Major projects aluminium of formwork civil engineering

GOPAL JAKHAR

A

PROJECT REPORT

ON

ALUMINIUM FORMWORK

Submitted in partial fulfillment of the requirements

of

B. Tech. in Civil Engineering

Submitted By: Guided By:

GOPAL JAKHAR PROF. AMBESH RATNU

(13ESLCE409)

Submitted To:

Head of department, civil engineering

SLBS Engineering College, Jodhpur.

(Rajasthan Technical University, Kota)

SLBS ENGINEERING COLLEGE

GOPAL JAKHAR

ACKNOWLEDGEMENT

This is unforgettable moment of contentment on the successful fulfillment of an

ambition fostered for long. I prostrate at the feet of almighty god whose silent

blessing gave me the courage, energy and patience to overcome all the

hindrances that come in my way to reach the goal.

It is my privilege to acknowledge, with deep sense of

gratitude, my esteemed supervisor, professor AMBESH RATNU of S.L.B.S.

engineering college jodhpur (raj.) for his invaluable help, guidance, ever-

encouraging and affectionate attitude at every stage of my research work and

above all for his faith/belief in me.

I am grateful to Prof. R.P.VISHNOI HOD of civil

department of S.L.B.S. engineering college, Jodhpur Rajasthan for his ceaseless

encouragement constant inspiration endless co-operation, precious suggestion

and guidance about subjected inputs.

DATE:

PLACE: JODHPUR (GOPAL RAM)

CERTIFICATE


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This is to certify that the project entitled “ALUMINIUM FORMWORK”

is submitted by GOPAL RAM ID No. 13ESLCE409 is partial fulfillment of the

requirement of project embodies the work done by him under my supervision.

(Signature of the supervisor)

Name :

Designation :

Date :


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ABSTRACT

Rapid urbanization has resulted in drastic increase in housing demand

today. 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. Many methods have

emerged and have been tried out and are still being adopted all over the world.

These systems can be named as large-panel system, part pre-cast and part in-situ

construction etc.

Despite the enormous need for housing, India has not yet been able to practice

any of these methods with advantage and economy. The initial obstacles being

requirement of huge element of machinery, inadequate scope of compared to

huge inputs, composite construction failing on account of extreme atmospheric

conditions, not adhering to strict quality control and having tendencies to cut

corners for saving on costs, etc. 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.

Formwork systems are among the key factors determining the success of a

construction project in terms of speed, quality, cost and safety of the works. The

rapid advancement in the field of formwork along with the innovation in

concrete as a material has to lead to a revolutionary change where safer,

quicker, sustainable and more efficient construction is possible these days. The

Aluminium forms are recent scenario of the Indian construction industry. The

Aluminium formwork system saves cost, time and improves the quality of

construction. Aluminium formwork is successfully used in Japan, Singapore,

Malaysia and the Middle East for the construction of apartments and buildings,

both low and high rises. The aluminium formwork system is very cost effective.


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This is one of the systems identified to be very much suitable for Indian

conditions for mass construction, where quality and speed can be achieved at a

high level. The labor handles this method effectively to speed up the

construction, to assure quality control and durability.

Aluminium Formwork System, a comparatively a new technology in India,

saves cost, time and improves the quality of construction. Aluminium

Formwork is successfully used in Japan, Singapore, Malaysia and the

Middle East for the construction of apartments and buildings, both low and

high rises. For repetition of building layouts and for above-the-plinth work,

Aluminium Formwork system is very cost effective. This is one of the

systems identified to be very much suitable for Indian conditions for mass

construction, where quality and speed can be achieved at a high level. The

speed of construction of this system will surpass the speed of most of the other

construction methods/technologies. The labourhandles this method effectively

to speed up the construction, to assure quality control and durability.

Aluminium Formwork panels can be designed for any condition/component of

building such as bay windows, stairs, balconies and special architectural

features. This system is unique as all the components in a building, including

slabs, floors, walls, columns, beam, staircases, balconies and window hood, are

concrete and there is no need for block works or brick works. It gives a form

finish, eliminates the need for external and internal plaster and the walls can be

directly painted with a minimal skim coat, all these ultimately resulting in cost

saving

PREFACE


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Project report is an essential requirement for an engineering students as a

part of engineering study. It is committed by every student for the prescribed

time during the course.

According to our syllabus each student of engineering has to complete a

project report during the end of forth year.

This year I have completed my project report as far as utility of project is

concerned. It can be said that student get a chance during this project to apply

this theoretical knowledge about the subject in the project work and to clear the

difficulties in a better way looking the while process with his eyes.

I other words we get an opportunity to understand the practical aspects

and to develop it fine picture in his mind with change knowledge act as a face

when we entered the field in future.

A serious attempt has been made up to bring about all the detailed noticed

during the project work. I have tried my best to reproduce the thing as I was

seen in the project work

INDEX

S.NO. CONTENTS PAGE NO.


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1. Introduction 1

2. Description 3

3. Assembly System 4

4. Necessity of the Aluminium formwork System 5

5. Features of Aluminium formwork Technique 6

6. Aluminium formwork System Benefits (1) Advantages

(2) Disadvantages

8

7. Innovation in Construction 14

8. Formwork 18

9. Formwork component 25

10. Wall components 26

11. Construction Activities with aluminium Formwork 35

12. Speed of construction 41

13. Feature of aluminium formwork 42

14. Economy 44

15. Conclusion 51

16. References 52


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FIGURE INDEX

S.NO. CONTENTS PAGE NO.

