Vertical

Formwork
Supervisor: Prof. Dr Osama El-Nesr

5/23/2011
 Vertical Formwork

Contents

• Acknowledgment
• Abstract
1. Introduction
2. Factors Affecting the Selection of Vertical Formwork System
3. Types of vertical formwork
3.1. Conventional Wall/Columns Forming Systems
3.1.1. Procedures & after treatment of Formwork of Columns
3.1.2. Safety & Close out
3.2. Dependent & independent
3.2.1 Ganged Forming Systems
3.2.2 Jump Form
3.2.3 Slip-Form
3.2.4 Self-Raising
4 SOME COMMON CAUSES OF FORM FAILURES
5 Case Study
6 Conclusion
7 References

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 Vertical Formwork

• Acknowledgment
We would like to thank Dr. Osama El-Nesr for his great efforts.

• TEAM Group:

Ahmed Tarek Marzouk

Aly Ashraf Ibrahim

Belal Mohamed Aly

Rania mohamed

• Abstract
A good formwork system enables speedy completion of the concrete structure, following which
other subsequent trades can be started. However, the current intuitive judgment approach in the
selection of formwork systems cannot assure an optimal and consistent result. Artificial neural
networks may improve the selection process. Formwork represents a significant part of the cost
of concrete structure construction. Most subsequent trades including internal finishing and
external cladding depend on the completion of the building structure. A suitable formwork
system is thus crucial for maintaining the smooth flow of the various trades and a proper working
sequence of various work activities.

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1 Introduction

A formwork system signifies the molds used to store and hold wet
concrete until curing is achieved. Curing is a significant process in
concreteconstruction. Concrete has been demonstrated to be the most
suitable construction material for buildings and foundations since it
withstands fire and ensures protection against storms and extreme
temperatures. In addition, concrete contributes to the creative
modern architectural design. Therefore, modernization of formwork
systems was essential to keep pace with concrete advancement. As
tall structures have gradually emerged to be the modern trend,
formwork systems have also developed from being simple timber-
based to pre-engineered structures of steel, aluminum, timber,
plywood, and plastics. The formwork technology has translated into
rapid construction with less labor.

Form designers and builders are becoming increasingly aware of the need to keep abreast of
technological advancements in other materials fields in order to develop creative innovations that
are required to maintain quality and economy in the face of new formwork challenges.
Formwork was once built in place, used once, and subsequently wrecked. The trend today,
however, is toward increasing prefabrication, assembly in large units, erection by mechanical
means, and continuing reuse of forms. These
developments are in keeping with the increasing
mechanization of production in construction sites and
other fields.

Vertical formwork systems are those used to form the

vertical supporting elements of the structure columns,
core walls, and shear walls. The functions of the
vertical supporting systems are to transfer the floor
loads to the foundation and to resist the lateral wind
and earthquake loads. Consequently, the construction
of vertical structural elements precedes flat horizontal
work.
Typical vertical formwork systems utilized in
construction include conventional formwork, ganged forms, jump forms, slip forms, and self-
raising forms.

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 Vertical Formwork

Formwork systems for vertical concrete work can be classified into two main categories, namely,
crane-dependent systems and crane-independent systems. Gang formwork and jump form.

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 Vertical Formwork

2 Factors Affecting the Selection of Vertical Formwork System

Vertical supporting structures such as buildings’ cores in high-rise construction, towers, or silos
are typically a critical activity that controls the pace of the project progress. Consequently, when
selecting a core forming system, time is a critical factor. Duration that must be considered are the
movement of the form from floor to floor, original assembly, time to set rebar and inserts within
the form, stripping time, close-in time, and final disassembly.
Other factors to consider in formwork selection are the amount of labor required to strip, set,
pour, and control the system; the amount of precision needed as far as plumbness and corner
tolerances, ease of lifting, and the designer’s intent when developing the structural system. Other
methods substitute the manual labor with valuable crane time. The decision between labor or
crane time requires careful financial analysis.
Precision requirements make some systems better than others. On huge towers, cores must
remain very plumb due to elevator tolerance requirements. The formwork must have a method of
remaining plumb and level. If the formwork is moved piece by piece, each piece must be
checked for being plumb and level, which leads to a gross amount of field engineering. Most
systems become increasingly more difficult to keep plumb and level as wear and tear loosens
corners and the form deteriorates in general. Also, wind loads at higher elevations tend to reform
the system.
The architect usually doesn’t design a building with any particular form system in mind. In some
cases, such as slip forming, the design must reflect the method of forming. However, it is usually
assumed the building will be conventionally formed. Many other factors that affect the selection
of vertical formwork systems for buildings are similar to those factors affecting the selection of
horizontal formwork systems.
However, there are some factors that are particularly important to the selection of vertical
formwork systems. Among these are:

1. Factors related to building architectural and structural design, including lateral supporting
system(s) and building shape and size.

