Mar. 03, 2025
The use of the formwork method dates back to the time when concrete earned a position as a suitable building material. Formwork, ordinarily known as shuttering or moulding, refers to the type of casing or moulds used for creating the required shape of a structure in construction. It serves as casting cases or dyes for the ready-mix concrete until it attains sufficient strength to bear the desirable weight (both dead and alive). The concrete structural components poured into the moulds in its viscous state shapes itself as per the model formwork. Being one of the initial steps of construction, assembling of formwork takes time and involves a cost of at least 20-25% or above of the whole budget.
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There are various types of formwork available in the market. Steel, plastic, and timber formworks are few of the top listed options in the category, while Aluminium Formwork trumps the rest in terms of demand and popularity in the market. Re-usable plastic, permanent insulated fibre, and fibreglass are few other variants of formworks consumed by the construction industry. Due to the availability of different types of formwork in the construction industry, the choice is made based on the primary parameters like convenience in designing, fabricating, erection, and dismantling. And since aluminium formwork techniques can be conveniently mastered in all these domains, its demand has been on the rise lately.
The selection of formwork depends on the following factors:
Strength
Rigidity
Leakage control
Accessibility
Reusability
Cost efficiency
Endurance
Finishing
Here is a list of the different types of formwork materials that are readily prevalent in the industry:
1. Aluminium Formwork: Aluminium formwork has taken an edge over other formworks in the modern construction industry due to the extensive benefits it has to offer. Better completion timeline, quality management, and reliable performance are some of the perks of using aluminium formwork. It is used widely in India for residential units and mass construction projects. This type of formwork is suitable for requirements of tailor-made formwork for cast-in-situ concrete structures. Let us have a look at the pros and cons related to uses of Aluminium formwork.
- Advantages of using Aluminium Formwork:
Economy: The overall costing per square feet of Aluminium formwork is much less as compared to other conventional types of formwork materials due to high reusability factor. The erection process can be executed even by the unskilled labour force, without incurring high costs of hoisting cranes or lifting equipment.
Time: Features like easy mobility, adaptability, no plastering, and simultaneous casting of slab/walls reduce the construction time to 2/3rd of total time.
Eco Friendly: Zero usage of timber, manifold reusability make its environment friendly. The resulting structures are earthquake resistant.
Finishing: Superior wall finish saves finishing time and cost of plastering material.
Others: Custom designing, reusability in case of repetition of floor layouts, monolithic crack free structures, low maintenance.
- Disadvantages of using Aluminium Formwork:
Architectural modifications of the structure are not possible after fabrication.
The initial cost can be over budget in case of a small project.
The precision in alignment and safety standards requires a short training for labours to get equipped with the whole process. It is not a big challenge with Aluform technology though.
2. Steel Formwork: Steel formwork consists of thin steel plates panel stiffened at edges with the help of small steel angles. Steel formwork is a semi-traditional form used in case of large projects, with pre-planning of reusing the formwork material. Steel structures provide strength and durability in the form of finishing and no shrinkage in formwork. Steel formwork is used extensively for the construction of circular or curved structures. Massive projects like dams, bridges, tanks, chimneys, sewer tunnels require super strong structures, attainable from the steel formwork. Here are some of the pros and cons faced while opting for steel formwork over other types of formwork in construction.
- Advantages of using Steel Formwork:
Strength: The weight-bearing capacity and metal strength support gigantic structures.
Durability: Steel formwork is durable and has a longer life with excellent reusability. It does not warp or shrink and can be recycled.
Fabrication: Steel structures are easy to install and dismantle.
Finishing: The finish on the concrete is smooth and without any honeycombing.
Others: No moisture absorption from concrete, better exposed concrete surface, need lesser volume.
- Disadvantages of using Steel formwork:
Economy: The steel formwork is better suited for large budget projects due to high material costs.
Weight: This formwork is heavy and requires the assistance of machinery and lifting equipment.
Corrosion: The maintenance of steel from corrosion due to excess water contact is necessary for durability.
Limited moulding: The steel formwork has restricted shapes and sizes.
3. Plastic Formwork: There has been a visible rise in the popularity of plastic formwork in recent times. Plastic formwork has superiority over other types of formwork in terms of finish, customized designs, and negligible maintenance. The formwork gives the flexibility to create unusual designs and textures. Glass reinforced plastic, fibre-reinforced plastic, and thermoplastics are some of the trending types of formwork materials. Manufactured from a specific class of plastic, it prevents reaction due to chemicals in poured material, resulting in a clean finish on the reinforced concrete element.
