Aluminum form work system

Introduction and aluminum technology……………….. ………………………

Aluminum formwork project cycle……………………………………..
Comparison of conventional and Aluminum formwork……………
Merits and demerits……………………………………………………….
Cost analysis ………………………………………………………………
Labor productivity………………………………………………………
Aluminum form work component identification…………………..
Setting Out, Alignment & Verticality…………………………………
Safety and instructions…………………………………….…………….

ABDUL RAFEE
PROJECT MANAGER
Project: Sky high –Harsha developers
BLOCK A ,B, C, D & E 03 Basement + GF +21 Upper Floors +Terrace.
Club house - 03 Basements + GF + 04 Upper Floors +Terrace.

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 History of Aluminum Formwork

The Aluminium Formwork System was developed by W. J. Malone, a Canadian

Engineer in the late 1970s as a system for constructing low–cost housing unit in
developing countries. The units were to
be of cast-in-place concrete, with load
bearing walls using a formwork of
aluminum panels. To be erected by the
hundreds, of a repetitive design, the
system ensured a fast and economical
method of construction.

The concrete surface finish produced

with the aluminum forms allows
achievement of a high quality wall finish
without the need for extensive
plastering.
The urbanization in India has
increased in past 20 years in a very
rapid speed and expected to be 40% of
the total population by the end of 2030.
Due to this urbanization in India, the
infrastructure need has also transformed
by adaptation of the high-rise residential
complex culture which has increased.
India as developing state is
growing at a very rapid speed and is
updating their traditional technologies in
every sector. The positive
channelization of the youth power of
India has made the work easy but a lot
more need be achieved with their
potentials.
Mivan an aluminum formwork system
developed by a European construction
company. In 1990, the Mivan Company Ltd.
from Malaysia started manufacturing these
formwork systems.
The technology has been used extensively
in Europe, Gulf Countries, Asia and other
parts of the world. Mivan/MFE technology is
suitable for constructing large number of
houses in a short span of time using room
size forms to construct walls and slabs in
one continuous pour on concrete. In this
system of formwork construction, cast–in–
situ concrete wall and floor slabs cast monolithic provides the structural system in one
continuous pour. To facilitate fast construction, early removal of forms can be achieved by

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hot air curing / curing compounds. Large room sized forms for walls and floor slabs are
erected at site. These strong and sturdy forms are fabricated with accuracy and are easy
to handle.
The frames for windows, doors and ducts for services are placed in the form before
concreting. Staircase flights, façade panels, chajjas 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. High quality Mivan /MFE 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. Uses of Aluminum Formwork:3S –System of Construction –
Speed, Strength, Safety Column and beam construction are eliminated Walls and slabs
are cast in one operation Specially designed, easy to handle light weight pre-
engineered aluminum forms

INTRODUCTION

✓ 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 high level.
✓ The speed of construction by this system will surpass speed of most of the
other construction methods/technologies.
✓ The labor handles this method effectively to speed up the construction, to
assure quality control and durability. Adoption of this system reduces
overall cost of the structure.

✓ TECHNOLOGY
Aluminum 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.
✓ COST:
✓ 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 spaces
of 8 per cent over RCC design.
✓ TIME: For 100 per cent work, construction through slab beam wall
construction takes 10 times and through Aluminum Formwork technology the
time required is 1/6th of the 10 time.
✓ ENVIRONMENT FRIENDLY: 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.
✓ LIFTING: As the Aluminum Formwork is lightweight, no tower cranes are
required.
✓ LABORS: Due to simplicity of the assembly, only unskilled labors are required
with minimal supervision.
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✓ REPETITIONS: The Aluminum Formwork System is removable and can be
reused hundreds of times with little maintenance to be attended.
✓ SCRAP VALUE: Moreover, the requirement of steel is also reduced in this
technology as aluminum has a higher scrap value.

ASSEMBLY

✓ The simplicity of Aluminum Formwork and the repetitive nature of the

assembly process make it possible to accurately programmed construction
sequences and thus cycle times well in advance.

✓ In addition, this enables the unskilled labor to work with the formwork,
therefore reducing the burden on skilled labor when this is in short supply.
✓ On leaving the factory, all panels are clearly labeled 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

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 ➢ 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 aluminum 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

➢ High quality Aluminum 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 Aluminum 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 Aluminum 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.

Components Of aluminum Formwork

✓ The basic element of the formwork is the panel, which is an extruded
aluminum rail section, welded to an aluminum 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.

