Construction Practices Work Shop
Formwork
Estimation of formwork material requirement
• Pre Award Form Management Issues
Study of customer requirement, drawings, layout, schedule, constraints, evaluation of available information
Estimate cycle time of formwork activities
Selection of the formwork system
Formwork scheme preparation and consideration of factors of reuse
Computation of formwork material requirement
Cost Estimation of the formwork materials
Computation of Unit Rates of different formwork items
NICMAR Delhi NCR
• Guidelines for selecting formwork system
Sl. No. Structure Involved in the project Recommended System
1 Multi story Building with story height < 4 m Prop System with Steel Plates or plywood (depending
on repetition)
2 Factory Shed with floor height> 4 m Tower System of Staging with Steel Plates or Ply
(depending on repetition)
3 Tall Structures like Silo, Chimneys Climbing Formwork or Slip forming
4 Shell Roof Tower with Ply/Timber
5 Bridge or Dam Study Different Possibilities and Choose
NICMAR Delhi NCR
• Flex-Prop System
Sheathing Concrete
(Plywood)
Secondary Support
Four Way (Timber Beams/
Heads Walers)
Primary Support
(Steel/Timber
Beams/ Walers)
Collapsible
Telescopic (CT)
Prop
Tripods Firm Ground
(Alignment)
NICMAR Delhi NCR
• Flex Prop System
NICMAR Delhi NCR
• Flex System Do’s and Don’ts
• Use tripods only where the H-beams
are lapping or at the end.
• All the legs of the tripods to rest on
firm ground.
• Props to rest on the ground firmly.
• Ensure sufficient lap of H-beam in
both primary & secondary layer.
• Ensure the right spacing of H-beam &
Props.
NICMAR Delhi NCR
• Heavy Duty Tower System
NICMAR Delhi NCR
• Heavy Duty Tower System Components
HORIZONTAL BRACING
U - HEAD
UNIT WT. = 2.95 KG.
H.D. COUPLER BASIC FRAME
SHORT PROP
FOUR- WAY HEAD
UNIT WT. 3.49 KG.(H16)
UNIT WT.=3.99KG.(H20)
FOOT PLATE
NICMAR Delhi NCR
• HDT System components
BEAM SPAN - 2230
0.8m, 1.2m, 1.6m, 2m, 2.4 m
STANDARD STEEL WALER
16 DIA. SPRING
LOCKED PIN
BEAM SPAN EXTN.-1525
UNIT WT. = 11.20KG.
TOWER SPINDLE
UNIT WT. = 7.00 KG.
NICMAR Delhi NCR
• Key Points in erecting HD Tower system
• Ensure -
1. That the diagonal, horizontal and plan
bracing are in position
2. Bracings between towers / tower and
permanent structure used, required at
every 6.0 m intervals in height.
3. That the couplers are provided in each
basic frame at every level and they are
secured by the spring lock pin.
4. Tower spindles are provided at the top
and bottom.
5. Foot plates / U- Heads are used
wherever necessary along with the
tower spindles
NICMAR Delhi NCR
• Wall and Column Formwork System
NICMAR Delhi NCR
• Column Formwork System
NICMAR Delhi NCR
• Beam Forming System
ADJ. BEAM SIDE EXTN.
