Timber Shuttering:

While Roadform is the formwork of choice for simple slabs, there are situations where it is simply not possible of feasible to use it, and so the more traditional timber shuttering is used. The great advantage of timber shuttering over Roadform is that, because it is 'knocked-up' on site, it can be made to accommodate any situation, ranging from odd shapes, to greater depths. Timber shuttering is also the usual choice for vertical concrete work, although it is often used in conjunction with modular steel bracing elements. The part of the shutter in contact with the concrete is known as the form lining, while the support timbers are collectively known as 'bracing' and consists of horizontal walers and vertical noggins. The size of timbers used for the bracing depend upon the size of the formwork; a simple 300mm high shutter for a ground slab may use 50x50mm timber to form the walers and noggins, whereas a 1 metre high shutter would be more likely to use 100x50mm timbers. The bracings are formed from straight and true timber and are always used end on, that is, the deepest way, to give as much support as possible. The form lining is normally some form of plywood. 15mm or 18mm is the most commonly used, with WBP (Weather and Boil Proof) being preferred as it is less prone to delaminating in the damp conditions experienced by timber shuttering in contact with wet concrete and outdoors. Occasionally, hardboard may be used, or, increasingly, exterior grade MDF (Medium Density Fibreboard). On projects involving a substantial quantity of timber formwork, a film-faced special shuttering board may be used, but this is not always stocked by Builders' and Timber Merchants and needs to be ordered in advance.

Formwork carpentry is a specialist trade and for vertical structures, the bracing can become extremely complex, requiring design by structural engineers and the use of wedges to maintain alignment. Us simple folk in the groundworks trade, who rarely risk venturing above ground level, prefer to rely on straightforward raking braces to support the formwork we erect for ground slab construction.

The spacing between walers and between noggins also depends on the size of the shutter, but is generally 300-600mm. Bracing timbers are usually the same size, if not bigger than the timber used for the walers and noggins. In some cases, adjustable steel props known as 'Acrows' may be used as raking or horizontal braces. All brace members are securely fastened to the formwork, usually by nails, as they are easiest to withdraw when striking the formwork on completion of the work. This fastening is essential as it prevents the brace members 'springing', that is, flying loose under the pressure of the wet

concrete and finishing equipment.

The ground pegs should be driven in to a depth of at least 450mm. In soft ground, a spreader board may be needed behind the peg to prevent it being forced back into the ground by the weight of the concrete. Alternatively, a "sole plate", usually a plank, will span several pegs and help spread the loading more evenly. The raking and horizontal braces will then be nailed to the sole plate.

Flexible plywood can be used to construct the form lining to arcs and radii on timber shuttering. The plywood is traditionally 'kerfed' on one face to help the timber bend without breaking. This is done by sawing shallow notches (2-6mm deep) into the face or back of the form lining and then nailing it onto a pre-constructed waller bracing structure.

One face of form lining is "kerfed"

TYPES OF FORMWORK (SHUTTERING)

Formwork is an ancillary construction, used as a mould for a structure. Into this mould, fresh concrete is placed only to harden subsequently. The construction of formwork takes time and involves expenditure upto 20 to 25% of the cost of the structure or even more. Design of these temporary structures are made to economic expenditure. The operation of removing the formwork is known as stripping. Stripped formwork can be reused. Reusable forms are known as panel forms and non-usable are called stationary forms. Timber is the most common material used for formwork. The disadvantage with timber formwork is that it will warp, swell and shrink. Application of water impermeable cost to the surface of wood mitigates these defects.

A good formwork should satisfy the following requirements: 1. It should be strong enough to withstand all types of dead and live loads. 2. It should be rigidly constructed and efficiently propped and braced both horizontally and vertically, so as to retain its shape. 3. The joints in the formwork should be tight against leakage of cement grout. 4. Construction of formwork should permit removal of various parts in desired sequences without damage to the concrete. 5. The material of the formwork should be cheap, easily available and should be suitable for reuse. 6. The formwork should be set accurately to the desired line and levels should have plane surface. 7. It should be as light as possible. 8. The material of the formwork should not warp or get distorted when exposed to the elements. 9. It should rest on firm base.

