Formwork
Pre Concrete Post Concrete
During Concrete
Activities Activities
Receipt of Stand by During Strike Wall
Equipment on Site Concreting Formwork
Strike Deck
Level Surveys
Formwork
Clean, Transport
Setting Out and Stack
Formwork
Control/Correcting Strike Kicker
of Deviations Formwork
Strike Wall –
Erect Formwork Mounted Working
Platform
Erect Deck Erect Wall Mounted
Formwork Working Platform
Setting Kickers
Pre-pour Checklist
PRE-CONCRETE ACTIVITIES
1. RECEIPT OF EQUIPMENT ON SITE
Unload components from transport and where possible, stack by code and size. Panels can
normally be stacked safely up to 25 panels high on skids or pallets. When stacked, holing in the
formwork should be aligned allowing easy identification by code. Ensure the first panel at the
bottom of the stack has the contact face upwards. All pins, wedges, wall ties, P.E. sleeves, L.D.P.E.
sheet and special tools to be put into proper storage and only distributed as required. A check
requires to be carried out against the packing list ensuring all items stated are received.
2. LEVEL SURVEYS
A concrete level survey should be taken on all sites and remedial work carried out prior to the
erecting of formwork. All level surveys should be taken from a T.B.M. (Temporary Bench Mark). A
record of all surveys should be kept on file by the allocated Supervisor.
In certain cases it is good practice to mark the slabs with paint indicating a plus (+) or minus (-) as
the survey is being conducted. This eliminates unnecessary circulation of paper copies to site
personnel, and the Supervisor can identify at a glance any remedial work required. High spots
along the wall line to be chipped off to the proper level.
Low spots along the wall line should be packed to the required level, using plywood or timber.
Packing the corner and the centre of the wall length to the required level will normally be adequate,
as the formwork when pinned together will bridge across low spots.
Concrete up to (+6mm high) is acceptable, above 6mm must be chipped to the (correct level). After
concreting, level surveys should also be carried out on the top of the kickers. One reason for
structural deviation from the centre line can be on a - level kicker. This in turn means the formwork
is not plumb. Kickers are manufactured with a 26mm slotted hole on the face to allow for
adjustment after concreting.
As with the concrete level survey, proper records of the kicker survey should be kept on file by the
allocated Supervisor. Also a deviation survey requires to be carried out and kept on file.
3. SETTING OUT
Only approved shell drawings supplied by MFE Formwork Design should be used for setting out.
Setting out lines should continue through openings, external corners e.t.c., by a minimum of
150mm. This makes it easier to fix the formwork in position prior to concreting.
It is very important that the reference points and the setting out points are protected against
accidental movement or damage.
Transferring of reference points from the level below requires to be done quite accurately. Incorrect
reference points give incorrect deviations therefore creating unnecessary work for the formwork
erection. It is suggested a theodolite be used for transferring the points through openings provided
in the slab.
4. CONTROL / CORRECTING OF DEVIATIONS
A study of the deviation and kicker level survey should confirm what, if any, corrective action is
required. If the kicker requires adjustment for level, loosen the holding - in bolt by turning anti-
clockwise, adjust kicker to the required position and retighten the bolt. Once the vertical formwork is
fixed in position, the external corners should be checked for plumbness. This will determine if
further action is required to control the deviation.
In addition to the kicker levels, the formwork can be pulled by using bottle screws and chain blocks.
If the formwork requires to be pushed adjustable props can be used.
5. ERECT FORMWORK
For the initial set up only, 50mm x 25mm timber stays can be nailed to the concrete slab, close to
the internal an external corners, to ensure the formwork is erected to the setting out lines. All
formwork begins at a corner and proceeds from there. This is to provide temporary lateral stability.
A single panel at a corner will give sufficient lateral support to a very long section of wall. Ensure all
edges of the formwork and contact face are properly cleaned and oiled prior to fixing in place.
