What we will discuss

• Understand Different formwork systems

• Lessons learnt through hard way in different
formwork systems
FORMWORK Formwork is a die or a mould

including all supporting

structures, used to shape and

support the concrete until it

attains sufficient strength to

carry its own weight.

It should be capable of carrying

all imposed dead and live loads

apart from its own weight.

FORMWORK FACTS IN INDIA
 Formwork done using system formwork / engineered formwork is only
5% to 10%.
 Formwork cost constitutes 25% of the cost of concrete but involves
60% of the time.
 Advancements in formwork technology is limited as compared to
concreting & reinforcement.
GENERAL PERCEPTION ….
IN REALITY No
Safety
costs
more
money
SAFETY FACTORS - FORMWORK DESIGN & DETAILING
Loads  Lateral Pressure
 Vertical Loads
 Horizontal Loads
 Impact
 Incidental/Other loads
Others  Permissible stresses
 Condition of materials at site
 Site Conditions
 Methodology of Construction
 Uncertainties of loading and skill of workmanship
The formwork designer should have specialist knowledge and experience not
only in design, but also in detailing of the formwork.
Attention to be paid to the detailing of connections to ensure that any local
failure does not lead to a progressive collapse involving the entire formwork.
 VS

A Traditional approach to Steel Brackets : An Innovative

construction of Dome Portion of approach to Dome casting
Over Head Water Tank
MATERIAL SAVING
Tonnage Saved – 94 MT
Time Saved – 1.8 Months
Bracket Weight - 0.9 MT (10 Nos.)

12m High Staging over Steel Brackets

5m Brackets for Cantilever Slab @ Zuari Cements – 4.5m Cantilever Slab

FORMWORK ENGINEERING Larsen & Toubro Limited
ECC DIVISION – B&F BSCC
Advantages of Using System Formwork

Built IN Economical
Safety as Repetitive use
Speed
Quality Technology like reshoring /reproping
can be applied
Standard Schemes for optimum
Utilization of material
Less Skilled labour required at job site
 L&T - FORMWORK SYSTEM
H-BEAMS
CLIMBING WALL

FLEX
COLUMN

&
ACCESS BFS

STAIR HDT
FLEX
 HDT – Heavy Duty Tower

1) Tall staging heights and heavier loading, capacity of 250 kN.

2) Inclined decking is also possible using tower spindles on top.
3) Tower as a whole can be shifted (rolled) manually by attaching
transport devices to the legs.
 Large panel wall formwork system
• Fast track construction
• Minimum no. of joints
• Reduces grout leakage &
sheath
• Peal off / bulging of concrete
surface
• Reduces number of handlings
for required area
 WALL

ADVANTAGES
1) Movement of large Wall System in single unit with
crane.
2) Walls of height 7-8 m can be cast in a single pour.
 COLUMN

1) High strength tie System bear maximum concrete

pressure so that load bearing struts can be avoided.
2) In case of tall structures the column panels are erected
along with Climbing Formwork System .
Climbing formwork system-Traveling
• Modular system
• High adaptability
• Short shifting times
• High loadability
• Superb workplace safety

1st section 2nd section 3rd section upward

 CLIMBING

1) Any Height of Wall can be done without any support

from the bottom.
2) A inclination of +/- 15 Degrees is achievable apart
from straight.
B. SHIFTING TROLLEY FROM SLAB EDGE TO INSIDE NEXT PANEL FOR LOWERING THE TABLE

Table formwork system:

C. LIFTING THE HYDRAULIC TROLLEY TO HOLD THE LOWERING TABLE & SHIFTING TO SLAB EDGE

12MM THICK PLYWOOD

H20 TIMBER BEAM
TABLE HEAD

H20 TIMBER BEAM

Erection of table form panels

using tower crane

PROP
Table formwork
Floor forms used for Footings & Rafts
LIFTSHAFT FORMWORK
 Tunnel formwork system

Setting out of Tunnel

Application
 Tunnel formwork system
Lifting of porticoes
with the help of
crane
MOCK UP ASSEMBLY OF ALUMINIUM FORMWORK FOR
DDA PRIOR TO DESPATCH -
 Aluminium formwork system

Quick strip prop head allows quick strip of

deck panels (for reuse) leaving propping
undisturbed

Enlarged view of wall ties, pin & wedge

Applications of Slip form Pylons

Water tank
RAIL COLUMNS – HEW, HAZIRA
PROJECT APPLICATIONS
Moving
Formwork
Arrangement
 APPLICATION

