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		Formwork Making - Course: Timberwork techniques. Instruction examples for practical vocational training (Institut für Berufliche Entwicklung, 23 p.)
			(introduction...)
			Preliminary Remarks
			Instruction Example 1.1. Prefabrication of Formwork Panels
			Instruction Example 1.2. Ceiling Formwork Making
			Instruction Example 1.3. Strip Foundation Formwork Making
			Instruction Example 1.4. Beam Formwork Making
			Instruction Example 1.5. Column Formwork Making

Instruction Example 1.1. Prefabrication of Formwork Panels

This example serves for practising the prefabrication of formwork panels for beam and column formworks, in particular the prefabrication of a bottom panel for beam formwork.

Material

Formwork boards - 25 mm thick
nails - 40 mm and 70 mm long

Figure

Hand tools and machines

Circular saw, hand saw, hammer, wrecking bar with claw

Measuring and testing means

Folding rule, try square, measuring rods

Auxiliary accessories

Pencil, paper

Necessary previous knowledge

Handling of length measuring tools, scribing, working with the circular saw and manual sawing

Explanations to the working drawing

1 formwork bottom, 2 cover strap projection, 3 sheeting thickness, 4 cover strap thickness 25 mm, 5 thrust-board width 100 mm

Sequence of operations

Comments

1. Prepare the work.

Make available the tools and materials. A work table is to be manufactured (See Fig. 10 in the Trainees' Handbook).

2. Enter all sizes required into the working drawing.

Derive the sizes from the dimensions of the beam for which the formwork is to be made. Prepare the size distribution of the cover straps in particular.

3. Cut up the boards.

The board width should not exceeded 140 mm. Do not place the rough edge of the board to the inside of the formwork!

4. Cut the stiffening cover straps to length.

Cover straps to have a width of approx. 55 mm with 25 mm projection for comer joints!

5. Put the cover straps on the arranged boards according to the size distribution made.

Use measuring rod, if necessary!

6. Nail the cover straps on the board-panel.

It is provisional nailing with short nails (40 mm). Use as many nails as necessary to make the panel stable in itself.

7. Nail the cover straps on the boards from the opposite side.

Turn over the provisionally nailed board-panel and nail it with 70 mm long nails. Two nails per board are to be diagonally arranged at the cover strap joint!

8. Clinch the nail tips.

Turn over the panel again and clinch the penetrated nail tips!

Prefabrication of Formwork Panels

Sequence of operations	Comments
1. Prepare the work.	Make available the tools and materials. A work table is to be manufactured (See Fig. 10 in the Trainees' Handbook).
2. Enter all sizes required into the working drawing.	Derive the sizes from the dimensions of the beam for which the formwork is to be made. Prepare the size distribution of the cover straps in particular.
3. Cut up the boards.	The board width should not exceeded 140 mm. Do not place the rough edge of the board to the inside of the formwork!
4. Cut the stiffening cover straps to length.	Cover straps to have a width of approx. 55 mm with 25 mm projection for comer joints!
5. Put the cover straps on the arranged boards according to the size distribution made.	Use measuring rod, if necessary!
6. Nail the cover straps on the board-panel.	It is provisional nailing with short nails (40 mm). Use as many nails as necessary to make the panel stable in itself.
7. Nail the cover straps on the boards from the opposite side.	Turn over the provisionally nailed board-panel and nail it with 70 mm long nails. Two nails per board are to be diagonally arranged at the cover strap joint!
8. Clinch the nail tips.	Turn over the panel again and clinch the penetrated nail tips!