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✓ The panels are made from high strength aluminum 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 problem.

Aluminum Formwork - Project cycle

Day 1
Wall reinforcement
Day 10
De-shuttering slab & Day 2
beam panels, upper Wall reinforcement
level reinforcement

Day 9
Day 3
De-shuttering vertical
Formwork Erection
formwork

Day 8
Day 4
Concrete pouring
Formwork Erection

Day 7 Day 5
Electrical work and Beam and slab
overall checking reinforcement
Day 6
Slab reinforcement and
electrical

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Aluminum formwork System Benefits

Advantages

• 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 in one go.

• 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 100 times.

• Erected using unskilled labor.

• Requires no cranes or heavy lifting equipment.

• Suitable for low as well as high rise buildings.

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• More seismic resistance: - The box type construction provides more
seismic resistance to the structure.
• Increased durability: - The durability of a complete concrete structure is
more than conventional brick bat masonry.
• Lesser number of joints thereby reducing the leakages and enhancing
the durability.
• Higher carpet area- Due to shear walls the walls are thin thus
increasing area.
• Integral and smooth finishing of wall and slab- Smooth finish of
aluminum can be seen vividly on walls.
• Uniform quality of construction – Uniform grade of concrete is used.
• Negligible maintenance – Strong built up of concrete needs no
maintenance.
• Faster completion – Unsurpassed construction speed can be achieved
due to light weight of forms.
• Lesser manual labor- Less labor is required for carrying formworks.
• Simplified foundation design due to consistent load distribution.
• The natural density of concrete wall result in better sound transmission
coefficient.
• High quality formwork ensures consistence of dimensions.
• On removal of mould a high quality concrete finish is produced to
accurate tolerances and verticality.
• Can be erected using unskilled labor.
• Quicker Construction Cycles and Cost Saving Factors.

Disadvantages of Aluminum formwork.

• Because of small sizes finishing lines are seen on the concrete
surfaces.
• Concealed services become difficult due to small thickness of
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 components.
• It requires uniform planning as well as uniform elevations to be cost
effective.
• Modifications are not possible as all members are caste in RCC.
• Large volume of work is necessary to be cost effective i.e. at least
100 repetitions of the forms should be possible at work.

• The formwork requires number of spacer, wall ties etc. which are
Placed @600m c/c; these create problems such as seepage,
leakages during monsoon. care must be taken.
• Due to box-type construction shrinkage cracks are likely to appear.
• Heat of Hydration is high due to shear walls.

• 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.

• The major problem in Aluminum formwork is mismatching of

holes. To avoid this 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 Aluminum formwork system.

Since the sheet panels are made by welding the rails on four sides the
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 joints will easily get damaged. To avoid this problem use 450mm wide
panels which are being made by welding two ‘L’ shaped extrusions. So
the corners will be stronger than the sheet panels
• Initial high investment.
• Compares very poorly on modifications, against brick work constructions.
• Fear of theft of valuable Aluminum 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
aluminum work.
• Initial setup takes time
• .Construction joints should be executed properly.
• Alignment maintenance needs skilled laborers.
• Holes caused by wall tie should be grouted properly with GP2 else the
will be problem of leakage in walls.
• Due to box-type construction, contraction cracks are likely to appear
Heat of hydration is high due to shear walls. It is rigid in design once
placed, as any alteration becomes tough later
Remedial Measures:
It is possible to minimize contraction cracks by providing control strips
in the structure which could be concreted with a delay of about 3-7
days after major concreting.

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 RELATIVE COMPARISON ALUMINUMFORM SYSTEM WITH CONVENTIONAL
CONSTRUCTION

S. FACTO CONVENTIONAL ALUMINUM FORM REMARKS

N R SYSTEM
o
S superior in – Situ casting of whole
structure and transverse walls
done in a continuous operation,
using controlled concrete mixers
obtained from central batching, Superior
1 Quality Normal mixing plants and mechanically quality in
placed through concrete buckets “System
using crane and compacted in housing”
leak proof moulds using high
frequency vibrators