2. Factors related to project (job) specification, including concrete appearance and speed of
construction

3. Factors related to local conditions, including area practices, weather conditions, and site
characteristics

4. Factors related to the supporting organizations, including available capital, hoisting

equipment, home-office support, and availability of local or regional yard supporting facilities.

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3 Types of vertical formwork

Formwork systems for vertical concrete work can be classified into two main categories, namely, crane-
dependent systems and crane-independent systems. Gang formwork and jump formare classified under
crane-dependent systems. On the other hand, slip form and self-raising formwork are classified as crane
independent systems in which formwork panels are moved vertically by other vertical transportation
mechanisms. This chapter focuses primarily on crane-dependent formwork systems and their application
and limitations.

The conventional wall system is the only hand-set system. The other four formwork systems are made of
prefabricated modular panels before they can be transported by cranes or any other vertical transportation
system.

3.11 Preparation and after treatment of Formwork

Before placing the concrete, the formwork is to be cleaned and checked again for proper
execution.
After cleaning, the cleaning holes of wall and column formworks are to be tightly closed since
the maximumpressure of the concrete mix is occurring at the foot of the formwork where the
cleaning holes are situated.For this purpose, the sheeting pieces of the cleaning holes are always
to be put against the thrust−board andagainst formwork bearers. If necessary, additional
formwork bearers are to be mounted. Immediately beforeconcreting, the formwork is to be
thoroughly wetted with water because thereby less water will be extractedfrom the concrete mix
and later stripping will be facilitated. When placing the concrete, it is to be made surethat no
changes take place with the formwork.Stripping of the formwork must not be started unless the
site engineer in charge has given the respectiveexpress instructions. Too early removal of the
formwork parts may cause heavy damage to the structureand/or injury of persons.Stripping is to
be done very carefully. Neither the concrete nor the formwork timbers must be
damaged.Emergency columns are the last to be removed. When stripping, greatest attention is to
be attached to thestructural direction of forces of the formwork. All nails are to be removed from
the stripped formwork timbers,

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3.12 Safety

1- GENERAL
a)All form components and/or hardware must be kept clean, and if appropriate, lubricated to
insure proper performance and to allow for proper inspection.

b)All form components must be inspected regularly for damage or excessive wear. Equipment
found to be in these conditions must be replaced immediately and not re-used.

c)Field repair of modular formwork components (other than plywood repairs) must not be
undertaken without consulting the manufacturer’s qualified representative

d)The forming layout shall be prepared or approved by a person qualified to analyze the loadings
and stresses which are induced during the construction process. The layout shall be at the jobsite.

e)Forming installation and pouring procedures must comply with safe practices and with the
requirements of the law and governmental regulations, codes and ordinances.

2- ERECTION OF FORMWORK

a)Do not deviate from layout drawings when erecting formwork without the approval of a
qualified designer.

b) Be certain that all wall ties are in place and secured as per manufacturer’s
recommendations.Do not weld, bend or otherwise alter wall ties as it may seriously reduce their
strength.

c)Adequate temporary bracing must be in place while initially setting formwork. Assurethat
formwork is properly braced and stabilized against wind and other external forces.

d)Safe working platforms must be installed as per applicable safety standards.

e)When gang forming, lifting devices must be properly spaced and securely attached as
permanufacturer’s recommendations. Rigging must be arranged so that any one lifting bracket is
notoverloaded and that lifting cables are not at excessive angles, which will reduce
allowableloads. Spreader beams with load equalizers are recommended for all but simple two
point lifts.Follow manufacturer’s/suppliers recommended procedures concerning capacity and
use of liftinghardware and crane.

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 Vertical Formwork

f)A minimum of two tag lines must be used to control movement of crane-handled formwork.Do
not allow personnel on or directly under any gang form while it is being moved or suspendedin
air.

g)Do not erect gang forms when jobsite wind conditions prevent safe maneuvering of
gangs.Assure that all rigging connections are properly made in accordance with safe practices
andprocedures.

h)Formwork should be adequately braced, reanchored, or otherwise secured prior to releasing

lifting mechanism.

i)Wall forms must not be erected so as to support deck concrete loading unless the wall forms are
a designed part of the deck supportsystem.

