5 Things to Know Before Buying Concrete Formwork Systems

Concrete formworks are temporary structures that support fresh concrete until it gains enough strength to become a self-supporting unit. These formworks are indispensable in construction processes and play a critical role in ensuring the quality, strength, and durability of concrete structures. In this article, we will highlight the top five concrete formwork systems that enhance construction efficiency, their benefits, application areas, and how to choose the right one for your project.

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Understanding Concrete Formwork

Concrete formwork refers to the temporary moulds or structures used to contain and support freshly poured concrete until it has set and developed enough strength to support itself. These systems are crucial in determining the final appearance, strength, and quality of concrete structures.

Types of Formwork Materials

Concrete formworks can be made from various materials, each offering distinct advantages:

Material Description Advantages Wood Traditional and versatile Economical, readily available, adaptable Steel Durable and reusable High strength, long-lasting, suitable for large projects Aluminum Lightweight and corrosion-resistant Easy to handle, resistant to rust Plastic Ideal for curved surfaces and special designs Flexible, lightweight, quick setup Fiber-reinforced polymers Strong and lightweight Resistant to corrosion, highly durable

Importance of Efficient Formwork Systems

Efficient formwork systems offer numerous benefits that contribute to the overall success of a construction project. Some key reasons for their importance include:

Benefit Description Increased Construction Speed Formwork systems help speed up the construction process by reducing setup time and improving labor efficiency. Improved Quality and Accuracy They ensure that the concrete structure is accurately, minimizing defects. Enhanced Safety Proper formwork reduces the risk of accidents by providing stable support for workers and materials. Cost Reduction Efficient systems reduce waste, downtime, and the need for repairs, leading to cost savings. Sustainability By optimizing material use and reducing waste, efficient formwork practices contribute to environmentally-friendly construction.

Choosing the Right Formwork System

When selecting a concrete formwork system, several factors should be considered:

Factor Considerations Project Scope and Size Larger projects may require more durable and reusable systems, while smaller ones can benefit from lightweight options. Material Availability Availability and cost of materials in your location can influence your choice of formwork. Design Requirements Special designs or curved surfaces might need specific formwork, such as plastic or custom molds. Project Timeline If time is of the essence, fast-setting formworks like plastic or aluminium may be ideal. Budget Evaluate the total cost of materials, setup, and labour when selecting a system.

By carefully considering these factors, you can ensure the selection of the most efficient and cost-effective formwork system for your construction project.

Top 5 Concrete Formwork Systems

The following are the top five concrete formwork systems that offer various advantages, and their application areas:

A. Metal Formwork Systems

Metal formwork systems are available in steel and aluminium and boast several advantages in strength, durability, and reusability compared to traditional timber formwork.

Material Advantages Disadvantages Applications Steel Highly strong and durable Heavy weight and higher initial costs High-rise buildings, large infrastructure projects Aluminium Excellent for repetitive use Requires more maintenance for corrosion protection Repetitive structural elements (columns, beams, etc.) Precise and smooth concrete finishes May not be suitable for small projects Less labour costs due to speedy assembly Higher transportation costs due to weight

The fast and precise assembling of metal formwork systems saves labour costs and time for the whole project. They can also bear high pressures of concrete, making them suitable for constructing high-rise structures with high-quality finishes.

B. Plastic Formwork Systems

Plastic formwork systems find increasing usage due to their lightweight and resistance to corrosion.

Material Advantages Disadvantages Applications Plastic Light in weight and easy to handle Less durable for heavy or repetitive use Architectural concrete elements Resistance to corrosion Limited reusability compared to metal Curved walls and structures Can be used on curved surfaces and in complicated geometries Not suitable for high-pressure concrete projects Projects in corrosive environments Cleaning and maintenance are very easy Less precise finish compared to metal forms

Plastic concrete formwork is especially helpful in developing special shapes and designs for concrete structures. Its light weight enables easy transportation and handling at the site, and its resistance to corrosion makes it long-lasting even in corrosive environments.

C. Prefabricated Formwork Systems

Prefabricated concrete formwork systems, including precast concrete panels and modular formwork options, speed up construction activities by allowing fabrication and assembly off-site.