When satisfied the corner is stable and the internal corner is positioned to the setting out lines
continue erecting the formwork to one wall. Use only 2 no pins and wedges to connect the
formwork at this stage as the pins and wedges will have to be removed later to insert the wall ties.
Alternatively the wall ties can be positioned as the formwork is erected. For ease of stripping, pin
the wall panels to the internal corners with the head of the pin to the inside of the internal corner if
possible.
Wall ties should be coated with the releasing agent provided before being fixed to the formwork. Fit
the wall ties through slots in the wall formwork and secure in position with pins and wedges. Prior to
closing the formwork, pre-wrapped corrugated PVC sleeves are placed over the wall ties. Please
ensure, since preparation of the sleeves they have not been abused in any way before installing, as
this can have an adverse effect on the removal of the wall tie after concreting. Also, ensure they are
located properly to the contact face of the formwork on each side of the wall. Sleeves installed with
one end fixed between the side rails of two adjoining panels, exposes the wall tie at the opposite
end, therefore impossible to retrieve the wall tie after concreting.
When deviations of external walls occur, they must be brought back to the correct plan location as
quickly as possible. This is done by slightly tilting the external wall forms in one plane. If a deviation
from plumb has occurred in two directions, then this should be improved over two floors, one for
each direction. A realignment in two directions should not be attempted on a single lift. A maximum
of 6mm in vertically improvement in one lift is sufficient.
6. ERECT DECK FORMWORK
Before fixing in position the soffit lengths (SL) and soffit corners (SC) should be coated on the
contact face plus the top and bottom rails with a release agent. When connecting the soffit lengths
and soffit corners to the vertical formwork, the pins should be inserted from the top prevent the
possibility of the pin falling out during concreting. After fixing of the soffit lengths the deck panels
can be pinned at the corners again ensuring oil has been applied to the edges only. In most cases
the deck beams to support the deck formwork, can be assembled on the concrete slab. Lay the
beam components on the floor as per the deck layout drawing.
Components are held together by pinning BB 350 (Beam Bars) through two adjoining beams with a
D.P. 200 (Deck Prop) located between using the 132mm pin. Fit the prop lengths to the
preassembled beam with the shoe of the prop facing in the direction of the beam. This protects the
bottom of the prop length when striking the prop. Using the prop lengths lift the beam into position.
The beam is held in place by inserting a pin from the beam, through the end of the deck panel
already fixed to the corner. Ensure side rails of the Deck beam has been oiled prior to fixing.
The first panel in a row has to be pinned to the soffit length and the deck beam. The second panel
should be pinned to the first deck panel only, (two pins are normally enough). Ensuring the second
panel is not fixed to the deck beam will leave sufficient movement in the beam to place the third
panel of that row. Fix the third panel to the second panel, and then pin the second panel to the deck
beam. Place the remaining panels in the row using the same method. A numbers of rows can be
fixed simultaneously. The face of the deck panels on completion can be oiled prior to the placing of
the slab reinforcement. On the completion of fitting the deck panels a survey team is required to
check the level of all soffit formwork and adjust accordingly if required, by shimming the bottom of
the PL's.
7. SETTING KICKERS
Where there is a continuous vertical wall, e.g. lift shaft, external face of the building etc., a kicker
forms the perimeter of the slab and also acts as the connecting component for the vertical formwork
on the next level. After casting of the first level of formwork, two levels of kicker are required, one
coming off the previous floor to which the formwork is fixed and the other fixed to the top of the wall
formwork which forms the perimeter of the slab. This kicker remains in place after concreting and is
used to start the wall form on the next level.
DURING CONCRETING
1. STAND BY DURING CONCRETING
At least two operatives should be on stand by during concreting, to cover both sides of the wall
being casted. During concreting, the ideal position is slightly in front of the pour, checking pins,
wedges and wall ties as the pour is in progress. Pins, wedges or wall ties missing could lead to a
movement on the formwork and the possibility of the formwork being damaged. This effected area
will then require remedial work after striking of the formwork.
Things to look for during concreting :
(a) Dislodging of Pins/Wedges due to vibration.