1. Installation process 11

2. Substainal Stock of Raw Material 12

3. Unique Barcoding System 13

4. Material ready for Despatch 14

5. Aluminium Construction work 15

6. Aluminium formwork 22

7. Wall of components (1) Wall panel (2) Rocker 26

8. (3) Kicker (4) Stub Pin 27

9. Beam Components (1) Beam Side Panel (2) Prop Head Soffit Beam

28

10. Beam Soffit Panel (1) Beam soffit (2) Bulk-Head

29

11. Deck Component (1) Deck panel (2) Deck Prop 30

12. (3)Prop length (4) Deck Mid- Beam 31

13. (5) Soffit length (6) Deck Beam Bar 32

14. Other Components (1) External Soffit Corner (2) Internal Soffit Corner

33

15. (3) External Corner (4) Internal Corner 34

16. Fixing aluminium Plates 36

17. Concreting Work of Column , Beam slab 37

18. Erection of Platform 39

19. Striking of Formwork 39

20. Positioning of Platform 40


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21. Removal of Kicker 40

22. Cost Analysis of Graph 47

23. Different panel used in formwork system 50


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INTRODUCTION

Aluminium Formwork System, a comparatively a new technology in India, saves cost, time

and improves the quality of construction. Aluminium Formwork is successfully used in

Japan, Singapore, Malaysia and the Middle East for the construction of apartments and

buildings, both low and high rises. For repetition of building layouts and for above-the-plinth

work, Aluminium Formwork system is very cost effective. Aluminium Formwork panels can

be designed for any condition/component of building such as bay windows, stairs, balconies

and special architectural features. This system is unique as all the components in a building,

including slabs, floors, walls, columns, beams, staircases, balconies and window hood, are

concrete and there is no need for block works or brick works. As all the periphery of resulting

structure/component is concrete and at the same time we can control the concrete quality, the

durability of the structure increases. It gives form finish, eliminates the need for external and

internal plaster and the walls can be directly painted with a minimal skim coat, all these

ultimately resulting in cost saving.

Aluminium Formwork System is highly suited to load bearing wall construction whereas

traditional formwork consisting of plywood and timber is not suitable to the high pressures of

fresh concrete on the wall. Use of this formwork in load bearing design gives an average of

15 per cent cost saving in the structure of the building and increased usable floor space of 8

per cent over RCC design.

For 100 per cent work, construction through slab beam wall construction takes X time and

through Aluminium Formwork technology the time required is 1/6th of the X time. The

technology is environment friendly as there is no use of timber. The formwork gives the box

or cellular design resulting in the walls giving support to the super structure in two directions.

As a result, the structures are more resistant to earthquakes than the traditional RCC column

and beam designs. As the Aluminium Formwork is lightweight, no tower cranes are required

for the same unlike in tunnel framework. Due to simplicity of the assembly, only unskilled

labours are required with minimal supervision. The Aluminium Formwork System is

removable and can be reused hundreds of times with little maintenance. Moreover, the

requirement of steel is also reduced in this technology as aluminium has a higher scrap value.

Formwork is defined as temporary structure whose purpose is to provide support and

containment for fresh concrete until it can support itself. It moulds the concrete to the desired

shape and size and controls its position and alignment. The development of formworks is


GOPAL JAKHAR

parallel with the growth of concrete construction throughout the 20th century. The

advancement of technology, increase of population and the space limitation lead the way to

construct high-rise buildings. But the task was not very easy at the beginning but now the

man made the task easy by inventing new machinery and new techniques. The most

important factor in terms of cost, quality and speed in a high-rise building construction

project is the type of the formwork used in the project. The first formwork type to be used is

the conventional type formwork where the timber planks were supported on timber columns.

With the advancement of technology it developed gradually and people used ply wood sheets

instead of timber planks and steel pipes with jacks were used to support the ply wood. Then

people invented small units of formworks and connect the repeating units in the construction.

The larger units were invented like formworks for slab panels, formworks for columns,

beams etc. when the same elements are repeating. Then finally the whole system of formwork

is made and initially the material used to it was steel and it was very heavy. Then the aim was

to reduce the weight of the system and the materials for formwork have extended to

aluminium, plastic, fibre glass etc.

Aluminium formwork system provides aluminium formwork for RCC load bearing or

RCC framed multi-storied buildings and enables the walls and slabs to be poured in same

operation. These increases efficiency and also produces an extraordinarily strong structure

with excellent concrete finish. Due to the fine tolerance achieved in the machined metal

formwork components, consistent concrete shapes and finishes are obtained floor after floor.

This allows plumbing and electrical fittings to be prefabricated with the certain knowledge

that there will be an exact fit when assembled. As described by the manufacturers a low-cost

system for housing using aluminium formwork. Aluminium formwork system is construction

system for forming cast in place concrete structure of building. It is also a system for

scheduling and controlling the work of other construction trends such as steel reinforcement,

concrete placement and mechanical and electrical conduits. This type of construction requires

a restructuring of the entire conventional construction process to enable interaction between

the design phase and production planning in order to improve and speed up the construction.

The speed of construction by this system will surpass speed of most of the other construction

method.


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DESCRIPTIONThis system is based on a handled light aluminium formwork system. It is capable of forming

the concrete for both, load bearing wall design and column beam design. Unlike other

systems it is equally suited to both high rise and low rise buildings. In case of load bearing

wall design, the systems forms all of the concrete in a building, including walls, floor slabs,

columns, beams, stairs, window hoods and balconies. Specifically designed to allow the rapid

construction of multiple unit projects at optimum productivity, the aluminium formwork can

be used for a broad range of applications, from straightforward panels to more complicated

structures involving bay windows, stairs and A/C hoods. The degree of pre engineering and

inherent simplicity of the aluminium formwork enables unskilled labour to be used. Every

component is light enough to be handled by one operative, minimizing the need for heavy

liftingequipment.