- Advantages of using Plastic formwork:
Cost Efficiency: Plastic formwork is highly cost-effective in terms of reusability, low maintenance, and minimal efforts for installation.
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Designing: It gives independence in the form of complex shape structures, intrinsic designs.
Weight: It is remarkably lightweight and easy to handle.
Break free: Plastic formwork is resealable with a hot air gun in - situ in case of breakage.
Others: Water-resistant, easy to erect and dismantle, recyclable, and excellent finishing.
- Disadvantages of using Plastic Formwork:
Requires pre-planning and designing as field fabrication is not possible.
Depending upon the class and durability of the chosen plastic material, it can be a little expensive.
Requires special attention to heat damage from accelerated curing of concrete poured into the formwork.
Lesser load endurance than other types of formworks in construction.
4. Timber formwork: It is the most traditional formwork that has been in use since ancient times. As timber has been in use since the beginning, the construction of the framework is well known to the labourers. Timber formwork is adaptable to changes on the site, hence provides flexibility in design changes after planning also. It is the most economical formwork among different types of formworks in construction. Usually, timber forms of plywood, planks, or joist are prevalent in the formwork market. Here is an overview of the pros and cons of traditional timber formwork.
- Advantages of using Timber Formwork:
Economy: Timber formwork is economical for low budget and small construction projects. The requirement of skilled labour is low. Among various types of formwork material, timber is one of the least costly.
Weight: Timber is light in weight and does not require heavy lifting equipment.
Thermal Insulation: For its heat resistant quality, timber is very suitable for cold regions, to protect concrete from any damage due to low temperature.
Designing: It is easy to craft designs and shapes with timber.
Others: Easy erection and dismantling, no splitting due to nails, and easy replacement of damaged parts.
- Disadvantages of using Timber Formwork:
The construction industry comes only second to the agriculture industry in its size and employability.
There has been a drastic surge in the use of Aluminium in the construction industry. Make In India initiative and Smart City schemes, have pushed the demand for the Aluminium to a next level high. The support of the government has accelerated the use of Aluminium in the formwork and infrastructure sector. Increased number of the high rise, clustered, and symmetrical projects at lower costs have given an open market for the use of Aluminium as the prime formwork material. The steel industry is a significant part of the Indian economy, also termed as the backbone of the economy. The contribution of the Steel industry is directly proportional to GDP. Therefore with the growth of Megaprojects and skyscrapers, steel formworks will be in fluent demand. The plastic industry has seen double-digit growth in the past year in the country. The technological advancement with Plastic formwork in construction has given an extended new market for plastic industry other than traditional needs for pipes, wires, waterproofing membranes, etc. A strong stand for eco-friendly, environment-supporting, and sustainability practices have reduced the market for timber. Being a traditional formwork method, demand for timber formwork has taken a small back foot, limiting it to projects that have a specific need for the same.
Technological inventions and growth have flooded the construction industry with diverse types of formwork material. The need for modern construction practices, flexible and convenient structure shape and size, and other parameters (as discussed above) have become the deciding factors for the formwork in the current competitive market. Currently, government incentives, global market pricing, technological support and quality, and timely rapid completion are the major influencing factors for the selection of formworks in the construction sector.
Concrete formwork is used in a wide variety of construction projects where pouring concrete is involved. Pouring the foundation of a building or structure, such as a house or a bridge, requires concrete formwork. Walls, columns, slabs, and floors made of concrete all utilize concrete formwork for pouring and casting. Beams, girders, and other support structures for buildings and bridges also depend on reliable concrete formwork during the pouring and curing process.
Whether you own or rent your equipment, Concrete formwork plays a critical role in ensuring poured concrete takes the desired shape, meets the right dimensions, and has the strength to support intended structural loads.
Concrete formwork refers to the molds or structures used to shape and support freshly poured concrete. Concrete formwork can be temporary or permanent and provide the shape and finish necessary for a concrete structure. When using formwork on a job site, it is important to understand the different types of concrete formwork to ensure the concrete is poured in the correct dimensions and shape for the intended outcome. Utilize concrete formwork to help the project gain sufficient strength and allow the concrete to support its own weight and any loads that may be placed on it.
Concrete formwork can be made from a variety of materials, including:
When choosing the right concrete formwork for a project, the formwork must be able to withstand the weight of the wet concrete and the pressure as it forms. Learn more about the different types of concrete, including their pros and cons, to determine the best choice for a quality, strong, and durable finished concrete structure.
