry varying recommendations for use on different form
materials, which have smooth, textured or profiled surface finishes.
The engineer will decide the surface treatment to be used from the
previous experience of similar work. Where high quality of concrete
surface is required the supplier may be contacted for specialist advice
prior to construction commencing, sample panels may be cast on the
job to test performance.
TYPES OF RELEASE AGENT
The three main types of release agents are
Neat oils with surfactant
These are dark in color and consist of mineral oils of low viscosity with
small quantity of surfactant added. The surfactant increases the wetting
capabilities of the oil when applied to the form surfaces. Soap is a common
form of surfactant and its use as an additive in release agents help reduce the
formation of blow holes on the surface on the concrete. Neat oils with
surfactant are a general purpose release agent which are found particularly

5
useful for steel forms but may be used for all types of formwork surface
except plastics such as GRP or polypropylene.
Mould Cream Emulsions
These are milky white in color and consist of water and emulsifying
agents. Mould cream emulsion is an effective release agent and helps to
minimize blow holes. However it is only suitable for use on absorbent timber
or plywood forms. These generally need several coats of release agents to
seal the surface before they can be used for the first time. Emulsion type
release agents will freeze in winter conditions and also have a tendency to be
washed from form surface by heavy rain.
Chemical release agent
These are usually a light yellow brown in color and consist of very low
viscosity oil containing a small amount of chemical additive. After
application the oil evaporates leaving a chemical deposit on the surface of
forms. This reacts with the concrete on formwork to provide excellent
release qualities. Chemical release agents are recommended for all high
quality work and can be used on any type of formwork surface. They are
resistant to removal by rain and can be left for long periods before placing
the concrete yet still provide satisfactory release.

Application
Release agent should be applied with particular care and only coated
on the surfaces in a thin uniform film.
None must be allowed to come in contact with any reinforcement or
construction joints.
Careless excessive application is not only costly and wasteful; it will
stain and seriously affect the durability of concrete surface.
If too much is applied by mistake, the excess should be wiped off.


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Formwork Sealers
These are paints, varnishes, lacquers or other special impermeable
coatings, which are applied on form surface to improve their qualities.
Sealers are normally referred to as barrier paints. They cover the form
face and edges with hard protective coating producing a surface
resistant to abrasion and effectively sealed against moisture
penetration. This treatment greatly increases the life of forms.
Sealers are mostly used on timber or plywood forms to help produces
quality concrete surface which are uniform in both color and surface
appearance.
They must be applied only when the form surface is new, dry and has
not been previously treated with release agent. The most common type
of sealer is polyurethane resin; this is air drying with a clear to pale
yellow finish.
A minimum of two coatings must be necessary but the manufactures
instruction must always be carefully followed. When the surface
becomes damaged or scoured from concrete abrasion the forms must
be recoated. The forms must be prepared by removing all traces of
release agent with detergent and the surface roughened with glass
paper before resealing.










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FORM WORK DOS AND DONTS






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MATERIAL PRODUCTIVITY
COLUMN FORM WORK WITH CRANE
S.No Items Quantity Required
per Sq.m for Making
Material
Productivity
1 L & T steel in kg
134 KG
22.33 Kg month /
sq.m
2 H beams in Rmt
5.6 Rmt
0.93 Rmt month /
sq.m
3 Plywood in sq.m
1. 12 mm
2. 19 mm
1.1 sq.m 0.042
4 Timber in cft
0.20 cft 0.007 cft / sq.m

Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n =6 for L & T steel and H beams
N =25 for plywood, timber and structural steel.
COLUMN FORM WORK WITHOUT CRANE
S.No Items Quantity Required
per Sq. m For Making
Material
Productivity
1 L & T steel in kg
110 KG
18.33 Kg month /
sq.m
2 H beams in Rmt
5.6 Rmt
0.93 Rmt month /
sq.m
3 Plywood in sq.m
1. 12 mm
2. 19 mm
1.1 sq.m 0.042
4 Timber in cft
0.20 cft 0.007 cft / sq.m
Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n =6 for L & T steel and H beams