3- BRACING
a) Aligners (alignment devices, plumbingstruts) are considered only as alignment deviceswith no
provisions for withstanding concretepressure or any portion thereof. Maintain formsplumb
during pour to ensure that aligners are notsupporting or stabilizing concrete pressures.

b) Braces used to withstand concrete pressuremust be designed by a qualified formworkdesigner.

c) Unless specified, wind loading and otherexternal lateral loads are not considered in
themanufacturer’s layout drawings.

d)The adequacy of stakes, dead-men, sills,anchor-bolts, etc., must be determined to assuresafe

support of the imposed brace loads. Theresponsibility for adequate anchorage of bracesshould be
assigned only to those personnel with sufficient experience to assure sound judgment.

e) Before removing braces, assure that theconcrete has attained sufficient strength to
safelysupport the imposed load at support locations.

f) Do not exceed the rated load of the braces.

g)Inspect installed braces immediately afterinstallation for correctness of spacing and

properattachment device.

4) WALKWAY SYSTEMS
a)All walkway systems must be properlypositioned, spaced and fastened as permanufacturer’s
specifications and all applicablesafety regulations.

b)Walkway systems must be in place along theupper level of formwork. Workers must
neverattempt to walk or stand on top of forms.

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 Vertical Formwork

c) Scaffold brackets must be attached with themanufacturer’s recommended connectors.

Neveruse substitutes or make-shift devices. Never hang brackets from wall ties after removal
offorms.

d)All walkway platforms must utilize at leasttwo (2) planks laid side by side, and mustoverlap
their support ledger by not less than 6inches. Unsupported ends of scaffold planksmust not
project more than 12 inches past theirsupport ledger.

e)Scaffold planks must be minimum 2 inch x10 inch nominal lumber and must be scaffoldgrade
as recognized by approved grading rulesfor the species of lumber used, or must be ofmaterials
having equivalent or greater strength.Scaffold planks must safely support a minimumof 25
pounds per square foot over a maximumspan of 8 feet.

f)When deemed appropriate by the competentperson, scaffold planks must be nailed

andclinched, bolted or otherwise positively securedagainst dislodgement from effects of
wind,weather, gang form lifting operations or the like.Bolt heads and nails must be driven flush
withtops of planks to prevent tripping hazards.

g)All scaffold bracket platforms must beequipped with guardrails, midrails and toeboardsalong
all open sides and ends and be maintainedsecure and in good condition at all times.Guardrails
must be of at least 2 x 4 nominal sizedlumber, with minimum 1 x 6 or 2 x 4 nominalmidrails,
with toeboards at least 4 inches high,
supported by 2 x 4 nominal lumber uprightsspaced not more than 8 feet apart, or must be ofother
materials providing equivalent or greaterstrength and protection.

h)Maximum spacing between scaffold bracketsis eight feet. Never exceed this distance unlessthe
walkway system has been specificallydesigned for a greater distance. Followmanufacturer’s
recommendations as to loadingand spacing of scaffold brackets. Unlessdesigned otherwise,
scaffold brackets aredesigned to support a maximum load of 25pounds per square foot when
spaced on 8 foot
centers. Scaffold brackets are not designed forthe additional loads imposed from stacking rebaror
placing other equipment on walkways.

I)Always brace and/or otherwise secure formsand scaffold from overturning due to
attachmentand use of scaffold brackets.

j) Never allow persons to work on one levelof walkways if others are working directly belowor
overhead unless proper protection is provided,such as safety nets.

k)It is unsafe and unlawful for persons tooccupy any form walkway while the form isbeing
moved.

l)Access ladders or other suitable safemethods must be used to obtain access to

Walkway platforms. Do not position ladders sothat their weight while being used can affect
thestrength or stability of the scaffold andformwork.

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m)Do not use form panels as a ladder.

n) If using walkway systems is not practical,personnel must be protected against falls bymeans
of personal fall arrest system attached tocomponents having adequate strength to meet orexceed
applicable codes or by safety nets orother equivalent protection. Personnel protectedby personal
fall arrest system must exerciseadditional care when handling formworkcomponents.

