Shuttering is the process of building temporary retaining structures for concrete casting. Formwork is used to give concrete shape and prevent leaks or uneven surfaces. Workers must check and double-check the formwork before pouring concrete. Once the concrete sets, the formwork is removed and cleaned for future use. Builders are trained to construct formwork and may assist in pouring concrete.
Shuttering is a term used to describe the process of building formwork, or temporary retaining structures, used in the concrete casting process. Concrete formwork is done to help give the concrete a shape while it is setting, thus preventing leaks, cracks or uneven surfaces. Wood can be used to bolt concrete, as well as metal structures known as road form. The shutter pieces of material are held in place with rods and other safety components known as falsework that can be removed once the concrete has set. Most formwork is temporary and will be removed once the concrete sets.
The concrete formwork process begins long before the concrete is even poured. First a plan must be developed to determine where the formwork pieces are to be placed; this is usually done by drafting a project. Then it must be decided which type of formwork will be used. Water-resistant plywood is a common choice, although metal street form can be used in some cases. Plywood is less expensive and usually easier to store and transport, so it’s the more common choice for most projects. Once the plan has been developed, formwork can be put in place and dummy can be used to fix the forms in place.
This is not a quick process and several workers are likely to end up placing formwork on larger projects. The formwork needs to be checked and double checked to make sure it is seated correctly and all corners are tight. This will prevent the concrete from leaking out of the spaces between the shapes and will also help ensure that all faces of the concrete are flat and straight after curing. Once the concrete has hardened, the shapes will need to be removed and cleaned so they can be reused for future projects. In some cases, plywood may not be reusable, so it will be discarded after use.
Shutters can be quite a complex task, especially if particularly tall forms are to be built, or complex foundations with many corners or winding paths. Builders are usually specifically trained to construct formwork prior to a concrete pouring project, and in some cases, the formwork carpenter may have a hand in the actual pouring of the concrete to ensure the forms are positioned correctly and will not shift as they concrete is poured. If necessary, small changes to the shapes can be made during the casting process.
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