Cassaform’s 6-Step Process for Self-Performing Slab Formwork

1. Budgeting and Tendering

• Assess project requirements for formwork: When reviewing project plans, Cassaform can provide expert consultation on the most efficient formwork and propping systems for both suspended slabs and vertical concrete elements, helping to reduce excess material and labour costs.  

• Estimate excavation, retention, steel fixing, and concrete placement: Establish a list of specialist contractors required to collaborate with you on designing custom solutions for elements such as basement retention systems, piling, capping beams, excavations, shotcrete works, basement retention, concrete reinforcement, and placement etc and obtain specialist pricing estimates. Engaging specialist will optimise designs and plan for efficiency.   

• Budget finalisation & Tender Preparation: From the proposals received, select the most cost-efficient and optimal solutions for your project being sure to select preferred subcontractors that are willing to work with and will support you.  Remember cheapest is not always best.  Review the project scope and ensure that all elements are included. Cassaform can supply a wide range of modular and special formwork systems suited to the job. We ensure the correct installation of our formwork solutions by providing coordination designs with quantities and pre-loading inspections.  

2. Site Preparation and Layout for Formwork

• Formwork Layout: Once the basement has been excavated, retention is in place, and the ground slab is poured you are ready to move into the formwork stage of columns and suspended slabs. Cassaform’s engineers can prepare formwork layout plans based on the system that is best suited to the project as well as optimise designs to reduce costs.  

• Formwork Options & Solutions: Cassaform has a variety of both conventional and modular formwork systems, such as the P300 Wall Formwork System for vertical elements or our Slabform and Greenform slab systems for horizontal elements.  You can rest assure that whatever system is recommended you will find them flexible and very easy to use.   

• Lateral Design Stability: Regardless of the system used, Cassaform will discuss safety concerns and ensure that full lateral stability is designed into the systems and maintained during the entire construction phase. 

• Material Readiness: Cassaform conducts through inspects and maintains all rental and sales equipment to the highest standard available in the industry today.  This couple with our timely on-site delivery service will ensure that your construction program requirements are adhered to therefore reducing costly downtime.  

3. Formwork Elements 

• Vertical Elements – Vertical element usually consist of items like retaining walls, columns, shear walls, feature walls, lift and stair shaft core walls etc.  When our Engineers consider these vertical elements on your project, they will usually consider wall area volumes, column quantities, number of lifts or floors on the project and programme time frame allocated.  If there is sufficient programme time or the wall area volumes or column count are small or low, then we would usually recommend that it be built conventionally.  If the construction programme is tight and the wall areas are larger, or we believe that you can save labour resources through the use of a system then we would consider the use of our P300 modular wall system  

• Horizontal Elements:  When considering horizontal elements our Engineers will review architectural and structural drawings to determine formwork areas on the project, slab thicknesses, concrete pour breaks, number of floors, design complexity (i.e. beams or flat pan) construction programme duration and sequences etc.  From this information and based on our clients’ preferences and skills levels we would typically propose a couple of systems or options.  For example, 

• Conventional System – Super Shore Frames, Bearer and Joist Timber (if required or client supplied), Formwork Ply Sales  

• Green Formwork Pan and Drop Head Propping System – This is an entry level environmentally friendly product which significantly reduces labour costs and material wastage.  Usually, better suited to large areas with 2-4 floors levels 

• Slabform Pan, Beam and Drop Head Propping System – This is an extremely labour efficient and environmentally friendly “Premium light weight system” that has minimal material wastage.  Best suited to multi-storey structures of at least 3 levels plus. Three men can install approx. 500m2 per day where you can achieve floor cycles of approx. 3.5 days.   

4. Training & On-Site Support 

• On-Site Support Training: Cassaform has a full and comprehensive range of propping and formwork solutions to suit almost any design and application. Even if your project is unique, we can source specialised equipment from anywhere around the globe to find the best and most cost-efficient solution just for you.  No matter what solution is offered, our experienced sales and engineer teams are here to help and can provide on-site training and support, free of charge, throughout the entire project – Start to Finish. In addition, we also offer on-site pre-pour inspections service if required.

5. Reinforcement and Safety Check

• Install reinforcement: Place rebar or mesh reinforcement inside the formwork as per the structural engineering specifications. Ensure proper spacing and concrete cover to prevent exposure after pouring.  

• Safety checks: Inspect all formwork for structural integrity, ensuring that props, beams, and panels are secure and correctly positioned. Cassaform can provide on-site sign-off at this stage to confirm the formwork has been installed correctly. Ensure scaffolding and access platforms are safe for workers.  

6. Pouring and Stripping

• Pour concrete: Begin pouring concrete evenly across the formwork, starting from the farthest corner. Ensure proper compaction using a vibrator. If you do not have experience at concrete placement, it is recommended that you use professional concreters.  

• Cure the slabs: Let the concrete cure for the specified time. Cassaform’s drop-head props for the Slabform Aluminium Pan System allow for early stripping of formwork as it continues to fully support the slab even after the pans and beams have been stripped.   

• Strip formwork: Regardless of which Cassaform modular systems is used, they can all be easily stripped and reused on other areas of the project.  Stripping can usually be done within a few days of pouring which therefore reduces the volume of equipment required to meet the program and significantly speeds up your program time frame.    

• Return or reuse formwork: Depending on the formwork schedule and number of structure levels, you can repeat steps 2-6 for upper levels or return the formwork to Cassaform, eliminating the need to clean, maintain, and store the equipment on site.  

By partnering with Cassaform you can leverage our off our industry-leading formwork and propping experience to improve efficiency, reduce labour costs, and ensure the safety and success of your project. Cassaform’s engineering expertise and modular solutions enable customised, innovative formwork setups that meet your project’s specific needs, keeping timelines and budgets on track.