ASSEMBLY

The simplicity of Aluminium Formwork and the repetitive nature of the assembly process


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make it possible to accurately programme construction sequences and thus cycle times well

in advance. In addition, this enables the unskilled labour to work with the formwork,

therefore reducing the burden on skilled labour when this is in short supply. On leaving the

factory, all panels are clearly labelled to ensure that they are easily identifiable on site and

can be smoothly fitted together using the formwork modulation drawings.

SIMPLE ASSEMBLY SYSTEMS

PIN AND WEDGE SYSTEM

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

through holes in the outside rib of each panel.

QUICK STRIP PROP HEAD

One of the principal technical features which enables this speed to be attained

using a single set of formwork panels is the unique V shaped prop head which

allows the 'quick strip' to take place whilst leaving the propping undisturbed.

The deck panels can therefore be reused immediately.

SPEED

The in-situ construction of all walls and partitions reduces the

requirement for follow-on wet trades.

The concrete surface finish produced with the aluminium forms allows

achievement of a high quality wall finish without the need for extensive

plastering.

Doors and windows are formed in position, with this high degree of

precision items such as door and window frames can be directly installed on site

with minimal re-sizing required

QUALITY


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High quality Aluminium Formwork panels ensure consistency of

dimensions. On the removal of the Formwork mould, a high quality concrete

finish is produced to accurate tolerances and verticality. The high tolerance of

the finish means that no further plastering is required. Typically a 3mm to

4mm skim coat is applied internally prior to finishing and a 6 mm build up coat

prior to laying tiles.

Necessity of the Aluminium Form work System

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 &

high rise buildings 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.

Aluminium Formwork System

Aluminium Formwork System is a construction system for forming 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 conduits.

The System is fast, simple, adaptable and very cost effective. It is unique

because it forms all of the concrete in a building including walls, floor slabs,

columns, beams, stairs, window hoods, balconies and various decorative features


GOPAL JAKHAR

in exact accordance with the architects' design. The dimensional accuracy of

the concreted work also results in consistent fittings of doors and windows. The

smooth–off form finish of the concrete eliminates the need for costly plastering.

Aluminium Formwork System provides Aluminium Formwork for RCC load

bearing or RCC framed multi-storied buildings and enables the walls and slabs

to be poured in the same operation. These increases efficiency and also produces

an extraordinarily strong structure with excellent concrete finish. Due to the fine

tolerance achieved in the machined metal formwork components, consistent

concrete shapes and finishes are obtained floor after floor. This allows

plumbing and electrical fittings to be prefabricated with the certain

knowledge that there will be an exact fit when assembled.

Unlike other construction systems, Formwork Systems of aluminium forms can

be erected by unskilled labour and without the need for hoisting cranes. The

largest panel weighs not more than 25 kgs which means it can be handled by a

single worker.

FEATURES OF ALUMINIUM FORMWORK TECHNIQUE

Features of aluminium formwork technique are as follows: -

1. Versatility

2. Speed

3. Quality

4. Durability

5. Cost.

1) Versatility: -

a) Architect is not required to change the building layout to suit the technology.

b) It is capable of forming any type of structural design.

c) The system is unique in that it forms all of the concrete in a building including; walls,

columns, beams, floor slabs, staircases, balconies, window hoods, storage lofts.


GOPAL JAKHAR

d) No need for bricks, blocks or plastering.

e) All the equipments are comprised of standard size pieces of formwork, as a result, as high

as 70% of the standard size formwork components are reused for one building layout.

2) Speed: -

a) Multi-Storey Housing - structures are completed at the rate of four days per floor

regardless of floor size.

b) Thousands of tenements can be completed annually.

3) Quality: -

a)Precision in fabricating the formwork results in accurate and consistent forming of the

concrete.

b) The quality of the concrete finish is the same regardless of whether the system is used for

low cost housing or luxury housing.

4) Durability: -

Two issues related to durability;

a) Durability of the housing units,

b) Durability of the aluminium formwork.

a) Durability of the housing units: -

All concrete (walls, slabs, staircases etc.) are poured monolithically, therefore, there are no

construction joints and no problems of leaking joints.

Smooth concrete finish means that no plastering is required. The tendency of plastering to

break away is well known.

All four walls in a room, as well as the floor and ceiling, are cast-in-place reinforced

concrete.

The result is a rigid reinforced “box” structure, which has no joints and is very durable.

b) Durability of the aluminium formwork: -

Formwork is made with an aluminium alloy, which has high tensile strength and is also very

hard.

Aluminium does not rust like steel; therefore, the aluminium formwork can be re-used

hundreds of times.

Aluminium being lightweight is easy to handle.


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Aluminium formwork System Benefits

Advantages

NO Plastering required.

Savings on overhead expenses due to speedy construction (4 days per floor).

Monolithic crack free structures.

Doesn't require timber or plywood for construction activities.

Casting of walls and slabs possible simultaneously.

Doesn't require skilled labour.

Floor slab forms removed without moving props.

Earthquake resistance of resulting structures increases manifold.

The Formwork is specifically designed to allow rapid construction on all types of

architectural layouts.

Total system forms the complete concrete structure.

Custom-designed to suit project requirements.

Unsurpassed construction speed .

High quality finish.

Eliminates plastering, saves almost 50 percent construction time.

The system becomes cost effective where there is considerable repetition of

floor layouts on a project such as in the case of low cost mass housing.

Panels can be re used up to 280 times.

Erected using unskilled labour.

Requires no cranes or heavy lifting equipment.