5- STRIPPING FORMWORK
a)Follow manufacturer’s recommended fieldprocedures - generally, reverse the order
ofprocedures used in erection of formwork. Becertain that concrete has sufficiently set to carryits
own weight and any imposed loads prior tostripping formwork.

b)When gang-forming, secure the liftingmechanism prior to removal of ties, anchorsand/or

bracing.

c)Use extreme caution for all formwork toassure that no panel, walkway bracket, brace orany
other form component is unfastenedprematurely.

d) Assure that all disconnects have been madeand the bond of the formwork to concrete hasbeen
broken prior to lifting of gang form.

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Types of vertical formwork

Crane dependent Craneindependent

1. Crane dependent

1.1GANGED FORMING SYSTEMS

• Ganged forms are large wall form units that are made of panels joined together with
special hardware and braced with strong backs or special steel or aluminum frames.

• Gang forms can be made on the site, rented, or purchased from formwork manufacturers.

Sizes and Materials

Sizes of gang forms vary substantially from smaller units that are handled manually, too much
larger units that are handled and raised by cranes.

• Smaller gang forms(modular forms):

(2 _ 8 ft) (0.61 _ 2.44m) and (4 _ 8 ft) (1.22 _ 2.44 m), mass = (23 and 45 kg).
• Larger gang forms (gang forms):
(30 _ 50 ft) (9.1 _ 15.2 m).

• Gang forms can be made of:

1. Aluminum (all-aluminum),
2. Plywood face and aluminum frame,
3. Plywood face and steel frame,
4. Steel.

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1. All aluminum

All-aluminum gangs forms consist of aluminum sheathing supported by an aluminum frame

along with enter mediate stiffeners.

• The aluminum sheathing can be plain or take the shape of a brick pattern for architectural
finish.
• Aluminum sheathing is not popular because of its relatively higher cost and the tendency
of concrete to react chemically with aluminum.
• A common module for all-aluminum gang is 3 _ 8 ft (0.91 _ 2.44 m) panels.

2. Aluminum frame with plywood

• A more popular and widely used alternative to the all-aluminum gang forms is the
aluminum frame with plywood.
• This system is lighter and less expensive than the all-aluminum gang form.
• Plywood is attached to the aluminum frame by aluminum rivets or nail-type joist
• A common module for this system is 2 _ 8 ft (0.61 _ 2.44 m) panels.

3. Steel frame with plywood

• The third type of gang forms consists of a plywood face supported by steel walkers.
• Walers are typically made from double channels to allow ties to be inserted between the
channels and to reduce the deflection of the gang form.
• The advantage of this system over the above mentioned systems is its ability to carry
greater loads at longer distances between walers.

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• A common module for this system is the 4 _ 8 ft (1.22 _ 2.44 m) panel.

4. All – steel

• The all-steel gang form is made of steel sheathing and steel studs and Wales.
• This system is used to support fresh concrete for high, thick, and multiple lifts.
• This system has an unlimited number of reuses as long as good storage practices are
followed.
• A common module for this system is the 2 _ 8 ft (0.61 _ 2.44 m) panel because of its
heavy weight.

Gang Forms Assembly

1. Ganged forms are assembled on the ground, raised into place, and stripped as one unit.
2. Assembly of gang forms starts by placing the walers above lumber blocks on flat and
level ground.
For faster and more efficient assembly, a gang assembly table can be used instead of
assembling the gang on the ground.
3. Walers are then leveled, aligned, and locked in their proper position.
4. The nailer type beams are then placed on, and perpendicular to, the walers.
5. The nailer-type beams are attached to the walers by clips.
6. Twolumber-end pieces are then placed and attached to the walers.
7. The plywood is then placed and fastened by screws. Tie rod holes can be placed on the
ground; however, it is good practice to drill holes and insert tie rods when gang forms are
erected to ensure that holes on the two sides of plywood are matched.

Economy and Advantages of Gang Formwork

1. Productivity of gang forms is higher than traditional forms because they are assembled on
the ground and stripped as one unit.
2. Gang forms produce high-quality smooth concrete with fewer joints. Also, form liners
can be attached on the plywood to produce architectural concrete.
3. Gang forms have higher reuse value than traditional allwood formwork systems. Also,
plywood can be replaced without any need to replace the supporting frame

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1.2 JUMP FORMS

• Jump form systems are used where no floor is available on which to support the wall
formwork, or the wall and column proceed ahead of the floor.
• Jump forms consist of a framed panel attached to two or more strong backs.
• They can be one-floor high, supported on inserts set in the lift below, or two sets can also
be used, each one-floor high that alternately jump past each other

Jump Form Components

• Jump forms consists of two parts: an upper framed panel form with its supporting system

and working platform, and a supporting

structure that is attached to the concrete wall below the wall being placed.
• The function of the upper framed panel form is to support the freshly placed concrete.
• The supporting structure is attached to a stiff concrete wall.
• Its function is to support the upper framed panel form.