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N =25 for plywood, timber and structural steel.
WALL FORM WORK WITH CRANE
S.No Items Quantity Required
per SQ M For Making
Material
Productivity
1 L & T steel in kg
48.1KG
9.62 Kg month /
sq.m
2 H beams in Rmt
3.5 Rmt
0.70 Rmt month /
sq.m
3 Plywood in sq.m
1. 12 mm
2. 19 mm
1.1 sq.m 0.044
4 Timber in cft
0.18 cft 0.007 cft / sq.m
Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n =5 for L & T steel and H beams
N =25 for plywood, timber and structural steel.

WALL FORM WORK WITHOUT CRANE
S.No Items Quantity Required
per SQ M For Making
Material
Productivity
1 L & T steel in kg
68 KG
13.80 Kg month /
sq.m
2 H beams in Rmt
3.8 Rmt
0.76 Rmt month /
sq.m
3 Plywood in sq.m
1. 12 mm
2. 19 mm
1.1 sq.m 0.044
4 Timber in cft
0.18 cft 0.007 cft / sq.m

Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n =5 for L & T steel and H beams

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N =25 for plywood, timber and structural steel.
FLEX SYSTEM USING PLYWOOD AS SHEATHING.
(With beam form work by conventional)

S.No Items Quantity Required
per SQ M For Making
Material
Productivity
1 L & T steel in kg
22 KG
11.0 Kg month /
sq.m
2 H beams in Rmt
2.7 Rmt
1.35 Rmt month /
sq.m
3 Plywood in sq.m
1. 12 mm
2. 19 mm
1.1 sq.m 0.11 sq.m / sq.m
4 Timber in cft
1.17 cft 0.12 cft / sq.m
Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n = 2 for L & T steel and H beams
N =10 for plywood, timber and structural steel.

FLEX SYSTEM USING PLYWOOD AS SHEATHING.
(With beam form work by Beam forming support system)
S.No Items Quantity Required
per SQ M For Making
Material
Productivity
1 L & T steel in kg
22 KG
11.0 Kg month /
sq.m
2 Beam forming
support
12 Kg
4 Kg month /
sq.m
3 H beams in Rmt
2.7 Rmt
1.35 Rmt month /
sq.m
4 H Beams in Rmt
1.84 Rmt
0.92 Rmt month /
sq.m
5 Plywood in sq.m
1. 12 mm
2. 19 mm
1.1 sq.m 0.11 sq.m / sq.m
6 Timber in cft 1.17 cft 0.12 cft / sq.m

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Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n =2 for L & T steel, H beams and 3 for Beam
forming supports
N =10 for plywood, timber.
HEAVY DUTY TOWER SYSTEM USING PLYWOOD AS
SHEATHING.
(For 6 m Floor height or 5 m staging height below beams)
(With beam form work by conventional)

S.No Items Quantity Required
per Sq m For Making
Material
Productivity
1 L & T steel in kg
46.6 KG
46.6 Kg month /
sq.m
2 H beams in Rmt
2.0 Rmt
2.0 Rmt month /
sq.m
3 Plywood in sq.m
1. 12 mm
2. 19 mm
1.1 sq.m 0.11 sq.m / sq.m
4
Timber in cft 1.1 cft 0.11 cft / sq.m
Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n =1 for L & T steel and H beams
N =10 for plywood, timber.
For every 1 m increase in height of the tower add 7.5 Kg.