Material Advantages Disadvantages Applications Prefabricated Panels Less on-site labour Requires significant upfront planning and design Large-scale residential and commercial projects Modular Systems Better quality control Can be expensive depending on scale Standardized building elements Faster project completion May need specialized handling and storage space Projects with tight schedules Consistent concrete finishes Limited flexibility for custom designs

These systems significantly reduce on-site labour, improve quality control, and accelerate project completion. They are particularly useful for projects with repetitive elements or those requiring rapid construction.

D. Slip form Concrete Systems

Slip form concrete systems involve a continuous pouring method where the formwork moves upward as concrete is poured, creating tall structures efficiently.

Material Benefits Disadvantages Applications Slip form Systems Rapid construction of tall structures Requires skilled operators Silos and storage tanks Continuous concrete placement Limited to certain types of structures Bridge piers and towers Reduced formwork assembly and disassembly time High initial setup cost High-rise buildings Uniform concrete quality Limited flexibility for irregular shapes

This method is highly efficient for constructing tall, uniform structures like silos, bridge piers, and high-rise buildings. It allows for continuous concrete placement, resulting in a seamless structure with minimal cold joints.

E. Traditional Timber Formwork

Despite advancements in formwork technology, traditional timber formwork remains a cost-effective and versatile option for many construction projects.

Material Benefits Disadvantages Applications Timber Low initial cost Limited durability for large or repetitive use Residential construction Easily customizable on-site Requires more time for assembly and disassembly Small-scale commercial projects Suitable for small-scale projects Not ideal for high-pressure or complex designs Custom or unique structural elements Familiar to most construction workers Limited reusability compared to other materials

Timber formwork is particularly useful for projects with unique or custom elements that require on-site modification. Its low initial cost makes it attractive for smaller projects or those with limited budgets.

By selecting the appropriate concrete formwork system based on your project's specific needs'whether it's for high-rise buildings, small-scale projects, or specialized designs'you can ensure efficient construction processes and cost-effectiveness.

Benefits of Modern Formwork Systems

Modern concrete formwork systems come with a load of advantages over traditional ones, hence the increased efficiency and quality in construction projects.

A. Increased Efficiency

The modern formwork system, especially prefabricated and modular designs, hugely saves labour costs and enhances the speed of construction3. This means faster completion of projects and reduced site disruption.

B. Quality and Accuracy

Advanced formwork systems are pre-engineered for consistent, smooth concrete finishes and superior structural integrity3. Such heightened quality reduces the necessity of expensive rework, generally improving the appearance of the finished structure.

C. Improved Safety

Formwork systems can provide a stable and secure structure on which workers can operate, reducing the risk of accidents and injuries1. Modern systems are designed to bear wet concrete weight with minimal chance of collapse or other structural failure.

D. Cost-Effectiveness

While the initial investment in modern formwork materials is higher compared to traditional methods, the possibility of reusing forms multiple times reduces the cost substantially in the long run1. Greater efficiency and accuracy can also have a major impact on improving labour costs and reducing rework.

E. Sustainability

Many of the formwork systems today are produced with recycled materials and significantly reduce waste, thus giving a greener construction. The reusability and durability of the formwork systems further reduce environmental impacts at the construction site.

Selection of Concrete Formwork System

The right concrete formwork system is imperative for any concrete construction to be successful. There are several factors that have to be considered in arriving at the right choice of formwork system.

A. Factors to Consider When Choosing a Formwork System

Selecting the right formwork system is a critical step in ensuring the success of a concrete construction project. Below are the key factors to evaluate:

Factor Description Project Requirements Analyse the design needs of the structure, including shape, size, complexity, loading, and durability. Site Conditions Consider weather, soil conditions, and site access to ensure compatibility with the environment. Budget Evaluate initial costs, long-term value, reusability, and potential labour savings. Construction Timeline Assess the impact of assembly and disassembly times on the project schedule. Concrete Finish Determine the desired surface finish, as formwork material can influence appearance. Safety Prioritize systems offering enhanced safety features and stability. Reusability Opt for formwork with high reuse potential to lower the cost per cycle. Flexibility Select systems that can adapt to changes or complex shapes as required by the design.

B. Matching Concrete Formwork to Project Needs

To ensure the chosen formwork system meets the demands of your project, follow these steps:

1. Assess the specific requirements of your project, including structural design, timeline, and budget constraints.
2. Consider the expertise of your construction team and their familiarity with different formwork systems.
3. Evaluate the long-term cost-effectiveness of each option, including potential for reuse in future projects.
4. Consult with formwork suppliers or specialists to get expert advice on the best system for your specific needs.

