A formwork scaffold constitutes the load-bearing and walkable structure that supports formwork during concreting and also provides working and protective functions. It combines the requirements of falsework, working scaffold, and temporary shoring. In new construction, in existing structures, and in specialized deconstruction, it is used wherever fresh concrete pressure, self-weight, and erection forces must be safely transferred into the ground or into temporary auxiliary structures. In practice, the topic often intersects with controlled concrete demolition and the adaptation of existing components—tools such as concrete pulverizers and hydraulic rock and concrete splitters from Darda GmbH are used to separate components with low noise and vibration or to create predetermined breaking points.
Definition: What is a formwork scaffold
A formwork scaffold is a temporary structure made of posts, ledgers, frames, and bracing that accommodates formwork for walls, slabs, foundations, columns, cantilevers, or vaults. It serves the load transfer of fresh concrete pressure, the self-weight of the formwork, and additional loads (materials, personnel, equipment). Depending on the task, the formwork scaffold combines the functions of falsework (carrying loads), work and protection scaffold (access, fall protection), and, where applicable, temporary shoring for adjacent components. Typical configurations include frame systems, modular or tower falsework, yoke-girder solutions, and special designs for bridge or tunnel cross-sections.
Configuration and components of a formwork scaffold
The structural configuration follows a modular principle so that loads are transferred in an orderly manner and assembly can be carried out efficiently and safely. In terms of materials, steel and aluminum dominate; timber is used for formwork sheathing, ledgers, or embedded parts.
Main elements
- Posts and frames: vertical load-bearing elements, often height-adjustable via spindles or head spindles.
- Ledgers, yokes, and girders: horizontal members for supporting the formwork, distributing point loads, and providing bracing.
- Diagonals and alignment braces: for spatial bracing and tipping stability.
- Bearing and load distribution elements: base plates, sleepers, load distribution plates to adapt to the subgrade.
- Work platforms, brackets, guardrails: access, safety, and ergonomics for personnel.
- Formwork sheathing and formwork anchors: the contact surface with the concrete as well as means for taking up fresh concrete pressure.
Material selection and system construction
Steel offers high load reserves and robustness; aluminum reduces self-weight and facilitates assembly, especially in confined areas or for manual handling. System construction (modular or frame scaffold) increases process reliability; custom constructions are common for complex geometries. The connectors (pins, wedges, couplers) ensure positive locking and are decisive for overall load-bearing capacity.
Structural principles and load transfer
Sizing and use of a formwork scaffold are based on the governing loads: self-weight, fresh concrete pressure (depending on consistency, placement rate, and temperature), live loads from personnel and materials, as well as erection and wind loads. Load paths must be clearly defined and verified by calculation; bearing zones and the subgrade must be checked for load-bearing capacity and settlement behavior.
Fresh concrete pressure and concreting sequence
The concreting rate, placement height, and concrete mix composition influence fresh concrete pressure. A coordinated pour sequence and compaction plan limits load peaks. For high walls or large form bodies, additional yokes, tighter tie spacing, or reinforced girder layers must be considered.
Anchorage, bracing, tipping stability
Spatial bracing of the formwork scaffold prevents tipping, buckling, and lateral buckling of individual elements. Connections must be made with positive and force-locked engagement, and anchor forces must be transferred via suitable compression/tension paths. Interfaces with existing components require particular care to avoid unintended restraint.
Formwork scaffold in existing structures, deconstruction and adjustments
In existing structures, formwork scaffolds encounter existing load-bearing systems with partially unknown conditions. Temporary shoring secures slabs or walls during interventions. Concrete demolition is coordinated with the residual load-bearing capacity, and vibrations are to be minimized. Selective hydraulic methods are used to avoid influencing adjacent scaffolds.
Strengthening and temporary shoring
For openings, partial removals, or load redistributions, a formwork scaffold is used as an auxiliary structure until new components have cured. A defined release cut and controlled load redistribution are essential before load-bearing parts are separated.
Influence of demolition works on formwork scaffolds
Low-vibration methods protect the connections, bearings, and load distribution of the formwork scaffold. Concrete pulverizers from Darda GmbH enable the selective deconstruction of reinforced concrete with limited vibration excitation; rock and concrete splitters create controlled cracks and relieve massive areas before lifting. The prerequisite is that the affected zones have been structurally released and that the formwork scaffold does not have to take on unintended additional loads.
Tools and methods around formwork scaffolds
The choice of tools depends on component thickness, degree of reinforcement, accessibility, and proximity to the formwork scaffold. The goal is a controlled, clean cutting or splitting process with minimal impact on the temporary constructions.
Concrete pulverizers: selective concrete demolition in confined spaces
Concrete pulverizers from Darda GmbH grip and crush reinforced concrete locally, creating openings for anchor access, niches for brackets, or release cuts at bearing areas. Their advantage lies in the metered introduction of force and in the ability to process reinforced concrete including rebar. They are powered by hydraulic power units, which can be positioned either mobile or stationary.