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HEAVY DUTY TOWER SYSTEM USING PLYWOOD AS
SHEATHING.
(For 6 m Floor height or 5 m staging height below beams)
(With beam form work by Beam forming support system)

S.No Items Quantity Required
per Sq m For Making
Material
Productivity
1 L & T steel in kg
46.6 KG
46.6 Kg month /
sq.m
2 Beam forming
support
12 Kg
4 Kg month /
sq.m
3 H beams in Rmt
2.4 Rmt
2.4 Rmt month /
sq.m
4 H Beams in Rmt
1.84 Rmt
1.84 Rmt month /
sq.m
5 Plywood in sq.m
1. 12 mm
2. 19 mm
0.97 sq.m
0.12 sq.m
0.061 sq.m /
sq.m
.008 sq.m / sq.m
6 Timber in cft
0.06 cft
0.004 cft / sq.m


Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n =1 for L & T steel and H beams
N =15 for plywood, timber.
For every 1 m increase in height of the tower add 7.5 Kg.


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FLEX TABLE FORM WORK SYSTEM FOR SLAB USING
PLYWOOD AS SHEATHING
S.No Items Quantity Required
per Sq m For Making
Material
Productivity
1 L & T steel in kg
51 Kg
25.5 Kg month /
sq.m
2 H beams in Rmt
(secondary
members only)
2.85 Rmt
1.43 Rmt month /
sq.m
3 Plywood in sq.m
1. 12 mm
2. 19 mm

0.97 sq.m
0.12 sq.m

0.061 sq.m /
sq.m
0.008 sq.m /
sq.m

Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n =2 for L & T steel and H beams
N =10 for plywood.
FOUNDATION FORM WORK USING FLOOR FORMS

S.No Items Quantity Required
per sq m For Making
Material
Productivity
1 L & T steel in
kg
1. 0.800 m
waler
2. 1.200 m
waler
130 Kg
136 Kg

16.25 Kg month /
sq.m
17.00 Kg month /
sq.m
Material productivity = Quantity required per sq.m for making
No. of cycles per month (n) or total number of uses
of the material (N) n =6 for L & T steel.


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ACCESS SCAFFOLDING

S.No Items Quantity Required per Sq m For Making
1

Doka steel in
kg

14 Kg

Two level working platform is considered using scdaffold platform.


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SAFETY IN FORMWORK
System formwork consists of a range of pre-engineered
components, which are used to make moulds or dies, to hold
concrete till it hardens to create the desired shape. About 200
formwork system components are used in various applications.
SAFETY ASPECTS IN FORM WORK DESIGN
The following safety requirements are in-built in the design of
Formwork System:
1. Adequate Factor of Safety for Formwork System and individual
Components.
2. Components are pre-engineered and every component has
design value.
3. Components can be inspected easily to check design adequacy
and acceptance criteria.
4. Consideration of concrete pressure and rate of pouring in
formwork design.
5. Formwork System is self aligning and self standing.
6. Easy to fasten accessories.
7. System integrated aligning and bracings.
8. Work-platform with handrails for the works at height.
9. Integrated climbing arrangements.
10. Sturdy components light in weight for easier handling.
11. System-integrated handles / lifting hooks for easier
handling.
PROCEDURE FOR THE USE OF FORMWORK
1. Procedures are established for all applications
2. Systems need not be compromised for different applications
3. System can be understood by traditional workmen with
minimum instructions

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4. Clear instructions, Dos and Donts, are available for Engineers,
Supervisors and Workers to understand the system well.
5. Part of workmen is trained at L&T-ECCD (CSTI) Training
Center.
6. Minimized deviations and mistakes due to established
procedures.

ERRECTION OF FORM WORK SCAFFOLD















1. Erection of two stages of scaffold is completed as shown in the
picture.
2. The Derrick is fixed to the scaffold as shown in above sketch.
3. Using the derrick, the items required for scaffold and work
platform are lifted for further erection.
200 mm
Mi i
1500 mm
Work-
l tf
Derrick
Trestle Scaffold Erection Procedure

21
4. The ladder secured to the scaffold is used for climbing up and
down.
5. Safety belt is used from second stage onwards.
6. Red Tag shall be provided to caution that the scaffold is under
erection.
WORK-PLATFORM








1. Every work-platform shall be provided with guardrails as shown.
2. Height of the guardrail shall be from 900mm to 1200mm.
3. Intermediate guardrail and toe-board are provided. Height of
toe-board should be minimum 100mm.
4. Scaffold boards shall be well secured without any ply.
5. Work-platform shall be provided with proper access, like a
ladder secured to the scaffold.





