There are simple uncertainties in the differences of formwork and falsework utilised in scaffolding, primarily among individuals that are new to the building and construction industry. This guide aims to provide all the essential information needed to grasp the concepts behind formwork and falsework: what they are, how to reduce 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 features the forms on or within which the concrete is poured and the frames and bracing which provides stability. Though generally linked with the formwork assembly, the joists, bracing, foundations, bearers, and footings are technically referred to as falsework.
Formwork construction usually involves more high risk tasks such as operating powered mobile plants including cranes, excavating foundations, and operating at heights.
Falsework
Falsework may be described as the temporary structure used to support a permanent structure, material, plant, equipment, and people, until the construction of the permanent structure has progressed to the point where it is self-contained.
Falsework can be used to support a wide range of permanent structures prior to 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 handled?
Formwork
It’s important to mention that the design of the final concrete structure has a substantial effect on the health and safety of workers throughout the construction process. In most cases, the more straightforward and basic the final concrete structure, the safer it is to construct, erect and dismantle the formwork.
A capable formwork designer must be consulted with in the design phase of in-situ concrete structures to verify that all health and safety risks are examined. Appropriate risk assessments ought to be finalised and actions taken in accordance with the ‘Hierarchy of Risks’ rankings. The formwork designer should have a comprehensive understanding of documenting work platforms and special equipment required to ensure safe formwork construction.
The formwork designer should include the details of the construction method and erection sequences in the formwork drawings as necessary. In the case where formwork will be recycled in the future, the formwork design should be certain 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 mix of technical engineering standards relevant to the design to be sure the final product meets regulatory requirements. Engineering principles should be utilised that incorporate mathematical and scientific procedures, based on engineering standards.
It’s relevant to keep in mind that falsework designers need to take into consideration all loads that may be applied during its use, including dead, live, environmental and other loads. If the falsework involves a complex structure, such as 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
- 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. Whilst not always practical, permanent structure design steps that can reduce these risks include:
- Ensuring there is consistent floor depth which makes it much easier to erect and decrease 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 ascertains the amount of manual handling required in formwork construction, so this must be considered during the design phase.
Falsework
There are numerous technical assumptions and specifications that need to 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 such as member sizes and materials, dimensions, erection procedures, and levels. Alongside this, details concerning bracing, dimensions, and foundations must be supplied to ensure that falsework construction can be performed as safely as possible.
Support systems that are purchased ‘off-the-shelf’ are generally not suitable for complex falsework. A geotechnical evaluation needs to be carried out to enable the designer to factor in the existing ground conditions. As well as this, it’s vital 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 conducted to make sure that health and safety risks are mitigated during construction.
Anybody who erects, alters or dismantles formwork and falsework must be qualified with relevant experience. In addition, 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 must comply with AS 3610: Formwork for concrete. A knowledgeable engineer with structural design experience should inspect and certify that the completed formwork complies with the design specifications at numerous stages during construction, particularly when the formwork is being loaded.
For both formwork and falsework, a knowledgeable engineer has to complete a Formwork Structural Certificate and supply this to management, most commonly the principal contractor. As well as this, there are specific requirements that ought to be inspected and certified to control entry to the scaffold.
Inspection and Maintenance
- Common Hazards
As discussed in the above sections, it’s vital that the formwork and falsework structures are designed to reduce health and safety risks resulting from the large number of likely hazards. Some of the most prevalent hazards are:
- Formwork decks – falls are conceivable and to minimise injury, particular joist design and dimensions should be complied with when building the formwork deck. Additionally, uneven floors can increase the risk of falls so it’s imperative 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 create hazards for people 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 regarding 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.
Formwork and Scaffolding | Uni-Span 