Rock and concrete splitters: controlled splitting of massive components
Rock and concrete splitters from Darda GmbH use wedge-shaped splitting cylinders to produce a defined crack path. This allows massive blocks, upstands, or abutments to be broken down into manageable pieces without introducing impact or percussive energy into the formwork scaffold. Especially in special deconstruction or with thick, heavily reinforced walls, predetermined breaking points help reduce follow-up work with pulverizers or shears.
Complementary hydraulic tools
- Combination shears and multi cutters: for cutting smaller steel sections, embedded parts, and insert rails in the formwork environment.
- Steel shears: for sections, girders, or temporary steel structures, provided they have been structurally released.
- Hydraulic power units: power supply and control of attached tools with attention to hose routing, leak protection, and positioning away from load paths.
Applications in the fields of use
Concrete demolition and special deconstruction
In selective deconstruction near formwork scaffolds, components are removed in clearly defined sequences. Vibrations and uncontrolled load redistributions must be avoided.
- Survey and release: clarify structural behavior, define temporary shoring and the formwork scaffold.
- Preparatory cuts: create predetermined breaking points using rock and concrete splitters.
- Selective removal: use concrete pulverizers on freed edges or Concrete Crushers, release reinforcement in a controlled manner.
- Disposal and logistics: handover of pieces without drop, short routes, clear workflows.
- Control: visual inspection of the formwork scaffold after each sequence, retighten connectors.
Strip-out and cutting
During strip-out inside buildings, formwork scaffolds serve as work and protection levels or temporary props. Openings in slabs and walls are worked out with concrete pulverizers; splitting cylinders facilitate breaking edge zones when separation cuts are difficult. A coordinated sequence is important so that no unintended loads are introduced into the scaffold.
Rock demolition and tunnel construction
In tunnel construction, formwork scaffolds appear as falsework and formwork carriage superstructures. For adjusting inverts, abutments, or crown areas, rock and concrete splitters are useful to initiate cracks and release breakouts in a controlled manner. This reduces vibrations that could affect the precise seating of formwork sheathing, yoke girders, and bracing.
Natural stone extraction
In natural stone extraction, adjacent working scaffolds and temporary platforms are under load. Controlled splitting with hydraulic devices minimizes vibration and protects the bearings and feet of the scaffolds. Where concrete foundations or plinths need to be adjusted, concrete pulverizers support precise removal.
Special applications
In special settings (confined courtyards, listed structures, medical facilities), strict noise and vibration limits apply. Formwork scaffolds must remain reliably in place while components are adjusted. Hydraulic methods with pulverizers and splitters from Darda GmbH are suitable due to their controlled introduction of force, provided they are embedded in an approved work concept.
Planning, assembly and safety
Planning and assembly follow the recognized rules of engineering and the relevant codes. Key factors are a complete structural analysis, an assembly and use plan, qualified personnel, and continuous supervision.
Assembly sequence
- Check the subgrade and define load distribution (plates, sleepers, pads).
- Preassemble elements, align plumb and true, secure connections.
- Add bracing and guardrails, keep access routes clear.
- Fit the formwork, plan tie locations, account for fresh concrete pressure.
- Pre-acceptance and documentation, trial load where required.
- Concreting with coordinated sequencing; continuous monitoring of connections.
Occupational safety and environment
Fall protection, load underpinning, secured access, and defined storage areas are indispensable. Dust and noise reduction are achieved by suitable methods and tools. Low-vibration removal with concrete pulverizers and splitting with rock and concrete splitters help to protect adjacent structures.
Quality assurance, documentation and deconstruction
Regular visual and functional checks, retightening of connections, and the documentation of changes ensure serviceability. During deconstruction, a clear sequence and unobstructed load paths apply so that no parts give way uncontrollably.
Dismantling the formwork scaffold: sensible sequence
- Release after curing and proof of load-bearing capacity of the new components.
- Unload in defined steps, lower the spindles evenly.
- Dismantle bracing and ledgers in reverse assembly order.
- Controlled removal of embedded parts; if required, targeted removal with concrete pulverizers at anchor or bearing areas.
- Removal and visual inspection of components for reuse.
Sustainability and resource efficiency
Durable system components, careful handling, and reuse reduce resource demand. Selective methods such as splitting and pulverizer removal reduce secondary damage, rework, and disposal volumes. This benefits projects in which formwork scaffolds are redeployed multiple times.
Typical mistakes and how to avoid them
- Insufficient load transfer: clarify load paths before assembly, strengthen the subgrade.
- Lack of bracing: install diagonals and nodes according to the system, provide tipping/overturning checks.
- Stripping too early: wait for curing and proofs; plan time buffers.
- Interference with demolition works: interface management with clear exclusion and working zones.
- Inadequate documentation: record changes, define responsibilities, log visual inspections.