(b) Beam/Deck props adjacent to drop areas slipping due to vibration.
(c) Ensure all bracing at special areas stays intact.
(d) Overspill of concrete at window openings etc.
Operatives on stand by should have the following equipment (at hand) :
(a) Pins and Wedges
(b) Adjustable props
(c) Masonary nails
(d) Joinery saw and hammer
(e) A few lengths of timber for additional bracing, (if required).
POST CONCRETE ACTIVITIES
1. STRIKE WALL FORMWORK
Normally wall formwork can be struck after 12 hours. Striking times are confirmed on a project to
project basis.
Before striking wall formwork ensure the following are removed :
(a) All timber stays nailed to the concrete slab.
(b) Walers (if any).
(c) Vertical soldiers.
(d) All pins and wedges from the panels identified for striking.
(e) Care must be taken when removing pins and wedges on the external and void areas, especially
on the safety issue. Also considerable amount of pins and wedges can be lost over a short period
of time due to inadequate care taken when removing.
Ensure commencement of work on the thickest walls first therefore enabling commencement of
extracting the wall ties as soon as possible. The wall ties can be removed before the removal of the
formwork. The sooner they are extracted from the wall, less force required and less time
consuming.
External walls are also critical to enable the progress of installing the scaffold bracket for placing of
the formwork on the next level. While removal of the wall ties is in progress ensure they are kept
neatly in an appropriate area where they can be prepared for the next level.
As soon as the removal of ties is progressing then striking of the formwork can commence.
All components must be cleaned as soon as they are removed. The longer the cleaning process is
delayed, the more difficult it will be. Wall panels are designed to be struck by pulling the top of the
panel away from the concrete where a rocker is fitted.
The rocker at the bottom of a panel enables the panel to pivot about a point against the concrete
slab. Where the wall formwork is pinned to a kicker, the panels are removed by pulling the bottom
away first.
The first panel in a row is the most difficult to remove as it is also held by the adjacent panels. If
properly cleaned and oiled prior to concreting and using the panel pullers provided, the panels will
come away with ease. The remainder of the wall panels on this wall will strike easily by breaking
the bond to the adjacent panel using the panel puller as mentioned above.
To strike internal corners the wall ties are removed first as the wall ties prevent the removal of the
internal corner.
As the wall panels are being removed, removal of the sleeves can commence. The same situation
applies to the sleeves as to removal of the wall ties, the sooner they are extracted from the wall the
less time consumed. Also less damage will occur therefore maximum uses can be achieved per
sleeve.
Sleeves are removed by using long nose pinch pliers. Ensure the sleeves are being stored in a
proper container when removed and returned to the preparation location as they can be prepared
for the next use.
When moving the formwork to the next area, proper stacking of panels is a clear sign of a well run
operation. Stacking at the right place and in the right order greatly benefits the following erection
work, and prevents clutter that impedes all activities.
Striking of the external walls also requires urgent attention to enable the installation of the working
platform bracket.
2. STRIKE DECK FORMWORK
Normally deck panels can be struck after 36 hours. Striking times should be confirmed on a project
to project basis. The striking begins with the removal of deck beam. Remove the 132mm pin and
the beam bars from the beam which has been identified for removal.
This is followed by removing the pins and wedges from the deck panels adjacent to the deck beam
to be removed.
The Deck beam can now be taken out.
As the first panel in a row rests on the support lip of the soffit length, the adjacent panel should be
removed first. After removing the pins and wedges from the panel to be removed, a panel puller
can be used to break the bond from the adjacent formwork.
Where there is no deck beam supports and the panels span from wall to wall, one wall will have the
supporting lip of the soffit length removed.
Pins and wedges only to be removed on the identified component that is to be struck.
Deck panels remain in place longer than wall panels and will not come away easily unless proper
cleaning and oiling is done during the erection process. Panels should be cleaned immediately after
striking. Consequently the sequence of striking should confirm to the sequence of erection.
