Different Materials Used for Formwork – Advantages and ...

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A Formwork is a temporary structure used as mold for the original structure. There are different materials available to construct the formwork. Formwork Material is selected depending upon many factors like cost, requirement, type of structure etc.

Different Formwork Materials

Different formwork materials and their advantages and disadvantages are discussed below.

1. Timber
2. Plywood
3. Steel
4. Aluminum
5. Plastics
6. Magnesium
7. Fabric

1. Timber as Formwork Material

Timber is the most commonly used material for formwork. Timber logs, lumber etc. are used as bracing members from ancient times. So, the Timber formwork is also called as traditional formwork. It is most economical material used for formwork. This is used in sites as formwork material for number of years so, the method of constructing timber framework is well known to the workers.

Advantages

• Timber can be cut into any required size easily.
• Timber is light in weight and it can be handled easily.
• Timber has good thermal resistance which prevents the damage of concrete in colder regions.
• It is easy to understand the construction method of timber formwork hence, skilled workers are not necessary.
• It is easy to replace the damaged parts of timber forms.
• Timber formwork can be easily dismantled.

Disadvantages

• Dry timber may absorb water from wet concrete which result in the reduction of strength in concrete structure.
• Wet timber having high moisture content compress the wet concrete and forms cracks in the structure and grout may leaked through joints when shrinking occurs.
• Timber forms have limited usage. So, they cannot be useful for more times.

A Formwork is a temporary structure used as mold for the original structure. There are different materials available to construct the formwork. Formwork Material is selected depending upon many factors like cost, requirement, type of structure etc.Different formwork materials and their advantages and disadvantages are discussed below.Timber is the most commonly used material for formwork. Timber logs, lumber etc. are used as bracing members from ancient times. So, the Timber formwork is also called as traditional formwork. It is most economical material used for formwork. This is used in sites as formwork material for number of years so, the method of constructing timber framework is well known to the workers.

Fig 1 : Timber Formwork

2. Plywood as Formwork Material

Plywood which is a manufactured product of timber is also used for formworks. It consists number of veneer sheets or plies in layers. Now a days, the use of plywood formwork increases especially for facing panels. The reason behind it is that the plywood formwork provides smooth finish when compared to normal timber formwork. Hence, finishing cost may reduce by the use of plywood. For formwork, special type of plywood called exterior plywood is used. The veneer sheets of exterior plywood are bonded with strong adhesive to make it watertight. The plywood boards are available in thicknesses from 7mm to 32mm. In general, plywood of size x and 18mm thick boards are sufficient for most of the works. For curved structures, special types of plywood with sufficient thickness are also available.

Advantages

• Plywood can also be cut into required size easily.
• Plywood Strong, durable and light in weight.
• Provides smooth finish on the surface.
• Very Large size plywood sheets are available which makes the construction of formwork quicker and easier.
• Curved formworks can also be prepared using plywood.
• When compared to timber, it gives more number of reuses.

Disadvantages

• When compared to timber it is costly.
• Thin plywood sheets cannot sustain the weight of concrete they may bow out if proper thickness is not provided.

Plywood which is a manufactured product of timber is also used for formworks. It consists number of veneer sheets or plies in layers. Now a days, the use of plywood formwork increases especially for facing panels. The reason behind it is that the plywood formwork provides smooth finish when compared to normal timber formwork. Hence, finishing cost may reduce by the use of plywood. For formwork, special type of plywood called exterior plywood is used. The veneer sheets of exterior plywood are bonded with strong adhesive to make it watertight. The plywood boards are available in thicknesses from 7mm to 32mm. In general, plywood of size x and 18mm thick boards are sufficient for most of the works. For curved structures, special types of plywood with sufficient thickness are also available.

Fig 2 : Plywood Formwork

3. Steel as Formwork Material

Steel can also be used as formwork material. It is very costly but it can be used for more number of times than others. They provides excellent finish to the concrete surfaces. For mass strictures like dams, bridges, etc. steel from work is so strong and safe.

Advantages

• Steel forms are durable and stronger.
• Provides uniform and smooth surface finish to the structure.
• Great reusability.
• Easy to fix the formwork and also easy to dismantle.

Disadvantages

• Cost is very much higher.
• It is heavy in weight and requires lifting equipment for large structure formworks.
• Corrosion will occur when there is a frequent contact with water.
• The size and shapes of forms available are limited.

Steel can also be used as formwork material. It is very costly but it can be used for more number of times than others. They provides excellent finish to the concrete surfaces. For mass strictures like dams, bridges, etc. steel from work is so strong and safe.

Fig 3 : Steel Formwork

4. Aluminum as Formwork Material

Aluminum formwork is used often for pre-fabricated formworks. It is getting more popular because of its light weight and good strength. It requires fewer supports and ties.

Advantages

• Easy to fix and easy to dismantle.
• It can be handled easily because of its light weight.
• It can be re-used for many times.
• The walls and slabs of structures can be casted simultaneously.
• Monolithic crack free structures can be built using aluminum formwork.

