Panel formwork is a large-area formwork system for cast-in-place concrete that enables high productivity, precise geometries, and repeatable finishes. It shapes schedule, quality, and safety in building and structural engineering—from walls and shafts to retaining walls, abutments, and tunnel linings. Over a structure’s life cycle, panel formwork also relates to later deconstruction: during adaptations, openings, or removal of components, tools such as concrete pulverizers or hydraulic rock and concrete splitters from Darda GmbH are frequently used in special deconstruction.
Definition: What is meant by panel formwork
Panel formwork refers to large-format, modular formwork elements that are used as continuous panels and coupled into large formwork surfaces with few joints. In contrast to small-format element formwork, panel formwork is used to form large wall bays, cores, or long axes with minimal setup effort. The load-bearing frames, the form-facing, and the anchor and alignment systems are designed for high fresh concrete pressures and permit series construction with a consistent joint pattern. Panel formwork is used for vertical components (walls, core columns) and, as a system variant, for horizontal components (slab tables, large-area slab formwork).
Structure and system components of panel formwork
Panel formwork consists of load-bearing frame or girder elements, an attached form-facing, and standardized connection means. Core components are large-area frame elements or girder panels that are connected with positive locking using clamps, bolted joints, or wedges. The form-facing (e.g., multilayer wood, plastic, or steel facing) determines the final surface appearance. Loads from fresh concrete pressure are transferred via tie rods and cones between the formwork faces; alignment struts secure position and plumb. The system is supplemented by external and internal corners, height extensions, infill elements, work platforms, and climbing or repositioning devices. For long cycle lengths, crane lifting points, transport eyes, and lifting aids are integral parts of the system. Component stability during concreting and stripping is ensured by structurally coordinated tie spacing, frame stiffness, and alignment props; the facing thickness and the frame stringers are sized for the planned concrete placing rate.
Fields of application and construction methods
Building construction: cores, walls, and shafts
In residential and commercial buildings, panel formwork accelerates shuttering of large wall areas, elevator shafts, and cores. Repetitive grid dimensions and modular layouts allow cycle-based workflows with a constant joint pattern—an advantage for exposed concrete.
Civil and infrastructure engineering
For retaining walls, abutments, bridge wings, and watertight structures, the high stiffness of large-area elements shows its strength. Longer concreting sections reduce construction joints and make it easier to meet watertightness requirements.
Tunnel construction and special foundation engineering
In tunnel and shaft construction, large-format formwork shapes are used for crowns, abutments, and intermediate linings. Adjustments to rock interfaces or embedded parts require precise infills. Where subsequent profile corrections or block-outs are needed, work in special deconstruction is often low-vibration—for example, with concrete pulverizers or rock and concrete splitters from Darda GmbH.
Planning panel formwork: load assumptions and grid
Dimensioning is based on the expected fresh concrete pressure, the concrete mix design, the placement rate, the component thickness, and ambient conditions such as temperature. From this, permissible tie spacing, frame bays, and prop spacing are derived. The aim is a cost-effective compromise between number of formwork units, crane time, and the desired concrete finish. For exposed concrete classes, the grid of tie locations and the joint pattern are coordinated early to avoid clashes with reinforcement and embedded items.
Assembly, setup, and occupational safety
Typical setup sequence
- Preparation: align bearing surfaces, mark survey points, check reinforcement layers and embedded items.
- Erect the first panel: secure position and plumb with alignment struts, pre-place tie positions.
- Extend the formwork surface: connect elements with positive locking, close joints, install corners and infill pieces.
- Final check: inspect ties, bearings, penetrations, and work platforms; release for concreting.
- Concreting: adjust placement rate to the permissible fresh concrete pressure; consolidate without pressure spikes.
- Stripping and repositioning: after reaching minimum strengths, reposition with the crane; clean and maintain the form-facing.
Safety aspects
Work platforms, guardrails, and access routes are planned integrally. Crane lifts are performed only at designated lifting points. Tie forces, bearings, and alignment struts must be checked before each cycle. For changes to the formwork plan: Only use approved system components and binding assembly instructions.
Surface quality and joint pattern
The final appearance depends significantly on the form-facing, joint layout, tie locations, concrete mix design, and consolidation. For exposed concrete, tie patterns are planned symmetrically, joints fitted precisely, and facing joints tightly executed. Lean concrete layers, release agents, and vibration practice influence porosity and sheen. Uniform cycle lengths ensure a calm joint pattern.