Suitable for low as well as high rise buildings

No need to use any timber or plywood.


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The resulting structures are highly durable and this ensures that the

expenditure on maintenance is kept to a minimum.

After the 25 cycles of reusing of our formwork system we will reach the

breakeven point of the conventional formwork cost.

Aluminium formwork supplied by other companies will consist of two panels.

i.e. standard panel up to the door level and special panels above the door level.

Since there is a joint in the door level, the panels will easily bulge which affects

the plumb of the wall/column. But our panels are designed for the full height of

the structure which will eliminate the above problem.

The major problem in Aluminium formwork is mismatching of holes. To avoid

this we do a moke- up in the factory itself so that all the problems will be

eliminated while dispatching the materials.

Sheet panels are generally used in the Aluminium formwork system. Since the

sheet panels are made by welding the rails on four sides the joints will easily

get damaged. To avoid this problem we use 450mm wide panels which are

being made by welding two ‘L’ shaped extrusions. So the corners will be

stronger than the sheet panels.

Disadvantages

Initial high investment.


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Compares very poorly on modifications, against brick work constructions.

Fear of theft of valuable Aluminium Extrusions & sheets & hence kit not being

complete at critical stages of construction.

Mass Housing projects are not as high for investing in large number of

Aluminium Formwork.

Architectural changes not possible on the structure (but some walls can be of brick work or

openings can be entertained).

Due to the tremendous speed of construction, working capital finance needs to be planned in

advance.

Paints for HIG schemes needs to be of superior quality. For LIG, form finish is more than

sufficient


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GOPAL RAM 13ESLCE409

Manufacturing facilities

Substainial stock of Raw material



Unique Barcoding system



Material ready for despatch



INNOVATION IN CONSTRUCTIONThe traditional mode of construction for individual houses comprising load bearing walls

with an appropriate roof above or reinforced concrete (RC) framed structure construction with

infill masonry walls would be totally inadequate for mass housing construction industry in view

of the rapid rate of construction. Further, such constructions are prone to poor quality control

even in case of contractors with substantial resources and experience.

“For undertaking mass housing works, it is necessary to have innovative technologies

which are capable of fast rate construction and are able to deliver good quality and durable

structure in cost effective manner”.

Several systems are adopted at different places in the world; eventually the systems

which are reasonably economical and easy for operation with skilled labor are useful in India.

Certain systems are in vogue and more and more contractors are trying to bring in new

technologies. These are essentially based on the basis of mode of construction, namely, pre-cast

construction or in-situ construction.

Cast-in-Situ Construction

Pre-cast and cast-in-situ are techniques that are used for quick construction. Pre-cast

includes the wall-panel units and slab units directly added to building structure. The use of

aluminium also evolved as one of the technique for quick construction by use of aluminium and

steel (tunnel) formwork. As a matter of fact the cost of the formwork may be up to 25% of

cost of the structure in building work, and even higher in bridges, it is thus essential that the

forms are properly designed to effect economy without sacrificing strength and efficiency.

Certain patented systems based on imported technologies such as “Mascon System”

(Canada), “Aluminium System” (Malaysia) have come on the Indian scene in recent years. In

these systems traditional column and beam construction is eliminated and instead walls and slabs

are cast in one operation at site by use of specially designed, easy to handle (with minimum labor



and without use of any equipment) light weight pre-engineered aluminium forms. Rapid

construction of multiple units of a repetitive type can be achieved with a sort of assembly

line production by deployment of a few semi-skilled labors.

The entire operation essentially comprises fitting and erecting the portion of shuttering as

already determined (the optimization in use is determined by appropriate planning) and then

carrying out concreting of the walls and slabs. Props are so designed that they stay in position

while de-shuttering of slabs and/or takes place. The dimensional accuracy of the formwork is of

high order. Therefore any possibility of errors does not rise.

“3-S” SYSTEM OF PRECAST CONSTRUCTION

An engineered system of building construction, namely “3-S” system was developed by

B.G.SHIRKE CONSTRUCTION TECH LTD., for achieving, speed, strength, safety

and economy in construction practices. The system involves structural elements such as pre-cast

hollow column shells pre-cast concrete beams, light weighed reinforced cellular autoclaved

concrete slabs for floor and roofs constituting the basic structural formwork. The “3-S” system

involves activities for construction of building such as:

I. Cast in-situ sub-structure including foundations, stem columns, plinth beams, plinth

masonry.

II. Erection of partial pre-cast components, jointing of these components using cast in-

situ concrete with appropriate reinforcement.

III. Lying of reinforced cast in-situ screed over slab panels, construction of panels,

construction of walling, flooring, plastering, water proofing etc.

Achieving the “3-S” system in the ALUMINIUM formwork is quite easy. ALUMINIUM

formwork has got the unsurpassed speed of construction due to saving time for required time in

masonry and plastering. The strength of raw aluminium is very less but when alloyed with other

materials prove to be strong enough to use as a formwork. To ensure safety in the site, an

integrated safety/ working platform is developed which ensures labor safety during erection and

striking of the formwork. Economy is also one of the main factors of any system. The

ALUMINIUM formwork proves to cost efficient as it can be used efficiently for 250 times.



FORMWORK

When concrete is placed, it is in plastic state. It requires to be supported by temporary

supports and castings of desired shape till it becomes sufficiently strong to support its own

weight. This temporary casing is known as the formwork or forms or shuttering. The term

moulds is sometimes used to indicate formwork of relatively small units such as lintels, cornices

etc.

Definition of formwork

“Forms or moulds or shutters are the receptacles in which concrete is placed, so that

it will have desired shape or outline when hardened. Once concrete develops the adequate

strength to support its own weight they can be taken out”.