The pace of
construction is slow In this system, the walls and
due to step – by – step floors are cast together in one
completion of different continuous operation in matter of
stages of activity the few hours and in built accelerated
masonry is required to curing overnight enable removal System
2 Speed of be laid brick by brick. and re-use of forms on daily cycle construction is
construction Erection of formwork, basis. much faster.
. concreting and de
shuttering forms is a
two – week cycle. The
plastering and other
finishing activities can
commence only
Thereafter.
The Room – Sized wall panels
In the case of RCC and the ceiling elements cast
structural framework against steel plates have smooth
of column and beams finishing and the interiors have
with partition brick walls neat and clean lines without
3 Aesthetics. is used for construction, unsightly projections in various
the columns and beams corners. The walls and ceilings
show unsightly projections also have smooth even surfaces,
in room Interiors. which only need colour/white
wash

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 External Cement plastered Textured / pattern colored Permanent
4
Finishes. brickwork, painted Concrete facia can be Facia finishes
with cement –based Provided. This will need no feasible with minor
Paint. Finishing needs Frequent repainting. extra
painting every in three initial cost
years.
Consumption of basic raw materials
5 Cement. Normal Consumption somewhat more Although
than that used in conventional greater
structures. consumption
strength and
Durability is also
more.
Reinforcing steel required It may, however will be
Steel
is less as compared to the slightlymore than
requirement is
6 Reinforcing in situ construction as RCC corresponding load – bearing
more, as it is
Steel framework uses brick wall brick wall construction for which,
required for
as alternative requirements of IS 456 have to be
the shear wall
followed for system housing.
construction.
But shear wall
construction
increases
safety against
earthquake.
7 Maintenance In maintenance cost, the The walls and ceiling being It can be
major expenditure is smooth and high quality concluded that
involved due to Repairs concrete repairs for plastering maintenance
and maintenance of and leakage’s are not at all cost is
plaster of walls / ceiling required frequently. Negligible.
etc.

Painting of outer and

inner walls.

Leakages due to
plumbing and sanitation
installation.

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Aluminum form work Cost Analysis:

Objective of study to compare the conventional formwork & aluminum formwork on the
basis of
1) Cost Parameter,
2) Time parameter,
3) Quantity Parameter.
Range is 155 US$ per m2 to 225 US$ per m2, most common being 160 US$ per m2 &
assumed for cost comparison purpose.

Cost of Aluminum Formwork is 160 US $ per sqm.

Consider 71.3.00 Rs/US$. Add 25.0 % duties (+ Octroi/Entry Tax/Local Body Tax)

So Total Cost will be app 14000Rs/sqm. (160 X 71.3 X 1.25)

Your project offers 100 uses (for 10 blocks of 10 storeys) considered.

Final cost per sqm on item rate basis will be 140 Rs per sqm.(Rs14000 Formwork
Cost/100 Uses) Depending on quality of use and maintains, traditional formwork (Plywood
& Batten) costs between 80 & 150 Rs/sqm

Construction period in above example:

1st Tower 1st slab – 21 days

2nd slab – 18 days
3rd slab – 15 days
4th slab – 12 days
5th slab – 9 days
6th to 22th slab – 119 days (@ 7 days per floor)
Total – 184 days = 7.07 months considering 26 working days per month.

Next each tower (22 slabs)… 174 days = 6.69 months considering 26 working days per

month.
The actual material cost is considered from Aluminium material supplying cost & also
based on site practical experience and it will be differ from site to site skilled manpower.

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Working of Aluminum technology steps

Step 1:- Shuttering detailed drawings is provided and before manufacturing or fabrication
all the building architecture and structural drawings are freeze. If any revision in drawing
during the execution of works it will be cumbersome so utmost care to be taken.

Step 2:- When marking of walls is done by the surveyor, the fixing of Aluminum shuttering
is done after the reinforcement column work is completed.

Step 3:- Reinforcement of beams, slabs and conduit work takes place after fixing and

erection of vertical wall panels.

Step 4:- Pouring of concrete take place after the slab and beam shuttering with conduit
work is done.
Load carrying capacity

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 It has 7-8 tones per square meter capacity.
Due to use of aluminum as a material, it is light in weight.
It weighs around 18-20kg per square meter.
Striking time

Vertical formwork - 12hours after concreting or when concrete attends strength of

02N/mm2 to 2.5 N/mm2.

