Aluminum Formwork System provides Aluminum 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 an 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 aluminum forms can be erected by unskilled labor 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.
Advantages of Aluminum Formwork
The aluminum formwork system is a building system used to form cast-in-place concrete structures of buildings. This formwork is made of aluminum alloy, which has high tensile strength and is very hard. Aluminum does not rust like steel. Therefore, the aluminum formwork can be reused hundreds of times. Lightweight aluminum is easy to handle, quick to operate, and due to its rapid construction, it is highly adaptable and highly cost-effective. It is different because it completely conforms to the architect's design and constitutes all the concrete in the building, including walls, floors, columns, beams, stairs, window coverings, balconies, and various decorative features. The dimensional accuracy of concrete products can also ensure the consistency of doors and windows.
The aluminum formwork system allows pouring walls and floors in the same operation. Not only does it improve efficiency, but it also produces an exceptionally strong structure with an excellent concrete finish. Since good tolerances are achieved in the processed metal formwork components, consistent concrete shape, and finish is obtained layer by layer.
➤ No Plastering required
➤ Savings on overhead expenses due to speedy construction ( 7 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 labor
➤ 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 200times
➤ Erected using unskilled labor
➤ Requires no cranes or heavy lifting equipment
➤ Suitable for low as well as high rise buildings
No. |
Factor |
Conventional |
Aluminum Formwork |
REMARKS |
1 |
Quality |
Normal |
Superior casting of whole structure and transverse walls done in a continuous operation, using controlled concrete mixers obtained from central batching, mixing plants and mechanically placed through concrete buckets using crane and compacted in leak proof moulds using high frequency vibrators |
Superior quality in "System housing" |
2 |
Speed of Construction |
The pace of construction is slow due to step – by – step completion of different stages of activity the masonry is required to be laid brick by brick. Erection of formwork, concreting and deshuttering forms is a two – week cycle. The plastering and other finishing activities can commence only thereafter. |
In this system, the walls and floors are cast together in one continuous operation in matter of few hours and in built accelerated curing overnight enable removal and re-use of forms on daily cycle basis. |
System construction is much faster. |
3 |
Aesthetics |
In the case of RCC structural framework of column and beams with partition brick walls is used for construction, the columns and beams show unsightly projections in room interiors. |
The Room – Sized wall panels and the ceiling elements cast against steel plates have smooth finishing and the interiors have neat and clean lines without unsightly projections in various corners. The walls and ceilings also have smooth even surfaces, which only need colour/white wash |
|
4 |
External Finishes |
Cement plastered brickwork, painted with cement – based paint. Finishing needs painting every in three years. |
Textured / pattern coloured concrete facia can be provided. This will need no frequent repainting. |
Permanent facia finishes feasible with minor extra initial cost |
5 |
Useful Carpet Area as % of Plinth Area. |
Efficiency around 83.5% |
Efficiency around 87.5% |
More efficient utilization of land for useful living space. |
6 |
Consumption of Basic Raw Materials:
Cement |
Normal |
Consumption somewhat more than that used in conventional structures. |
Although greater consumption strength and durability is also more |
Consumption of Basic Raw Materials:
Reinforcing Steel |
Reinforcing steel required is less as compared to the in situ construction as RCC framework uses brick wall as alternative |
It may, however will be slightly more than corresponding load – bearing brick wall construction for which, requirements of IS 456 have to be followed for system housing. |
Steel requirement is more, as it is required for the shear wall construction. But shear wall construction increases safety against earthquake. |
7 |
Maintenance |
In maintenance cost, the major expenditure is involved due to :
➤ Repairs and maintenance of plaster of walls / ceiling etc.
➤ Painting of outer and inner walls.
➤ Leakages due to plumbing and sanitation installation. |
The walls and ceiling being smooth and high quality concrete repairs for plastering and leakage's are not at all required frequently. |
It can be concluded that maintenance cost is negligible. |
Aluminum Formwork Construction Process
1. Construction preparation
(1) Measuring the payoff
(2) Leveling
(3) Formwork positioning benchmark
(4) Chiseling
(5) Formwork release agent coating
2. Measuring the pay-off line and steel banding
3. Wall column formwork assembling
4. Beam plate formwork assembling
5. Formwork assembling tips
1) The base surface of the wall formwork system should be leveled, the lower end should be close to the positioning reference.
2) The bolts on the side of the wall beam should be straight and opposite. When inserting the bolt, the hardtop should not be pulled diagonally. When changing the position of the hole, the machine should be drilled. It is strictly forbidden to use electric and gas welding holes.
3) The back part should adopt the entire rod. If that joint was used, upper back and lower back joints should be staggered. The staggered position should not be less than 400mm, and the joint length should not be less than 200mm.
4) For cast-in-place concrete beams and slabs with a span greater than 4 m, the formwork shall be arched according to the design requirements, and the arching shall not reduce the section height of members.
5) Regarding embedded parts, pre-buried holes, reserved holes, hanging angle steel and window sill cover shall not be missed.
6) The axis deviation of vertical support of upper and lower layers of the early-release formwork support system shall not exceed 15 mm, and the deviation of the verticality of the support force column shall not exceed 1/300 of the layer height.
6. Formwork reinforcement
