The quality and durability of column formwork is determined by the material you select for the project. If you have a say in column formwork selection, put some effort into researching material options. Choose wisely and the labor will be easier, the structure will be sounder and your client will be happy with the end result.
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Whether you work for a construction company, supplier, manufacturer or other related business, your choice of formwork material has a ripple effect throughout the entirety of the project. The efficiency and overarching success of the project is largely shaped by your choice of material, systems and equipment used for installation.
Each unique formwork material has specific advantages. Some materials are ideal for specific construction needs while others are better for on-site conditions and nuanced client requirements. Choose wisely and your formwork will provide sufficient load-bearing capacity that supports the hefty weight of concrete without faltering. Such structural integrity is fundamental to the project’s success.
The right material also provides dimensional stability to prevent distortion and warping when subjected to concrete pressure. Favor light material for formwork and you’ll find it is easier to handle during installation. The best formwork material is also leak-proof, providing comprehensive security.
This is your guide to the different materials used for construction formwork projects, highlighting their nuanced merits and also some of their weak points.
Concrete formwork is commonly used for columns as it is strong, durable and nearly indestructible. Reinforced concrete is especially sturdy. Whether the columns necessary for your project are small, midsize or large, you cannot go wrong with concrete. Sweat the small stuff during the installation process to prevent concrete formwork failure and this reliable material will provide solid support for decades to come.
Timber is light in weight and more malleable than most assume. Choose timber for your formwork and you’ll be able to alter both height and size to your exact specifications. Timber is also appealing as it is affordable. However, timber isn’t as efficient as other materials for expansive projects.
Moreover, if flexible formwork is required for elaborate concrete poured onto the site, timber is not the optimal material choice. One final caveat: if you elect to proceed with timber as your selected material, double-check it to guarantee it is not laden with termites.
Formwork of the permanent insulation variety is concrete with polystyrene boards serving as the insulation and additional support. The purpose of insulating the formwork is to improve the energy efficiency of the structure. Polystyrene boards boost the structure’s energy efficiency while simultaneously enhancing fire resistance. The material is also highly resistant to invasive rodents. Shop around and you'll find advanced material options provide a plethora of additional benefits including fireproofing. Moreover, permanent insulated formwork dampens sound vibrations.
Plywood is a manufactured wood material often used in combination with timber for a cohesive formwork system whole. Plywood is lightweight, durable, structurally sound and also features a smooth surface with an aesthetically pleasing finish
The plastic formwork system features interlocking components often referred to as modular components. If you are working on a relatively small project that requires repetitive formwork, plastic might be the best material. Plastic is lightweight, has an attractive surface finish and is cleaned with ease. The primary shortcoming with plastic formwork is it is typically prefabricated, meaning its flexibility is inherently limited.
A project that requires durable and strong formwork that can stand the test of time should be built with steel or aluminum. Though these metals are typically more expensive and heavier than other materials, they minimize honeycombing, generate a smooth concrete surface and can even be used for curvature. If you prefer formwork that is light in weight, opt for aluminum over steel. If strength is the primary concern, choose steel.
Formwork that stays in its current position is carefully designed to remain in place after concrete fully cures. Stay-in-place material bolsters reinforcement along with shear and axial strength. The stay-in-place variety also helps minimize environmental damage and corrosion.
If your project requires columns or piers, consider stay-in-place formwork’s prefabricated components made of plastic and you’ll find they are surprisingly easy to assemble. The reliable structural support is an added bonus.
If your project is characterized by distinct shapes and architectural qualities, give serious consideration to fabric as a material. Fabric formwork is becoming more popular with each passing year thanks to its dexterity. Fabric formwork consists of strong sheets for molding formwork. The sheets are easy to work with as they are light in weight, empowering you to design the project exactly as envisioned.
Removable formwork is an option though such systems have the potential to damage the surface of the concrete. If you choose removable formwork, opt for one that is designed to permit damage-free removal that preserves concrete.
Take your time when reviewing formwork material options. Consider a wide variety of factors including the project specifications, timeline for assembly and ability to function based on the project requirements. The best formwork construction is efficient to the point that it maintains its original shape. However, other nuances such as weight also matter.
Be aware that formwork materials have the potential to be difficult to handle and install, necessitating specific equipment. Opt for a material that is light in weight and your work crew will be appreciative of its ease of handling during the transportation and installation processes.
Though project costs are an important consideration, formwork durability and lifespan are more important. Weigh the benefits of fabrication and reuse with other factors such as the quality of the material finish and you'll make an educated decision with full confidence.
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.
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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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