TIEROD 3
TUBE CONE
4
2
WING NUT ANCHOR
3 BFS EXTN. 60 .80. 100 PLATE
1
TIEROD
TUBE
2 BEAM FORMINIG SUPPORT
4a
TIEROD
1 H-16 BEAM, H-20 BEAM
NICMAR Delhi NCR
• Formwork Quantity estimation – Essential Formula
𝑆𝐴 ×𝐶1
• 𝐴𝑟𝑒𝑎 𝑡𝑜 𝑏𝑒 𝑐𝑎𝑡𝑒𝑟𝑒𝑑 (𝐶𝐴) =
𝑅
• SA= shuttering area executed per month = total shuttering area/duration in months for the activity
• C1=risk factor = 1.1 (to account for delay due to replacement, spare, additional mobilization)
• R= No. of repetitions per month = working days/cycle time
• Rearranging, we can say -
• 𝐹𝑜𝑟𝑚𝑤𝑜𝑟𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑜𝑟 𝑚𝑜𝑏𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 =
𝑇𝑜𝑡𝑎𝑙 𝑓𝑜𝑟𝑚𝑤𝑜𝑟𝑘 𝑎𝑟𝑒𝑎 𝑝𝑙𝑎𝑛𝑛𝑒𝑑 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑚𝑜𝑛𝑡ℎ × 𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒
𝑁𝑜. 𝑜𝑓 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑑𝑎𝑦𝑠 𝑖𝑛 𝑎 𝑚𝑜𝑛𝑡ℎ
NICMAR Delhi NCR
• Effect of cycle time on formwork mobilization
Quantity to be executed Cycle time Effective working days per Formwork needed to be mobilized
(sq.m) (days) month (days) (sq.m)
1000 × 5
1000 5 25 = 200 𝑚2
25
1000 × 4
1000 4 25 = 160 𝑚2
25
1000 × 3
1000 3 25 = 120 𝑚2
25
1000 × 2
1000 2 25 = 80 𝑚2
25
NICMAR Delhi NCR
Useful Data
Breakup of different formwork elements in a typical building project:
Sl. No Type of Formwork The percentage of total formwork area
1 Footing 5%
2 Column 10%
3 Wall 15%
4 Slab & Beam 65%
5 Domes/Precast elements 5%
Typical possible usage and cycle time for various formwork activities
Type of Formwork Possible Usage Cycle Time Days
Footing 8 uses/month 3
Column 5 uses/month 5
Wall 8 uses/month 3
Slab & Beam 2 uses/month 15
NICMAR Delhi NCR
Useful Data Contd.
Thumb Rules useful for computation of formwork materials requirement as preliminary estimate
Item Description Steel Timber H Beam
(Kg/m2) (m3/m2) (Rm/m2)
Footing, raft, Pile Caps 20 0.085
Walls 60 0.006 3.5
Column 100 0.006 7
Beams, Slabs (Ht up to 4.5 m) 25 0.028 4
Beams, Slabs (Ht 6 m) 75 0.028 3.5
Access Scaffolding (Elevation area) 16
NICMAR Delhi NCR
• Illustrative Example
Item Description Steel Timber H Beam
(Kg/m2) (m3/m2) (rm/m2)
Material Coefficient for Wall formwork (Rough Estimate) 60 0.006 3.5
Total Wall area = 1000 m2 | cycle time = 5 days | working days = 25 days
1000×5
catering area = = 200 𝑚2
25
Requirement of steel = 200X60 = 12000 kg
1.2 m3
Requirement of Timber = 0.006X200 =
Requirement of H Beam = 3.5X200 = 700 rm
NICMAR Delhi NCR
• Illustrative Example
Type of elements Cycle Time Total Quantity Duration Month-wise split-up of quantity of formwork
(sqm) (months) planned to be executed (sqm)
1 2 3 4 5
Footings/Rafts/Pile Caps 3 4796 1 4796
Walls 3 44667 5 8933.4 8933.4 8933.4 8933.4 8933.4
Columns 7 11352 5 2270.4 2270.4 2270.4 2270.4 2270.4
Beams & Slabs < 4m ht 10 41479 5 8295.8 8295.8 8295.8 8295.8 8295.8
Beams & Slabs > 4m ht 14 16325 5 3265.6 3265.6 3265.6 3265.6 3265.6
Staircase 14 2706 5 541.2 541.2 541.2 541.2 541.2
Footings/Rafts/Pile Caps Floor Form
Walls Column Formwork (Modular)
Columns Wall Formwork (Modular)
Beams & Slabs < 4m ht Flex Table System
Beams & Slabs > 4m ht Heavy Duty Tower System
Staircase Flex System
NICMAR Delhi NCR
• Illustrative Example
BOQ Qty Duration In Cycle Time in Area to be catered
Description
(sqm) months days (SAXC1/R)|(R = 26/CT)
4796
Foundation 4796 1 3 × 1.1 = 609 𝑠𝑞𝑚
26/3
11352/5
Columns 11352 5 3 × 1.1 = 288 𝑠𝑞𝑚
26/3
44667/5
RC Walls 44667 5 7 × 1.1 = 2646 𝑠𝑞𝑚
26/7
41479/5
Slab < 4 m 41479 5 10 × 1.1 = 3510 𝑠𝑞𝑚
26/10
16328/5
Slab > 4 m 16328 5 14 × 1.1 = 1934 𝑠𝑞𝑚
26/14
2706/5
Staircase 2706 5 14 × 1.1 = 321 𝑠𝑞𝑚
26/14
NICMAR Delhi NCR
• Formwork Labor Requirement Calculation
Item Description Man hours/sqm (for labor)
Footings/Rafts/Pile Caps 0.9
Walls 1.7
Columns 1.8
Beams and slabs with floor height <4 m 1.5
Flat Slabs 0.8
Beams and slabs with floor height up to 6 m 2
Access Scaffolding (Area in elevation) (Assembly of HDT) 0.2
• For 1000 sqm formwork in walls, the man hours required = 1.7*1000 = 1700 man hours.