“Formwork is the term given to either temporary or permanent moulds into which

concrete or similar materials are poured”.

Requirements of a good formwork

The essential requirements of formwork or shuttering are: -

a) It should be strong enough to take the dead and live loads during construction.

b) The joints in the formwork should be rigid so that the bulging, twisting, or sagging due

to dead and live load is as small as possible. Excessive deformation may disfigure the surface of

concrete.

c) The construction lines in the formwork should be true and the surface plane so that the

cost finishing the surface of concrete on removing the shuttering is the least.

d) The formwork should be easily removable without damage to itself so that it could be

used repeatedly.

Types of Formwork

The material most commonly being used to date is timber. However, due to the depleting

forest reserves and increasing cost of timber the use of alternate materials such as plywood and



steel has become prominent. More recently, materials such as plastics and fiberglass are also

being used for pre-fabricating formwork. The type of material to be used depends on the nature

of construction as well as availability and cost of material. The constraints on the project such as

overall cost, time of completion also play a major role in the use of a Particular material for

formwork.

a) TIMBER FORMWORK

Timber is required for practically all jobs of formwork. The timber bring used for

formwork must satisfy the following requirements. It should be durable and treatable. It should

have sufficient strength characteristics. It should be light weight and well seasoned without

warping. It should hold nails well. It is economical for small construction jobs. It is design

flexible and easy to erect. It has good thermal insulation which makes it useful to be used in

colder Regions. It can easily be made into any shape or size. And it is easy for transporting

purpose for in between sites.

Fig 3.1Timber Formwork

b) STEEL FORMWORK

Mostly used in large construction projects or in situations where large number of re-uses

of the same shuttering is possible. It is Suitable for circular or curved shaped structures such as

tanks, columns, chimneys etc. and also used for structures like sewer tunnel and retaining wall.


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Strong, durable & have longer life. Reuses can be assumed to vary from 100 to 120 wares timber

varies from 10 to 12.Steel can be installed & dismantled with greater ease & speed resulting in

saving in labour cost. Excellent quality of exposed concrete surface obtained. No danger of

formwork absorbing water from the concrete and minimizing honeycombing.

Fig 3.2 Steel Formwork

c) PLASTICS FORMWORK

These forms have become increasingly popular for casting unique shapes and patterns

being designed in concrete because of the excellent finish obtained requiring minimum or no

surface treatment and repairs. Different types of plastic forms are available like glass reinforced

plastic, fiber reinforced plastic and thermoplastics etc. The material allows greater freedom of

design. Unusual textures and designs can be molded into the form. It allows the contractor to

pour structural and finished concrete simultaneously. Because sections can be joined on the job

site in such a way so as to eliminate joints, there is no size limitation. If carefully handled, a

number of reuses are possible making it highly& Economical. It is lightweight and easily

stripped. The disadvantage of using plastic forms is that it does not lend itself to field fabrication

hence, the design and planning of this form must be carefully carried out. Also care must take

not to damage the plastic by the heat applied for accelerated curing of the concrete. Trough and


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waffle units in fiberglass are used in construction of large floor areas and multistoried office

buildings.

Fig 3.3 Plastic Formwork

d) ALUMINIUM FORMWORK

Forms made from aluminum are in many respects similar to those made of steel.

However, because of their lower density, aluminum forms are lighter than steel forms, and this is

their primary advantage when compared to steel. As the strength of aluminum in handling,

tension and compression is less than the strength of steel, it is necessary to use large sections.

The formwork turns out to be economical if large numbers of reuses are made in construction.

The major disadvantage of aluminum forms is that no changes can be made once the formwork is

fabricated.


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Fig 3.4 Aluminium Formwork

Loads acting on Formwork

In Construction, the formwork has to bear, besides its own weight, the weight of wet

concrete, the live load due to labor, and the impact due to pouring concrete and workmen on

it. The vibration caused due to vibrators used to compact the concrete should also be taken care

off. Thus, the design of the formwork is an essential part during the construction of the building.

For the design of planks and joists in bending & shear, a live load including the impact

may be taken as 370kg/m². It is however, usual to work with a small factor of safety in the design

of formwork. The surfaces of formwork should be dressed in such a manner that after deflection

due to weight of concrete and reinforcement, the surface remains horizontal, or as desired by the

designer. The sheathing with full live load of 370 kg/m² should not deflect more than 0.25 cm

and the joists with 200kg/m² of live load should not deflect more than 0.25cm.

In the design of formwork for columns or walls, the hydrostatic pressure of the concrete

should be taken into account. This pressure depends upon the quantity of water in the concrete,

rate of pouring and the temperature.

The hydrostatic pressure of the concrete increases with the following cases:-

Increase in quantity of water in the mix.

The smaller size of the aggregate

The lower temperature.

The higher rate of pouring concrete

If the concrete is poured in layers at an interval such that concrete has time to set, there

will be very little chance of bulging. Aluminium as usual is not a very strong material. So the


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basic elements of the formwork system are the panel which is a framework of extruded

aluminium sections welded to an aluminium sheet. It consists of high strength special aluminium

components. This produces a light weight panel with an excellent stiffness-to-weight ratio,

yielding minimal deflections when subjected to the load of weight concrete. The panels are

manufactured in standard sizes with nonstandard elements produced to the required size and size

to suit the project requirements.

ALUMINIUM: - A Versatile Formwork

The system of aluminum forms (ALUMINIUM) has been used widely in the construction

of residential units and mass housing projects. It is fast, simple, adaptable and cost – effective. It

produces total quality work which requires minimum maintenance and when durability is the

prime consideration. This system is most suitable for Indian condition as a tailor–made

aluminum formwork for cast–in–situ fully concrete structure.