SYSTEM
L&T- HEAVY DUTY TOWER SYSTEM
STRUCTURE
4 CELL TUNNEL
PROJECT
METRO CORRIDOR MC 1A - DMRC
 CASE STUDY 1

PROBLEM
Failure of H – Beams near the compression strut while lifting the
panels.
WallPW-20-95e
Formwork with safe working platform and compression strut
 40mm thick
Timber plank
as
compression
strut
Angle should
not be less
than 60º

Normal Lifting
Position
Recommended nail
location for fixing
compression strut
with H-Beam

Actual mistake done

at site while fixing
compression strut
with H-Beam using
Nail
PROBABLE REASONS
Using plywood instead of 40mm thick plank for the compression strut
Improper connection (nailing) of compression strut to H Beams
Lifting position or the inclination of slings.
Quality of H- beam
Improper connection between at the lifting bracket location.
ACTUAL REASONS

 Fixing of plywood instead of 40mm thick compression strut.

 Improper nailing at location of H –Beam to the plywood
 Included angle between the slings less than 60º

EFFECT OF THE PROBLEM

 Failure of the compression strut and total collapse of the panel.
 Lead to fall over the person under neath.
PREVENTIVE MEASURES

 40 mm thick Timer plank as compression strut.

 Nail connection between the H – Beam and the compression strut
 Included angle of the slings should not be less than 60º .
 Flange claw assembly at lifting bkt locations.
 CASE STUDY2

PROBLEM
Failure of Props in Slab Formwork.
PROBABLE REASONS
 Overloading.
 Design failure
Quality of the components.
Proper Connection between the components.
Proper lapping of H – Beams at the junctions.
ACTUAL REASONS

 Concrete heaping leading to overloading of few props.

EFFECT OF THE PROBLEM

 Buckling of props which results in failure.
 Leads to the accidents to the people beneath the slab.
REMEDIAL MEASURES

 Heaping of concrete should be avoided.

 Formwork should be implemented as per the scheme drawings and no
deviation is allowed.
 Any revisions or alterations should be conveyed to the design
engineers immediately
.
Table form work
 CASE STUDY3
PROBLEM
Failure of C Frame in Flex Table Formwork.
C Frame Failure due to heavy weight of the Tableform
Pin Location in C Frame

Broken Pieces of the Pin

 Table form work

PROBABLE REASONS
 Overloading
 Wrong usage of C Frame as per the scheme drawing issued.
Mis-alignment CG of the Flex table, C frame and the crane sling.
Proper Connection between the components.
ACTUAL REASONS

 Capacity of the C frame and weight of the Flex table.

 No proper inspection of the materials.

EFFECT OF THE PROBLEM

 Failure of the connection pin between the horizontal and vertical
profile.
 Tearing of the vertical profile in C frame.
REMEDIAL MEASURES

 Flex table should be designed based on the capacity of the C Frame.

 CG of the Flex table, C frame should be well balanced with the crane
sling.
 All the schemes should be implemented as per the scheme drawing.
 Proper inspection of the materials and components at regular intervals
before implementing at site.
 CASE STUDY 4

PROBLEM
Failure of Heavy Duty Tower System.

PROBABLE REASONS
Heavy Loading.
Verticality of the tower.
Missing components at its appropriate location.
Connection between Tower to Tower and permanent structure.
Deviation from scheme drawing.
ACTUAL REASONS

 Non usage of bracings.

 No tower to tower connections.

EFFECT OF THE PROBLEM

 Collapse of the Heavy Duty Tower system.
PREVENTIVE MEASURES

 Usage of all the components at its appropriate location.

 Proper bracing in and of the tower system.
 Implementation of the system as per the scheme drawings.
 Proper inspection of the materials and components at regular intervals
before implementing at site.
 Soil compaction before erection of the Heavy duty Tower system.
 Usage of concrete sills or the Timber planks above the soil.
Improper spacing of H - Beams
Shuttering / Deshuttering
 Victim fallen from this
Victim’s working Location
height
Collapse of Slab Shuttering – Slide 1 of 3
Collapse of Slab Shuttering – Slide 2 of 3

BROKEN PROPS

INTERMEDIATE PROPS
W/O NAILING
.
A PROJECT SITE AFTER ACCIDENT
Accident
happened due to
caving in of slab
connecting these
two pillars when
the scaffolding
below gave way.
Contd………..A PROJECT SITE AFTER ACCIDENT
Contd……….. A PROJECT SITE AFTER ACCIDENT
Contd……….. A PROJECT SITE AFTER ACCIDENT
 Ledgers

Swivel Clamps

Twisted swivel
clamp