Horizontal formwork – 36 hours after concreting or when concrete attends a strength of

10N/mm2

Cost comparison of formwork

Shuttering counts for 50% of the total project cost. So for the same purpose Cost Analysis of
various systems of shuttering in various construction practices and depending on the type of project
in hand, Cost Analysis

COST ANALYSIS & COST COMPARISON

Comparative: Mivan Shuttering v/s Conventional

S.No. Description Aspect in Aluminum Conventional Shuttering
Consideration Shuttering
1 Material Cost Cost/Sq.ft 14.0 105.00
Cost/Sq.Mtr 140.0(100uses) 1,131.00
2 Labor Cost Cost/Sq.ft 14.86 22.46
Cost/Sq.Mtr 160 241.68
3 Repetitions 100 No’s/set of 29.50 6.00
Considered shuttering
material
4 Minimum Days 7.00 15.00
Duration of
Slab Cycle
5 Quality Surface Finish Form Finish Comparative
Poor
6 Surface Gypsum / Internal Internal
Application Plaster / Gypsum Gypsum
Naked
7 Workability Material Ease Harder than
Handling, etc aluminum

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 As per site practical consideration Tower-B -2nd floor area

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Aluminum form work component identification

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PRE CONCRETE ACTIVITIES Setting Out, Alignment and Verticality

SURVEY PROCEDURES.
Setting Out, Alignment & Verticality
o Base or Primary Setting Out

▪ Base Control Points

▪ Transferred Setting Out Point
▪ Bench Mark
▪ Temporary Bench Mark (TBM)

o Day to Day Detail Survey

▪ 300mm Offset Line

▪ Concrete Level Survey
▪ Kicker Level Survey
▪ Deviation Survey
▪ Analysis of Survey Results
▪ Method of Adjustment
▪ Deviation Survey Not Making Sense
▪ Plumb and Alignment of Walls

o Keeping of Survey Records

o Miscellaneous:

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 ➢ Simplified Plan of Marking Out Principles
➢ Control and Adjustment of Vertical Alignment by Packing
➢ Everyday Survey Check
➢ Bench Marks
➢ Plumbing
➢ Buildings and Tall Structures

1. LEVEL SURVEYS
A total of 3no of Surveys are listed below and must be carried out for the smooth running
operation of the aluminum formwork & kept on file by an allocated Supervisor:-
(a) Concrete Level Survey. (b) Kicker Level Survey. (c) Deviation Survey [verticality check of the
structure]
Prior to the commencement of the Wall Form a concrete level survey to be taken and the
appropriate remedial works carried out if required.
Levelling surveys should be taken from a T.B.M. (Temporary Bench Mark).
In certain cases it is good practice to mark the slabs with paint indicating a plus (+) or minus (-)
as the survey is being conducted. This eliminates unnecessary circulation of paper copies to
site personnel, and the Supervisor on site can identify at a glance any remedial work required.
High spots along the wall line to be chipped off to the proper level.
Low spots along the wall line should be packed to the required level, using plywood or timber.
Packing corner and the centre of the wall length to the required level will normally be adequate, as
the formwork when pinned together will bridge across low spots.
Concrete up to (+6mm high) is acceptable, above 6mm must be chipped to the (correct
level). Level surveys also to be carried out on the top of the kickers.One reason for a
structural deviation from the centre line can be due to an uneven level. This in turn means
the formwork is not plumb.Kickers are manufactured providing a 26mm slotted hole through
the contact face to facilitate adjustment after concreting, should verticality need improved.
2. SETTING OUT

Only approved shell drawings supplied by Formwork Design to be used for setting out.

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Setting out lines should continue through openings, external corners e.t.c., by a minimum of 150mm.This
makes it easier to fix the formwork & identify it’s position prior to concreting.

It is very important that the reference points and the setting out points are protected
against accidental movement or damage.

Transferring of reference points from the level below requires to be done quite accurately. Incorrect
reference points give incorrect deviation results only creating unnecessary work for the formwork
installation. It is suggested an electronic instrument with optical plum or Laser instrument is used for
transferring the points Through openings provided in the slab.

3. CONTROL / CORRECTING OF DEVIATIONS

A study of the deviation and kicker level survey should confirm what, if any, corrective action is
required.

If the kicker requires adjustment for level, loosen the holding - in bolt by turning anti-clockwise,
adjust kicker to the required position and retighten the bolt.

Once the vertical Formwork is fixed in position, the external corners should be checked
for plumbness.This will determine if further action is required.

In addition to the kicker levels, the Formwork can be pulled by using bottle screws and chain. If the
formwork requires to be pushed adjustable props can be used. This method of adjustment should
only be used if necessary & kept to a minimum.