By carefully considering these factors, you can choose a formwork system that ensures the success of your concrete construction project while maximizing efficiency and quality.

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Frequently Asked Questions

What is the most common type of formwork?

Traditional timber formwork remains one of the most common types due to its versatility and low initial cost. However, metal and plastic formwork systems are increasingly popular for larger or more complex projects.

How long does concrete take to set in formwork?

The setting time for concrete in formwork depends on concrete mix, temperature, and humidity. Normally, the concrete attains initial set in 24-48 hours but takes 7-28 days to achieve complete strength.

Can formwork be reused?

Yes, most modern formwork systems are designed to be used many times. Metal and plastic formworks can be re-used hundreds of times; however, timber formwork may be used a fewer number of times.

What is the difference between concrete formwork and shuttering?

Formwork and shuttering are two terms that are very much used interchangeably. However, shuttering does refer to the vertical forms for walls and columns, while formwork is the general term for temporary structures that carry and shape concrete.

Conclusion

The various effective concrete formwork systems that modern concrete construction presents offer efficiency, quality, safety, and cost-effectiveness. It is important to understand different types of formwork systems and consider project requirements very carefully in order for a construction professional to choose an appropriate system that will meet the demands of successful and efficient concrete construction.

With the development of technology, we can very well expect further innovations in formwork systems, which will translate into greater improvements in construction efficiency and sustainability. The use of such advantages will no doubt be highly relevant to securing competitiveness within an ever-changing construction environment.

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Summary

Whether it's better for a company to rent or purchase formwork items and systems depends on the kind of project under development and the time it will take to complete. Either way, the supplies needed must be of high quality and durability to ensure the timely, accident-free completion of the work. This means that your formwork provider should be a professional who has the requisite capacity to meet a project's needs, as well as the technical know-how to customize options and deliver.

Therefore, it is advisable that you watch out for suppliers with a limited product range. Often they will cut prices on standard-forming jobs but will have to quit when it comes to the more challenging part where know-how is needed. By contrast, a more experienced provider with an extensive range can supply custom-made forms.

Ultimately, it pays to only buy or rent from established companies with extensive experience. Ensure that the company you select offers professional and on-time design, with the technical capabilities to provide support to your engineering teams. You should be wary of formwork companies that offer discounted rates as they tend to use counterfeit products. Moreover, they do not maintain equipment to the best standards. This fails to provide the safety and peace of mind that you need to ensure quality work on your project.

In this report, we highlight what you should look out for when choosing a formwork provider for your construction needs.

INDEX

1. Safety and quality
2. Value for money
3. Experience
4. Ease of assembly
5. Capacity and deliverables

ADDITIONAL FORMWORK RECOMMENDATIONS

5 THINGS YOU NEED TO KNOW WHEN CHOOSING YOUR FORMWORK PROVIDER

When it comes to choosing your formwork provider, you cannot afford to make your decision too quickly. There are specific things that you need to look for when purchasing or hiring formwork systems. The correct formwork can make a construction project a success, whereas using the wrong systems can literally bring down a building.

Formwork makes up about 1.2% of the total costs of a building's structural work. But you would be incorrect in thinking the role it plays is simple and insignificant. In fact, choosing good quality from a reliable provider is one of the most important decisions you'll make for your project.

Here are five things you need to look for when selecting a formwork provider for your next construction project.

1. Safety and quality

It goes without saying that safety and quality are of the utmost importance with any type of formwork or scaffolding. That's why you should look for a provider who is committed to the following:

