Title: Aluminium Formwork Systems in Highrise

Building Constructions

HYPOTHESIS: If the population rises rapidly, aluminium formwork is the only fastest
solution to tackle the rapid house construction challenge.

AIM: To allow rapid construction of multiple unit projects at ideal potency.

OBJECTIVES:

• To study the techniques of construction

• To understand the sustainable qualities of construction
• To list down the positive and negative qualities of aluminium formwork construction
• To study the issues which don’t happen on the site due to unskilled or skilled labours.
• Our study aims to prove, for mass housing low-rise constructions, Aluminium Formwork
System will be the best suitable formwork system in terms of Safety, Quality, Cost and Duration
over the conventional formwork system.

SCOPE: The research will only cover the understanding of how aluminium formwork reduces
cost, time and safety of construction of buildings.

METHODOLOGY:

• With the literature review and the observations from site visits, a problem statement
was been formed.
• Interviews and surveys were been conducted with different contractors, surveyors and
project managers, builders and developers.

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. This paper deals with
 the necessity, components and advantages of aluminium formwork system. It also
compares the AFS with conventional method.

Keywords: Aluminium, Aluminium Formwork, AFS, Aluform, construction, rapid

1) Introduction

Aluform is a construction system for forming cast in place concrete structure of a

Building. Aluform system provides aluminium formwork for RCC, loadbearing, multi-
storeyed buildings and enables the walls and slab to be poured in the same operation.
This increases efficiency, and also produces an extra-ordinarily strong structure with
excellent concrete finish. Due to the fine tolerances achieved in the machined metal
formwork components, consistent concrete shapes and finishes are obtained floor after
floor, building after building, confirming to the most exact standards of quality and
accuracy. This allows plumbing and electrical fittings to be prefabricated with the
certain knowledge that there will be an exact fit when assembled. The dimensional
accuracy at 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.
The system of Aluminium Forms has been used widely in the construction of residential
units in both low-rise & high-rise buildings. It has proven to be very successful in the
construction of mass housing projects in various parts of the world. The system most
suitable for Indian conditions is a tailor-made aluminium formwork for cast-in-situ
fully concrete structure. It is also a system for scheduling and controlling the work of
other connected construction trades such as steel reinforcement, concrete placement
and mechanical & electrical inserts. The formwork system is unique because it enables
the construction of the entire structure of a building in R.C.C. with all the members
including walls, floor slabs, window hoods, balconies, sunken floors and various
decorative features, being cast integrally for each floor as per the architect’s
requirement.

2) Literature review

In this literature factors affecting selection of formwork were identified through

literature study. This study focused on identifying the qualitative factors affecting the
selection of the formwork at various constructions. Adaptability & Flexibility (Fixable
Sizes) Formwork should be modular and adaptable for various sizes and shapes of the
structural system, so that it can be used for many projects. Formwork should be viable
for the particular project based on cost and availability, Quality Surface Finish Quality,
of structural finish, Availability Material and supplier availability, Cost, Type of
Structure, Time Factor Faster floor cycle is always affecting the formwork selection are
also adaptability, flexibility, quality cost, type of structure, time factors play major role
while selection of formwork. The purpose of choosing Mivan Technology over
conventional method was the speedy construction, Monolithic homes in landslide prone
zone and Strengthened structure in high rainfall intensity area. Due to complexity of
reinforcement and less thickness of wall, problems of honeycombing and shear cracks
due to mass concreting are observed on sites and also, the problem was identified on
other sites too. Therefore, these problems need to be tackled in effective way to ensure
quality and safety of structure. These problems can be reduced by improving concrete
characteristics to meet the objectives; performed the compression test and slump cone/
flow table test on the concrete using admixture. On site only M25 grade was used as
the structure was single story building. But we have tested the M35 and M45 also
because the result will be beneficial to multi story building which use the M45 and M
35 commonly and in combinations. Thus, this project concludes that the problem of
honeycombing will be reduced and the strength is increased by used of admixture.
Discussed on the rise of the population of the country, the task of construction process
as monumentally increased. As we all know the construction of high-rise building is
becoming a trend and the process of construction of these high-rise building takes more
time and hence to reduce the duration and cost of the project advanced technology are
adopted. The new advanced technologies are manufactured for the construction of multi
stored project which leads to production of cost efficient and speedy construction on
residential projects. For a country like India where population and inflation have faded,
poor people dream of owning a home will be made true only by government sponsored
affordable schemes. Pradhan Mantri Awas Yojana (Gramin)is one such scheme
launched by P.M Narendra Modi in 2015 to provide shelters to the homeless by 2022
(i.e.) within 7 years which is a time constrain. This technology can be made useful for
the PMAY scheme. In this scheme technology used for construction of affordable
houses gives quality and speed achieved at high degree, which is the need of the day.
The cost of construction done by the aluminium formwork technology is 18.4%lesser
than the conventional method. There will be no need to borrow money through loan or
from lenders for excess cost as in the case of conventional method. Over all government
sending for these projects can be saved up to average20%cost. This cost can be used
for implementing renewable energy like solar power for the same house itself. Duration
of construction by aluminium formwork technology is less than conventional. In
seismic zones this technology will be best suitable than conventional and also
prefabricated structures because of use of shear reinforcement for wall also. This
method is best suitable for a row houses scheme which gives cost effectiveness over
the construction.

