Steel Formwork in Concrete Construction Projects

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Steel Formwork in Concrete Construction Projects

The visual appeal of brick-and-mortar structures is undeniable. However, their construction is time-consuming and requires skilled artisans, adding to the builder’s costs. Furthermore, over 2000 years ago, the builders of ancient Rome recognised that brickwork lacked the durability and versatility of concrete. Even without the benefit of modern steel formwork, they created concrete buildings, aqueducts, and bridges that remain standing today. Some, like the Pantheon, built in 127 A.D., are still functional.

Concrete is predominately water to which cement and aggregate are added. The cement and aggregate provide concrete’s durability, while the initial fluid state that enables it to be moulded into any required shape explains its versatility. Those Roman builders exploited the latter property with a more primitive formwork from sacking and reeds to fashion load-bearing structures like beams and ornate columns.

Today, some small builders still rely on natural materials for this purpose. However, while timber and plywood may cost less initially, continued exposure to water causes warping and rotting, so frequent repairs and replacements are an ongoing expense.

The Benefits of Steel Formwork

Steel was first manufactured commercially in the mid-1800s when an Englishman named Henry Bessemer developed a process to purify molten pig iron by blowing air through it. The addition of carbon at high temperatures then completed the conversion to steel. That simple addition formed a more durable alloy with an increased tensile strength that can be cast or pressed to any desired shape, the perfect choice for manufacturing circular or box column and beam formwork.

That being said, steel quality varies. Hence, all materials used by Johannesburg-based scaffolding and formwork manufacturer Disc-O-Scaff are SABS-approved, ensuring vital benefits like:

  • Superior Strength and Load-Bearing: Steel formwork can withstand massive volumes of wet concrete without fracturing or distorting during the curing process. Its high load-bearing capacity makes it ideal for high-rise projects.
  • Increased Efficiency: The modular design and interlocking action enable metal formwork to be assembled and dismantled rapidly, saving a construction company time and money, especially when tackling large projects.
  • Sustainability: Concrete is today’s building material of choice, but its carbon footprint is substantial. The longevity and the ease with which steel can be recycled offer a more eco-friendly option that can help offset some of the industry’s negative environmental impact.
  • Cost-Effectiveness: The inherent durability and longevity of steel allow formwork to remain effective for multiple uses, unaffected externally by harsh weather conditions or by moisture from the raw concrete within.

These are just a few of the many benefits that will more than justify a decision to invest in world-class steel formwork from a leading South African manufacturer. Contact us today.

The Role of Beam Formwork in Modern Concrete Construction

Posted on by carl

The Role of Beam Formwork in Modern Concrete Construction

Today’s construction industry owes a huge debt of gratitude to the builders of ancient Rome, who perfected the composition of concrete and introduced many new applications for this durable and versatile building material. Their ability to create massive, complex structures that, like the Pantheon and Colosseum, have survived for millennia is all the more remarkable when one considers their primitive column and beam formwork was fashioned from reeds and sacking.

In its uncured state, concrete is liquid. So, like molten silver or gold, it must be moulded to the desired shape and left to harden. In the case of concrete, the moulding process is achieved using formwork or shuttering.

While some smaller building companies choose to make shuttering from timber or plywood, it is susceptible to warping and damage from prolonged contact with moisture and requires frequent repair or replacement. By contrast, larger construction companies tend to prefer using ready-made steel shuttering to fashion crucial structural elements like columns and beams.

Beam Formwork in Structural Support

Concrete beams provide essential load-bearing support in a structure. They act to distribute weight and reinforce the framework of buildings, bridges, and other load-bearing structures. The use of well-constructed formwork ensures that each beam is formed to the precise specifications essential to optimise the stability of a building.

All formwork required for this purpose is available in South Africa from us at Disc-O-Scaff and typically comprises interlocking panels of various shapes and sizes. Because this steel shuttering must withstand the extreme pressure exerted by the wet concrete until it sets, all materials used in its manufacture have been SABS-approved.