• Assuming 10 hours per day of work, this gives 170 man days.
• For 25 working days, we require 170/25 = 6.8 ≈ 7 workmen in to finish the work in a month.
NICMAR Delhi NCR
• Formwork Cost Planning
No. of possible
Area to be Requirement of steel
Type of elements Total Area reuse of form Timber Purchase Plywood purchase Labor Work hours
catered components
sets
Footings/Raft/Pile 4796 609 8 609 X 20 = 12180 609 X 0.085 = 51.77 609 X 1.1 = 669.90 4796 X 0.9 = 4316.4
Walls 44667 2646 17 2646 X 60 = 158760 2646 X 0.006 = 15.88 44667 X 1.1/12 = 4094.48 44667 X 1.7 = 75933.9
(Considering life
of ply = 12 uses)
Columns 11352 288 39 288 X 100 = 28800 288 X 0.006 = 1.728 11352 X 1.1/12 = 1040.60 11352 X 1.8 = 20433.6
(Considering life
of ply = 12 uses)
Beams and Slab < 41479 3510 12 3510 X 25 = 87750 3510 X 0.028 = 98.28 3510 X 1.1 = 3861.00 41479 X 1.5 = 62218.5
floor ht 4m
Beams and Slab > 16328 1934 8 1934 X 75 = 145050 1934 X 0.028 = 54.15 1934 X 1.1 = 2127.40 16328 X 2 = 32656
floor ht 4m
Staircase 2706 321 8 321 X 25 = 8025 321 X 0.028 = 8.99 321 X 1.1 = 353.10 2706 X 2.5 = 6765
Total 440565.00 230.798 12146.48 202323.40
NICMAR Delhi NCR
• Formwork unit cost calculation formulas
𝑘𝑔
𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝑖𝑛𝑠𝑞𝑚 × 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝑝𝑒𝑟 𝑘𝑔
• 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑜𝑤𝑛𝑒𝑑 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑠𝑒𝑠 𝑖𝑛 𝑎 𝑚𝑜𝑛𝑡ℎ
𝑘𝑔
𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝑖𝑛 × 𝐻𝑖𝑟𝑒 𝑐ℎ𝑎𝑟𝑔𝑒 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝑝𝑒𝑟 𝑘𝑔
𝑠𝑞𝑚
• 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠(𝐻𝑖𝑟𝑒𝑑) =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑠𝑒𝑠 𝑖𝑛 𝑎 𝑚𝑜𝑛𝑡ℎ
𝑐𝑢𝑚
𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡𝑖𝑚𝑏𝑒𝑟 𝑖𝑛 𝑠𝑞𝑚 ×𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑡𝑖𝑚𝑏𝑒𝑟 𝑝𝑒𝑟 𝑐𝑢𝑚
• 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑡𝑖𝑚𝑏𝑒𝑟 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 =
