Aluminium Formwork System Speeds Up Construction

GOPAL JAKHAR
SLBS ENGINEERING COLLEGE Page 1
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)

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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, costand 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

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20. Positioning of Platform 40
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.

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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
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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DESCRIPTION
This 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.

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ASSEMBLY
The simplicity of Aluminium Formwork and the repetitive nature of the assembly process
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
requirem ent 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

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QUALITY
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,

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

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

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hundreds of times.
Aluminium being lightweight is easy to handle.
Aluminium formwork SystemBenefits
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.

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Suitable for low as well as high rise buildings
No need to use any timber or plywood.
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.

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Disadvantages
Initial high investment.
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
SLBS ENGINEERINGCOLLEGE
Manufacturingfacilities
Substainial stock of Raw material

Unique Barcoding system

Material ready for despatch

INNOVATION IN CONSTRUCTION
The 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.
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
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.
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:-
er temperature.
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
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.
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:
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.

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
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.

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.
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
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.

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:

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.

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:

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

Fig 4.22:- Striking of formwork
Fig 4.23: - Positioning of Platform

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.

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.

Fig 4.25 Cost Analysis Graph
4.9 Comparison of Aluminum Form Construction Technique over
Conventional Forms:

Table 4.2 Comparison Between Aluminium and Conventional Form Work

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

Aluminium Formwork System Speeds Up Construction

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