ALUMINIUM FORMWORK SYSTEM USING IN … formwork System is a system for forming the cast in-place...

http://www.iaeme.com/IJARET/index.asp 29 [email protected]

International Journal of Advanced Research in Engineering and Technology (IJARET) Volume 8, Issue 6, Nov - Dec 2017, pp. 29–41, Article ID: IJARET_08_06_004

Available online at http://www.iaeme.com/ijaret/issues.asp?JType=IJARET&VType=8&IType=6

ISSN Print: 0976-6480 and ISSN Online: 0976-6499

© IAEME Publication

ALUMINIUM FORMWORK SYSTEM USING IN

HIGHRISE BUILDINGS CONSTRUCTION

R. Thiyagarajan

Teaching Fellow, Division of Structural engineering, College of Engineering Guindy,

Anna University, Chennai – 600025, Tamil Nadu, India

V.Panneerselvam

Research Scholar, Division of Structural engineering, College of Engineering Guindy,

Anna University, Chennai – 600025, Tamil Nadu

K. Nagamani

Professor and Head, College of Engineering Guindy,

Anna University, Chennai – 600025, Tamil Nadu, India

ABSTRACT

Construction is one of the significant sectors of Indian economy and is an integral

part of the development. Today India’s urban population is the second largest in the

world and its future development leads to increased demand for housing to cope with

this problem India should desperately need to plan for acquisition of land and rapid

creation of dwelling units. One of the most important factors in determining the success

of a construction project in terms of speed, quality cost and safety of work is the

formwork used in the project as it accounts about 35 to 40 percent of the total project

cost of the structure. When considering a construction projects both the client and

contractor want to finish the job early as the client wants to use the building for the

intended purpose as soon as possible. The contractor wants to finish the construction

as soon as possible to gain a higher profit. The most efficient way to speed up the work

in mass housing construction is by achieving a very short floor cycle. The floor cycle

of a building mainly depend on the formwork type, as it is the main time factor of a

building project. The aim of our study is to present about the existing formwork system

used in mass housing construction in Tamil nadu and to show how each one will affect

the project duration, project cost and the quality of the work. For that, a research has

been carried out and the results will present in this paper.

Key words: Aluminium System, Aluform System, Block Work and Plastering,

Construction, Deck Panel, Formwork, Wall Panel.

Cite this Article: R. Thiyagarajan, V.Panneerselvam and K. Nagamani, Aluminium

Formwork System Using In Highrise Buildings Construction. International Journal of

Advanced Research in Engineering and Technology, 8(6), 2017, pp 29–41.

http://www.iaeme.com/ijaret/issues.asp?JType=IJARET&VType=8&IType=6

Aluminium Formwork System Using In Highrise Buildings Construction


1. INTRODUCTION

Construction is one of the significant sectors of Indian economy and is an integral part of the

development. Today India’s urban population is the second largest in the world and its future

development leads to increased demand for housing. To cope with this problem India should

desperately need to plan for acquisition of land and rapid creation of dwelling units.

Construction is a complex process involving basically the areas of Architectural planning,

Engineering and Construction. According to the Federation of Indian Chamber of Commerce

and Industries (FICCI), keeping in view the existing housing crisis, the country shall need

addition of more 2.5 million new dwelling units annually”(Kulkarni, 2001). The recent years

voiced the active participation of private sectors in finding the solution over the prevailing

situation on housing front. Keeping in view the gigantic task of providing affordable shelter to

masses, adoption of a cost – effective technology assumes greater significance. The present

strain on Indian economy and the overgrowing demands for housing calls for adoptions of

appropriate building technology which could lead to economy and speed in construction. As a

result of experimentation of innovate construction techniques and modern construction

management it is now possible to achieve an overall saving to the extent of 10 percent in the

total cost of housing construction compared to the cost of traditional housing. There is growing

realization today that speed of construction needs to be given greater importance especially for

large housing projects. This is not only essential for the faster turnover of equipment and

investment also leading possible to the reduction in the housing cost – but also for achieving

the national objective of creating a large stock to overcome shortest possible time.

2. OBJECTIVE OF STUDY

Our study aims to prove, for mass housing low-rise constructions, Aluminium Formwork

System will be the best suitable formwork system in terms of Safety, Quality, Cost and

Duration over the conventional formwork system, by analyzing the on- going projects in Tamil

Nadu and referencing the completed projects all over India.