• Meets certification: Devastating accidents can happen when forms are removed too soon before the building material has set. Equally, poor and under-designed formwork can bend or even break during the filling process because it does not meet certification.
  Make sure your supplier and their products meet the necessary safety standards set by your country or region for construction work and products. It pays to familiarize yourself with the certificates required, and cross-check if your formwork provider has them.
• Cares about quality: You must consider your provider's product in the decision-making process.
  For example, steel-framed wall formwork with standard plywood facing requires more maintenance and repair than a hot-dipped galvanized steel frame that uses specially manufactured plywood designed for longer life.
• Meets maintenance standards: Before deciding on your formwork provider, you need to ensure that they thoroughly inspect and test their hire equipment to guarantee the strength and quality of each piece.
  You will be surprised to find out that not many companies invest in the meticulous upkeep and maintenance of their hire equipment.
• Does not use counterfeit materials: The use of counterfeit products is a major cause of accidents on project sites. That's why it's important to know the difference between a genuine product that can bear your required workload.
  Sourcing from an inexperienced or questionable formwork provider means that you may receive a faulty product, which can have dangerous consequences. It helps to know that the Middle East is a major market for counterfeit products due to the high number of imports and exports in the region.One way you can identify counterfeit formwork products is if the discount is too good to be true. Products certified by the manufacturer will not be available at steep discounts, whereas counterfeit items, which use inferior materials, can offer a lower price point, but it comes with the potential for catastrophic consequences.
• Enjoys good industry reputation: A formwork provider who has repeat business and customer recommendations will also have a market reputation for safety and quality.

2. Value for money

The simple truth is that quality formwork systems do not have to be exorbitantly expensive. In designing and building formwork, you should aim for maximum economy, which you can do by focusing on the following points:

• Clever design can contribute greatly to the overall costs. Find a form provider who can offer expert engineering and technical support to projects of all shapes and sizes.
  The formwork should be well-priced, with systems that are durable, reusable, and quick to erect. Well-engineered formwork will give your project enhanced productivity whilst reducing expense.
• Your formwork provider should offer updated systems to help you reduce, or ideally altogether remove, the need for conventional formwork like timber and plywood.
  More old-fashioned kinds of formwork have more wastage and are typically designed as single-use.  Using a modern, more up-to-date system is better for your project's bottom-line and the environment.
• Be wary of huge price differentials. Expanding on the point above, as a buyer you need to be conscious of how products should be priced so that you can understand when you are getting a cost-effective solution versus a suspect, possibly counterfeit, product.
  If the product is more than 20% cheaper than other systems, that should raise some red flags. More likely than not, heavily discounted products are counterfeit and could be ineffective, or possibly dangerous.

3. Experience

Look for someone with proven formwork experience across a variety of sectors. The following factors will help you determine if a possible provider has the experience you need for your project.

• Market reputation: Reputations are built through repeat success, over several different kinds of projects.
  Not all projects are the same, and you want a provider with a commitment to service excellence and a 'can-do' approach, no matter the type of project.
• Low accident rate: Whilst it may not be possible to find a formwork provider with absolutely no accidents in their entire history, you should look for someone with the least number of incidents.
  Ensure that the formwork they provide is strong and well-maintained and can work across all weathers ' especially bear the expansion and contraction that comes from extreme heat and cold.
• Local industry familiarity: Sourcing someone who has worked in the local market means that they are familiar with the nuances of climate constraints, logistics support, as well as local workforce idiosyncrasies. It also gives them the added advantage of responding quickly and with flexibility.
• Credit history: It's an industry fact that the formwork and scaffolding sector continues to grapple with payment challenges, especially with the pandemic disrupting all industries.
  As a customer looking to hire modular support, it is better to use caution and choose a company with a reliable credit history. A formwork provider who is caught between payment cycles will be strapped for cash and may fall behind on material upkeep.

4. Ease of assembly

Formwork systems should be quick and easy to erect and dismantle and have the following attributes:

• Scalability: Finding a local formwork provider means that, in addition to being able to respond quickly to your need to scale scaffolding or modular formwork up or down, they can also quickly recycle panels, beams, and features.
  Sourcing from a smart provider who has provisions means that vertical formwork products with fewer components than traditional econo-form panels have the added advantage of saving you time and effort on shutter assembly.
• Customizable solutions: A formwork company needs to be able to identify each project's needs and develop an appropriate solution. You should choose a provider who can customize existing modular structures to suit your specific requirements. Some projects may require a self-climbing system, for example, and your formwork supplier needs to be able to provide such solutions.

5. Capacity and deliverables

Make sure your formwork supplier has sufficient product and capacity by examining these elements.