Upper Framed Panel Form

• The upper part consists of three main elements:
(1) framed panel form,
(2) supporting brace,
(3) working platforms.
• The framed panel form consists of a plywood face supported by two or more
strong backs.
• The frame panel form and the stong backs are supported by an adjustable pipe brace.
• The brace is used for plumbing and stripping of the frame panel form.

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• The strong back beams and the pipe brace are rested and connected to a horizontal beam
that is anchored to the top of the concrete wall underneath the wall being poured.
• The strong backs, brace, and the horizontal beam are forming a truss system that supports
the freshly placed concrete.
• Another function of the horizontal beam is to support the walkway under the lower
working platform.
• After the concrete gains enough strength to support its own weight, the framed panel
form is moved away from the concrete wall to allow the attachment of landing brackets
for the next pouring position and to finish concrete patching.
• The framed panel form is moved away by either tilting or moving horizontally by rollers
away from the concrete wall.
• There are two working platforms in the upper framed panel form. The upper working
platform is used to place and vibrate concrete and to attach the landing bracket (jump
shoe).
• The lower working platform has two functions:
(1) to allow construction workers to remove form ties and anchor bolts
(2) to clean and re-oil form panels.

The Supporting Structure

• The supporting structure is basically a support

mechanism for the framed panel form and its working
platforms.
• The lower part of the supporting structure is used as a
walkway for repair work of concrete.
• A ladder can be used and extended between the walkway
and the horizontal beam for repair work along the wall
height.

Process efficiency
• Fast construction can be achieved by careful planning of
the construction process.
• Crane availability is critical for normal jump form.
• Self-climbing formwork cuts down the requirement for
crane time considerably.

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• By allowing the crane to be used for other construction work this may reduce the total
number of cranes needed on site.
• The formwork is independently supported, so the shear walls and core walls can be
completed ahead of the rest of the main building structure.
• This can help to provide stability to the main structure during its construction and can
have the beneficial effect of taking the jump form core off the project critical path.
• High quality surface finishes are possible.
• Climbing forms can be designed to operate in highwinds (when the use of a crane is less
viable).
• This allows construction work to be carried out at reduced risk from adverse weather.
• The highly engineered nature of jump form systems allows quick and precise adjustment
of the formwork in all planes.
• Some formwork systems can be used at an inclined angle, which is particularly useful on
bridge pylons or where walls vary in thickness.
• A small but skilled workforce is required on site.
• It is easier to plan construction activities due to the repetitive nature of the work.

Safety

• Working platforms, guard rails, and ladders are built into the completed units of market-
leading formwork systems.
• Complete wind-shield protection on platform edges is also possible.
• Self-climbing formwork systems are provided with integral free-fall braking devices.
• The completed formwork assembly is robust and provides a stable working platform.
• The reduced use of scaffolding and temporary work platforms results in less congestion
on site.
• The setting rate of concrete in those parts of the structure supporting the form is critical in
determining the rate at which construction can safely proceed.
• The repetitive nature of the work means that site operatives can quickly become familiar
with health and safety aspects of their job.
• Formwork suppliers provide materials and resources to help train the labor force

Other considerations
• Jump form is typically used on buildings of five storeys or more; fully self-climbing
systems are generally used on structures with more than 20 floor levels.
• However, a combination of crane-handled and self-climbin platforms can be viable on
lower structures.
• Different systems have varying platform widths.

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• Wider platforms allow the shutter to be fully retracted when struck for cleaning and steel
fixing while narrower platforms use a tilting mechanism for shutter access.
• Trailing and suspended platforms are used for concrete finishing and retrieving cast-in
anchor components (climbing brackets) from previous pours.
•
Assembly and lifting operations for self-climbing formwork systems require personnel to
be comprehensively trained to ensure competence.
• It is necessary to understand and comply with suppliers’ method statements at all times.
• The raising operation must be carefully planned and coordinated, and access to the
working area during lifting should be restricted to essential personnel.
• Self-climbing systems can be designed to incorporate additional platform levels above
the main construction level.
• This enables steel fixing for the next casting cycle to start before striking and lifting the
formwork, enabling multiple operations to be performed simultaneously and offering
shorter construction cycle times.

