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.

Recommended Strategies For Maintaining Steel Formwork

Posted on by carl

Recommended Strategies For Maintaining Steel Formwork

Steel formwork for moulding concrete structures has revolutionised construction, but proper maintenance is essential to ensure its performance and longevity. Also known as shuttering, the concept of using various materials to maintain the shape of freshly poured concrete until it hardens can be attributed to the builders of Ancient Rome, who used short-lived, disposable materials like reeds and fibre.

Optimising the Lifespan of Steel Formwork

Today, steel shuttering offers a more long-term solution if suitably cared for. Adopting the following strategies will optimise its lifespan and ensure its performance:

  • Regular Cleaning: A wire brush or high-pressure water jet should be used to remove concrete residue and rust immediately after each use to avoid a build-up of debris that could cause corrosion.
  • Inspection: Metal formwork should be inspected before and after use for signs of wear and tear, like cracks and buckling, and any damaged components should be repaired or replaced. 
  • Anti-Corrosion Measures: Repeated exposure to moisture and chemicals can cause steel to corrode. Applying a protective coating like an epoxy paint or galvanisation will prevent rust formation and extend its lifespan.
  • Proper Storage: Even when not in use, steel shuttering can deteriorate. It should be stored on a raised platform to prevent contact with the ground, where it could absorb water, and covered with a tarpaulin to protect it from the weather.
  • Lubrication: Regular oiling is essential to ensure that the moving parts of steel formwork, like hinges and connectors, continue to move freely. In addition, the regular use of a suitable lubricant will help to reduce the frictional force that can lead to short-term wear and tear.
  • Using a Release Agent: Concrete can sometimes stick to the surface of formwork, resulting in surface damage when removed. Applying a release agent like castor oil or petroleum jelly thinned with kerosene will prevent this. Commercial products are also available for this purpose.
  • Scheduled Maintenance: It will help to establish a routine maintenance schedule to ensure all the above measures are carried out systematically. Keeping a detailed written record of all maintenance activities will help you monitor the condition of your steel formwork and schedule any necessary interventions.
  • Awareness Training: Maintaining steel shuttering should be a team effort, so all those who use it must be thoroughly trained in its care. Well-informed workers are more likely to observe the strategies that will ensure its longevity and efficiency.

Purchasing High-quality Steel Formwork

We at Disc-O-Scaff are a leading South African manufacturer and supplier of scaffolding and formwork. Our SABS-approved materials guarantee longevity and performance. We invite you to contact us for more information about these world-class products.

The Use of Steel Formwork Offers a Number of Benefits over Other Types of Formwork

Posted on by carl

Using moulds to create the desired shape of a structure is a concept that dates back to ancient Rome. With the growing demand for better and more modern infrastructure, where once reeds and fibre were used, steel formwork has taken its place, allowing construction companies to build at a much faster pace. At Disc-O-Scaff, we manufacture several types of formwork panels made from durable steel, assisting in making architectural plans a reality.   

Steel Formwork for Construction Projects

Understanding the different types of shuttering available helps you gain a better perspective on why many construction companies opt for steel formwork from us at Disc-O-Scaff.

  1. Timber
    After the fall of ancient Rome, timber became the preferred choice of formwork. Timber is still the most commonly used formwork; however, if it is not well-seasoned or free from loose knots, it can affect the surface of the exposed concrete work. Always make sure that the wood is lightweight and easily workable without splitting.
  1. Plywood
    Made from layers of resin-bonded plywood sheets, this type of shuttering is often combined with timber formwork for panels of a required size. The cost of plywood compares favourably with timber formwork and is simplistic to assemble and remove.   
  1. Plastic
    Plastic formwork has the advantage of being lightweight and flexible, allowing for the construction of complex shapes and unique features. Unfortunately, plastic doesn’t have a high load-carrying capacity, is quite costly, and is prone to heat damage.   
  1. Steel Formwork
    Between the 1910s and 1950s, steel formwork became the shuttering of choice amongst construction crews. Wider-scale projects were done at a much faster pace by using this formwork over other types. The strength, durability, and longevity that steel presents make it possible for formwork to be designed according to the structural element being built and for it to be used multiple times without compromising the framework of the steel formwork.

Unlike other types of formwork where the quality of the exposed concrete might not be up to par, the modular design of steel formwork is excellent and the surfaces don’t need further treatment. During the setting process, steel does not shrink or warp and, once cured, can be easily and safely removed.

Importance of Using the Right Type of Formwork

Even though steel formwork is more expensive than plywood or timber, it has the distinct advantage of having a longer lifespan and being able to handle heavy load-carrying capacities. As steel is rigid enough to hold its shape, using this type of formwork in construction ensures that various sections can be removed without damaging the concrete. Circular, curved, or rectangular steel formwork is a formidable component of the construction industry.

For over 10 years, we at Disc-O-Scaff have manufactured and supplied superior-quality formwork and scaffolding solutions to major construction companies in South Africa. Contact us for more guidance on which steel formwork components will offer the best results for your specific project.