If Kickers are adjusted accordingly & the rectification of concrete levels carried out as required it
should not be necessary to use such methods.

When deviations of external walls occur, they must be brought back to the correct plan location as
quickly as possible. This is done by slightly tilting the external wall forms in one plane.If a
deviation from plumb has occurred in two directions, then this should be improved over
two floors, one for each direction. A re-alignment in two directions should not be attempted
on a single lift.

Maximum of 6mm in vertically improvement in “one lift is acceptable”

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4. ERECT FORMWORK

For the initial set up only, 50mm x 25mm timber stays can be nailed to the concrete slab, close to
the internal and external corners, to ensure wall Formwork is erected to the setting out lines.

All formwork begins at a corner and proceeds from there providing temporary lateral stability. A
single panel at a corner will give sufficient lateral support to most walls.

Ensure all edges of the Formwork and contact face are properly cleaned and oiled prior to fixing in
place.

When satisfied the corner is stable and the internal corner is positioned to the setting out lines
continue erecting the formwork to one wall. Use only 2 no pins and wedges to connect the
formwork at this stage as the pins and wedges will have to be removed later to insert the wall
ties.

Alternatively the wall ties can be positioned as the Formwork is erected. For ease of stripping, pin
the wall panels to the internal corners with the head of the pin to the inside of the internal corner
where possible.

Take Note: After the 1st floor casting all Formwork on all external walls including voids where
Kickers has been cast in place, Formwork must be installed prior to erecting the opposite face of
the wall.

Proper aligned Kickers from the previous casting, is the control of alignment of the Formwork on the
next level.

Wall ties also to be coated with Formwork release agent prior to being installed. Fit the wall ties
through slots in the wall formwork and secure in position with pins and wedges.

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Prior to closing the formwork, pre-wrapped corrugated PVC sleeves are placed over the wall ties.
Please ensure, since preparation of the sleeves they have not been abused in any way prior
to installation, as this can have an adverse effect on the removal of the wall tie after concreting.
Also, ensure they are located properly to the contact face of the Formwork on each side of the
wall.
Sleeves installed with one end fixed between the side rails of two adjoining panels, exposes the wall
tie at the opposite end, therefore causing great difficulty & a possibility of unable to retrieve the
wall tie after concreting.

It is important Wall Ties are kept clean & in good condition & not left lying exposed on the floor slab
to the human traffic. Do not use the hammer to knock the end of the Wall Tie when installing or
removing as they become damaged [burred] at the ends again causing difficultly or possibility of
unable to extract from the wall later.

METHOD OF ERECTING FORMWORK

Maximum efficiency is important to define a sequence of erection to be followed by each team.

One side is erected using only on upper and lower pin and wedge connection. Later, ties are
inserted at the other connections and fixed with pin and wedge. Then the previously installed pins
is removed and those ties inserted and pinned. Subsequently, panels for the other side are
inserted between the existing ties and fixed with pins and wedges.

The Advantages of This Erection Method Are As Follows:-

(1) Rooms can be closed and squared by assembling only one side of wall panels. If misaligned, it is
easier to shift rows of single panels.

(2) If steel reinforcement is likely to interfere with the placement of the ties, it can be seen and
corrected without delaying the panel erection.

(3)Enables fast start up of deck teams as the first rooms can be closed quickly.

(4)Continuous steel reinforcement for the walls, creates a barrier between the two sides of the
formwork, so the work proceeds at the pace of

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Special care must be taken at the lift shafts. The interior panels will align properly on their own
because they are set on the kicker from the formwork below. By ensuring the kickers are level
will not affect the verticality of the Wall form. However, the matching panels set on the concrete
slab may not be level. If the concrete is too high, it can distort the alignment of the four sides of the
lift shaft and must be chipped to allow a level base.

Care must be taken so that the concrete and in particular the reinforcement does not become
contaminated due to excessive application of

The ends of walls and door openings should be secured in position by nailing timber stays
to the concrete slab. Walls require to be straightened by using a string line and securing in
place by nailing timber stays to the concrete slab. During this operation verticality of door
openings also requires to be checked for plumb. Where possible, door spacers should be fitted.
7. SETTING KICKERS
After casting of the first level of Formwork, two levels of kicker are required, one coming off the
previous floor to which the Formwork is fixed and the other fixed to the top of the wall formwork
which forms the perimeter of the
position Kickers are manufactured with a 26mm x 16.5m vertical slotted hole. Prior to concreting,
16mm diameter M.S bolt is fixed to the kicker, always located tight to the bottom of the slot. This
bolt remains fixed to the casted concrete with a flat washer and nut to act as anchor. After
concreting the slotted hole allows for an adjustment if required for improvement on the level of the
kicker also controlling the verticality of the formwork.
DURING CONCRETING

8. STAND BY DURING CONCRETING

Minimum of two operatives should be on stand by during concreting, to cover both sides of
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each & every wall being cast. During concreting, the ideal position is slightly in front of the
pour, checking pins, wedges and wall ties as the pour is in progress.

