SPECIFICATION 821

FORMWORK
Copyright MAIN ROADS Western Australia

MAIN ROADS Western Australia

Contract xxx/xx

Specification 821 Formwork

Document 04/10135 Issue 11/06/10

Page 1 of 13

SPECIFICATION 821
FORMWORK
REVISION REGISTER
Date

Clause
Number

Description of Revision

Authorised
By

11 June 10

Clause
821.02

Redundant AS 2271
removed

A/SDSE

1 Aug 06

Whole
document

Complete revision of Issue

1.3 to new format

MCP

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Specification 821 Formwork

Document 04/10135 Issue 11/06/10

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CONTENTS
Clause

Page No

GENERAL ........................................................................................................................ 4
821.01 SCOPE ......................................................................................................... 4
821.02 REFERENCES ............................................................................................. 4
821.03 821.05 NOT USED ...................................................................................... 4
PRODUCTS AND MATERIALS ...................................................................................... 4
821.06 GENERAL..................................................................................................... 4
821.07 OFF-FORM CONCRETE FINISHES ............................................................ 4
821.08 TIMBER FORMWORK ................................................................................. 5
821.09 OTHER TEMPORARY FORMWORK ........................................................... 5
821.10 PERMANENT DECK SOFFIT FORMWORK ................................................ 5
821.11 VOID FORMERS .......................................................................................... 6
821.12 821.25 NOT USED ...................................................................................... 6
OPERATIONS.................................................................................................................. 6
821.26 FORMWORK DESIGN ................................................................................. 6
821.27 FORMWORK CONSTRUCTION .................................................................. 6
821.28 REMOVAL OF FORMWORK ....................................................................... 7
821.29 TOLERANCES FOR CONCRETE CONSTRUCTION .................................. 8
821.30 PROVISION FOR THERMAL MOVEMENT ................................................. 8
821.31 821.70 NOT USED ...................................................................................... 8
AS BUILT AND HANDOVER REQUIREMENTS............................................................. 9
821.71 821.90 NOT USED ...................................................................................... 9
CONTRACT SPECIFIC REQUIREMENTS ...................................................................... 9
821.91 821.99 NOT USED ...................................................................................... 9
ANNEXURE 821A.......................................................................................................... 10

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Specification 821 Formwork

Document 04/10135 Issue 11/06/10

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SPECIFICATION 821
FORMWORK
GENERAL
821.01

SCOPE

1.
The work under this specification consists of the design and
construction of formwork required for the proper construction of concrete
for structures in the permanent Works to the tolerances specified herein.
821.02

REFERENCES

1.
Australian Standards, MAIN ROADS Western Australia
Standards and MAIN ROADS Western Australia Test Methods are
referred to in abbreviated form (e.g. AS 1234, MRS 67-08-43 or WA
123). For convenience, the full titles are given below:
Australian Standards
AS 1761

Helical Lock-Seam Corrugated Steel Pipes

AS 3610

Formwork for Concrete

Australian/New Zealand Standards

AS/NZS 2271 Plywood and Blockboard for Exterior Use

Main Roads Specifications
Specification 820
821.03 821.05

CONCRETE FOR STRUCTURES

NOT USED

PRODUCTS AND MATERIALS

821.06

GENERAL

1.
Formed concrete surfaces shall comply with the
requirements of Section 3 of AS 3610.
821.07

OFF-FORM CONCRETE FINISHES

1.
Surface Finishes shall meet the requirements of AS 3610 to
the classes designated on the Drawings.
2.
Particular importance is attached to the achievement of good
"off-the-form" concrete finishes throughout the Works. Formwork shall
be designed and fabricated and erected and dismantled so that all
formed concrete surfaces achieve the specified uniform surface finish
and texture without patching or plastering or cement washing or any
treatment after removal of the formwork.

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Specification 821 Formwork

Document 04/10135 Issue 11/06/10

Surface
Finish

Page 4 of 13

3.
All formwork made up from separate panels shall be so
designed that the pattern of exposed panel joints complements the
overall geometry of the structure and does not detract from the final
appearance of the structure. The Contractor shall detail proposed soffit
and side formwork panel arrangements on the formwork Drawings.

Panel
Arrangement

4.
In order to minimise the number of joints, formwork panels
shall be supplied in the maximum practicable width and length. Plywood
when used shall be placed with the grain of the outer plys in the direction
of the span.

Plywood
Panels

821.08

TIMBER FORMWORK

1.
Timber for formwork shall be well seasoned and free from
loose knots and other defects. Timber which has become warped or
unsuitable for use shall be replaced at no cost to the Principal.