The Benefits of Beam Formwork

In addition to its pivotal role in providing structural support when fashioning concrete beams, steel formwork offers construction companies several other advantages, including the following:

  • Durability and Longevity: Because it’s made of steel, it can be used repeatedly without significant degradation. It’s also weather-resistant, making it suitable for indoor and outdoor use.
  • Versatility: It can be adjusted to accommodate various beam sizes, making it suitable for diverse projects, such as residential and commercial complexes, industrial facilities, viaducts, and bridges.
  • Quality Assurance: Steel beam formwork provides the reliable performance essential for compliance with stringent building regulations.
  • Increased ROI: Decreased material usage and labour expenses serve to offset the initial investment costs.
  • Enhanced Finishes: Steel shuttering enables cleaner and more precise concrete finishes, improving the visual appeal of the final structure.

These are just five of the many compelling reasons for construction companies in South Africa to invest in high-quality steel beam formwork. Contact us for more information.

The Benefits of Prefabricated Concrete Shuttering

Posted on by carl

The Benefits of Prefabricated Concrete Shuttering

Also known as formwork, concrete shuttering is essential for moulding freshly poured concrete into the often complex shapes typical of modern construction. That said, the origins of formwork can be traced to when the Romans built the Colosseum, Pantheon, and the Arch of Constantine. While they used fabric and fibres to form their moulds, other materials have since proved more effective. These include timber, plywood and, most recently, steel.

The owners of smaller building companies are often reluctant to meet the initial cost of modern prefabricated steel shuttering, preferring to make their own from timber or plywood. However, by doing so, they are forsaking a highly cost-effective, long-term solution for short-term savings. In the next section, we will compare the merits of this DIY solution with those inherent in modern prefabricated formwork:

Plywood vs Steel Concrete Shuttering

The primary function of formwork is to maintain the shape of freshly poured concrete structures while they harden, so how does a construction company decide which type is best? The following comparisons should help simplify the decision:

  • Time-Saving: Prefabricated shuttering is delivered ready for use, significantly reducing the time spent on measuring, cutting, assembling, and fitting plywood or timber formwork. In construction, time is money, so every hour saved is cash in the bank.
  • Precision and Quality: Commercially manufactured steel shuttering is produced in a controlled factory environment with stringent quality control to ensure precise measurements and high-quality finishes beyond the scope of the hand-crafted alternative.
  • Durability and Reusability: When maintained with care, the superior durability of prefabricated steel concrete shuttering should be good for a hundred uses or more without loss of integrity. By contrast, warping and swelling from contact with water degrades wooden formwork after a few uses, leading to higher material costs in the long term.
  • Labour Efficiency: Unlike the labour-intensive assembly and dismantling of wooden formwork and the associated cost, the ease with which one can manage these actions when employing steel shuttering eliminates the need for suitably skilled labourers, thus reducing costs.
  • Environmental Impact: Construction is one of the world’s least sustainable industries, and, in many countries, companies face heavy fines for non-compliance with green requirements. Because it is reusable, prefabricated steel concrete shuttering is considered a more sustainable option than wooden formwork.
  • Logistics and Storage: Due to its modular design and durability, steel formwork is easy to transport and store. By contrast, wooden shuttering requires more space and careful handling to prevent damage.

Concrete Shuttering in South Africa

We at Disc-O-Scaff are an acknowledged leader in the manufacture of steel scaffolding and formwork. We invite you to contact us for more details about our products, which are made exclusively with SABS-approved materials.

A Comparison of Residential and Commercial Formwork in Construction

Posted on by carl

A Comparison of Residential and Commercial Formwork in Construction

The role of formwork in construction is to serve as a temporary mould to shape concrete. However, its use in commercial and domestic projects differs significantly. Formwork has been used since Roman times. Structures like the Pont du Gard in France and the Library of Celsus in Turkey are proof of its efficiency. 

The following paragraphs explain the differences in the use of formwork in residential and commercial construction and the unique challenges and solutions of each.

The Challenges of Residential Construction

Although residential projects are typically smaller and less complex than commercial ones, they still present challenges, such as:

  • Cost Constraints: Budgets for small projects are usually tight, calling for cost-effective formwork solutions that won’t compromise quality or safety.
  • Customisation: Curved walls, intricate cornices, and other complex design elements are frequent features of residential buildings, creating a need for equally complex formwork in construction projects.