Background

Aluminium is basically an aluminium formwork system developed by one of the

construction company from Europe. In 1990, the Aluminium Company Ltd from Malaysia

started the manufacturing of such formwork systems. Now a days more than 30,000 sq m of

formwork used in the world are under their operation. In Mumbai, India there are number of

buildings constructed with the help of the above system which has been proved to be very

economical and satisfactory for Indian Construction Environment.

The technology has been used extensively in other countries such as Europe, Gulf

Countries, Asia and all other parts of the world. ALUMINIUM technology is suitable for

constructing large number of houses within short time using room size forms to construct walls

and slabs in one continuous pour on concrete. Early removal of forms can be achieved by hot air

curing / curing compounds. This facilitates fast construction, say two flats per day. All the

activities are planned in assembly line manner and hence result into more accurate, well –

controlled and high quality production at optimum cost and in shortest possible time.

In this system of formwork construction, cast – in – situ concrete wall and floor slabs

cast monolithic provides the structural system in one continuous pour. Large room sized forms

for walls and floors slabs are erected at site. These forms are made strong and sturdy, fabricated



with accuracy and easy to handle. They afford large number of repetitions (around 250). The

concrete is produced in RMC batching plants under strict quality control and convey it to site

with transit mixers.

The frames for windows and door as well as ducts for services are placed in the form

before concreting. Staircase flights, facade panels, chajjas and jails etc. and other pre-fabricated

items are also integrated into the structure. This proves to be a major advantage as compared to

other modern construction techniques.

The method of construction adopted is no difference except for that the sub – structure is

constructed using conventional techniques. The super–structure is constructed using

ALUMINIUM techniques. The integrated use the technology results in a durable structure.

Modular Formwork

The formwork system is precisely-engineered system fabricated in aluminium. Using this

system, all the elements of a building namely, load bearing walls, columns, beams, floor slabs,

stairs, balconies etc can be constructed with cast in place concrete. The resulting structure has a

good quality surface finish and accurate dimensional tolerances. Further, the construction speed

is high and the work can be done in a cost effective manner.

The modular nature of the formwork system allows easy fixing and removal of formwork

and the construction can proceed speedily with very little deviation in dimensional tolerances.

Further, the system is quite flexible and can be easily adapted for any variations in the layout.

The availability of concrete from ready mix concrete facility has augured well for the use

of this work system. However, the proliferation of RMC facilities in the cities in India and the

willingness to use mechanized means of transport and placing of concrete, the use of aluminium

formwork system has received a boost. The quality of the resulting concrete is found to be

superior.

Structurally speaking, the adoption of the closed box system using monolithic concrete

construction has been found to be the most efficient alternatives. The stresses in both the

concrete and steel are observed to be much lower even when horizontal forces due to wind or

earthquake are taken into consideration.



The formwork system can be used for construction for all types of concrete systems, that

is, for a framed structure involving column beam –slab elements or for box-type structure

involving slab-walls combination.

FORMWORK – COMPONENTS

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

section, welded to an aluminium sheet. This produces a lightweight panel with an excellent

stiffness to weight ratio, yielding minimal deflection under concrete loading. Panels are

manufactured in the size and shape to suit the requirements of specific projects. The panels are

made from high strength aluminium alloy with a 4 mm thick skin plate and 6mm thick ribbing

behind to stiffen the panels.

The panels are manufactured in ALUMINIUM’S dedicated factories in Europe and South

East Asia. Once they are assembled they are subjected to a trial erection in order to eliminate any

dimensional or on site problems.

All the formwork components are received at the site whining three months after they are

ordered. Following are the components that are regularly used in the construction.

WALL COMPONENTS

1) Wall Panel: - It forms the face of the wall. It is an Aluminium sheet properly cut to fit the

exact size of the wall



FIG 4.1 WALL PANEL

2) Rocker: - It is a supporting component of wall. It is L-shaped panel having allotment holes

for stub pin

FIG 4.2 ROCKER

3) Kicker: - It forms the wall face at the top of the panels and acts as a ledge to support.


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FIG 4.3: KICKER

4) Stub Pin: - It helps in joining two wall panels. It helps in joining two joints

FIG 4.4 STUB PIN

4.3.2 BEAM COMPONENTS:


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1) Beam Side Panel: - It forms the side of the beams. It is a rectangular structure and is cut

according to the size of the beam

FIG 4.5 BEAM SIDE PANEL

2) Prop Head for Soffit Beam: - It forms the soffit beam. It is a V-shaped head for easy

dislodging of the formwork.

FIG 4.6 PROP HEAD FOR SOFFIT BEAM.

3) Beam Soffit Panel: - It supports the soffit beam. It is a plain rectangular structure of

aluminium.


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FIG 4.7 BEAM SOFFIT-PANEL

4) Beam Soffit Bulkhead: - It is the bulkhead for beam. It carries most of the bulk load.

FIG 4.8 BEAM SOFFIT BULKHEAD

4.3.3 DECK COMPONENT


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1) Deck Panel: - It forms the horizontal surface for casting of slabs. It is built for proper safety

of workers.

FIG 4.9: - DECK PANEL

2) Deck Prop: - It forms a V-shaped prop head. It supports the deck and bears the load coming

on the deck panel.

FIG 4.10 DECK PROP

3) Prop Length: - It is the length of the prop. It depends upon the length of the slab.


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FIG 4.11 DECK PROP LENGTH

4) Deck Mid – Beam: - It supports the middle portion of the beam. It holds the concrete.