LADDER




Lifting Bracket
Ply
Al ignment
System
H-Beam
Work
Platform

Steel
Waler

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1. Ladder shall be of sound in construction having rungs equally
placed. Makeshift ladder shall not be used.
2. Ladder shall be secured to the scaffold as shown.
3. Ladder shall be extended at least 1m above the work-platform.
4. Horizontal distance between the base of the ladder and the
work-platform shall be of the height of the work-platform.
Dismantling of Scaffold











1. Scaffold dismantling area shall be cordoned and only skilled
workmen shall be used for this work.
2. The scaffold being dismantled shall be provided with Red Tag
to indicate it is unsafe to work on it.
3. Dismantled materials shall be lowered using Derrick and Pulley
arrangement.

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4. Each tier shall be completely dismantled and the material
lowered to the ground before beginning to dismantle the next
tier.
5. Dropping materials shall be avoided to prevent damage to
materials and injury to the workmen below.
6. While removing jammed or rusted scaffold components
workmen can lose their balance and fall. Hence, anchoring
safety belt to a scaffold frame or lifeline before attempting to
loosen stuck or jammed parts is essential.
7. At the end of the day, if a scaffold is going to left half-
dismantled, it is essential to lower all the loose scaffold
materials down and ensure that the scaffold is braced
adequately to the building.
8. All the dismantled materials shall be stacked in the appropriate
manner at the designated place.

SCAFFOLD INSPECTION AND TAGGING PROCEDURE
Erection / Dismantling of Scaffold
1. Erection of any scaffold shall be done only by the nominated
scaffolding gang under the supervision and guidance of
formwork engineer.
2. "Red coloured Tag" is fixed on the scaffold when it is under
erection / dismantling by the formwork engineer or by the
nominated foreman.
3. Once the erection is completed, Formwork Engineer or the
nominated competent foreman shall inspect the scaffold. After
inspection if the scaffold is found to be safe for use, the
formwork engineer / nominated foreman shall fix the Green

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coloured Tag replacing the red tags. The formwork engineer /
nominated foreman will fix the Green coloured Tag after signing
and writing the date.
Inspection of Scaffolding
1. All the scaffolding being used at site shall be re-inspected by
the form work engineer / nominated foreman once in a week.
Green Tags of the Scaffolding which are found safe shall be
renewed with date of inspection and signature of the Form work
Engineer / nominated foreman.
2. If any scaffold is found unsafe for use, formwork engineer /
nominated foreman shall place a red scaffold tag and stop the
usage of scaffold until rectification.
Extension and Alterations of Scaffolding
1. Any extension, alteration or shifting of scaffold (except in the
case of mobile scaffold) shall be done only by the scaffolding
gang under the supervision and guidance of the Formwork
Engineer.
2. When such work is being carried out in scaffold, a Red Scaffold
Tag shall be placed on the scaffold indicating the restriction in
use of scaffold only by the scaffold gang.
3. After carrying the works, the formwork engineer shall inspect
the scaffold and certify it safe for use by placing the green tag if
found safe. Else the red tag shall remain until rectification is
done.
Red Scaffold Tag
This tag indicates that the scaffold is under erection or
dismantling or has not been inspected or is not safe for use (by
anyone other than scaffold gang).

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Green Scaffold Tag
This tag indicates that the scaffold is complete & it has been
inspected by competent person and is safe for use. GREEN scaffold
tag is valid for one week from the date of last inspection.
" SCAFFOLD RED TAG" " SCAFFOLD GREEN
TAG"














PERSONAL FALL PROTECTION SYSTEM
Safety Belt / Full Body Harness
1. While working near edges or openings, safety belt should be
used to limit the worker's movement so that he is unable to reach a
location where there is a risk of falling.



