9 Ways to Prevent Concrete Formwork Fails
Proper use of formwork is essential in preventing collapses during concrete construction. Concrete formwork that isn’t used as it should be poses safety risks for workers, can slow down a project, and can affect the overall quality of the project upon completion. Despite the important role formwork plays in concrete construction, formwork fails are still common. Luckily, they’re avoidable if the necessary precautions are taken. Here are nine key ways to prevent concrete formwork fails and costly collapses:
1. Use pre-fabricated formwork if possible. Opting for pre-fabricated formwork, rather than formwork you construct on-site, helps minimize errors that can occur as a part of the on-site construction process. It also speeds things up and tends to lower costs associated with life-cycle, which are definitely perks too.
2. Make sure the formwork is strong enough for the job. It has to be sturdy enough to take on the weight of the concrete during a pour and during vibration. It also has to be strong enough to support workers, equipment, and incidental loads. Making sure you have the proper strength of formwork before a pour begins is one of the most important things you can do. Formwork that isn’t tough enough for the job can cause major headaches and put workers at risk.
3. Take caution with older formwork. Formwork is meant to be re-used, and re-using it makes sense from an economic standpoint. Be careful, though, to diligently inspect and test older formwork. Over time, its load capacity can diminish, and you shouldn’t necessarily use the capacity data from when the formwork was new to estimate how much it can support. Expect its load capacity to change over time, and test it to see what it can sustain.
4. Secure the formwork in place. It has to be properly stationed and braced, vertically and horizontally, to allow for the right shape once a pour begins. Joints should be tight to protect against leakage. Levels must have a planar surface, and formwork should be set to the required line. Of course, it should also rest on a secure foundation or base.
5. Inspect once in place. Have a qualified employee make sure formwork is ready to provide enough support for the job. Make sure the person doing the inspection isn’t underqualified or inexperienced. Formwork that appears secure to the untrained eye isn’t always durable enough. That’s why it’s so important to have formwork inspected by someone who knows what to look for.
6. Ensure that all components are properly connected. Loose connections may make dismantling quicker and easier, but they can also result in serious collapses. Make sure nails, bolts, and wedges are in place, tight, and secure.
7. Don’t remove formwork too early. It’s imperative that formwork stay in place until concrete is adequately cured. If a project is on a strict deadline, it can be tempting to remove formwork early to use it for another pour. This, however, isn’t a good idea and can result in damage to the concrete and the formwork.
8. Install shoring correctly. Shoring that isn’t properly installed is one of the leading causes of formwork fails. Without adequate shoring, jobsites are at risk for collapses due to impact from debris and concrete. Shoring needs to be installed so that it provides an uninterrupted load path from the foundation to the formwork.
9. Never proceed without a firm foundation. Without a firm foundation, there’s a risk of failure to transfer a load to the base/ground. An inadequate foundation also reduces the formwork’s carrying capacity. Make sure your foundation is secure and not placed in weak subsoil.
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