Disadvantages

• When the load reaches its maximum limit, the lighter sections may deflect.
• Architectural modifications are not possible when aluminum formwork is used.

Aluminum formwork is used often for pre-fabricated formworks. It is getting more popular because of its light weight and good strength. It requires fewer supports and ties.

Fig 4 : Aluminum Formwork

5.Plastics as Formwork Material

Plastic is another type of formwork material which is used for small concrete structures or for complex portions of the structure. It is light in weight and durable for long periods. For complicated concrete structures, Glass reinforced plastics (GRP) and vacuum formed plastics are used.

Advantages

• Plastic is light in weight and can be easily handled.
• Formwork for complex shaped structures can be prepared easily.
• Good resistant against water.
• The damaged plastic sheets can be recycled and useful to make new sheets.
• Good quality plastic has great re-usability.

Disadvantages

• Plastic is weak against heat.
• It is costly material.
• It does not take much load when compared with others.

Plastic is another type of formwork material which is used for small concrete structures or for complex portions of the structure. It is light in weight and durable for long periods. For complicated concrete structures, Glass reinforced plastics (GRP) and vacuum formed plastics are used.

Fig 5 : Plastic Formwork

6.Magnesium as Formwork Material

Magnesium is another metal element which is used for formwork. Magnesium is not directly used for formwork and is used with the combination of oxygen atoms which forms magnesium oxide, usually called magnesia or MgO. Magnesium oxide boards or MgO boards are famous in some countries because of their multiple applications. MgO boards are available in required sizes and grades.

Advantages

• Mgo boards are light in weight and easy to handle.
• They are fire proof and waterproof.
• Bio friendly boards cause no harm to the environment.
• They are strong to resist heavy loads.

Disadvantages

• When Mgo boards meet wet concrete, the magnesium chloride present in MgO boards may dissolve and cause corrosion to the reinforcement.
• Skilled supervision is required for installation.
• MgO boards cannot sustain in humid conditions. They absorb moisture easily from atmosphere so, they are called as crying boards.

 

Magnesium is another metal element which is used for formwork. Magnesium is not directly used for formwork and is used with the combination of oxygen atoms which forms magnesium oxide, usually called magnesia or MgO. Magnesium oxide boards or MgO boards are famous in some countries because of their multiple applications. MgO boards are available in required sizes and grades.

Fig 6 : Magnesium Oxide Boards

7.Fabric as Formwork Material

Fabric formwork is the modern technology in construction sector. Fabric can be mold into any required shapes which makes it more famous formwork for architectural purposes.

Advantages

• It weighs very less when compared to any other formwork material.
• It is economical.
• Any complex shape can be constructed using fabric formwork.
• It is waterproof.
• Doesn&#;t affect the concrete properties.
• Easy to removal after the hardening of concrete.

Disadvantages

• For installation skilled workers are required to form perfect and required complex shapes.

Fabric formwork is the modern technology in construction sector. Fabric can be mold into any required shapes which makes it more famous formwork for architectural purposes.

Fig  7 : Installation of Fabric Formwork

Each building in the construction industry needs diverse scaffolding and formwork methods. It is particularly well suited in preparing molds for pouring the concrete in structures, ceilings, and flooring of buildings. It may also employ in the automobile sector as truck and container built environment, shipbuilding, and furnishings. This article will talk about the plywood and formwork plywood alternatives.

Why Formwork Plywood?

It is particularly well suited to molds for pouring concrete into structures. Also, Plywood formwork is a low-cost, long-lasting, and environmentally friendly technology for producing a high-quality concrete cast surface. Plywood has a natural ability to absorb humidity, giving it a sponge-like appearance. However, people may use the formwork plywood alternatives.

> Read more: 20 Types Of Plywood And Grades Used In Interior And Exterior

Formwork Plywood Alternatives

Formwork is a crucial element to concrete construction, so selecting the correct formwork is essential to any job. Wildfires, shortages of labor, and supply issue chains are making plywood harder to get and is now more expensive. So, here are the various formwork plywood alternatives that are less expensive, endure longer, and may be used hundreds of times.

1- Wood Polymer Formwork

In the building industry, commercially produced wood-cement panels are utilized in permanent formwork. The fracture and flexural characteristics of natural fibers reinforced epoxy polymer concrete have improved.

The flexural modulus of wood-plastic formwork is lower than plywood formwork for construction. However, by increasing the thickness, the shortcomings can be improved. They have a complicated architecture characterized by multi-scale porosity and are often very porous with a low apparent density and a low apparent density.

The wood-plastic composite template is used 20-30 times and has a significant residual value when considering the number of cycles and residual value.

They&#;re ideal for warm, humid locations where termites and deterioration are significant issues. So, the wood polymer formwork becomes an excellent option to resist moisture. It&#;s cheaper than other formwork plywood alternatives and more comfortable to work with.