Timber

2.
Plywood used in formwork lining shall comply with the
relevant provisions of AS/NZS 2271.

Plywood

821.09

OTHER TEMPORARY FORMWORK

1.
Forms made from materials other than plywood will be
permitted provided that the requirements for strength and rigidity and
tightness are met and that all bolts and rivet heads are countersunk and
the finished concrete appearance is not inferior to that obtained with
good quality plywood. Steel forms shall be suitably treated to prevent
rusting of the face to be in contact with the concrete. The minimum
thickness required for steel formwork is 4mm.

Steel Forms

2.
Polystyrene used as formwork shall be lined with a 3mm
thickness of plywood on the face that is to be in contact with the
concrete to be poured and such facing shall be glued with a suitable
adhesive to the polystyrene.

Polystyrene

821.10

PERMANENT DECK SOFFIT FORMWORK

1.
Where indicated on the Drawings, permanent deck soffit
formwork shall be used between the beams. Such permanent formwork
shall be "BONDEK" with thickness as detailed on the Drawings or an
equivalent material approved by the Superintendent.

Bondek or
Similar
Approved

2.
Due care shall be exercised in achieving an effective seal at
the seating joint between the "BONDEK" and the beams. The minimum
width of the seating on the beams shall no be less than that detailed on
the Drawings.

Seating of
Bondek

3.
The Contractor's attention is drawn to the tendency of the
"BONDEK" formwork to 'walk' off the beam seating. The Contractor
shall ensure it is installed so that it cannot move during any stage of
construction. The joining ribs shall be securely fastened together with
self tapping screws or equivalent method approved by the
Superintendent. The "BONDEK" profiled ends shall be sealed in
accordance with the manufacturers published recommendations.

Securing
and Sealing
Bondek

4.
The fixing of "BONDEK" formwork to the steel beams, where
used, shall be by tack or puddle welding. The fixing of BONDEK
formwork to timber stringers shall be by spiking.

Fixing of
Bondek

5.
Care shall be taken to align the BONDEK ribs across the
bridge section prior to fixing deck reinforcement.

Alignment

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Document 04/10135 Issue 11/06/10

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821.11

VOID FORMERS

1.
Non-recoverable void formwork as shown on the Drawings
shall be helical lock seam corrugated galvanised steel pipe of 1.6mm
minimum sheet thickness. The void former and material shall be in
accordance with the relevant sections of AS 1761. The Contractor shall
ensure that the void former is held rigidly in position until the surrounding
concrete has set.
821.12 821.25

Corrugated
Steel Pipe
Void
Formers

NOT USED

OPERATIONS
821.26

FORMWORK DESIGN

1.
AS 3610.

The design of all formwork shall be in accordance with

2.
Formwork shall be so designed and constructed that it can
be removed without damage to the concrete. In the case of prestressed
concrete the design of the formwork shall permit movement of the
members to occur during prestressing without damage to the permanent
Works. Formwork shall be set to the profiles and pre-cambers shown on
the Drawings and due allowance shall be made in setting the levels of
the formwork to compensate for any deflection or deformation due to the
weight of the concrete. Formwork shall be designed and constructed to
withstand the vibration required during placing of the concrete as
specified in Specification 820 CONCRETE FOR STRUCTURES.
3.
Where concrete is poured in more than one operation the
Contractor shall take all necessary precautions to hold the formwork
tight against the previous pour to avoid any discontinuities in the finished
off-form surface.

Construction
Joints

4.
At least two weeks prior to commencing formwork
construction the Contractor shall supply to the Superintendent
design details and Drawings checked and certified by a qualified
structural engineer that the formwork complies with the
Specification.

HOLD
POINT

821.27

FORMWORK CONSTRUCTION

1.
Forms shall be built true to line and level and braced in a
substantial and unyielding manner to maintain correct position and
shape.
2.
On all exposed concrete surfaces the joints and splices in
formwork panels shall be arranged in a manner suitable to the shape
and area being formed. Wherever possible, joints in adjoining panels
shall be positioned to be either staggered by half panel lengths or placed
in line.

Joints

3.
Forms shall be mortar tight and the edges of all joints shall
be sealed with a suitable type of sealant. Forms subject to external
water pressure shall be watertight.

Sealing

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4.
Forms shall be held in correct alignment and spacing by bolt
and rod assemblies designed so that when the forms are removed no
metal shall be closer to the surface of the concrete than the minimum
cover specified on the Drawings. The rods shall be held in place by
devices capable of developing the strength of the rod attached to the
walings. Bolt and rod assemblies shall be arranged so that cavities
caused by their removal shall form a regular pattern appropriate to the
area being formed. All such cavities shall be wetted and carefully
packed with colour matched mortars and brought to an even surface.

