What exactly is formwork for? A formwork system is used in the building industry to envelope the concrete during casting and contribute to the grip and hardening, that is the two phases the material passes from the fluid to the solid state and develops the mechanical characteristics necessary to perform its function.
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The invention of formwork dates back to the early days of our civilization’s construction activities when building materials were much simpler, such as clay.
People have always used formwork to build more or less complex structures, but it is only in recent decades that studies, techniques and materials have enabled us to develop advanced tools.
Over the construction sector you may find a number of different systems designed to meet different market demands and specific needs: formworks for walls, floors, curved walls, pillars and special designs.
In turn, formworks can be categorized according to the materials they’re made of – wood, metals or plastic compounds – and the technology they use: frame, beam and modular.
Frame formworks are composed of a panel and a perimeter, aluminum or steel as it may be, which guards and protects the edges from mechanical stresses. They stand out for their robustness and consequently for their reusability and durability over time. However, they are also easy to assemble thanks to the predefined mounting diagrams.
Beam formworks are composed of planks that support the deck and are adaptable to any project and ideal for surfaces without imperfections when the surface finish of the concrete required is “fair-faced” (béton brut). The assembly is more complex than frames with longer times, but it is also an alternative characterized by higher load capacity and high flexural strength.
Circular formworks are a very versatile category of systems consisting of pre-assembled standard modules that allow you to quickly assemble circular walls with any radius of curvature as happens with ramps, silos, tanks and purification plants.
Special formworks are tools made according to a specific project, where the dimensions fit right in the construction site as needed and more formwork systems can be integrated with each other to enhance their functionality.
The formworks can also be classified for the main function they offer, generally in formworks for vertical structures and formworks for horizontal structures.
Formworks for vertical structures, often also called wall formworks, are solutions adaptable to every need, construction site condition and use to create walls, pillars, elevator shafts, batteries, pulvini, bridges and foundations.
Condor wall formworks are: Comax, large panel for any use, Optimo, practical and manageable formwork, Adatto ALU, modular and versatile formwork, Haliform, ideal for the casting of foundations, walls, pillars and beams, O-ROUND, formwork for curvilinear walls, circular metal formwork for the casting of pillars and columns, Beam Flex formwork, modular beam formwork that allows any type of configuration.
In addition to these solutions, the MF ramp system and the OMNI earth-retaining system must also be included to be combined with different types of formwork to meet more complex construction site needs. Earth-retaining systems can be assembled following different combinations and used with wall formworks in particular for the casting of single-sided walls.
The SRC-240 rampant support system is a quick and safe solution for casting on a higher level and when structure heights become challenging it can be an affordable alternative to propping towers.
Formwork for horizontal structures, or even slab formworks, are structures designed with the aim of supporting the concrete casting for the slab construction and generally consist of horizontal supporting structures, on which the cladding panels are placed in contact with the casting, which transfer the loads to an underlying support system.
Each formwork in the Condor range is absolutely safe, characterized by manageability, modularity and high quality finishes. Our slab formworks are expertly designed to offer greater safety on site and allow construction companies and designers to get excellent results, reduce costs and processing times.
Our slab formworks are Aludeck and Aluplus, modular aluminum formworks, manageable, and therefore transportable without the need for cranes, which allow early disassembly with consequent positive effects on processing times and costs.
20 Flex is an affordable system consisting of props, fork heads and wooden beam frames on which panels are fixed. It requires few elements and, thanks to the free design, is adaptable to any shape, height and thickness.
The Eco System for free-designr slabs offers the possibility of early disassembly, drastically reducing time. It consists of a few elements, adaptable and can be integrated with different panels depending on the degree of finish of the concrete required.
Multiportal is a table system with a pre-assembled structure that is particularly affordable and ideal in the case of large slabs or for the realization of repetitive plans that require simplicity and functionality.
ECON, CEP 10, CEP20, CEP30, D55, ALU CP props complete the offer of Condor slab systems. Handy and versatile, they cover heights ranging from 1.80 to 6 meters and can be used in conjunction with the main systems in the range.
The choice of the most suitable formwork system for your business or single construction project is determined by a number of factors to be considered carefully and professionally: budget and costs, size of the company, number of uses expected, characteristics of the project, type of construction and conditions of the construction site, desired finish, experience of the workers, crane availability, time.
The following is something you should consider prior to commissioning any project:
It is best to always bear in mind every and all formwork types while in the design phase so that you can make the best and most valid decision.