3.) Data collection

The panels of aluminium formwork are made from high strength aluminium alloy, with
the face or contact surface of the panel, made up of 4mm thick plate, which is welded
to a formwork of specially designed extruded sections, to form a robust component.
The panels are held in position by a simple pin and wedge arrangement system that
passes through holes in the outside rib of each panel. The panel fits precisely, securely
and requires no bracing. The walls are held together with high strength wall ties, while
the decks are supported by beams and props. Since the equipment is made of
aluminium, it has sections that are large enough to be effective, yet light enough in the
weight to be handled by a single worker. Individual workers can handle all the elements
necessary for forming the system with no requirement for heavy lifting equipment or
skilled labor. By ensuring repetition of work tasks on daily basis it is possible for the
system to bring assembly line techniques to construction site and to ensure quality
work, by unskilled or semi-skilled workers. Trial erection of the formwork is carried
out in factory conditions which ensure that all components are correctly manufactured
and no components are missed out. Also, they are numbered and packed in such a
manner so as to enable easy site erection and dismantling. The panels of aluminium
formwork are made from high strength aluminium alloy, with the face or contact
surface of the panel, made up of 4mm thick plate, which is welded to a formwork of
specially designed extruded sections, to form a robust component The panels are held
in position by a simple pin and wedge arrangement system that passes through holes in
the outside rib of each panel. The panel fits precisely, securely and requires no bracing.
The walls are held together with high strength wall ties, while the decks are supported
by beams and props. Since the equipment is made of aluminium, it has sections that are
large enough to be effective, yet light enough in the weight to be handled by a single
worker. Individual workers can handle all the elements necessary for forming the
system with no requirement for heavy lifting equipment or skilled labor. By ensuring
repetition of work tasks on daily basis it is possible for the system to bring assembly
line techniques to construction site and to ensure quality work, by unskilled or semi-
skilled workers. Trial erection of the formwork is carried out in factory conditions
which ensure that all components are correctly manufactured and no components are
missed out. Also, they are numbered and packed in such a manner so as to enable easy
site erection and dismantling.

COMPONENTS OF ALUMINIUM FORMWORK

The basic element of the formwork is the panel, which is an extruded aluminium rail
section, welded to an aluminium sheet and other components are extruded section. This
produces a lightweight component with an excellent stiffness to weight ratio, yielding
minimal deflection under concrete loading. Panels and extrusions are manufactured in
the size and shape to suit the requirements of specific projects.

COST COMPARISON BETWEEN CONVENTIONAL AND ALUMINIUM

FORMWORK SYSTEM
In typical floor construction, around 20 percent of cost saving is possible in box type
structure over framed structure. Almost 40 percent savings in project duration in Box
type structure over framed structure. Construction cost escalation, Labor rates increases
every year at the percent of 2 to 5. Cement and steel price increases every year at the
percent of 10 to 15. Around 5 to 8 percent Savings in project cost is possible on reducing
over heads by early completion of projects. High return on investment is possible.
COMPONENTS OF ALUMINIUM FORMWORK
The basic element of the formwork is the panel, which is an extruded aluminium rail
section, welded to an aluminium sheet. 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. Once they are assembled,
they are subjected to a trial erection in order to eliminate any dimensional or on-site
problems. Following are the components that are regularly used in the construction.
BEAM COMPONENTS
The beams like soffit corners are shaped to support floor slab panels during their
placements. Props of unique design in turn support the beams. They have maximum
length of 1500 mm to minimize deflection. The beam soffit panels are used as beam
side cover. The beam soffit bulkheads are used as beam bottoms above openings such
as doors and windows. Fig no. 3 shows the components of beam formwork.
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
Prop Head for Soffit Beam: - It forms the soffit beam. It is a V-shaped head for easy
dislodging of the formwork.
Beam Soffit Panel: - It supports the soffit beam. It is a plain rectangular structure of
aluminium
Beam Soffit Bulkhead: - It is the bulkhead for beam. It carries most of the bulk load.

