Understanding Modular Formwork: Applications & ...

Modular formwork is an important construction technique that has transformed the way concrete structures are built. With its prefabricated panels and components, modular formwork offers versatility, efficiency, and cost-effectiveness from project to project, making it a preferred choice in the construction industry. This innovative system offers wide applications in various construction projects, including residential buildings, commercial complexes, bridges, and industrial structures. The advantages of modular formwork are numerous, ranging from time and cost savings to enhanced quality and improved worker safety. By streamlining construction processes and providing reliable formwork solutions, modular formwork continues to shape the future of the construction industry.

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Modular Formwork Systems 101

Modular formwork is a construction technique that involves the use of prefabricated modules or panels to create the formwork for concrete structures. Formwork refers to the temporary molds or frameworks that are used to shape and support freshly poured concrete until it sets and becomes self-supporting. Modular formwork systems are designed to be easily assembled and disassembled, which allows for efficient and cost-effective construction processes. These modular systems typically consist of standardized panels, frames, and accessories that can be quickly interconnected and adjusted to create various shapes and sizes of concrete structures, including walls, columns, beams, and slabs. The panels used in modular formwork are typically made of materials like steel, aluminum, or high-density plastic, depending on the specific requirements of the project. These panels are lightweight, durable, and often have surface treatments to improve the quality and finish of the concrete surface.

Types of Modular Formwork

There are different types of modular formwork available in the construction industry. The choice of modular formwork system depends on the specific requirements of the project, such as the shape and size of the concrete elements, the desired finish, and the construction method. Here are some commonly used types of modular formwork:

Panel Formwork

This type of modular formwork consists of large panels that are joined together to create the formwork for walls and columns. The panels are typically made of steel, aluminum, or plywood and can be easily interconnected and adjusted to form various configurations.

Slab Formwork

Slab formwork systems are used to support and shape the horizontal concrete slabs during construction. They consist of modular panels or beams that can be adjusted to the required height and size of the slab. Slab formwork can be either traditional (timber or plywood) or modular (steel or aluminum), depending on the project requirements.

Climbing Formwork

Climbing formwork is used for constructing vertical structures like tall walls, cores, or towers. It is designed to be vertically moved as construction progresses, allowing for continuous upward construction. The formwork is usually supported by a climbing system that is anchored to the structure.

Tunnel Formwork

Tunnel formwork is a specialized modular system used for the construction of repetitive structures like residential or commercial buildings with a continuous wall and floor system. The formwork is typically made of steel or aluminum and is designed to be easily assembled and moved horizontally to create the formwork for walls and slabs.

Modular Formwork Applications in the Construction Industry

Modular formwork finds wide applications in the construction industry, including various residential, commercial, and industrial construction projects. This type of system allows for efficient and precise construction of walls, columns, beams, and slabs, ultimately enabling faster completion of building structures.

Walls

Modular formwork systems are frequently used for constructing walls, both vertical and inclined. The formwork panels can be easily interconnected and adjusted to create the desired shape and dimensions of the walls. This includes various types of walls, such as shear walls, retaining walls, basement walls, and exterior walls.

Beams and Slabs

Formwork systems are also utilized in constructing horizontal members like beams and slabs. Modular formwork is used to create the formwork for these structural elements, and they provide support and shape to the concrete during the pouring and curing processes.

Columns

Modular formwork is extensively used for casting columns of different shapes and sizes. The formwork panels can be arranged and fastened together to create the formwork for round, square, or rectangular columns. Modular systems offer flexibility in adjusting the formwork to meet specific column dimensions.

Advantages of Modular Formwork Systems in Construction

Using modular formwork systems in construction offers several advantages. Here are five key benefits of modular formwork:

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• Efficiency and Time Savings: Modular formwork systems are designed to be easily assembled, adjusted, and disassembled. The prefabricated panels and components can be quickly interconnected, which allows for rapid formwork setup and concrete pouring. This streamlined process helps to reduce construction time, leading to improved project efficiency and faster completion.

• Cost-effectiveness: Modular formwork systems also offer cost savings in multiple ways. Firstly, the reusability of modular formwork minimizes material waste because the formwork components can be dismantled and used for other parts of the project or for future projects. Secondly, the faster construction process reduces labor costs and allows for more efficient utilization of equipment. Additionally, the precise fit and adjustment capabilities of modular systems contribute to minimizing concrete over-pours, leading to material savings as well.

• Flexibility and Versatility: Modular formwork systems offer flexibility in adapting to various shapes, sizes, and configurations of concrete structures from project to project. The panels and components can be easily adjusted, allowing for quick modifications and alterations during construction. This adaptability is especially valuable when dealing with complex architectural designs or when changes need to be made on-site.

• Quality and Finish: Modular formwork systems often have surface treatments or coatings that enhance the quality and finish of the concrete surface. This results in improved aesthetics for the final structure. The precise alignment and stability provided by modular systems also contribute to achieving high-quality concrete finishes with minimal imperfections.