Bolt and
Rod
Assemblies

5.
The use of wires and/or bolts extending to the surface of the
concrete shall not be permitted except where shown on the Drawings.
Wires or bolts or fastenings for forms or fixing reinforcement shall have
the same concrete cover as specified for reinforcement.

Cover

6.
All balustrade and traffic barrier sockets and hole formers
and all other fittings shall be accurately located. Bolts, pipes and bars
used to form holes in the structure shall be well greased and arranged
so that they may be removed from the concrete without excessive jarring
or hammering before removal of forms.

Fittings

7.
Form lubricants shall be of the non-staining type which do
not adversely affect the surface of the concrete. Lubricants shall be
used after the fabrication of forms and prior to the placing of any
reinforcing steel or other embedded item. The lubricant shall be
uniformly applied in a thin film and any surplus shall be removed prior to
placing concrete. Care shall be taken that such coatings do not soil the
surface of reinforcement.

Lubricant

8.
Where the bottom of a panel is inaccessible from within then
access panels shall be provided to permit thorough removal of rubbish
before placing concrete.

Access
Panels

9.
Prior to concreting all forms shall be clean and free from
sand and shavings and tie wire ends and other debris. Surplus water
shall be drained and any temporary openings closed in a proper manner.

Cleaning

10.
Forms for re-entrant angles shall be chamfered and forms for
corners shall be filleted. The bevel in each case shall have a width of
20mm on each side unless otherwise shown on the Drawings.

Chamfers &
Fillets

821.28

REMOVAL OF FORMWORK

1.
Formwork shall be removed in such a manner to ensure that
no damage to the concrete occurs.

Removal

2.
Based on average conditions in accordance with AS 3610,
formwork support and formwork to reinforced concrete deck soffits and
pier cap beams shall not be removed until a minimum of 7 days has
elapsed and the concrete has achieved a cylinder strength of 30Mpa.
For other environmental conditions, AS 3610 Table 5.4.1 shall be used
to determine minimum formwork stripping times.

Timing

3.
Formwork support and formwork to prestressed concrete
deck soffits and pier cap beams shall not be removed until the concrete
has achieved the transfer strength specified on the Drawings and the
concrete has been prestressed. In addition, the minimum formwork
stripping times given in As 3610 Table 5.4.1 shall be met.

Timing

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Document 04/10135 Issue 11/06/10

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4.
Based on average conditions in accordance with AS 3610,
for other parts of the structure other than the deck, formwork shall not be
removed until a minimum of 48 hours has elapsed and the concrete has
attained a cylinder strength of 20 Mpa. For other environmental
conditions, AS 3610 Table 5.4.1 shall be used to determine minimum
formwork stripping times.
821.29

Timing

TOLERANCES FOR CONCRETE CONSTRUCTION

1.
The materials for forms and form arrangements shall be
such as to result in finished concrete work complying with the tolerances
shown in Table 821.1
TABLE 821.1

TOLERANCES FOR CONCRETE CONSTRUCTION

Footings to Piers and Abutments:

(a)

Variation of dimensions in plan and

elevation

- 5mm + 20mm

(b)

Misplacement or eccentricity of centreline

+ 10mm

(c)

Variation in specified level

+ 10mm

Abutment Walls, Columns and Column Cap Beams:

(a)

Variation from vertical or specified batter.

The lesser of 1:300

or
+ 5mm in full height

(b)

Variation in cross sectional dimensions

- 5mm+ 10mm

(c)

Misplacement or eccentricity of centreline

+ 5mm

(d)

Variations from specified level of

surfaces other than bearing surfaces

+ 5mm

(e)

Variation from specified level of all

bearing surfaces

+ 3mm

Bridge Superstructures:
(a)

Departure from specified alignment of

centreline and edges

+ 10mm

(b)

Departure from specified profile

+ 10mm

(c)

Variation in cross-sectional dimensions

- 3mm + 5mm

(d)

Variation from specified level of all

bearing surfaces

+ 3mm

821.30

PROVISION FOR THERMAL MOVEMENT

1.
The Contractor's attention is drawn to the need for the
formwork for all deck diaphragms other than the fixed piers to be
supported off the steel beams in a manner that will permit temperature
movement of the deck diaphragms relative to the cap beams during
construction.
821.31 821.70

NOT USED

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Document 04/10135 Issue 11/06/10

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AS BUILT AND HANDOVER REQUIREMENTS

821.71 821.90

NOT USED

CONTRACT SPECIFIC REQUIREMENTS

821.91 821.99

NOT USED

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Document 04/10135 Issue 11/06/10

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ANNEXURE 821A

(Insert as required. Include tables, diagrams, etc as necessary. Delete Annexure page
if not required.)

