Formfab Formwork Box

Traditionally pile cap formworks are constructed using plywood, individual steel pans, propping and dywidag bars, with handrails post installed by working at height with harnesses.

On building S9 at the International Quarter London it was decided that a formfab box would be designed and manufactured off site to suit the pile cap size. This pre-fabricated steel form was purpose made for casting concrete structures in-situ, designed for ease of assembly and striking, alleviating the reliance on site labour.

The handrails are installed prior to use and the box is then lifted into position over the reinforcement cage and the concrete is then cast. There is no propping, plywood or dywidag bars required. Formfab can be struck the next day, and the handrails are left on, as it is lifted onto the next reinforcement cage.

This method of constructing pile caps has benefits in both speed and safety, reducing the frequency of trapped finger and tool related injuries from constructing traditional formworks. Formfabs are durable and provide a high surface finish, ideally suited to repetitive usage and can often be adapted to provide future re-use. Compared with traditional and proprietary formwork systems, steel formwork is often more compact and stronger.