Each type of concrete formwork has its own advantages and disadvantages based on the materials and intended usage. Here are a variety of types of concrete formwork, their uses, and the pros and cons for each.
Wooden formwork is inexpensive and readily available, which makes it a common choice for a variety of construction projects. Wooden formwork is also easy to work with and can be easily cut to the required shape and size for the specific project. The two main types of wooden formwork are timber and plywood.
Timber formwork material is made from solid wood, like pine or spruce. Typically used for small to medium-sized projects, timber formwork is easy to work with and a cost-effective option in a variety of contexts. Timber formwork also provides good insulation and helps to regulate temperature and humidity during the concrete curing process. However, timber formwork is more prone to warping or splitting and will require regular maintenance to prevent rot or decay.
Plywood formwork material is made from thin layers of wood veneer that get bonded together with adhesive before use. Wooden formwork made of plywood is more common for large or complex projects because of how easily plywood can be cut to specific shapes and sizes to meet design standards. Plywood can be reused multiple times and is also lightweight and easy to handle. However, plywood may require additional support or bracing to help prevent deformation during the concrete pouring and curing process. Plywood formwork materials are typically more expensive than timber formwork materials.
Metal for concrete formwork is known for its durability and ability to withstand the weight and pressure of wet concrete. This type of formwork can be reused many times and involves easy assembly and disassembly. The two main types of metal concrete formwork are aluminum and steel.
Aluminum formwork material is lightweight and easy to use in a variety of contexts, including large-scale products. This type of formwork material can help reduce construction time and labor costs because of how easy it is to assemble and disassemble. Aluminum formwork also provides a high-quality surface finish and is resistant to corrosion and weathering. However, aluminum formwork can be more expensive than other materials, like wooden formwork, and is not as strong as steel formwork.
Steel formwork material is very strong and durable, which makes it suitable for heavy loads like high-rise structures. Steel formwork provides good dimensional stability and can be adjusted to fit the required dimensions of a project. However, steel formwork is heavy and may require specialized training or machinery to move around. Steel formwork will also require protective measures to help prevent rust and corrosion.
Plastic formwork is lightweight and easy to move around, which makes it a great choice for projects that require reusable forms and minimal maintenance. The durability of plastic formwork makes it ideal for small to medium-sized projects. Plastic formwork typically does not require additional forming work because it provides a smooth finish to the concrete. Plastic is also resistant to moisture and chemicals, making plastic formwork suitable for use in harsh environments. However, plastic formwork is not as strong as other types of concrete formwork materials like steel or aluminum or projects that require heavy loads.
Insulated concrete formwork is made up of two layers of foam insulation that has a hollow space in between where the concrete gets poured. This type of concrete formwork offers excellent insulation for concrete during the pouring and curing process, which can also reduce energy consumption. Insulated concrete formwork, or ICF, is known for its strength and durability for a wide range of structures, including small home projects and large commercial builds. However, ICF can be more expensive than other materials and may require specialized equipment and labor for proper installation.
Stay-in-place formwork, also known as permanent formwork, is a type of concrete formwork that does not get removed after the concrete has been poured and cured. This type of formwork is commonly used in applications where a smooth, uniform finish to the concrete is necessary or desired for both sides of the concrete structure. Some stay-in-place formwork, like precast concrete formwork, may be reinforced with steel. Utilizing stay-in-place formwork eliminates the need for additional formwork removal and reduces waste. However, it is not suitable for all applications.
Foam concrete formwork is made of a lightweight foam material that gets coated with a layer of plaster or stucco to create a smooth, uniform finish on both sides of a concrete structure. This type of concrete formwork molds the foam material into the desired shape and size for the concrete structure. Foam concrete formwork is easy to handle and can be molded into a variety of shapes and sizes, making this a popular choice for custom designs. This type of material is also lightweight and easy to transport, which can reduce costs and time. However, foam concrete is typically only recommended for smaller projects and may require additional finishing work compared to other types of concrete formwork.
Fabric formwork is a type of formwork that involves stretching a fabric material over a mold or frame. Then concrete is poured into the fabric to create the desired shape or structure. Fabric for formwork material can be made from a variety of materials, including canvas, PVC, and woven or non-woven polypropylene. Fabric formwork is lightweight and easy to handle, especially for complex and irregular shapes. It also provides a unique aesthetic appeal because of how the fabric imprints onto the surface of the concrete. However, fabric formwork does have reduced durability compared to traditional concrete formwork materials and has limitations in the size and shape of the project.
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