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Specification 821 Formwork

Document 04/10135 Issue 11/06/10

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SPECIFICATION 821 GUIDANCE NOTES

DELETE THESE GUIDANCE NOTES FROM FINAL DOCUMENT AFTER USING FOR
REFERENCE
All edits to downloaded TDP documents shall be tracked (most word processing
software allows this to be done automatically). Deletions shall be struck through e.g.
example. Insertions shall be in italics e.g. example. If all information relating to a clause
is deleted then the clause number should be retained and the words "NOT USED"
should be inserted.

The proposed documents with tracked changes shall be submitted to the Project
Manager for review, prior to printing the final batch of documents. When this final
printing is carried out, the tracked changes option is to be turned off.
The Custodian of this specification is the Structures Design and Standards Engineer.

1.

PERMANENT DECK SOFFIT FORMWORK (Clause 821.10)

If the design and Drawings nominate the use of TRANSFLOOR permanent concrete
deck soffit formwork then CONTRACT SPECIFIC REQUIREMENT clause 821.91
should be included and clause 821.10 deleted and replaced with Not Used.

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CONTRACT SPECIFIC REQUIREMENTS TO ADD OR DELETE

The following clause is to be placed under the CONTRACT SPECIFIC

REQUIREMENTS as required. Note that if more than 1 Clause is required in this
Section the Clause numbers may be varied within the range allocated to this section to
suit the requirements of the project and the remaining Not Used numbers adjusted
accordingly. Also the Clause number and heading style should be altered to, H2 DSB
so that it will be included in the specification Contents page.

821.91

PERMANENT DECK SOFFIT FORMWORK

1.
As indicated on the Drawings, the design has assumed the
use of "TRANSFLOOR" precast concrete, permanent formwork for the in
situ concrete deck slab.
2.
The Contactor shall be responsible for designing the
"TRANSFLOOR" formwork in accordance with the details shown on the
Drawings.
3.
Particular care shall be taken in detailing the location of
reinforcement in the panels and the beam shear stud layout to avoid
clashes.
4.
The Contractor may propose alternative types of permanent
formwork. In this case, the Contractor shall provide details of any
required modifications to the deck slab. If steel permanent formwork is
proposed, it may only be used between the beams, not for the cantilever
or parapet.
5.
Tenderers shall provide details of their proposed alternative
deck formwork with their Tender.

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Document 04/10135 Issue 11/06/10

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SPECIFICATION AMENDMENT CHECKLIST

Specification Name: No:
Project Manager:

821

Revision No: _______Title:

FORMWORK

Name: _______________Signature: ____________Date:______

Checked By: Name: _______________Signature: _______________Date:______

Contract No: ______ Contract Description:____________________________________
ITEM

DESCRIPTION

SIGN
OFF
All changes/amendments must be shown in Tracked Change mode until

Note:
approved.
1.
Project Manager has reviewed Specification and identified
Additions and Amendments.
2.
CONTRACT SPECIFIC REQUIREMENTS addressed?
Contract specific materials/products/clauses added? (Refer
Specification Guidance Notes for guidance).
3.
Any unlisted Materials/Products proposed and approved by the
Project Manager? if Yes provide details at 15.
4.
Standard Clauses amended? MUST SEEK approval from
MCP.
5.
Clause deletions shown as NOT USED.
6.
Appropriate INSPECTION & TESTING parameters included in
Spec 201 (Test Methods, Minimum Testing Frequencies
verified).
7.
ANNEXURES completed (Refer Specification Guidance Notes).
8.
HANDOVER and AS BUILT requirements addressed.
9.
Main Roads QS has approved changes to SMM.
10.
Project Manager certifies completed Specification reflects intent
of the design.
11.
Completed Specification independent verification arranged by
Project Manager
12.
Project Managers review completed.
13.
SPECIFICATION GUIDANCE NOTES deleted.
14.
TABLE OF CONTENTS updated.
15
Supporting information prepared and submitted to Project
Manager.
Further action necessary:

Signed:

(Project Manager)

MAIN ROADS Western Australia

Contract xxx/xx

Specification 821 Formwork

Document 04/10135 Issue 11/06/10

Date:_______________

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