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2. Crane independent
2.1Slip form
• Slip form is similar in nature and application to jump form, but the formwork is raised
vertically in a continuous process. It is a method of vertically extruding a reinforced
concrete section and is suitable for construction of corewalls in high-rise structures – lift
shafts, stair shafts, towers, etc.
• It is a self-contained formwork system and can require little crane time during
construction.
• This is a formwork system that can be used to form any regular shape of core.
• The formwork rises continuously, at a rate of about 300 mm per hour, supporting itself on
the core and not relying on support or access from other parts of the building or
permanent works.
• Commonly, the formwork system has three platforms. The upper platform acts as a
storage and distribution area while the middle platform, which is the main working
platform, is at the top of the poured concrete level. The
• lower platform provides access for concrete finishing.

The basic construction sequence using this formwork

is as follows:

1. The formwork and

the access platform
are assembled
on the ground.
2. The assembly is
raised using hydraulic
jacks.
3. As the formwork
rises continuously,
continuous concrete
and rebar supply are
needed until the
operation is finished.
4. At the end of the
operation the

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formwork is removed using a crane.

5. The entire process is thoroughly inspected and highly controlled.

Process efficiency
• Prudent and careful planning of construction
can achieve high rates of production.
• The slip form does not require a crane to
move upwards so the need for crane time is
reduced.
• Concrete supply, on the other hand, can be
heavily dependent on crane time or lift
availability since volumes required are well
below the capacity of normal concrete
pumps.
• As this formwork operates independently,
formation of the core in advance of the rest
of the structure takes it off the critical path.
• This can help to provide stability to the main
structure during its construction.
• The availability of the different working
platforms in the formwork system allows the
exposed concrete at the bottom of the rising
formwork to be finished, making it an
integral part of the construction process.
• Certain formwork systems permit construction of tapered cores and towers.
• Slip form systems require a small but highly skilled workforce on site.
Safety
• Working platforms, guard rails, ladders and wind shields are normally built into the
completed system.
• Reduced use of scaffolding and temporary work platforms results in a less congested
construction site.
• The completed formwork assembly is robust and provides a stable working platform.
• The strength of the concrete in the wall below must be closely controlled to achieve
stability during operation.
• The uniform and continuous nature of the work ensures that site operatives can quickly
become familiar with health and safety aspects of their job.
• Formwork suppliers provide materials and resources to help train the labour force.
• High levels of planning and control mean that health and safety are normally addressed
from the beginning of the work.

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Other sustainability features

• The repetitive uniform nature of the work, combined with the engineered nature of the
formwork, allows fine tuning of the construction operations, which in turn leads to
reduced concrete wastage.
• The formwork system is reusable with little waste generated compared to traditional
formwork.
• Slip form systems can offer safe and cost effective solutions for certain high-rise building
structures.
Other considerations
• This formwork is more likely to be economical for buildings more than seven storeys
high.
• Extensive planning and special detailing are needed as the process has little flexibility for
change once continuous concreting has begun.
• Standby plant and equipment should be available though cold jointing may occasionally
be necessary.
• The structure being slip formed should have significant dimensions in both major axes to
ensure stability of the system.
• The setting rate of the concrete has to be constantly monitored to ensure that it is matched
with the speed at which the forms are raised.
• Assembly and operations require personnel to be comprehensively trained to ensure
competence.
• It is necessary to understand and comply with suppliers’ method statements at all times.

Benefits
• Careful planning of construction process can achieve high production rates
• Slip form does not require the crane to move upwards, minimizing crane use.
• Since the formwork operates independently, formation of the core in advance of the
rest of the structure takes it off the critical path enhancing main structure stability.
• Availability of the different working platforms in the formwork system allows the
exposed concrete at the bottom of the rising formwork to be finished, making it an
integral part of the construction process.

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• Certain formwork systems permit construction of tapered cores and towers.

• Slip form systems require a small but highly skilled workforce on site.
Limitations
• This formwork is more economical for buildings more than seven stories high.
• Setting rate of the concrete had to be constantly monitored to ensure that it is matched
with the speed at which the forms are raised.
• The structure being slip-formed should have significant dimensions in both major
axes to ensure stability of the system.
• Extensive planning and special detailing are neededas the process has little flexibility
for change oncecontinuous concreting has begun.