FIG 4.12 DECK MID-BEAM

5) Soffit Length: - It provides support to the edge of the deck panels at their perimeter of the

room.


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FIG 4.13 SOFFIT LENGTH

6) Deck Beam Bar: - It is the deck for the beam. This component supports the deck and beam.

FIG 4.14 DECK BEAM BAR

OTHER COMPONENTS

1) Internal Soffit Corner: - It forms the vertical internal corner between the walls and the


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beams, slabs, and the horizontal internal cornice between the walls and the beam slabs and the

beam soffit.

FIG 4.15 INTERNAL SOFFIT CORNER

2) External Soffit Corner: - It forms the external corner between the components

FIG 4.16 EXTERNAL SOFFIT CORNER

3) External Corner: - It forms the external corner of the formwork system.


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FIG 4.17 EXTENAL CORNER

4) Internal Corner: - It connects two pieces of vertical formwork pieces at their exterior

intersections.

FIG 4.18 INTERNAL CORNERS

CONSTRUCTION ACTIVITIES WITH ALUMINIUM FORMWORK

The construction activities are divided as pre – concrete activities, during concreting and

post – concrete activities. They are as follows:


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PRE – CONCRETE ACTIVITIES:

a) Receipt of Equipment on Site – The equipments is received in the site as ordered.

b) Level Surveys – Level checking are made to maintain horizontal level check.

c) Setting Out – The setting out of the formwork is done.

d) Control / Correction of Deviation – Deviation or any correction are carried out.

e) Erect Formwork – The formwork is erected on site.

f) Erect Deck Formwork – Deck is erected for labours to work.

g) Setting Kickers – kickers are provided over the beam.

After the above activities have been completed it is necessary to check the following.

i. All formwork should be cleaned and coated with approved realize agent.

ii. Ensure wall formwork is erected to the setting out lines.

iii. Check all openings are of correct dimensions, not twist.

iv. Check all horizontal formwork (deck soffit, and beam soffit etc.) in level.

v. Ensure deck and beam props are vertical and there is vertical movement in the prop lengths.

vi. Check wall ties, pins and wedges are all in position and secure.

vii. Any surplus material or items to be cleared from the area to be cast.

viii. Ensure working platform brackets are securely fastened to the concrete.



Fig 4.19 Fixing Aluminium Plates

4.4.2 ON CONCRETE ACTIVITIES:

At least two operatives should be on standby during concreting for checking pins, wedges

and wall ties as the pour is in progress. Pins, wedges or wall ties missing could lead to a

movement of the formwork and possibility of the formwork being damaged. This – affected area

will then required remedial work after striking of the formwork. Things to look for during

concreting:

i. Dislodging of pins / wedges due to vibration.

ii. Beam / deck props adjacent to drop areas slipping due to vibration.

iii. Ensure all bracing at special areas slipping due to vibration.

iv. Overspill of concrete at window opening etc.


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Fig 4.20 Concreting Work of Column, Beam, Slab

4.4.3 POST – CONCRETE ACTIVITIES:

i) Strike Wall Form- It is required to strike down the wall form.

ii) Strike Deck Form- The deck form is then removed.

iii) Clean, Transport and stack formwork

iv) Strike Kicker Formwork – The kicker are removed.

v) Strike wall – Mounted on a Working Platform the wall are fitted on next floor.

vi) Erect Wall – Mount Working Platform and the wall is erected.

Normally all formwork can be struck after 12 hours. The post – concreting activities includes:

4.4.4 CLEANING:

All components should be cleaned with scrapers and wire brushes as soon as they are

struck. Wire brush is to be used on side rails only. The longer cleaning is delayed, the more

difficult the task will be. It is usually best to clean panels in the area where they are struck.

4.4.5 TRANSPORTING:


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There are basic three methods recommended when transporting to the next floor:

i. The heaviest and the longest, which is a full height wall panel, can be carried up the nearest

stairway.

ii. Passes through void areas.

iii. Rose through slots specially formed in the floor slab for this purpose. Once they have served

their purpose they are closed by casting in concrete filter

4.4.6 STRIKING:

Once cleaned and transported to the next point of erection, panels should be stacked at

right place and in right order. Proper stacking is a clean sign of a wall – managed operation

greatly aids the next sequence of erection as well as prevents clutters and impend other activities

Fig 4.21: - Erection of Platform


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Fig 4.22:- Striking of formwork

Fig 4.23: - Positioning of Platform


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Fig 4.24: - Removal of kicker

4.5 SPEED OF CONSTRUCTION

4.5.1 Work cycle

ALUMINIUM is a system for scheduling & controlling the work of other connected

construction trades such as steel reinforcement, concrete placements & electrical inserts. The

work at site hence follows a particular sequence. The work cycle begins with the deshuttering of

the panels. It takes about 12-15hrs. It is followed by positioning of the brackets & platforms on

the level. It takes about 10-15hrs simultaneously.

The deshuttered panels are lifted & fixed on the floor .The activity requires 7-10hrs

Kicker and External shutters are fixed in 7 hrs. The wall shutters are erected in 6-8 hrs. One of

the major activity reinforcement requires 10-12 hrs. The fixing of the electrical conduits takes

about 10 hrs and finally pouring of concrete takes place in these.


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This is a well synchronized work cycle for a period of 7 days. A period of 10-12 hrs is

left after concreting for the concrete to gain strength before the beginning of the next cycle. This

work schedule has been planned for 1010-1080 sq m of formwork with 72-25cu m of concreting

& approximate reinforcement.

The formwork assembling at the site is a quick & easy process. On leaving the

ALUMINIUM factory all panels are clearly labeled to ensure that they are easily identifiable on

site and can be smoothly fitted together using formwork modulation drawings. All formwork

begins from corners and proceeds from there.