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In a nutshell, formwork is the mold wherein fresh concrete is poured and formed. The mold, which can be permanent or temporary, holds the poured concrete and shapes it until it solidifies and becomes strong enough to support itself and other loads.
Formwork is also known as “shuttering.” However, in certain parts of the world, shuttering refers to using plywood or timber to create the mold.
Formwork systems can be classified according to the following parameters:
Construction costs usually consist of building materials (ca. 45%), labor (ca. 45%), and operating expenses (ca. 10%). Formwork material comprises 15% of the total building material and contributes roughly 44% of the total labor. Meanwhile, formwork construction accounts for up to 25% of the total cost of building the structure. For this reason, many builders and construction companies prefer reusable forms (panel forms). The process of removing formwork is called “stripping.”
As the name suggests, column formwork is used in the construction of circular or rectangular columns. Columns have formwork sections with a “closed load transmission,” which is supported by the formwork’s design and the guaranteed tensile strength rather than by using ties.
Steel formwork is often used to form circular columns as it is economical and available in incremental dimensions. Single-use forms, which are destroyed and disposed of during stripping, can be used as an alternative. However, using single-use formwork is not advisable if you need to construct multiple circular columns.
Meanwhile, rectangular columns are formed using three systems depending on their specifications. For instance, classic timber girders with steel walers and a plywood facing are often used when builders need to construct a significant number of columns with special dimensions. The windmill system, which is composed of columns or multipurpose panels of frame formwork systems, is suitable for building single columns with a standard dimension.
Finally, a foldable column formwork is highly suitable for columns with great heights. Because all the essential components (panels, connecting devices, ladders, and access platforms) are integrated into this type of column formwork, it helps builders reduce their construction time and costs.
Wall formwork comes in different types and classifications, as outlined below.
Conventional
Conventional wall formwork consists of boards or sheets and squared timber. It is flexible, but it can be costly and time-consuming as each component must be assembled on-site. In addition, all of its parts should be made according to the project’s specifications, and they must be nailed together and dismantled again after concreting.
Girder
This is a better version of the conventional formwork. Its components, which usually consist of dimensionally stable girders with two chords and one web, have been standardized to facilitate the assembly of identical and ready-to-use panels. The connection of the panels has also been systematized.
Frame
This type of wall formwork helps reduce labor time since its essential components (forming face, support for forming face, and steel walers) are assembled as one panel. The profile nose of the frames protects the edges of the forming face, thereby extending its lifespan. Connecting devices are used when assembling the frame panels to large-sized units, which are then usually transported by crane.
Crane-independent (hand-set)
This type of formwork can be moved by hand. Because of weight considerations, it is usually made of aluminum or plastic. It can take less concrete pressure than crane-dependent formwork, and is often used in housing and municipal construction projects.
Crane-dependent
Crane-dependent formwork systems feature a large frame and formwork panels, usually made of steel. As a result, they cannot be moved manually. Since they can resist more fresh concrete pressures than crane-independent forms, they are suitable for the construction of commercial buildings and other extensive infrastructure projects.
Two-sided
As the name implies, two-sided formwork is erected on both sides of the wall. Its formwork ties, which are usually sleeved by spacing plastic tubes so they can be reused, take up the fresh concrete pressure. Push-pull props or large heavy-duty braces are attached to the formwork to align and secure it against wind loads during operation.
Single-sided
Single-sided formwork is used when the concrete has to be poured against existing structures or when builders need to do concreting against a hill or soil. This is why it is most suitable for reconstruction jobs. With this type of formwork system, concrete pressure is transferred from the formwork to the base plates through a support structure.
Prefabricated
This formwork consists of two prefabricated concrete panels which are assembled in advance, and then transported and filled with concrete on-site. Braces and push-pull props are often used to secure the walls, while working and safety scaffolds are installed with the help of special adapters to make the construction process more cost-effective. Prefabricated formwork helps minimize project duration and labor costs. However, pre-planning is required to ensure that it is transported safely to the site.
Circular
Circular formwork is designed for the construction of curved and polygonal walls. It is also quite useful in the construction of specific concrete structures, such as septic tanks and car park ramps. This formwork system comes in three different types:
Climbing
Climbing formwork is quite useful in the construction of high-rise concrete structures, such as control towers and skyscrapers, because it climbs with the wall. It comprises large wall formwork mounted to a climbing scaffold. There are three different types of climbing formwork:
MEVA is an industry leader offering a wide variety of wall formwork systems that provide highly efficient shuttering, flexibility, and reliability. Our products are lightweight and easy to assemble, and therefore will facilitate the rapid completion of your construction projects. Click here to learn more.
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