3. CLEAN, TRANSPORT AND STACK FORMWORK
Cleaning- All components should be cleaned with scrapers and wire brushes as soon as they are
struck. Wire brush is to be used on side rails only. The longer cleaning is delayed, the more difficult
the task will be. It is usually best to clean panels in the area where they are struck.
Transporting
There are 3 basic methods recommended when transporting to the next floor level :
(a) The heaviest and longest which is full height wall panels can be carried up the nearest stairway.
(b) Passed up through void areas.
(c) Raised through slots specially formed in the floor slab for this purpose. Once they have served
their purpose they are closed by casting in concrete filler.
Striking- Once cleaned and transported to the next point of erection, panels should be stacked at
the right place and in the right order. Proper stacking is a clear sign of a well-managed operation
and greatly aids the next sequence of erection as well as preventing clutter and impeding other
activities.
4. STRIKE KICKER FORMWORK
Only the kicker pinned to the bottom of the wall panels should be struck. The top kicker will be used
for starting the wall formwork on the next floor level.
Once the wall panels are removed, disconnect the lower kicker, remove the cast in bolt. This leaves
the kicker free to be taken off and prepared of reuses. i.e. cleaned and oiled. Ensure the cast in
bolts are also cleaned by wire brush after each use.
Each level of kicker will "leap-frog" up the building.
5. STRIKE WALL - MOUNTED WORKING PLATFORM
The lower level of scaffold must be struck on the day of casting the floor above, and prepare for
fixing the following day. Safety should be the priority in everyone's mind during this operation first
principle is to ensure the working platform is free from any debris.
One member of the team should be on the working level above to receive the material from the
level below. Another team member should be on the lower level and it is COMPULSORY that this
person wears an approved Safety Harness and Fall Arrest Block.
The Fall Arrest Block is attached to the bracket above, using a quick release shackle. The Fall
Arrest Block will be moved to its next fixing point by the helper on the level above. Remove the toe-
board and decking, passing them to the helper above. This is followed by the removal of the
handrail.
The scaffolders must ensure that no part or parts are left partially removed, as this will endanger
themselves and their fellow workers. Another section of the team will follow behind to remove the
scaffold brackets and the same crew will be responsible for fitting the scaffold bracket on the next
level.
As there are two complete levels of scaffold brackets, one team member will be on the upper level
and another inside the building on the level below. The worker on the upper level will require a rope
attached to a S type steel hook which he will hook to the scaffold bracket below.
The worker inside the building will then commence to unscrew and remove the tie nut, thus
releasing the scaffold bracket, and allowing the worker holding the rope on the upper level, to
gently raise the rope while the tie rod is being gently knocked through from the inside, until the
bracket is completely free from the building. At this stage, the safety bracket is pulled to the next
level in preparation for fixing to the level above.
6. ERECT WALL MOUNTED WORKING PLATFORM
Before commencing the operation, ensure the following equipment has been procured:
(a) Scaffold brackets and all the necessary fixings.
(b) Scaffold bracket, vertical safety post.
(c) Safety harness and fall arrest block.
(d) Timber and all materials for the platform decking and handrails.
For the initial set up of the formwork and when using the wall mounted scaffold brackets, 20mm
diameter holes require to be drilled through the formwork to position the PVC sleeves, which when
cast in the concrete, should be used for fixing the scaffold brackets. This hole also accommodates
the bolting up of the formwork to control the alignment at the kicker level.
As the external formwork is being removed, a team of allocated people working in pairs will
commence erecting the working platform. With the tie-rod through the hole provided in the working
platform bracket, and using a small ladder, fix the bracket by pushing the tie rod through the PVC
sleeve which is cast in the concrete. A helper inside the building can fix and tighten the locking nut.
During this operation, the person on the external must have his safety belt secured to the kicker
above. As this operation progresses along the building, another pair of the team should follow,
placing the decking, toeboard and hand rails. One person should remain on the lower platform and
pass the decking to his helper on the upper level. When working on the outside edge, safety
equipment MUST be worn at all times.