The system usually follows a four day cycle: -

Day 1: -The first activity consists of erection of vertical reinforcement bars and one side of the

vertical formwork for the entire floor or a part of one floor.

Day 2: -The second activity involves erection of the second side of the vertical formwork and

formwork for the floor

Day 3: - Fixing reinforcement bars for floor slabs and casting of walls and slabs.

Day 4: -Removal of vertical form work panels after 24hours, leaving the props in place for 7

days and floor slab formwork in place for 2.5 days.

4.6 FEATURES OF ALUMINIUM FORMWORK

1) Sheet Thickness & Panel Sizes

• The concrete face of panels (Al Sheet) is 4 mm thick.

• Standard sizes of Panels are: 2000x600, 2000x300, 1200x300, 850x300.

• Apart from above any size as required shall be manufactured and delivered.



2) Load Carrying Capacity

• High load carrying capacity of 7-8 Tonnes Per square meter

• Weight

• Light weight is the main advantage over conventional formwork technology.

• Aluminium formwork weighs around 18-20 kg per meter square.

3) Cycle Time

High speed of construction can be achieved by this system that means faster completion

of project. 7 Days per floor.

4) Striking time

• Vertical (Wall) Formwork – 12 hours after concreting or when concrete strength has reached

2N/mm2.

• Horizontal (Deck) Formwork – 36 hours after concreting or when concrete strength has reached

10N/mm2.

5) Pouring System

Monolithic pouring for:

• Slabs

• Walls

• Columns

• Beams

6) Durability

• The panels are made out of Structural Grade Aluminium alloy.

• Around 200 repetitions can be achieved while using Aluminium Formwork System.



4.7 Design Aspects

The comparison is done between buildings constructed by: -

i) Conventional RC columns, beams, and slab construction (RC moment resisting frame d

structure)

OR

ii) RC load-bearing walls and slabs.

In the case of RC moment-resisting framed structures, the horizontal forces due to wind

or earthquake are resisted by the frames resulting in the bending moments in columns to resist

bending moment and vertical loads would be more than that required to resist vertical loads

without bending moment. Similarly, additional reinforcement will be required in beams at

supports. In the case of RC load-bearing walls, monolithic casting of slab along with RC walls

results in a box type structure, which is very strong in resisting horizontal forces due to wind or

earthquake. In view of large depth of shear walls, the resulting stresses due to bending moment

and vertical loads are smaller and in many cases, concrete alone is capable of resisting these

forces.

On evaluating these alternatives, it is seen that the beam column frame system in

i) Performs poorly against earthquake forces compared to RCC wall and slab

construction. Recent changes in the IS Codes, as well as recommended good practice demand

provision of additional reinforcement comply with ductility requirements.

ii) The sizing and detailing of columns needed to be –that they are 20% stronger than

beams they support.

4.8 ECONOMY

The cost per flat (or per m² built up area) using ALUMINIUM shuttering system depends

upon the number of repetition and period of completion of the project. As the formwork can be

reused over 250 times, the initial cost per unit of forming area is less when compared to

traditional methods. The reduction of cost is also due to the elimination of brickwork and plaster

and also due to reduction in time. The cost of the project gets substantially reduced due to shear

wall construction. These are due to the reduced consumption of steel, masonry, and plaster even



though the use of concrete decreases. For the same number of repetition, the cost will be less if

the period of completion is longer. This is because for a shorter completion period, the area of

formwork is more than required for longer completion period. Cost of formwork is illustrated in

Table 4.1.

The aluminium formwork provides an integrated scaffolding system which reduces the

cost of scaffolding requirements. The mechanical and electrical installation is simplified as

conduits are embedded in the structure by precise engineering of outlets and service ducts. Thus,

we can conclude that the overall cost of the project is lesser when compared to project using

traditional methods of formwork.

4.8.1 Cost comparison of aluminium and conventional formwork

Initial cost of aluminium formwork is high when compared with conventional formwork.

Aluminium formwork is economical when floors are typical and also labour cost for aluminium

is slightly less when compared with conventional formwork. Aluminium formworks are more

durable, maximum repetition of 300 can be achieved where as in conventional maximum

repetition of 10 can be achieved which makes aluminium formwork more economical.



Fabrication with robotic concept

single stroke holes/slot formation



Table 4.1 COST COMPARISON

Following the graphical representation of the above study of rates at the different rates of

formwork. The chart shows the aluminium formwork is economical when the use of cycle. The

steel formwork is economical than the other formwork.


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Fig 4.25 Cost Analysis Graph

4.9 Comparison of Aluminum Form Construction Technique over

Conventional Forms:


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Table 4.2 Comparison Between Aluminium and Conventional Form Work


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Different panel used in formwork system



CONCLUSION

From the above study, We can conclude the following points,

1) In the Aluminium Formwork System, because of its fast construction the overhead charges

reduce subsequently.

2) Also, the interest on the capital invested for Aluminium Formwork System is comparatively

less than the conventional framed structure.

3) In addition, the returns on the capital invested will be recovered quickly on this Aluminium

Formwork System.

But along with the advantages it has the major disadvantage that architectural changes are not

possible at all.

Hence the common man may not opt to reside in such type of structure.



REFERENCE

1. www.wikipedia.org// aluminiumformwork

2. www.mfsformworksystem.com

3. Formwork for concrete by ACI

4. www.aluminiumindustry.nic


http://www.mfsformworksystem.com/

Major projects aluminium of formwork civil engineering

Engineering

Transcript of Major projects aluminium of formwork civil engineering