3. NEED FOR STUDY

The disparity between the supply and demand for affordable housing is tremendous. Rapid

urbanization has resulted in a geometric increase in the housing demand, which cannot be

fulfilled using conventional materials and methods of construction. The traditional or

conventional method of construction for mass housing is comparatively, a slow process and

has limited quality control, particularly when a large size project is involved. It is therefore

obligatory to work out a method or a scheme where the speed and quality of construction are

controlled automatically by a systematic approach. Therefore Aluminium Formwork System

(AFS) identified to be suitable for Indian conditions for mass housing construction where

quality and speed can be maintained at a reasonably high level. It is adoptable for any design

of a building and establishes a kind of assembly line production.

The methodology of using aluminium formwork takes in to consideration on the following

important parameters such as the number of housing units and the time that is available and

works out the component of input as formwork. The whole structure is constructed with cast-

in-situ load bearing walls by using pre-engineered aluminium forms with form-finished

concrete and no plaster on any face.

R. Thiyagarajan, V.Panneerselvam and K. Nagamani


4. FORM WORK

Formwork is a die or a mould including all supporting structures, used to shape and support

the concrete until it attains sufficient strength to carry its own weight. It should be capable of

carrying all imposed dead and live loads apart from its own weight. Formwork has been in use

since the beginning of concrete construction. New materials such as steel, plastics, fiber glass

and Aluminium are used in formwork. Greater attention is being given to the design,

fabrication, erection and dismantling of formwork as a temporary structure. Form work

includes the surface in contact with the concrete and all necessary supporting structure.

5. PRESENT TECHNOLOGY AVAILABLE IN INDIA

Some of the advanced technologies of formwork catering to the speed of construction are given

below:

5.1. Pre-Fabrication Technology

The Pre-cast concrete elements in roofs, floors and in walls have become more common as

these eliminate shuttering; centering and plastering labor and saves material cost.

Figure 1 Prefabricated Technology (Larsen & Toubro Limited, Bhoiwada, Mumbai)

5.2. Tunnel Formwork Technology

It is a technology, constructing large number of housing within short time using steel forms to

construct walls & slabs in one continuous pour in Fig.2.

5.3. Aluminium formwork System

Aluminium formwork System is a system for forming the cast in-place concrete structure of a

building. It is also a system for scheduling and controlling the work of other construction trades

such as; steel reinforcement, concrete placement, and mechanical and electrical trades in Fig.

3.



Figure 2 Tunnel Formwork Figure 3 Aluminium Formwork

6. ANALYZING THE CURRENT MARKET TREND IN PRIVATE

SECTOR

6.1. Housing Scenario in India

The progress made by the construction industry of any country could be considered as the index

of development of that country. Further, the number of pucca houses built in any country could

be another index. While there has been a progressive rise in stock of housing in India since

independence, the speed thereof has not kept pace with the rapid growth of population and

urbanization. As a result, the shortage of accommodation is increasing continuously and the

situation has become acute in urban areas.

As per 2011 census, the country had a population of 1210.98 million, out of which, 377.10

million (31.16 percent) lived in urban areas. During 2001 – 2011, the urban population of India

grew at a CAGR of 2.8 percent, resulting in the increase in level of urbanization from 27.81

percent to 31.16 percent.

This growing concentration of people in urban areas has led to problems of land shortage.

Considering these factors, there currently exists a wide gap between the demand and supply of

housing (both in terms of quality and quantity) in urban India. According to estimates of the

technical Group constituted by the ministry of housing shortage in the country at the end of the

10th year Five – Year plan was estimated to be 24.71 million for 66.3 0 million households.

The group further estimated that

• 88 percent of this shortage pertains to houses for Economically Weaker Sections

(EWS)

• 11 for Lower-income Groups (LWS)

• 0.04 Million shortage for both Middle and High-income Groups.

During the 11th Five Year plan, the group estimated that the total housing requirement in

Indian cities by the end-2012 will be the tune of 26.53 million dwelling units for 75.01 million

households. If the current increase in backing of housing is maintained, a minimum of 30

million additional houses will be required by 2020.



6.2. Urban Population Set To Outgrow Overall Population Growth

India’s urban population has grown at a CAGR of 2.8 percent over 2001 – 2011, resulting in

an increase in the urbanization rate from 27.8 percent to 31.20 percent. Out of India 1.21 billion

population, 377 million people are Urban Dwellers. The Federation of Indian Chambers of

Commerce (FICCI) estimates that by 2050, the country’s cities would witness a net increase of

900 million people. Furthermore, over 2012 – 2050, the Pace of Urbanization is likely to

increase at a CAGR of 2.1 percent- Double than that of China.

Figure. 4 Outgrow Overall Population Growth.

6.3. State-Wise Housing Shortage In 2012

10 states contribute to three – Fourths of the urban housing shortage. The state wise data shows

a mixed picture where both developed as well as less developed states have families living in

poor housing conditions. Following states are housing shortage. The top 10 states, in terms of

urban housing shortage, contribute to 14.3 million or 76 Percent of housing shortage.