The Solutions: Formwork has evolved since Roman builders used fabric and reeds. Residential builders now have the following options to overcome their routine challenges:

  • Modular Formwork: The availability of modular formwork that can be easily assembled into multiple shapes has dramatically reduced operating costs for the small builder by increasing speed and efficiency.
  • Prefabricated Panels: Circular and rectangular shuttering composed of prefabricated bespoke panels are ideal for the ornate columns often required in residential buildings.

The Challenges of Commercial Construction

The markedly larger dimensions of commercial buildings pose the following challenges when using formwork in construction projects:

  • Scale and Load: Structures like office blocks and shopping malls must support much higher loads than the average home. Consequently, all formwork must be sufficiently robust to cope with the added pressure without compromising structural integrity.
  • Speed and Efficiency: Time is frequently a crucial factor for companies engaged in commercial construction. They often face stiff financial penalties for failing to meet agreed milestones and completion dates, so their formwork must enable rapid construction.
  • Height and Complexity: Commercial buildings frequently combine complex designs with high-rise architecture. Hence, the formwork used must cater to these requirements safely and efficiently.

The Solutions: The designers and manufacturers of modern formwork have developed the following options to circumvent the above challenges:

  • Advanced Systems: New developments in the industry include tunnel, jump, and climbing formwork to handle high-rise commercial construction projects safely and efficiently and help companies avoid costly delays.
  • Automation: Automated and self-climbing formwork cuts labour costs and significantly reduces construction times.

Sourcing Quality Formwork

If you use formwork in construction, you need quality, safety, efficiency, and versatility. These are the hallmarks of all steel scaffolding and shuttering products at Disc-O-Scaff. Please get in touch if you would like to learn more.

Basic Working Principles of Formwork in Construction

Posted on by carl

With concrete being the main choice of building material, formwork has introduced complex geometric designs and formidable-sized construction in urban development. This symbiotic relationship has proven that the architectural landscape can be built structurally sound, sustainably, cost-effectively, and at a faster pace.

As the leading formwork manufacturer, we at Disc-O-Scaff would like to emphasise the importance of quality formwork and the possible failures that could occur if incorrect shuttering is selected to build structural elements, such as beam and column formwork.

Factors that Can Affect the Quality of a Surface Finish, Especially in Formwork Applications

The method of using and handling formwork significantly impacts the finish of concrete. Obvious surface blemishes, such as poor form joints, offsets, and the use of inadequate facing materials, occur when the formwork material selection is unsuitable for the construction of the structural element. Achieving a high-quality concrete finish depends heavily on factors such as the concrete mixture, concreting temperature and practices, as well as careful formwork considerations before and during construction.   

Freshly poured concrete exerts lateral pressure affecting the height of the concrete formwork. The pressure of the formwork increases as the height of the fresh concrete increases and only ceases when further force from above is no longer transmitted. Should the incorrect formwork have been selected, this continuous rising pressure could result in sections of the formwork bulging or deflecting.

Causes of Concrete Formwork Failure

Several factors can contribute to the failure of formwork during and after construction, which need to be highlighted to ensure that these indispensable building structures remain structurally safe supports.  

  • Lack of Inspection

Often, failures occur due to inspection by unqualified or inexperienced inspectors. A competent person or engineer should always be on-site to inspect and certify that completed formwork meets design specifications and that it is structurally sound before it is loaded.

  • Improper Connections and Defective Components

As much as formwork can fail due to design flaws that do not take lateral forces and stability into account, a lack of maintenance will also lead to failure. Shuttering is used multiple times, and often, corrosion sets in and damages occur which, during assembly, are not always considered. If components are insufficiently connected with the proper wedge and clip assemblies, it can lead to progressive collapses and compromise the integrity of the formwork.     

  • Premature Removal of Components

Tight scheduling and budget constraints may lead to the premature removal of the shuttering. Formwork must only be removed once the concrete has adequately cured.

To safeguard against formwork failure, we at Disc-O-Scaff would advise that the correct procedures are followed during the assembly when the concrete is being poured, and once the concrete has cured, the formwork has been deemed safe to remove.

Armed with this knowledge and trusting your formwork solutions with the experts in the industry, we at Disc-O-Scaff will ensure that your choice of circular, economy panel, and column shuttering will provide ample structural support. Contact us for superior-quality steel scaffolding and formwork solutions.