What is the introduction of formwork?

Eiffel 101: Brief History of Concrete Formwork

Concrete formwork has been used since ancient times to shape and support concrete until it hardens. Early forms were simple but effective, making concrete construction faster and easier. Discover how this essential construction technology has evolved over the centuries in the article below:

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Ancient Rome

The earliest recorded use of formwork dates back to ancient Rome. Utilizing materials such as reeds and fiber, Roman builders could craft iconic structures like the Pantheon and the Colosseum. The success of their formwork techniques quickly spread worldwide.

Transition to Timber

Following the collapse of the Roman Empire, timber began to replace reeds as the primary material for formwork. Timber provided greater strength and water resistance, functions similarly to reed-based forms, and is still commonly used today.

Emergence of Fabric Formwork

Timber, while strong, lacked flexibility, which is where fabric formwork came into play. Popularized in the early 1900s, fabric forms offer both strength and flexibility, making them ideal for creating aesthetically sophisticated walls, pillars, and footings.

The Steel Revolution

Dramatic improvements in formwork occurred between the 1910s and 1950s, with steel emerging as a dominant material. Steel formwork could be reused multiple times and was first popularized in road construction. Its durability and efficiency made it suitable for large-scale projects such as bridges, tunnels, skyscrapers, and overpasses.

The Aluminum Era

In the 1960s, aluminum formwork emerged as a lightweight, cost-effective solution. It's still widely utilized today due to its affordability and ease of handling.

The Plastic Revolution

Entering the scene in the early 2000s, plastic formwork offered an affordable and flexible alternative, although it is less ideal for heavy-duty construction due to lower weight-bearing capabilities compared to steel and aluminum.

Modern Day

Today, professionals have a wide array of formwork options to choose from, including timber, fabric, steel, aluminum, and plastic. The ability to reuse steel and aluminum forms many times adds to their cost-efficiency, broadening the range of affordable options available.

The Future

The rich history of concrete formwork promises an exciting future. Innovations and advancements in this field will continue to be integral to construction projects, just as they have been for thousands of years.

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Formwork

Formwork consists of molds into which concrete or similar materials are either precast or cast-in-place. In concrete construction, falsework supports the shuttering molds. In specialty applications, formwork may be permanently incorporated into the final structure, adding insulation or reinforcing the finished structure.

Types

Formwork can be made of various materials including wood, metal, plastic, and composites:

1. Traditional timber formwork: Built on-site using timber and moisture-resistant plywood, it remains in use where labor costs are lower than the costs for procuring reusable formwork. It offers high flexibility even for complex sections.
2. Engineered Formwork System: Built out of prefabricated metal modules (usually steel or aluminum) and quickly assembled, providing faster construction and lower life-cycle costs compared to traditional timber formwork.
3. Reusable plastic formwork: Lightweight and robust, suited for variable but simple projects, especially in mass housing schemes. They offer protection against weather with galvanized roofs when necessary.
4. Permanent Insulated Formwork: Typically made from insulating concrete forms (ICF), this formwork remains in place after curing, offering advantages like speed, strength, and superior thermal insulation.
5. Stay-In-Place Structural Formwork: Made from prefabricated fiber-reinforced plastic forms, it stays in place after curing, acting as reinforcement and protection against environmental effects.
6. Flexible formwork: Employs high-strength fabric sheets to create optimized, architecturally interesting structures with less material, promoting sustainability.

Slab Formwork (Deck Formwork)

History

Roman engineers were among the first to build concrete slabs using compression-resistant designs like arches and domes. These early techniques paved the way for modern concrete construction, although widespread use came with the advent of Portland cement and reinforced concrete.

Traditional Slab Formwork

Traditional methods derived from masonry and carpentry used lumber and tree trunks to support the concrete. Boards or plywood were laid on these supports to form the slab.

Timber Beam Slab Formwork

This method replaces traditional supports with engineered wood beams and adjustable metal props, making it more systematic and reusable.