Figure 5 Category-Wise Housing Shortage In 2012



Figure 6 Category-Wise Based Income In 2012

7. ALUMINIUM FORMWORK

The panels of aluminium formwork are made from high strength aluminium alloy, with the

face or contact surface of the panel, made up of 4mm thick plate, which is welded to a formwork

of specially designed extruded sections, to form a robust component

The panels are held in position by a simple pin and wedge arrangement system that passes

through holes in the outside rib of each panel. The panel fits precisely, securely and requires

no bracing. The walls are held together with high strength wall ties, while the decks are

supported by beams and props. Since the equipment is made of aluminium, it has sections that

are large enough to be effective, yet light enough in the weight to be handled by a single worker.

Individual workers can handle all the elements necessary for forming the system with no

requirement for heavy lifting equipment or skilled labor. By ensuring repetition of work tasks

on daily basis it is possible for the system to bring assembly line techniques to construction site

and to ensure quality work, by unskilled or semi-skilled workers.

Trial erection of the formwork is carried out in factory conditions which ensure that all

components are correctly manufactured and no components are missed out. Also, they are

numbered and packed in such a manner so as to enable easy site erection and dismantling

Figure 7 Aluminium formwork (Larsen & Toubro Limited, Malad, Mumbai, 2016)



7.1. Merits of Aluminium Formwork

• In contrast to most of the modern construction systems, which are machine and equipment

oriented, the formwork does not depend upon heavy lifting equipment and can be handled

by unskilled labors.

• Fast construction is assured and is particularly suitable for large magnitude construction of

respective nature at one project site.

• Construction carried out by this system has exceptionally good quality with accurate

dimensions for all openings to receive windows and doors, right angles at meeting points

of wall to wall, wall to floor, wall to ceiling, etc, concrete surface finishes are good to

receive painting directly without plaster.

• System components are durable and can be used several times without sacrificing the

quality or correctness of dimensions and surface.

• Monolithic construction of load bearing walls and slabs in concrete produces structurally

superior quality with very few constructions joined compared to the conventional column

and beam slabs construction combined with filter brick work or block work subsequently

covered by plaster.

• In view of the four – day cycle of casting the floor together with all slabs as against 14 to

20 – day cycle in the conventional method, completed RCC structure is available for

subsequent finish trades much faster, resulting in a saving of 10 to 15 days per floor in the

overall completion period.

• As all the walls are cast monolithic and simultaneously with floor slabs requiring no further

plasters finish. Therefore the time required in the conventional method for construction of

walls and plastering is saved.

• As fully completed structural frame is made available in one stretch for subsequent –

finishing items, uninterrupted progress can be planned ensuring, continuity in each trade,

thereby providing as cope for employing increased labor force on finishing item.

• As the system establishes a kind of “Assembly line production” phase – wise completion

in desired groups of buildings can be planned to achieve early utilization of the buildings.

7.2. Limitation of Aluminium Formwork

• High initial investment cost.

• More number of components.

• High repair cost of Aluminium forms.

• Probability of theft is more.

• Segregation and stocking required more space.



7.3. Design of Aluminium Formwork

Figure 8 Edge Frame

Figure 9 Stiffeners



8. COMPONENTS OF ALUMINIUM FORMWORK

The basic element of the formwork is the panel, which is an extruded aluminium rail section,

welded to an aluminium sheet and other components are extruded section. This produces a

lightweight component with an excellent stiffness to weight ratio, yielding minimal deflection

under concrete loading. Panels and extrusions are manufactured in the size and shape to suit

the requirements of specific projects. Following are the components that are regularly used in

the construction.

8.1. Slab Components

• Slab Panel (SP)

• Slab Prop Head (SPH)

• Mid / End Beam (MB / EB)

• Slab Corner (SC)

• Beam Splice Bar (BSB)

• Prop Length (PL)

8.2. Wall Components

• Wall Panel (WP)

• External Corner (EC)

• Rocker (RK)

• Internal Corner (IC)

• Kicker (K)

• Pin and Wedge

8.2. Beam Components

• Beam Panel (BP)

• Bulk Head Horizontal (BHH)

• Beam Prop Head (BPH)

• Soffit Corner Internal (SCI)

• Beam Soffit Panel (BSP)

• Soffit Corner External (SCE)



Figure 10 Drawing –Plan for Aluminium frame work

9. COST COMPARISON BETWEEN CONVENTIONAL AND

ALUMINIUM FORMWORK SYSTEM

In typical floor construction, around 20 percent of cost saving is possible in box type structure

over framed structure. Almost 40 percent savings in project duration in Box type structure over

framed structure. Construction cost escalation, Labor rates increases every year at the percent

of 2 to 5.Cement and steel price increases every year at the percent of 10 to 15.Around 5 to 8

percent Savings in project cost is possible on reducing over heads by early completion of

projects. High return on investment is possible.