X
Date of
Inspection:
Signature of Competent

Date of
Inspection:
Signature of Competent


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2. Safety belt should be used to protect a worker in case of a fall
while working in an elevation. It should be used along with lifeline, fall
arrestors wherever applicable.

Safety Belt/Full body harness:







They shall confirm to National or International Standards. The
length of the lanyard used shall be not more than 2 m.
Anchorage Point
The lanyard of the safety belt or lifeline should be anchored to a
structure capable of withstanding at least 2.5 tons.
Lifeline
20 mm diameter polypropylene rope shall be used a lifeline and
properly anchored to an anchorage point as mentioned above.
Energy absorber
It is an optional attachment used in conjunction with the lanyard
to connect the harness to the anchorage point. In case of fall it
reduces the impact energy passed on to the worker considerably by
absorbing part of the energy.

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Precaution
All fall protection equipment including Safety belts, Full Body
Harness, Energy Absorbers, and Lifeline & Fall Arrestors shall be
removed from service if they are subjected to impact load once.
Safety Belt / Full Body Harness with Double Lanyard
Double Lanyard safety belt shall be used by workmen to protect
from fall during vertical or horizontal movements. Usage of this belt
ensures that at any point of time one of the lanyards of the belt is
anchored.
Fall Arrestors
Rope Grab Fall Arrestor
Rope grab type fall arrestors shall be used to protect fall of
workers during vertical movement such as ascending or descending
Scaffold towers, vertical ladders etc.











Retractable Type Fall Arrestor
This type of fall arrestors shall be used in places where high risk
of fall of workmen persists. This fall arrestor can be directly anchored

28
to the anchorage or can be used in conjunction with a lifeline as
shown below.

SAFETY GUIDELINES FOR VARIOUS TYPES OF FORMWORK
FOUNDATION FORMWORK












1. Care shall be taken while lowering the components into the
excavated pit to avoid damage the components and injury to
workmen.
2. Formwork components shall be stacked at a Safe distance (at
least equivalent to the depth of Excavation) from the excavation to
prevent falling of the components and sand slide into the excavated
pit. Also over stacking of the components should be avoided.
FOUNDATION
FORMWORK

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WALL / COLUMN FORM WORK









1. Proper Slinging and Rigging Practices should be followed
while lifting the formwork assembly.
2. Strength and Location of lifting hooks on the formwork should
be checked.
3. No loose materials should be kept on the formwork panels or
platforms.
4. Panels should be pre-checked before lifting.
5. Tightening of tie rods.

COLUMN WALL FORMWORK

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FLEX SYSTEM FORMWORK










1. All the main props should be fitted with folding tripod
2. All the intermediate should be fitted with supporting head
3. Do not use reinforcement steel in place of locking pin.
4. In ground level work, proper earth compaction and necessary
bearing below the prop should be given.
5. Props should not be inclined. Verticality should be maintained.
HEAVY DUTY TOWER SYSTEM









FLEX SYSTEM
HEAVY DUTY TOWER

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1. Every 6m interval bracing should be fixed with permanent
structure or from one tower to the other.
2. Ground level earth should be compacted well for better loading.
3. Conditions of the components should be checked and the
damaged ones should not used.
4. Tor steel rod should not be used in place of lock pin.

STAIR TOWER













1. Ground level earth should be compacted well for safe loading.
2. Every 6m-interval bracing should be fixed with permanent
structure.
3. Old / damaged components should not be used.
4. Coir rope / binding wire should not used in place of M10 bolt
and Nut for fixing the gridiron with stair bracket.
STAIR TOWER

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5. Bracings and lock pins should not be omitted under any
circumstance.
ACCESS SCAFFOLD












1. Ground level earth should be compacted well for safe loading.
2. The system should be braced at every 4.5m height level with
the permanent structure.
3. Old / damaged components should not be used.
4. Coir rope / binding wire should not used in place of Platform
hanger
5. Bracings should not be omitted under any circumstance.
LIFT SHAFT FORMWORK
1. Proper Slinging and Rigging Practices should be followed while
lifting the formwork assembly.
2. Strength and Location of lifting hooks on the formwork should
be checked.
ACCESS SCAFFOLD

