Materials and Technology in Formwork

Module 5: Materials and Technology in Formwork

1. Innovative Materials

Modern formwork systems are leveraging advanced materials to improve efficiency, sustainability, and adaptability.

• Plastic Formwork

• Lightweight & Modular: Polypropylene systems (e.g., Nest-In by Tata Steel) for fast assembly.

• Advantages: Corrosion-proof, reusable (50+ cycles), and ideal for low-cost housing.

• Limitations: Lower load capacity than steel; not suitable for heavy structures.

• Fiberglass Formwork

• High-Strength & Weather-Resistant: Used in marine environments or chemical plants.

• Applications: Curved structures (e.g., tunnels, domes) due to flexibility.

• Challenges: Brittle under impact; requires careful handling.

• Hybrid Systems

• Composite Panels (GFRP + Aluminum): Combines lightweight and high durability.

• Example: PERI’s ACS (Aluminum Composite System) for bridges and high-rises.

2. Digital Tools for Formwork Planning

Digitalization is revolutionizing formwork design, reducing errors, and optimizing resource use.

• Building Information Modeling (BIM)

• 3D Visualization: Clash detection between formwork, rebar, and MEP systems.

• 4D Scheduling: Links formwork erection to project timelines (e.g., Navisworks).

• 5D Cost Estimation: Tracks material and labor costs in real-time.

• Formwork-Specific Software

• AutoCAD: Drafting precise formwork layouts and shop drawings.

• Tekla Structures: Detailing complex formwork connections and steel supports.

• PERI CAD / Doka iQ: Pre-configured modular formwork libraries.

• On-Site Digital Tools

• Laser Scanning: Verifies as-built vs. designed formwork alignment.

• Augmented Reality (AR): Overlays digital plans onto physical formwork (e.g., Trimble XR10).

Case Study: BIM in Burj Khalifa

• Used Tekla Structures to plan climbing formwork for the tower’s tapered wings.

• Reduced rework by 30% through clash detection before pouring.

Future Trends

• AI-Powered Optimization: Algorithms suggest material-efficient formwork designs.

• Robotic Assembly: Drones or robots for automated formwork placement.

Key Takeaways:

1. Plastic/Fiberglass forms offer niche benefits (lightweight, corrosion resistance).

2. BIM & Tekla minimize errors and improve collaboration.

3. AR/Scanning ensures precision in complex layouts.