Metal Beam Slab Formwork

This method replaces traditional stringers and joists with aluminum or steel beams, offering similar systematic benefits and reusability.

Modular Slab Formwork

Prefabricated modules, usually no larger than 3 to 6 feet, are arranged and pinned, clipped, or screwed together. These systems do not require cranes and allow for fast construction with unskilled labor.

Table or Flying Form Systems

These systems consist of reusable slab formwork "tables" that are either lifted by crane or elevator to higher stories, reducing manual labor and time. These tables vary in size and material, with some supported by integral trusses.

Structure

Constructed similarly to beam formwork but connected to be transportable, these tables use plywood, steel, or fiberglass sheathing. They can be rectangular or various other shapes.

Support

Support systems are adjustable to ensure correct height placement and removal after curing. Metal props, trusses, or even attachment to previously cast walls or columns can be used.

Size

The size of table forms can range from 70 to 1,500 square feet. Larger tables are typically moved by crane, while smaller ones can be shifted using trolleys or elevators.

Tunnel Forms

Tunnel forms allow for casting walls and floors in one pour, making them ideal for buildings with repetitive designs. This method saves both time and costs.

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Concrete-Form Oil

The primary purpose of concrete-form oil is to reduce adhesion between the structure and concrete, minimizing the risk of cracks and chips. Without form oil, removing the formwork can damage the concrete.

Climbing Formwork

Also known as jumpform, climbing formwork is used for vertical structures and moves upward with the construction process. This method is suitable for repetitive designs such as towers and skyscrapers.

Flexible Formwork

With increasing focus on sustainable construction, flexible formwork made from permeable fabric sheets offers a low-material, architecturally interesting alternative. It is backed by research from organizations like the International Society of Fabric Forming.

Iron Sheet Formwork

Developed by a Russian factory, this design uses perforated iron sheets that can be bent to form curves, allowing for innovative shapes like cylindrical columns.

Usage

After concrete is poured and set, formwork is removed. The timeframe for this process depends on job specifications and usually takes at least 24 hours. Failing to properly design or remove formwork can lead to structural failures.

Concrete exerts hydrostatic pressure, so formwork must be designed to withstand these forces to prevent blowouts, especially at the bottom where pressure is greatest.

Permanent formwork can also serve as reinforcement for the concrete structure.

Gallery

• The concrete structure of the Royal National Theatre carries the impression of the timber shuttering

• Plastic concrete formwork for cross wall

• Coal tunnel constructed using handset aluminum concrete forms

• Concrete pool construction using aluminum concrete forms

• Soffit formwork to a flight of concrete stairs

• Stair formwork showing the use of strongbacks to support the riser shutters

• Sketch showing the use timber props for beam forms

• Coal silo construction using radius concrete formwork

• Twin steel walers and tie bolts used to secure wall forms

• Column poured using spiral ducting

• Concrete slab poured on roll-formed galvanized steel with the form as a permanent part of the structure

• Concrete fence construction using aluminum forms to impart an ashlar stone impression in the finished product

• Concrete housing construction in Venezuela using aluminum concrete formwork

• Concrete construction in Brazil using handset aluminum concrete formwork

• Concrete construction in Moscow metro using special aluminum concrete formwork

• Engineered formwork system in Moscow metro

• Engineered formwork system in Moscow metro

• Pool construction using "Proster 21" flexible formwork.

See Also

• Cast in place concrete
• Climbing formwork
• Concrete cover
• Precast concrete
• Slip forming

Literature

• Matthias Dupke: Einsatzgebiete der Gleitschalung und der Kletter-Umsetz-Schalung: Ein Vergleich der Systeme. 2010, Verlag Diplomarbeiten Agentur, Hamburg, ISBN 978-3-8386-0295-0.
• The Concrete Society, Formwork: A guide to good practice.

References

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