Pins, wedges or wall ties missing could lead to a movement on the formwork and the possibility of
the formwork being damaged. This effected area will then require remedial work after striking of the
formwork.

(c) Vertical soldiers.

(d) All pins and wedges from the panels identified for striking.
(e) Care must be taken when removing pins and wedges on the external and void areas,
especially on the safety issue. Also considerable amount of pins and wedges can be lost over
a short period of time due to inadequate care taken when removing.
(f) Ensure all M&E fixings attached to the Formwork have been removed.

Ensure removal of the wall Formwork commences on the thickest walls first.
External walls are also critical to enable commencement of installing the scaffold brackets for
placing of the formwork on the next level.
It is advised while removing the wall Formwork on the external is raised immediately to the next
level & not to be stacked on the working platform.

As removal of the wall Formwork continues removal of the wall ties can commence also ensuring
they are collected & kept neatly in an appropriate area where they can be prepared for the next
level.

Wall ties are designed to facilitate removal prior to removal of the Wall formwork. The sooner Wall
Ties are extracted from the wall, less force required and less time consumed. It is always good
practice to implement the proper sequence on removal of wall ties by commencing on the thickest
walls first.

All Wall Ties must be removed the following day after placement of the concrete.
If these guidelines are not followed will only incur additional man hrs plus abuse of materials &
Tools.

All Formwork components must be cleaned as soon as they are removed. The longer the cleaning
process is delayed, the more difficult it will be.

Wall panels are designed to be struck by pulling the top of the panel away from the concrete where
a rocker is fitted.
The rocker at the bottom of a panel enables the panel to pivot about a point against the concrete
slab. Where the wall Formwork is pinned to a kicker, the panels are removed by pulling the bottom
away first.

The work involved in using Formwork shall be segregated into duties for specified
teams of workers as listed below.

Each team is responsible for following the correct procedures as laid out in the previous
sections.
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(a)Formwork Erection Team

(b)Formwork Striking Team

(c)Working Platform/Safety Team.

(d)Alignment Team.

(e)Kicker Team.

(f)Survey team.
SAFETY:
a) Ensure all scaffold brackets are in good condition and have not been damaged since the
last installation
b) Ensue platform is fully decked out and toe-board and handrail installed.
c) Penetration holes in the slab for transferring panels must be covered when not in use until
cast with correct.
d) Any workers working above platform level must wear safety belt attached to a secured
formwork component or the wall steel.
e) When removing of the timber batons from the floor after casting ensure no nails have
been left exposed.
f) Pins and wedges to be removed with care especially on the external of the building.
g) Handling of equipment.
h) Formwork should not be stacked on the scaffold.
INSTRUCTIONS:
To be imposed on every worker, are the following things not to be done:
· Do not lay bottom panel contact face down, when starting a stack
· Do not drop equipment from any height
· Do not use panels as ramp, bridges or scaffold
· Do not use hammer and wedges to pull panels together
· Do not drive wedges until full length of panels are butted together
· Do not use extreme hammer force when installing wedges
· Do not erect elements not properly cleaned and oiled

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CONCLUSIONS

With 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 technology is manufactured for construction of multi storied project which leads to
production of cost efficient and speedy construction of project.
A Case study was conducted on a residential project and comparison between the
conventional formwork and Aluminum technology was analyzed and results were determined.
It was determined that Aluminum technology is suitable for large scale building projects and
they can be reused for about 100 to 200 times. Even though the initial investment of
Aluminum technology is high, it provides cost efficient project and eliminated the need of
plastering work as it gives a good surface finish compared to conventional type of formwork.
The duration of project can be minimized by adopting Aluminum technology. And hence it is
concluded that Aluminum technology is not suitable for small scale project.

Thank you
Abdul Rafee.
Project manager
Anpcpmc
Haraha developers
Sky high Projecct

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