• Resources: It is imperative that your formwork provider has adequate manpower (including labor if required) and the technical expertise to do the job well.
  To determine the most efficient solution for a project, a contractor will evaluate several options to optimize resource utilization. Among the other considerations, the choice of formwork and how it is applied is of prime importance.
• Network: It also helps if a formwork company has multiple branches across cities, especially near your project sites. This gives you added coverage to ensure the timely supply and wide distribution of products and services.
• Consumables: If your formwork provider sells a range of handy formwork consumables, like tie cases, slab and wall separators, steel wool, and molding agents, among others, it is an added advantage as they can function as a one-stop-shop for your formwork needs and advice.
• Timeliness: During the construction process, the concrete formwork has a very central role to play in the construction timelines of the project. A provider who keeps to schedule will be an asset.

ADDITIONAL FORMWORK RECOMMENDATIONS

It goes without saying that you need to source the right kind of materials for specific construction requirements. A professional formwork provider knows these requirements.

Although many formworks have certain commonalities that can be used in most construction situations, in modern times, the design specificity and related mechanical requirements are more demanding on the bearing capacity of concrete buildings, and their shapes.  Therefore, you must be careful to choose an informed provider who has the latest equipment at their disposal.

To guide buyers through the challenge of sourcing technical formwork, we list some products here to help you familiarize yourself with available options.

You may consider asking your provider for more details when it comes to supporting your construction needs.

• Dokaflex: The Dokaflex is a hand-operated floor formwork system, which consists of only a few components, making it easy and fast to set up.
  The props' high load-bearing capacity is complemented by numbered holes for easier height adjustment. With special thread geometry, it is easier to release, even when under a high load. This reduces the user's handling time.
• Framax Xlife: Framax Xlife has been developed to meet the increasing demand for faster and more cost-effective forming by including long-life plywood.
  Due to the plastic coating on the Xlife sheet, the pre-designed panels offer durability and a high number of re-use cycles. Applicable to different wall heights and cross-sections of columns, the panels can be erected quickly and re-used for new applications.
• Peri GT24: The Peri GT24 is a girder, which is used for slab and wall formwork solutions. The product can be used in systems such as Peri's Multiflex, a slab formwork system used for any slab thickness, floor plan, and height, and Vario GT24, a girder wall formwork system with adjustable element connections.
• ACS climbing bracket: The ACS is a bracket, which climbs smoothly and evenly on climbing rails using hydraulic pumps. It has a lifting power of 100 kilonewtons and raises the unit to the next pour without the need for an intermediate anchor.
• Mammut 350: This wall formwork system has been on the market since . It incorporates an all-plastic facing, which lasts as long as the frame, never needs to be replaced, and survives an unlimited number of re-uses.
  The Mammut 350 is ideal for civil engineering projects, as well as for industrial and engineering construction. The system can take 100 kilonewtons per meter square of concrete.
• MEP shoring system: The MEP shoring system can support slab formwork at all heights, from underground carparks to high structures, and is integrated with a safety latch and two prop options for normal and heavy-duty loads in one system.
• H20 Wall and Column Formwork: With this system, wall and column elements are pre-assembled on-site and are used for all types of shear, core, and single-sided walls.
• GFT 20 Support Tower: This system incorporates galvanized steel frames. It is mainly used for high and heavy slabs, beams, and bridges.
• Ulma CC-4: CC-4 is a modular aluminum drop-head panel system used for large areas of flat deck slabs. It is a portable and light slab system that requires no crane. Early striking can be achieved with this product.
  Its main elements are made of aluminum, and it can be erected quickly as its stand-alone grid structure allows one team to set up the grid, whilst another team puts the panels in place.
• Ulma LGR: Launched in January , the LGR system is an engineer-profiled steel lightweight panel system specially designed for columns and extensively used in villa projects.
  LGR allows for an easy and fast erection because it is portable, and its accessories are fixed to the panel so there are no lost parts. Its formwork surface includes long-lasting plastic (no plywood) and it can withstand pouring pressures of up to 80 kilonewtons per meter square.
• Ischebeck Titan: The Ischebeck Titan's range of legs and props offers fast, effective support for formwork during in-situ and precast casting operations as well as for back-propping of recently cast slabs. Buyers can choose from Titan aluminum legs, push-pull props, steel props, and aluminum props.
• Ischebeck Noetop: Ischebeck Neotop is a large, high-strength formwork system used for efficient casting of walls in a wide variety of situations. The system sustains concrete pressures up to 88 kilonewtons.

For more information on modular formwork and scaffolding, what would work best for your project, and how you can get the support you need to ensure your construction is safe and efficient, contact the experts at SSF by clicking here.