Optimization of Vertical Formwork Layout Plans Using Mixed Integer Linear Programming

A formwork is a structure used to contain poured concrete and to mold it to the required dimensions. Different formwork systems provide a wide range of concrete construction solutions that can be chosen to suit the needs of a particular structure. The selection of panels and the design of the formwork layout for concrete structures, especially if the panels are to be reused many times to form different work zones, are one of the most complex tasks in formwork construction. It influences the quality of work, construction time, site safety and cost. The formwork costs account for a significant part of the total costs for concrete works. The problem of the selection and layout of reusable panel forms is solved mainly based on the intuitive judgment of experienced engineers in collaboration with the form system supplier. This study proposes a mixed integer linear programming modeling approach to support the formwork planning process. The problem consists in determining the number and sizes of the panels according to the geometry of the concrete elements to minimize the rental cost of wall shuttering in a building divided into work zones that are to be completed in sequence, reusing the chosen panels. The model can be solved using typical software dedicated to mixed integer linear programs. A simple example is used to illustrate the efficiency of the proposed approach, where the formwork rental cost is 7.31 % lower than the rental costs of panels and corners optimized without consideration of the reuse in consecutive zones.