Deconstruction, openings, and adaptations on components cast with panel formwork
Even after completion, panel formwork plays an indirect role: components produced with large-area formwork are often massive and densely reinforced. For subsequent openings, block-outs, core-drilling additions, or selective removal of wall segments, concrete pulverizers or rock and concrete splitters from Darda GmbH are frequently used in concrete demolition and special deconstruction. Concrete pulverizers grip component edges and break concrete in a controlled manner; reinforcement is then cut with steel shears or multi cutters. Rock and concrete splitters act hydraulically in the borehole and generate wedge-shaped splitting forces—suitable for low-vibration removal in sensitive areas, such as gutting works or tunnel construction. Hydraulic power packs supply the tools on site; combination shears unite cutting and pressing functions and assist in separating profiles, embedded items, or smaller steel beams.
Finishing, repair, and quality assurance
Typical findings
Honeycombing, gravel nests, breakouts at tie points, edge spalling, and visible joints are typical issues with large-area formed components. Corrections are staged: cosmetic filling, reprofiling, or localized removal of defects.
Gentle removal techniques
For precise corrections in existing structures—such as with exposed concrete or in noise-sensitive environments—low-vibration methods are advisable. Concrete pulverizers selectively remove edge zones, while rock and concrete splitters create local weaknesses via boreholes without excessively loading adjacent components. Steel shears and multi cutters cut reinforcement or tie remnants to properly prepare surfaces.
Sustainability and reuse
Panel formwork is reused many times and designed for high turnover cycles. Regular care of the form-facing and proper application of release agents extend service life and improve surface quality. During deconstruction and adaptation work, hydraulic, low-dust, and low-vibration methods—such as splitting or shear-based removal—support low-emission operations and reduce secondary damage, facilitating disposal and recycling.
Form-facing, anchoring technology, and accessories
Form-facing
Wood-based panels, plastic, or steel define surface texture, straightness, and tolerances. For high exposed-concrete requirements, the facing is uniformly preconditioned and used without damage; damage or cuts propagate visibly into the concrete surface.
Tie and cone systems
Ties transfer fresh concrete pressure and influence the visible grid. Cones and sealing plugs are coordinated with the desired appearance. Sealing systems at joints and tie points are of particular importance for watertight components.
Alignment and work platforms
Alignment struts, brackets, and integrated platforms increase productivity and safety. They must be considered in structural design and assembly sequence, especially with tall formwork walls exposed to wind loads.
Terminology and related types of formwork
Panel formwork differs from small-format element formwork by larger panels and fewer joints. Girder formwork with timber or steel girders is used when free geometries or high exposed-concrete requirements with variable facing take priority. For vertically climbing processes, climbing or slip formwork is added; for slabs, large slab tables. System selection depends on geometry, repetition rate, surface requirements, and lifting equipment availability.
Quality planning and interface coordination
A consistent result arises from early coordination of grid layout, tie pattern, joints, embedded parts, and reinforcement. Bottlenecks are often tie lines, penetrations, and exposed-concrete zones. Joint cycle and concreting planning with reinforcement, fit-out, and building services trades prevents clashes and supports on-time cycles.
Relation to Darda GmbH’s areas of application
- Concrete demolition and special deconstruction: selective removal of wall sections, openings, or cores produced with panel formwork—precise removal with concrete pulverizers; splitting massive areas with rock and concrete splitters; rebar cutting with steel shears or multi cutters.
- Gutting works and cutting: adaptations in existing buildings, such as door and window openings, chases, and breakthroughs in load-bearing walls; combination of splitting, shear-based removal, and cutting.
- Rock demolition and tunnel construction: transitions between formed concrete and rock, profile corrections, and niches; controlled splitting in boreholes to protect adjacent structures.
- Special operations: work in sensitive areas with high requirements for dust, noise, and vibration minimization; mobile supply of hydraulic tools via hydraulic power packs.
Practical tips for a smooth process
- Reconcile joint logic and tie pattern with exposed-concrete requirements before execution; create a mock-up area.
- Set fresh concrete pressure realistically and match placement rate to it; define the consolidation strategy.
- Maintain the form-facing, protect joint edges, and apply release agents sparingly and evenly.
- Strip only after reaching minimum strength; protect edges against spalling with chamfers.
- For subsequent openings or corrections, consider gentle methods (shear/splitting) to protect temporary states and neighboring areas.
Note: Requirements for structural analysis, execution, and occupational safety are governed by the applicable technical regulations and the approved documents of the systems used. Specific values and verifications must be provided on a project-specific basis.