The Ultimate Guide to Falsework and Formwork in Scaffolding

There are general misunderstandings in the differences of formwork and falsework used in scaffolding, primarily among those that are new to the building and construction industry. This guide aims to supply all the mandatory information required to understand the concepts behind formwork and falsework: what they are, how to reduce risks, and inspection procedures

What is formwork and falsework?

Formwork

Formwork can be illustrated as the surface of the form and framing used to contain and shape wet concrete until it's self-supporting.

Formwork consists of the forms on or within which the concrete is poured and the frames and bracing which provides stability. Whilst frequently associated with the formwork assembly, the joists, bracing, foundations, bearers, and footings are technically regarded as falsework.

Formwork construction often involves more high risk activities such as operating powered mobile plants such as cranes, excavating foundations, and operating at heights.

Falsework

Falsework can be defined as the temporary structure used to support a permanent structure, material, plant, equipment, and people, until the construction of the permanent structure has advanced to the point where it is self-contained.

Falsework may be used to support a range of permanent structures prior to their completion, including:

[if !supportLists]● [endif]Prefabricated concrete elements for building or civil construction

[if !supportLists]● [endif]Formwork and reinforcing steel for in-situ concrete structures

[if !supportLists]● [endif]Large steel beams and fabrications, and

[if !supportLists]● [endif]Bridge spans including arches

How can formwork and falsework risks be governed?

Formwork

It's necessary to bear in mind that the design of the final concrete structure has a notable impact on the health and safety of workers during the course of the construction process. Generally speaking, the more straightforward and basic the final concrete structure, the safer it is to construct, erect and dismantle the formwork.

A skillful formwork designer must be consulted with in the design phase of in-situ concrete structures to ensure that all health and safety risks are examined. The necessary risk assessments ought to be conducted and actions taken according to the 'Hierarchy of Risks' rankings. The formwork designer should have a detailed understanding of documenting work platforms and special equipment required to ensure safe formwork construction.

The formwork designer needs to include the details of the construction method and erection sequences in the formwork drawings as necessary. In the event where formwork will be recycled afterwards, the formwork design should ensure that the structural strength is maintained after allowing for the natural degeneration of materials through storage, use, and handling.

Falsework

Like formwork designers, falsework designers should use a combination of technical engineering standards specific to the design to make certain the final product satisfies regulatory requirements. Engineering principles should be applied that involve mathematical and scientific procedures, according to engineering standards.

It's important to mention that falsework designers will need to consider all loads that may be applied during its use, including dead, live, environmental and other loads. If the falsework involves a complex structure, for instance a stone arch bridge, the structure designer should involve the falsework designer to reduce its complexity and thus the health and safety risks to workers.

Things to consider before starting formwork and falsework

[if !supportLists]● [endif]Structure Design

Formwork

The structural design of the permanent structure substantially affects the risk of injury from slips, trips, and falls (including falling objects) during formwork construction and usage. While not always practical, permanent structure design steps that can decrease these risks include:

[if !supportLists]● [endif]Ensuring there is consistent floor depth which makes it much easier to erect and lower the risk of injury.

[if !supportLists]● [endif]Beams designed to provide suitable access across the beam recess

[if !supportLists]● [endif]Minimising the number of columns used

[if !supportLists]● [endif]Reducing cantilevered floor sections

The structural design also ascertains the amount of manual handling involved in formwork construction, so this must be taken into account during the design phase.

Falsework

There are several technical assumptions and specifications that should be complied with in the design drawings for falsework structures, including a statement of the loads and expected dimensional changes. The design drawings should detail factors which include member sizes and materials, dimensions, erection procedures, and levels. In addition to this, details concerning bracing, dimensions, and foundations must be provided to make sure that falsework construction can be carried out as safely as possible.

Support systems that are acquired 'off-the-shelf' are regularly not suitable for complicated falsework. A geotechnical assessment needs to be carried out to enable the designer to factor in the existing ground conditions. In addition to this, it's vital that the foundations and footings of the falsework maximise the structural integrity of the design.

[if !supportLists]● [endif]Competency and Licensing

The inspection and certification process for both formwork and falsework are carried out to be certain that health and safety risks are reduced during construction.

Anyone who erects, alters or dismantles formwork and falsework must be qualified with suitable experience. In addition, a licensed scaffolder is required to erect, alter or dismantle a scaffold in cases where material or a person can fall greater than four metres from a platform or structure. The high risk work licensing classes are listed in Schedule 3 of the WHS Regulations.

Formwork ought to comply with AS 3610: Formwork for concrete. A competent engineer with structural design experience should inspect and certify that the completed formwork satisfies the design specifications at numerous stages during construction, primarily when the formwork is being loaded.

For both formwork and falsework, a qualified engineer has to complete a Formwork Structural Certificate and supply this to management, most commonly the principal contractor. In addition to this, there are specific requirements that must be inspected and certified to control entry to the scaffold.

Inspection and Maintenance

[if !supportLists]● [endif]Common Hazards

As discussed in the previous sections, it's vital that the formwork and falsework structures are designed to lower health and safety risks resulting from the large number of potential hazards. A few of the most prevalent hazards are:

[if !supportLists]● [endif]Formwork decks - falls are entirely possible and to minimise injury, particular joist design and dimensions should be complied with when building the formwork deck. Equally, uneven floors can increase the risk of falls so it's imperative that the deck is progressively constructed from bottom to top.

[if !supportLists]● [endif]Cantilevers bearers and ply sheets can be dangerous if left unsecured. It's easy for material to fall from cantilevers so the use of cantilevers should be minimised during the design phase.

[if !supportLists]● [endif]Open penetrations like stairwells can cause hazards for people on the deck. It's vital that any penetration which poses a risk of a person or material falling should be guarded.

If you require further information relating to formwork or falsework, or would like to talk to someone about hiring labour or equipment for your project, contact Uni-span on 1300 882 825. With more than 40 years of experience, Uni-Span operates from three national locations, providing quality and cost-effective formwork and scaffolding solutions, equipment and services.

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