3.1 Self-raising system

SELF-RAISING FORMWORK SYSTEM
Self-Raising Forms
• In the last decade self-raising forms have become more popular in construction involving
repetitive vertical forming. Their popularity may be attributed to the fact that they raise
themselves, without crane assistance, in sequence with the casting operations. This crane
independent system is very efficient in congested sites. Therefore crane costs and
construction time are reduced. In addition, the concrete finish resulting from using self-
raising forms is of higher quality than the one produced by slipform.
• Self-raising forms have not been limited to the construction of exterior building walls.
They have also been used to construct building columns, dam faces, nuclear reactor
containment, cooling towers, bridge piers and elevator shafts. Along with special attached
form liners, a wide range of different architectural finishes or textures can be obtained.
Advantages
• Minimize Cost
• Speed of construction
• Reduce the labor Force
• Safety starting from planning and managementof a project continuing on down to the
equipment and theworkers.
• Quality

Limitations
• Experienced staff is needed for several weeks for field service and to train workers,
which may introduce addedcosts.
• Site must be fairly accessible since forms are preassembledand may be large in size.

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• The initial cost of the self-raising system is much largerthan other formwork systems.
• The formwork system is economically used only for structures20 stories or higher.
• Changes in wall size and/or location during constructionare expensive and impact
schedule.

4) SOME COMMON CAUSES OF FORM FAILURES

• Exceeding design (working) pressure:
(1) Excessive rate of pour
(2) Mix design not taken into account
(3) Improper vibration
(4) Temperature not taken into account
• Ties not placed properly.
• Ties in place, but improperly fastened (insufficient thread engagement, etc.).
• Improper design -- particularly when layouts were not provided by manufacturer.
• Job-built fillers, corners and bulkheads which are not adequately designed by
fieldpersonnel and become the weak-point of the system.
• Failure to brace at least one side of formwork.
• Connecting hardware not installed.
• Lack of inspection by qualified personnel to see that form layout has been interpreted

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5) Case study:
The tower was constructed by South Korean company, Samsung Engineering & Construction,
which also did work on the Petronas Twin Towers and Taipei 101. Samsung Engineering &
Construction built the tower in a joint venture with Besix from Belgium and Arabtec from UAE.
Turner is the Project Manager on the main construction contract.

Under UAE law, the Contractor and the Engineer of Record, Hyder Consulting, is jointly and
severally liable for the performance of BurjKhalifa.

The primary structural system of BurjKhalifa is reinforced concrete. Over 45,000 m3 (58,900
cu yd) of concrete, weighing more than 110,000 tonnes (120,000 ST; 110,000 LT) were used to
construct the concrete and steel foundation, which features 192 piles, with each pile is 1.5 metre
diameter x 43 metre long buried more than 50 m (164 ft) deep.BurjKhalifa's construction used
330,000 m3 (431,600 cu yd) of concrete and 55,000 tonnes of steel rebar, and construction took
22 million man-hours.A high density, low permeability concrete was used in the foundations of
BurjKhalifa. A cathodic protection system under the mat is used to minimize any detrimental
effects from corrosive chemicals in local ground water.In May 2008 concrete was pumped to a
then world record delivery height of 606 m (1,988 ft),the 156th floor. The remaining structure
above is built of lighter steel.

BurjKhalifa is highly compartmentalised. Pressurized, air-conditioned refuge floors are located

approximately every 35 floors where people can shelter on their long walk down to safety in case
of an emergency or fire.

Special mixes of concrete are made to withstand the

extreme pressures of the massive building weight; as is
typical with reinforced concrete construction, each batch
of concrete used was tested to ensure it could withstand
certain pressures. CTLGroup, working for SOM,
conducted the creep and shrinkage testing critical for the
structural analysis of the building.

The consistency of the concrete used in the project was

essential. It was difficult to create a concrete that could
withstand both the thousands of tonnes bearing down on it
and Persian Gulf temperatures that can reach 50 °C
(122 °F). To combat this problem, the concrete was not
poured during the day. Instead, during the summer months
ice was added to the mixture and it was poured at night
when the air is cooler and the humidity is higher. A cooler
concrete mixture cures evenly throughout and is therefore

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less likely to set too quickly and crack. Any significant cracks could have put the entire project in
jeopardy.

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