The Ultimate Guide to Falsework and Formwork in Scaffolding

There are general misconceptions in the differences of formwork and falsework utilised in scaffolding, mainly among people that are new to the building and construction industry. This guide attempts to provide all the fundamental information needed to grasp the concepts behind formwork and falsework: what they are, how to alleviate risks, and inspection procedures

What is formwork and falsework?

Formwork

Formwork may be described as the surface of the form and framing used to contain and shape wet concrete until it is self-contained.

Formwork includes the forms on or within which the concrete is poured and the frames and bracing which provides stability. While generally linked to the formwork assembly, the joists, bracing, foundations, bearers, and footings are technically regarded as falsework.

Formwork construction frequently involves more high risk activities such as operating powered mobile plants including cranes, excavating foundations, and working from heights.

Falsework

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

Falsework can be used to support a range of permanent structures before their completion, including:

●     Prefabricated concrete elements for building or civil construction

●     Formwork and reinforcing steel for in-situ concrete structures

●     Large steel beams and fabrications, and

●     Bridge spans including arches

How can formwork and falsework risks be effectively handled?

Formwork

It's important to keep in mind that the design of the final concrete structure has a major consequence on the health and safety of workers during the construction process. Generally, the more straightforward and basic the final concrete structure, the safer it is to construct, erect and dismantle the formwork.

A certified formwork designer must be consulted with in the design phase of in-situ concrete structures to confirm that all health and safety risks are investigated. Appropriate risk assessments ought to be performed and actions taken in accordance with 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 must include the specifications of the construction method and erection sequences in the formwork drawings as necessary. In the event where formwork will be reused later on, the formwork design should be sure that the structural strength is maintained after allowing for the natural deterioration of materials through storage, use, and handling.

Falsework

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

It's relevant to note that falsework designers should consider all loads that may be applied during its use, including dead, live, environmental and other loads. If the falsework involves a complicated structure, for example a stone arch bridge, the structure designer should involve the falsework designer to minimise its complexity and therefore the health and safety risks to workers.

Things to consider before starting formwork and falsework

●     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 the course of formwork construction and usage. Though not always practical, permanent structure design steps that can reduce these risks include:

●     Ensuring there is consistent floor depth which makes it simpler to erect and minimise the risk of injury.

●     Beams designed to provide suitable access across the beam recess

●     Minimising the number of columns used

●     Reducing cantilevered floor sections

The structural design also determines the amount of manual handling required in formwork construction, so this must be considered during the design phase.

Falsework

There are several technical assumptions and specifications that have to be followed 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. Alongside this, details regarding bracing, dimensions, and foundations must be supplied to make sure that falsework construction can be done as safely as possible.

Support systems that are purchased 'off-the-shelf' are normally not practical for complex falsework. A geotechnical assessment needs to be carried out to enable the designer to factor in the existing ground conditions. Along with this, it's integral that the foundations and footings of the falsework maximise the structural integrity of the design.

●     Competency and Licensing

The inspection and certification procedures for both formwork and falsework are done to be certain that health and safety risks are mitigated during construction.

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

Formwork should adhere to AS 3610: Formwork for concrete. A knowledgeable engineer with structural design experience should inspect and certify that the completed formwork satisfies the design specifications at multiple stages during construction, particularly when the formwork is being loaded.

For both formwork and falsework, a capable engineer must complete a Formwork Structural Certificate and deliver this to management, most commonly the principal contractor. As well as this, there are specific requirements that have to be inspected and certified to control entry to the scaffold.

Inspection and Maintenance

●     Common Hazards

As discussed in the above sections, it's essential that the formwork and falsework structures are designed to minimise health and safety risks due to the large number of likely hazards. A couple of the most common hazards are:

●     Formwork decks - falls are conceivable and to minimise injury, particular joist design and dimensions should be adhered to when building the formwork deck. Equally, uneven floors can increase the risk of falls so it's vital that the deck is progressively constructed from bottom to top.

●     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.

●     Open penetrations like stairwells can cause hazards for workers on the deck. It's vital that any penetration which presents 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 speak 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 premium and affordable formwork and scaffolding solutions, equipment and services.