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FRAMED FORMWORK
3. No loose materials should be kept on the formwork panels or
platforms.
4. Panels should be pre-checked before lifting
5. Adequate space (gap) should be ensured before lifting the inner
panel platform
FRAMED FORMWORK - FRAMI












1. Tie rod should be provided only where provision is given.
2. No component should be omitted.
3. Frami adjustable strut 260 should be anchored properly.
4. This system should not be used for the works done at height
more than 4.2m.

CLIMBING FORMWORK
1. Platform timbers should be free from cracks, fungus, attack and
dead knots.
2. Handrails should be fixed.

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3. Stop anchor threaded length should be 35mm +or 5mm.
4. Platform should be free from gap between timber joints.
5. Check for proper engagement of climbing cone.












SLIPFORM
1. Earthing of the system and ELCBs for power supply
2. Lightning arrester
3. Aviation Light
4. Communication arrangement
5. Safety in RG Hoist and Winches
(a) Operator competency
(b) Limit Switches
(c) Signal & Alarm system
(d) Maintenance of wire ropes
(e) Fleet angle between 0.5
0
to 1.5
0
for plain drum; for
grooved drum not more than 2
0

(f) Condition of Brake
CLIMBING FORM WORK

35
(g) Barrication of the wire rope way and cross over if
required
(h) Roller for the wire rope between first diversion pulley and
the winch
6. Bracing of access tower at every 6m height
7. Handrail and toe board in the platform
8. Safety nets to trap the falling materials
9. Wind protection cloth
10. Protective shed
11. Adequate illumination
12. Proper tightening of hardware
13. Fire Extinguishers
14. Workmen entry register
MIVAN FORMWORK


MIVAN FORM WORK

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1. Scaffold brackets should be in good condition and have not
been damaged since the last installation.
2. Work-platform should be decked out and toe-board and
handrails should be installed.
3. Penetration holes in the slab for transferring panels should be
covered when not in use until cast with concrete.
4. Nails should not be left on the work platform.
5. Pins and wedges should be removed with care, especially on
the external of the building.
6. Component of Formwork should not be stacked on the work
platform.







37
FORM WORK PLANNING
PLANNING PROCESS
The planning process is divided into three stages.
First stage
The necessary information and limiting conditions must be
collected and defined. When projects of similar nature are executed,
a checklist can be of immense help in obtaining information required
to prepare a complete scheme. Important information for planning
includes the time and materials available for the construction project,
the construction plans (geometry of the structure), and any other
special criteria as mentioned by the client. Limiting conditions may be,
for example, whether a crane can be used, or whether formwork
materials can be stored on the site.
Second stage
The formwork system to be used can be selected. In addition to
cost of the materials, the choice of the system will be influenced by
the experience of the planner and of the team, which has to set up
the formwork on the site, and by the project archive. A database /
project archive that captures the experience gathered over the years
can aid in cost effective system selection. Also, the interaction
between the planner and the formwork crew is vital in the successful
implementation of any scheme prepared. Once the decision has been
made, stage 3 of the planning process comes into force.
Third stage
This involves all engineering design tasks. This part of the
process is most time consuming. It is important to be able to allow for
changes arising at later phases of the project. A large number of

38
construction projects involve standard shapes and geometries for
which ready-to-use formwork can be used in its as-delivered state.
Planning is limited to showing arrangement of elements from the
chosen system. The emphasis should be on maximum reuse of
materials available and procuring minimum materials J ust-In-Time.