Economy in Formwork The following points are to be kept in view to effect economy in the cost of formwork: 1. The plan of the building should imply minimum number of variations in the size of rooms, floor area etc. so as to permit reuse of the formwork repeatedly. 2. Design should be perfect to use slender sections only in a most economical way. 3. Minimum sawing and cutting of wooden pieces should be made to enable reuse of the material a number of times. The quantity of surface finish depends on the quality of the formwork.

Formwork can be made out of timber, plywood, steel, precast concrete or fibre glass used separately or in combination. Steel forms are used in situation where large numbers of reuse of the same forms are necessary. For small works, timber formwork proves useful. Fibre glass made of pre-cast concrete and aluminium are used in cast-in-situ construction such as slabs or members involving curved surfaces.

Timber Formwork:
Timber for formwork should satisfy the following requirement: It should be 1. well seasoned 2. light in weight 3. easily workable with nails without splitting 4. free from loose knots

Timber used for shuttering for exposed concrete work should have smooth and even surface on all faces which come in contact with concrete.

Normal sizes of members for timber formwork:

Sheeting for slabs, beam, column side and beam bottom Joints, ledges Posts 50 x 70 mm to 50 x 150 mm 75 x 100mm to 100 x 100 mm 25 mm to 40mm thick

Plywood Formwork
Resin bonded plywood sheets are attached to timber frames to make up panels of required sizes. The cost of plywood formwork compares favourably with that of timber shuttering and it may even prove cheaper in certain cases in view of the following considerations: 1. It is possible to have smooth finish in which case on cost in surface finishing is there. 2. By use of large size panels it is possible to effect saving in the labour cost of fixing and dismantling. 3. Number of reuses are more as compared with timber shuttering. For estimation purpose, number of reuses can be taken as 20 to 25.

Steel Formwork
This consist of panels fabricated out of thin steel plates stiffened along the edges by small steel angles. The panel units can be held together through the use of suitable clamps or bolts and nuts. The panels can be fabricated in large number in any desired modular shape or size. Steel forms are largely used in large projects or in situation where large number reuses of the shuttering is possible. This type of shuttering is considered most suitable for circular or curved structures.

Steel forms compared with timber formwork:

reuses are more in number.

1. Steel forms are stronger, durable and have longer life than timber formwork and their

2. Steel forms can be installed and dismantled with greater ease and speed. 3. The quality of exposed concrete surface by using steel forms is good and such surfaces need no further treatment. 4. Steel formwork does not absorb moisture from concrete. 5. Steel formwork does not shrink or warp.

Construction of formwork:
This normally involves the following operations: 1. Propping and centring 2. Shuttering 3. Provision of camber 4. Cleaning and surface treatment

Order and method of removing formwork:

The sequence of orders and method of removal of formwork are as follows: 1. Shuttering forming the vertical faces of walls, beams and column sides should be removed first as they bear no load but only retain the concrete. 2. Shuttering forming soffit of slabs should be removed next. 3. Shuttering forming soffit of beams, girders or other heavily loaded shuttering should be removed in the end.

Rapid hardening cement, warm weather and light loading conditions allow early removal of formwork. The formwork should under no circumstances be allowed to be removed until all the concrete reaches strength of atleast twice the stresses to which the concrete may be subjected at the time of removal of formwork. All formworks should be eased gradually and carefully in order to prevent the load being suddenly transferred to concrete. Figure 1 to 6 shows formwork for different types of members in civil engineering construction.

Figure 1(a): Details of timber formwork for RCC beam and slab floor

Figure 1(b): Details at section (A) shown in above figure

Figure 2(a): Elevation

Figure 2(b): Details of timber formwork for circular RCC column

Figure 3(a): 150 3D View

Figure 3(b): Details of timber formwork for square or rectangular RCC column

Figure 4: Sectional plan showing details of timber formwork for an octagonal column

Figure 5: Details of formwork for stair

Figure 6: Timber formwork for RCC wall

Table: Period of removal of formwork

S. No. Description of structural member 1 2 Period of time

Walls, columns and vertical sides of beams 1 to 2 days Slabs (props left under) 3 days

3 4

Beam soffits (props left under) Removal of props to slabs (a) For slabs spanning upto 4.5 m (b) For slabs spanning over 4.5 m

7 days

7 days 14 days

Removal of props to beams and arches (a) Spanning upto 6 m (b) spanning over 6 m 14 days 21 days