• Safety and Ergonomics: Modular formwork systems are also designed with safety in mind. They provide stability and structural integrity during concrete pouring, which helps to reduce the risk of accidents or structural failures. Additionally, these systems are lightweight and easy to handle, which helps to reduce physical strain on workers. The standardized design and interlocking mechanisms of modular formwork also contribute to safer and more efficient construction processes.

Modular Formwork Systems with Forming America

Forming America offers top-notch formwork solutions, including the Symons steel ply forming system. One of the advantages of the Symons Steel-Ply system is its ease of use. No special equipment or dedicated tools are needed apart from a carpenter&#;s hammer for the wedge bolts. This eliminates the need for additional investments or complex setups, saving both time and resources for the construction team. At Forming America, we offer a diverse range of modular formwork options to suit different project requirements. Contact us today to discuss your construction needs.

3. Wall

Wall formwork comes in different types and classifications, including:

Conventional
It consists of boards or sheets and squared timber. It is flexible, but it can be costly and time-consuming since each component must be assembled on site. Also, all of its parts should be made specifically according to the project&#;s specifications and must be nailed together and dismantled again after concreting.

Girder
It is a better version of the conventional formwork. Its components, which usually consist of dimensionally stable girders with two chords and one web, have been standardised to facilitate the assembly of identical and ready-to-use panels. The connection of the panels has also been systematised.

Frame
This type of wall formwork helps reduce labour time since its essential components (forming face, support for forming face, and steel walers) are assembled as one panel. The profile nose of the frames protects the edges of the forming face, thus, extending its lifespan. Connecting devices are used when assembling the frame panels to large-size units, which are then usually transported by crane.

Crane-independent (hand-set)
This type of formwork can be moved by hand. Because of weight considerations, it is usually made of aluminium or plastic. It can take less concrete pressure than crane-dependent formwork and is often used in housing and municipal construction projects.

Crane-dependent 
Crane-dependent formwork systems feature a large frame and formwork panels, usually steel. As a result, they cannot be moved manually. Since they can resist more fresh concrete pressures than crane-independent forms, they are suitable for the construction of commercial buildings and other extensive infrastructure projects.

Two-sided
As the name implies, two-sided formwork is put up on both sides of the wall. Its formwork ties, which are usually sleeved by spacing plastic tubes so they can be reused, take up the fresh concrete pressure. Push-pull props or large heavy-duty braces are attached to the formwork to align it and secure it against wind loads during operation.

Single-sided
Single-side formwork is used when concrete has to be poured against existing structures or when builders need to do concreting against a hill or soil. This is why it is most suitable for reconstruction jobs. In this type of formwork system, concrete pressure is transferred from the formwork into the base plates through a support structure. 

Prefabricated
It consists of two prefabricated concrete panels, which are then assembled in advance and then transported and filled with concrete onsite. Braces and push-pull props are often used to secure the walls, while working and safety scaffolds are installed with the help of special adapters to make the construction process more cost-effective. Prefabricated formwork helps minimise project duration and labour. However, pre-planning is required to ensure that it is transported safely to the job site.

Circular
It is designed for the construction of curved and polygonal walls. It is also quite useful in the construction of specific concrete structures, such as septic tanks and car park ramps. This formwork system comes in different types: round girder, flexible girder, and polygonal.

• Round girder &#; timber spacers are added between the timber girders and steel walers so the formwork can be adjusted to the required radius. 
• Flexible girder &#; suited for the construction of curved walls with different radii. It comprises timber/steel girders and a spindle, which allows builders to adjust the formwork to the required radius without having to re-assemble the panels.
• Polygonal &#; existing &#;flat&#; frame formwork panels can be refurbished as polygonal formwork by adding supplementary radius panels and rails, allowing builders to minimise costs.

Climbing
Climbing formwork is quite useful in the construction of high-rise concrete structures, such as control towers and skyscrapers, because it climbs with the wall. It is composed of large wall formwork mounted to a climbing scaffold. There are different types of climbing formwork. They are: crane-dependent, self-climbing, single-sided climbing, and slipform.

• Crane-dependent &#; the climbing unit (scaffold and formwork) requires the help of a crane to reach the next cycle.
• Self-climbing &#; an automatic climbing system that doesn&#;t require a crane&#;s assistance to reach the next suspension point. Hydraulic rams/pumps lift the scaffold, secondary platform, and formwork to the next pouring cycle. It is ideal for the construction of very tall concrete structures.
• Slipform &#; a two-sided formwork that slides upwards along the structure being built at a rate of 20-25cm per hour. A system of pipe rods, which is integrated into the already set concrete, supports the slipform.
• MEVA is an industry leader offering a wide variety of wall formwork systems that provide efficient shuttering, flexibility, and reliability. Our products are lightweight and easy to assemble to facilitate the quick completion of your construction projects.