Formbau

Formbau is the process of constructing formwork, the temporary molds used to shape concrete and other materials during casting. In construction and manufacturing, formbau encompasses planning, fabrication, erection, and stripping of formwork systems that define the geometry, surface finish, and volume of the final product.

Formwork systems employ a range of materials and configurations. Common materials include timber and plywood for traditional forms, and steel, aluminum, or fiber-reinforced polymer panels for reusable or modular systems. Modern formwork often combines modular panels with connection hardware to enable rapid assembly, alignment, and reusability. Release agents and waterproofing are used to facilitate stripping and quality surface finish.

Design and engineering of formwork focus on safety, stability, and adequacy to resist fresh-concrete loads, hydrostatic pressure, and construction loads. Critical considerations include geometry and tolerances, load paths, material strengths, curing conditions, and the sequencing of supports and ties. Proper shoring, bracing, and inspection minimize deformation and prevent blowouts or misalignment.

Applications range from cast-in-place walls, slabs, columns, and beams to complex architectural forms and tunnels. Formwork is also used in precast production, where molds are made off-site and reused to manufacture multiple units. The formwork design may be integrated with BIM and construction planning to optimize quantities and schedules.

Historically, formwork evolved from timber frames to sophisticated modular and reusable systems. Developments include steel and aluminum frames, curved formwork for architectural shapes, and advanced sealants and waterproofing. Ongoing advances emphasize safety, efficiency, and sustainability in formwork practice.