Figure 11 Pie Chart for Framed Structure

Figure 12 Pie Chart for Box type Structure

Figure 13 Construction duration



10. CONCLUSIONS

The task of housing due to the rising population of the country is becoming increasingly

monumental. In terms of technical capabilities to face this challenge, the potential is enormous;

it only needs to be judiciously exploited.

• Traditionally, construction firms all over the world have been slow to adopt the innovation

and changes. Contractors are a conservative lot. It is the need of time to analyze the depth

of the problem and find effective solutions. Aluminium formwork serves as a cost effective

and efficient tool to solve the problems of the mass housing project all over the world.

Aluminium formwork aims to maximize the use of modern construction techniques and

equipment on its entire project.

• From the results obtained we can come to a conclusion that when the Aluminium formwork

is used in the construction project, the total project cost and the duration of the project is

lesser than the Conventional formwork system.

• The floor cycle will be 7 to 10 days when the Aluminium formwork used in typical floors,

and hence the structure duration will be reduced by 35 to 40 percent over the conventional

method of construction. At the same time, there will not be any additional activities such

as block work and plastering, which further reduces the overall project duration in the tune

of 3 to 4 months.

• The Aluminium Formwork System can achieve not only faster rate of construction but can

also bring down the structural cost by 20 to 25 percent over the conventional method with

lesser labour inputs.

• Not only the direct benefits, there are many indirect benefits of using aluminium formwork

system in the mass housing construction projects. For example Aluminium is the 100

percent recyclable materials, which saves our environments from the extraction of natural

resources such as mining of bauxite, reduces tree cutting.

REFERENCES

[1] K.Loganathan, K.E.Viswanathan, “on a study report on cost, duration and quality

analysis of different formworks in high-rise building,” International Journal of

Scientific & Engineering Research, Volume 7, Issue 4, pp. 190-195, ISSN 2229-5518,

April-2016.

[2] Nareshkumar Prajapati, Jayeshkumar Pitroda, Prof. Chetna M. Vyas, “on A Critical

Literature Review On Integrated Framework For Assessingfactors Affecting Human

Resource Management In Construction,” Journal Of International Academic Research

For Multidisciplinary, Issn: 2320-5083, Volume 2, Issue 12, pp. 114-123, January

2015

[3] Sandip.P.Pawar, P.M.Atterde, “on Comparative Analysis Of Formwork In Multistory

Building,” IJRET: International Journal of Research in Engineering and Technology,

ISSN: 2319-1163, Volume: 03, Special Issue: 09, NCETCE-2014, pp. 22-24, June-

2014.

[4] Aniket S.Kadam, Akshay T. Kokare, Sanket B. Samukhrao, Sanman N. Sawant, Miss.

Pritee Mistry, “on Cost Comparison & Effectiveness of Mivan Formwork over the

Conventional Formwork,” International Journal on Recent and Innovation Trends in

Computing and Communication, Volume: 4 Issue: 4, ISSN: 2321-8169, pp. 318 – 319,

April 2016.

[5] Miss. Patil Dhanashri Suryakant, Prof. Desai D B, “on Emerging Trends in Formwork

- Cost Analysis & Effectiveness of Mivan Formwork over the Conventional

Formwork,” IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), ISSN:

2278-1684, PP: 27-30.



[6] Ninjal M Parekh, Bhupendra M Marvadi, Umang Patel, “on Comparative Studies of

Construction Techniques Conventional Technique Vs Aluminium Formwork

Techniques,” Journal of Information, Knowledge and Research In Civil Engineering,

ISSN: 0975 – 6744| NOV 14 TO OCT 15 | Volume 3, Issue 2, pp. 279- 287.

[7] Arbaz Kazi1, Fauwaz Parkar, “on Comparative Study and Decision Making For a

Formwork Technique to Be Adopted On A Construction Site In Mumbai,” IJRET:

International Journal of Research in Engineering and Technology eISSN: 2319-1163 |

pISSN: 2321-7308, Volume: 04 Issue: 12, Dec-2015.

[8] Patel Abhiyan S, Neeraj Sharma D, Bhavin K Kashiyani, “on Selection Criteria of

Formwork by Users in Current Age In South Gujarat Region,” International Journal of

Innovative Research in Science, Engineering and Technology, ISSN: 2319-8753 ,Vol.

3, Issue 6, June 2014.

ALUMINIUM FORMWORK SYSTEM USING IN … formwork System is a system for forming the cast in-place...

Documents

Transcript of ALUMINIUM FORMWORK SYSTEM USING IN … formwork System is a system for forming the cast in-place...