2- Fiber-reinforced Boards Formwork

Fiber-reinforced boards are a novel structural and technical technique for the economical manufacturing of curved freeform formworks and single or double-curved textile-reinforced concrete parts.

The method is based on a multi-layered, flexible formwork system made of glass fiber&#;reinforced plastic. This technique employs lightweight, high-strength fabric sheets that are meant to adapt to the fluidity of concrete and produce unique architectural shapes.

> Read more: Understanding Oriented Strand Board (OSB) and Its Production Process

Fiber Reinforced Boards Formwork

The three-point bending tensile strength of the created textile-reinforced concrete was extremely high. In the longitudinal direction, it has better flexural strength than lumber.

Are you interested in learning more about slab formwork? Contact us today to secure an expert consultation!

Moreover, it is typically stronger than steel and aluminum. As a result, this formwork utilizes less concrete than rigid systems, resulting in cost savings and increased yield output.

3- ABS Plastic Formwork

Alternative formwork systems, such as ABS plastic formwork, can be a viable and cost-effective one to traditional formwork systems.

Because the formwork is comprised of ABS (Acrylonitrile Butadiene Styrene) plastic, it is lightweight while maintaining a high load-bearing capability.

Plywood can only be reused 3 to 5 times; however, ABS Plastic formwork may be used 100 times. As a result, Plastic Formwork is less expensive.

Plastic is waterproof by its nature. It&#;s impervious to corrosion and rust, making it ideal for use underground and in wet environments.

People are in love with the fact that the product is low in mass and is considerably easier to handle and carry on-site. As a result, no heavy lifting equipment is required.

> Read more: Understanding Different Types Of Wood And Their Uses

4- Quik-Tubes

Quik-Tubes are rigid fiber construction forms that do not require wood forms. Deck footings, goal posts, fence posts, mailboxes, and lighting are all applications.

Multiple layers of high-quality fiber fused with an adhesive and a unique moisture-resistant coating that aids uniform curing. You have to use up to three feet below grade and up to three feet above grade. Moreover, it is unnecessary to remove it because it degrades with time.

5- Reinforced Polyurethane Foam boards

Polyurethane Board is a type of board that is created from leftover polyurethane foam and used commonly as a formwork replacement.

The board has a low thermal conductivity (0.076 W/mK) and is damp and waterproof. Furthermore, fiberglass layers give strength to the high-density boards.

Polyurethane Foam Boards

Because it has a significant proportion (at least 90%) of non-connected sealed small cells saturated with inert gas, polyurethane foam is effective as an insulator.

Above all, the boards are naturally rot-resistant, ensuring a long-lasting framework for the construction method. They may also be a great substitute for plywood.

6- MDO Plywood

MDO stands for medium density overlay, which is significantly better/expensive than standard film faced plywood&#;s surface film. The ability of MDO plywood to cover defects gives concrete a high-quality finish.

It reduces the amount of wood grain that transfers to the concrete surface. A medium-density overlay produces a uniform color and a smoother texture, making it perfect for spraying or finishing.

7- Foam 3D Printing (F3DP) Formwork

Formwork investigates how foam 3D printing (F3DP) is utilized in casting the concrete to create distinctive designs for useful stay-in-place or temporary and recyclable formwork.

The mineral composite components that result could save up to 70% of concrete. This is one of those formwork plywood alternatives which are more lightweight and have better insulating characteristics.

> Read more: Characteristics Of Plywood &#; VINAWOOD

8- Aluminum Formwork

Aluminum For the construction of low and high-rise flats and structures, formwork is commonly employed. It is a relatively new technique that saves time, money, and improves the efficiency of a building.

This strategy may be used effectively by workers to accelerate construction while also ensuring quality control and longevity.

Aluminum Formwork provides a form finish, eliminates the need for exterior and internal plaster, and allows for direct painting with minimum skim coat, all of which add to cost benefits in the long run.

Aluminium Formwork Plywood Alternatives

9- HDO Forming Panels for Formwork

The faces of HDO overlay panels are bonded with resin-impregnated cellulose fiber sheets and can be single- or double-sided.

HDO forming panels feature a higher resin content in the overlay, making their surfaces hard and more water and impact-resistant than MDO-forming panels.

While using HDO Polyform, you may expect more applications and a better finish on the concrete surface. The concrete finish created by an MDO surface will be softer and less slick than HDO panels.

Conclusion &#; Formwork Plywood Alternatives

Formwork is a type of &#;mold&#; used in concrete buildings to pour concrete. Thus, when selecting the ideal material for the formwork plywood alternatives, keep these qualities in your mind:

• This must be cost-effective, readily available, and reusable.
• The formwork has a smooth, flat surface and follows a precise placement line.
• When released to the environment, the material will not get deformed.

You will handle any problem easily if you are sure about choosing the perfect material for the formwork plywood alternatives.

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