Module 2: Advanced Formwork Systems
1. Engineered Formwork
Engineered formwork systems are prefabricated, modular solutions designed for efficiency, precision, and large-scale construction projects. These systems reduce labor costs, improve cycle times, and enhance safety.
Table Forms (Flying Forms):
Large, pre-assembled horizontal platforms used for slab construction.
Supported by telescopic props or hydraulic jacks for easy adjustment.
Applications: High-rise buildings (repetitive floor layouts), parking structures.
Advantages: Rapid installation/reuse, reduced manual labor.
Slip Forms:
Continuously moving formwork that slides upward as concrete is poured.
Uses hydraulic jacks on vertical rods to lift the formwork at a controlled rate (~15–30 cm/hour).
Applications: Chimneys, silos, bridge piers, and core walls in skyscrapers.
Advantages: No joints, seamless construction, ideal for tall, uniform structures.
Climbing Forms:
Formwork that "climbs" upward in segments as each concrete section sets.
Can be self-climbing (hydraulic/powered) or crane-lifted.
Applications: High-rise cores, bridge pylons, and shear walls.
Advantages: Eliminates need for external scaffolding, improves safety at heights.
2. Modular and Reusable Systems
Modern construction emphasizes sustainability and cost-efficiency, driving demand for modular formwork.
Aluminum & Plywood Panel Systems (e.g., Mivan, PERI, Doka):
Mivan Formwork: Lightweight aluminum system for rapid mass housing projects.
Uses pre-fabricated wall & slab panels with pin connections.
Best for: Low-cost residential projects with repetitive layouts.
PERI/Doka Systems: Engineered plywood/steel hybrid systems with high reusability.
Adjustable wall formwork, girder slab systems, and column forms.
Best for: Commercial buildings, bridges, and industrial structures.
Cost-Benefit Analysis of Reuse:
Initial Cost vs. Long-Term Savings:
High upfront investment but reduces labor and material costs over multiple uses.
Example: Aluminum forms can be reused 200–300 times, plywood 10–20 times.
Time Efficiency:
Modular systems cut assembly time by 30–50% compared to traditional timber.
Sustainability:
Less waste generation, lower environmental impact than disposable formwork.
Maintenance Costs:
Steel/aluminum requires cleaning and minor repairs; timber degrades faster.
Key Takeaways:
Engineered formwork (slip, climbing, table forms) is ideal for fast, large-scale projects.
Modular systems (Mivan, PERI) balance speed, cost, and reusability.
Reuse economics favor long-term projects with repetitive elements.
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