DECK COMPONENTS: - Deck panels support maximum deck loading with minimal
deflection. They have maximum dimension of 450 mm X 1400 mm. They are supported
with beams within deck. At perimeters of the deck areas, they are supported by soffit
corners and soffit lengths. The soffit lengths are used in the straight portion of the corner
joint of wall and slab. Props support the beams. They stay in continuous contact of
concrete even while the wall and floor slab panels are being removed. Therefore, under
standard building practices the AFS allows for earlier removal of formwork, reduced
cycle time and a greater rate of production. Prop head are fitted on the top of the prop
and touch the concrete surface from the bottom.
Deck Panel: - It forms the horizontal surface for casting of slabs. It is built for proper
safety of workers.
Deck Prop: - It forms a V-shaped prop head. It supports the deck and bears the load
coming on the deck panel.
Prop Length: - It is the length of the prop. It depends upon the length of the slab
Deck Mid – Beam: - It supports the middle portion of the beam. It holds the concrete
Soffit Length: - It provides support to the edge of the deck panels at their perimeter of
the room.
Deck Beam Bar: - It is the deck for the beam. This component supports the deck and
beam.
WALL COMPONENT
Wall panels are the basic element of formwork, which consists of extruded aluminium
rail sections around the perimeter of the panel welded to an aluminium face sheet with
reinforcing ribs. This produces a lightweight panel with excellent stiffness/weight ratio
yielding minimum deflections under concrete loading. The panels are made of high
strength aluminium alloy with a 4 mm thin skin plate and a 6 mm thick ribbing behind
to stiffen the panels. Rocker is a unique feature attached to the bottom of wall panels.
This allows the panel to be struck by pulling the top of the panel away from the wall.
This action results in panel pivoting freely at the wall to floor slab joint. The panels are
connected to each other using simple steel pins and wedges. This allows panels to be
assembled into a full housing unit using only a hammer. The pins are made of mild
steel. The wall panels are kept in a fixed distance apart by wall ties, specially fabricated
from high specification steel for various wall thicknesses.
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.
2.) Rocker: - It is a supporting component of wall. It is L-shaped panel having allotment
holes for stub pin.
3.) Kicker: - It forms the wall face at the top of the panels and acts as a ledge to support
4.) Stub Pin: - It helps in joining two wall panels. It helps in joining two joints

The majority of the equipment comprises of panel sections while the rest includes
vertical and horizontal corner sections, bulkheads and special floor slab beams as shown
in Fig. No. 1 that can be dismantled without disturbing the props supporting the floor
slab concrete. All panels are numbered with a code in different colors, which determines
its predetermined location. Proper coding saves time and the work can be done speedily.
Nearly 99 percent of the equipment is made of aluminium, the other one percent is
steel.20
Aluminium Formwork System in India
In 1998, M/s. B. E. Bilimoria & Co. Ltd., of Mumbai imported Aluminium formwork
to construct residential housing complex for the Nagari Nivara Parishad housing project
in Malad (E), Mumbai. This was the first project in India. The second project was done
by M/s. Khurana Engineering of Ahmadabad to construct 1400 EWS units for the
Ahmadabad Urban Development Authority. The third project was done by M/s.
Naiknavare & Associates in Pune to construct 660 two BHK apartments in fifteen, 11
storey buildings. After experiencing the benefits of the system, M/s. Naiknavare &
Associates decided to develop a similar formwork system in India, instead of importing
the formwork. After one year of research and development M/s. Naiknavare &
Associates were successful in designing and manufacturing an improved Aluminium
formwork system namely ALUFORM
4.) Conclusion

The advantages of the Aluform System are obvious. Apart from speed due to simplicity
of the formwork, it eliminates the need for beam formwork and corresponding
centering. Number of cold joints in concrete work is reduced substantially. The joints
between brick masonry walls and beams & columns are eliminated which coupled with
the strong and dense controlled concrete used to satisfy the durability criteria as called
for by the specifications make these structures virtually maintenance-free for several
years. The walls and the slabs form a rigid, monolithic, and strong structure. It is also
worth noting that the dimensions and right angles at meeting points of wall-to-wall,
wall to floor, wall to ceiling etc. are very accurate. The Aluminium Formwork System
can achieve not only faster rate of construction but can also bring down the structural
cost by 20 to 25 % over the conventional method with lesser labour inputs. This system
is ideally suited for Indian conditions; where total dependence on heavy plants and
machinery as in case of precast factories can be avoided without sacrificing the speed
of construction. Hence Aluform System is an excellent solution to the problems in the
present housing situation because of its specific merits. We thus infer ALUMINIUM
form construction is able to provide high quality construction at unbelievable speed and
at reasonable cost. This technology has great potential for application in India to
provide affordable housing to its rising population. Thus, it can be concluded that
quality and speed must be given due consideration with regards to economy. Good
quality construction will never deter to projects speed nor will it be uneconomical. In
fact, time consuming repairs and modification due to poor quality work generally delay
the job and cause additional financial impact on the project. Some experts feel that
housing alternatives with low maintenance requirements may be preferred even if at the
slightly may preferred even if at the higher initial cost.