Available
time
Availabl
e
Constructi
on plans
Customer
requireme
Limiting
conditio
Evaluation of information
Choice of system
Customer
requireme
Customer
requireme
Customer
requireme
Project
archive
Execution
Structur Formwor
Formwork
with
Additional aids
Statics
Work
preparation
sheet
Project archive

STAGE 3
STAGE 2
Planning process

39
BENEFITS OF PLANNING
An increase in efficiency due to improved formwork planning
can be an important way of raising the level of competitiveness.
Important rules in formwork planning are:
Rule 1: When placing the formwork, dont forget to think of how
it is going to be removed.
Rule 2: A tidy site is also a safer site.
Rule 3: Sketches and clear layout plans can save work for
operatives on site.
Rule 4: Storage space costs money, in much the same way as
formwork materials lying around unused.
Planning is only one of the aspects of Formwork Management.
Planning becomes incomplete in relation to the total job when there is
no efficient system to implement the planned activities. Formwork
Management should address the following issues as well:
Mobilization of materials
The requirement of Formwork materials should be indicated by
the site to their Regional Office. The Regional Office will take into
account the requirements or releases from other job sites in their
region and if materials are required to be added from outside the
region the same will be intimated to Head Quarters Formwork
department.
Implementation guidance
During the execution of formwork, engineers should take
interest and give guidance in planning the arrangement and
correcting the abuses / misuses of materials. They should also ensure

40
that the materials are utilized to the full extent. Attention has to be
paid to prompt deshuttering of materials by keeping track the
concreting dates and curing time. This contributes towards the
increasing of the material productivity. Care should be taken to see
that the material procurement does not exceed the initial planned
quantities.
Demobilization
J ust as the requirement schedule was made in the beginning of
the project, the release schedule should be made towards the closing
stages of the job. For any large mobilization, the program should be
made three months in advance and informed to Regional Office and
Head quarters. Demobilization affects the planning of materials for
new projects, sometimes, unnecessarily leading to addition of new
materials.
Upkeep, maintenance
Repairs and maintenance of Formwork items is to be done by
the dispatching site. Unfortunately there are many occasions where
neither the dispatching site nor the receiving site takes up this work
resulting in unusable material lying stacked at sites.
Accountability of materials
Apart from losing materials due to abuse and rough handling,
accessories / small items are also lost due to bad housing and lack of
upkeep and maintenance. Every site towards the closing stages
should reconcile the materials receipt with dispatches and stock to
access the reduction in physical stock if any.
Training

41
It is important to disseminate information / knowledge to all staff
and labour on the job. The training of the staff and workmen can be
organized at the site level itself. For any additional help the site can
approach the Regional Office and Headquarters.

42
FORM WORK COSTING
ESTIMATING COST OF FORM WORK
The cost of formwork consists of the cost of
Materials
Labour for making Formwork
Labour for erection and dismantling
Repair of formwork
Labour for transporting, shifting materials
Plant and equipment used for making, erection,
dismantling, repair and transport
Cleaning and storage costs
Transportation costs
MATERIALS
Usually this is a major component of the total cost of formwork.
Material can be classified as
Direct materials
They are the main component of form work eg. Timber,
steel etc.
Consumables
Nails, shuttering oils etc. are treated as consumables.
The cost can be computed as
Total Rmt months used x Depreciation / Rmt/ month
Shuttering Area

Cost per sq.m of
timber beams

43
Total Ton months used x Hire charges / Ton/ month
Shuttering Area

Usually the first method is used for materials with short life like
timber and plywood and second method is used for materials with
long life like steel and metal components.
COST REDUCTION
The key areas of the cost reduction are
Right system for the right job
Considerable savings result when the appropriate system is
used for the job in hand. Several times the system best suited for the
job is not selected and hence the project may not be completed
profitably.
Planning for maximum reuse
Specification or local code requirements for stripping and
reshoring are an important factor in planning form reuse. Maximum
investment in forms is achieved by constructing the least number of
forms required for a smooth workflow and then reusing these forms
as often as necessary until the job is completed.
Economical form construction
When non - reusable forms are to be built in position on the job,
the planning should be such that inexpensive materials are used
which are easy to transport, handle and shape in the field.
Reusable forms must be more durable, made of strong
materials that can withstand continuing and usually must have added
features that make them easy to handle and to assemble.
Cost per sq.m of
steel =