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑠𝑒𝑠 𝑒𝑛𝑣𝑖𝑠𝑎𝑔𝑒𝑑
𝑠𝑞𝑚
𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑜𝑓 𝑝𝑙𝑦𝑤𝑜𝑜𝑑 𝑖𝑛 𝑠𝑞𝑚 ×𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑝𝑙𝑦𝑤𝑜𝑜𝑑 𝑝𝑒𝑟 𝑠𝑞𝑚
• 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑝𝑙𝑦𝑤𝑜𝑜𝑑 =
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑠𝑒𝑠 𝑒𝑛𝑣𝑖𝑠𝑎𝑔𝑒𝑑
• 𝐶𝑜𝑠𝑡 𝑜𝑓 𝐻16 𝑏𝑒𝑎𝑚𝑠 =
𝑟𝑚
𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑜𝑓 𝐻16 𝑏𝑒𝑎𝑚𝑠 𝑖𝑛 𝑠𝑞𝑚 ×𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑝𝑙𝑦𝑤𝑜𝑜𝑑 𝑝𝑒𝑟 𝑠𝑞𝑚 ×𝑑𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑚𝑜𝑛𝑡ℎ
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑠𝑒𝑠 𝑖𝑛 𝑎 𝑚𝑜𝑛𝑡ℎ
NICMAR Delhi NCR
• Formwork unit cost calculation formulas
𝐶𝑜𝑠𝑡 𝑜𝑓 𝑐𝑜𝑎𝑡𝑖𝑛𝑔 𝑎𝑔𝑒𝑛𝑡 𝑝𝑒𝑟 𝑙𝑖𝑡𝑟𝑒
• 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑐𝑜𝑎𝑡𝑖𝑛𝑔 𝑎𝑔𝑒𝑛𝑡 =
𝐶𝑜𝑣𝑒𝑟𝑎𝑔𝑒 𝑜𝑟 𝑆𝑝𝑟𝑒𝑎𝑑 𝑖𝑛 𝑠𝑞𝑚 𝑏𝑦 1 𝑙𝑡𝑟 𝑜𝑓 𝑐𝑜𝑎𝑡𝑖𝑛𝑔 𝑎𝑔𝑒𝑛𝑡
𝐶𝑜𝑠𝑡 𝑜𝑓 𝑛𝑎𝑖𝑙𝑠 𝑖𝑛 𝑘𝑔 𝑝𝑒𝑟 𝑠𝑞𝑚 ×𝑐𝑜𝑠𝑡 𝑜𝑓 𝑛𝑎𝑖𝑙𝑠 𝑝𝑒𝑟 𝑘𝑔
• 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑛𝑎𝑖𝑙𝑠 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑢𝑠𝑒𝑠 𝑒𝑛𝑣𝑖𝑠𝑎𝑔𝑒𝑑 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑓𝑜𝑟𝑚
𝐶𝑜𝑠𝑡 𝑜𝑓 𝑚𝑎𝑘𝑖𝑛𝑔 1 𝑠𝑞𝑚 𝑜𝑓 𝑓𝑜𝑟𝑚𝑤𝑜𝑟𝑘
• 𝐿𝑎𝑏𝑜𝑟 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑚𝑎𝑘𝑖𝑛𝑔 𝑡ℎ𝑒 𝑓𝑜𝑟𝑚𝑤𝑜𝑟𝑘 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑢𝑠𝑒𝑠 𝑒𝑛𝑣𝑖𝑠𝑎𝑔𝑒𝑑 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑓𝑜𝑟𝑚
• 𝐿𝑎𝑏𝑜𝑟 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑓𝑖𝑥𝑖𝑛𝑔 & 𝑟𝑒𝑚𝑜𝑣𝑖𝑛𝑔 𝑓𝑜𝑟𝑚𝑤𝑜𝑟𝑘 ∶ 𝐹𝑟𝑜𝑚 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑛𝑜𝑟𝑚𝑠 𝑜𝑟 𝑞𝑢𝑜𝑡𝑎𝑡𝑖𝑜𝑛
• 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 𝑎𝑛𝑑 𝑝𝑟𝑜𝑓𝑖𝑡𝑠 ∶ 𝑉𝑎𝑟𝑖𝑒𝑠 𝑓𝑟𝑜𝑚 𝑐𝑜𝑛𝑡𝑟𝑎𝑐𝑡𝑜𝑟 𝑡𝑜 𝑐𝑜𝑛𝑡𝑟𝑎𝑐𝑡𝑜𝑟
𝑼𝒏𝒊𝒕 𝒓𝒂𝒕𝒆 = 𝑪𝒔𝒕𝒆𝒆𝒍 + 𝑪𝒕𝒊𝒎𝒃𝒆𝒓 + 𝑪𝒑𝒍𝒚 + 𝑪𝑯𝟏𝟔 + 𝑪𝒐𝒊𝒍 + 𝑪𝒏𝒂𝒊𝒍𝒔 + 𝑪𝑳𝑴 + 𝑪𝑳𝑭 + 𝑷𝒓𝒐𝒇𝒊𝒕𝒔 & 𝑶𝒗𝒆𝒓𝒉𝒆𝒂𝒅𝒔
NICMAR Delhi NCR
• References
• Formwork for concrete structures, K N Jha, McGraw Hill Publication, 2012
• Standard drawings and handbooks of formwork – Proprietary material, L&T Construction
NICMAR Delhi NCR
Thanks!
NICMAR Delhi NCR