44
In choosing ties or inserts, the initial cost is not as important as
the labour involved in their installation and form striping.
Efficient setting and stripping practice
The full benefit of a plan for reuse of forms can only be realized
if the forms can be stripped and re-erected without too much lost time
and if the form is not wrecked in the process. Therefore, designing for
easy handling and disassembly is essential.
OTHER COSTS AFFECTED BY FORMWORK PLAN
Crew efficiency
Advance planning eliminates confusion and delay in the field,
where it is most costly. Where maximum reuse of forms if
emphasized every operation must be scheduled precisely to sustain
effective continuity of employment of craftsmen on site.
Concreting
The ease and speed of placing concrete is related to the
planned sequence and to some extent to the choice of form design.
Bar setting
If form design can enable the reinforcement to be pre-
assembled before installing, it may enable the reinforcing crew to
work under more favorable conditions.
Cranes and hoists
One object of planning should be to use cranes and hoists
efficiently so that there are just enough on a project to keep the work
going smoothly.


45
FCCE
FCCE is responsible for the following activities of L&T-ECC division's
projects:
1. Planning for FW material requirement for the projects
2. FW material mobilization within the region to project sites and
region to region
3. Monitoring and controlling the FW cost for each project
4. Execution of FW activities at project sites as per the Scheme
drawings and Work Instructions
5. Maintenance and re-conditioning of FW material stock available at
regional depots and sites
6. Execution of slipform, pre-stressing and grouting activities at sites
including material procurement.
QUALITYASSURANCE PROCEDURES
The Quality System is documented in a three tiered structure as
follows:
1. Quality Manual
Quality manual specifies the management responsibilities and
authority within the quality management system and identifies the
company requirements in addressing the various elements of ISO
9002:1994
2. Quality System Procedure
Quality system procedures are used to control the functioning
and organization set-up in each department. They define the

46
responsibilities and authorities within the department and cover
functioning arrangements.
3. Work instructions, Quality control procedures, Quality assurance
plans, Drawings and Specifications
These documents are used to control activities at work
locations. The preparation, approval and issue of these documents
shall be the responsibility of the concerned department head.
Internal quality audits are conducted to verify whether quality
related activities and related results comply with planned
arrangements and to determine the effectiveness of the Quality
System.
VALUE DRIVERS
In order to meet the corporate management requirements and
as well as for improvements in business, some areas of improvement
have been identified. The specified improvements are named as
"VALUE DRIVERS". A committee identifies these value drivers with
the targets for the department. The value drivers are targets to be
achieved by each individual in the department as assigned by the
department head. The results shall be periodically reviewed by the
Head of the department.
ROLES AND RESPONSIBILITIES

1. Preparation of Formwork programme based on the overall
construction programme
2. Finalization and coordination of shuttering scheme
3. Ensuring effective and proper utilization of shuttering and staging
materials

47
4. Planning and allocation of materials / labour / plant and machinery
for formwork activities in coordination with concerned persons at
site
5. Educating sub-contractors on System Formwork
6. Making mock-up of various System Formwork
7. Periodical reconciliation of Formwork materials
8. Preparing S6 A schedule (Requirement / Release) and sending
the same to Regional office
9. Preparing stock statement of formwork materials both in units and
in numbers, with area of shuttering done category wise, plywood /
timber procured during the quarter / till date and productivity report
10. Maintain close interaction with stores and site people for proper
accounting of materials
11. Despatch and receipt notes to be sent to Regional Office
12. Making of purchase requisition for plywood and timber after
thoroughly analyzing the number of repetitions
13. Receipts of plywood / formwork materials to be acknowledged
after quality checks to Regional Office on monthly basis
14. Arranging for painting of bracing's ends as per prescribed colour
code
15. 100 % materials reconciliation at the end of the job
16. Looking after pre-despatch maintenance
17. Ensuring that despatched materials are in usable condition.