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Enabling Structures: Aluminium Formwork
Enabling Structures: Aluminium Formwork
2010
ENABLING STRUCTURES
ASSIGNMENT
ALUMINIUM FORMWORK
FACULTY:
ALUMINIUM FORMWORK
ENABLING STRUCTURE
TABLE OF CONTENTS
ALUMINIUM FORMWORK ......................................................................................................2
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2.
3.
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15.
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The Low Cost Housing Units are constructed especially for the Economically Weaker Section of the
society, thus clearing the slum areas in the city & providing houses to the needy people.
The Formwork is provided such that, at any point of time, two of the cluster of buildings will be
under construction.
The speed of construction in this system is at the rate of four days per floor.
The formwork for all the components is erected at one time.
The system forms all of the concrete in the building. i.e. walls, slabs, stairs, window hoods,
cantilevered projections, etc.
The inserts are provided in the formwork at pre-determined locations to allow drainage, water pipe
lines & electrical conduits which will pass through the walls.
The construction cycling is established in such a manner that the concreting of 32 units is completed
in 16 calendar days.
Finishing work is then undertaken which consists of Flooring, Door & Window fixing, Staircase,
Parapet railing, Electrification, Sanitary, etc., which is completed in about 4-5 weeks after the
superstructure is completed.
Due to the Load Bearing Construction & Monolithic Construction possible with Aluminium
Formwork System, the structures are Box Type Structures which are highly resistant to seismic
conditions.
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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.
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Deck Panel: It forms the horizontal surface for casting of slabs. It is built for proper safety of workers.
2)
Deck Prop: It forms a V-shaped prop head. It supports the deck and bears the load coming on the
deck panel.
3)
Prop Length: It is the length of the prop. It depends upon the length of the slab.
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4)
Deck Mid Beam: It supports the middle portion of the beam. It holds the concrete.
5)
Soffit Length: It provides support to the edge of the deck panels at their perimeter of the room.
6)
Deck Beam Bar: It is the deck for the beam. This component supports the deck and beam.
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.
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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
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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.
2)
External Soffit Corner: It forms the external corner between the components
3)
4)
Internal Corner: It connects two pieces of vertical formwork pieces at their exterior intersections.
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5. FORMWORK ASSEMBLY
Aluminium Formwork aims in using modern construction techniques and equipment in all its projects. On
leaving the MASCON 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. All formwork begins at a
corner and proceeds from there.
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WALL FORMWORK
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WALL FORMWORK
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DECK FORMWORK
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STAIRCASE FORMWORK
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Erection of Platform
Striking of formwork
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Positioning of Platform
Removal of Kicker
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9. SALIENT FEATURES OF
CONSTRUCTION SYSTEM
THE
ALUMINIUM
FORMWORK
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Buildings can be constructed quickly and easily by unskilled labour with hammer being the only tool
required.
As the erection process is manual, tower cranes are not required.
The result is a typical 4 to 5 day cycle for floor to floor construction.
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QUALITY OF CONSTRUCTION
Precision in the fabrication of the Aluminium Formwork equipment results in the accurate, consistent
forming of the concrete, floor after floor, conforming to the most exacting standards of quality and
accuracy.
The formwork accuracy also allows plumbing and electrical fittings to be fabricated with the certain
knowledge that there will be an exact fit when assembled.
The smooth surface of the finish concrete walls reduces the need for the costly plastering.
The dimensions are accurately maintained throughout the structure irrespective of the speed or labour
employed.
DURABILITY
Using Aluminium Formwork Technology, all of the concrete in the walls and floor slabs is poured
together in one operation which results in the monolithic reinforced concrete structure without any
construction joints at the intersections.
Also if there is any sunk part, it is also concreted along with the slab and walls. Thus, there are no
construction joints in the sunk area, and no problem of leaking joints.
There is no plastering required in Aluminium Formwork system, which in case of conventional system
breaks away (i.e. cracks), which enables structure that will last for many years.
All of the aluminium used in the equipment is of high strength alloy which means that the aluminium
has not only high tensile strength, but is also very hard.
The aluminium formwork does not rust or corrode like steel; therefore, it has a longer life span than
steel.
Thus the aluminium formwork is very durable and can be reused hundreds of time with little
maintenance.
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WORK CYCLE
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Description
Type of
construction
Conventional
Formwork
Stem
L&T DOKA
Formwork System
Tunnel form
System
Aluform
System
RCC framed
Construction
Construction
RCC shear
Wall
Construction
Cast-in-situ
Cellular
Construction
Main formwork
Materials
Plywood and
Silver wood
Timber and
Steel
Mild steel
Aluminium
Speed of
construction
Eight days
Cycle per floor
Of 150 m2
Three days
Cycle per floor
Of 150 m2
Quality of
surface
Finish
Poor
Uniformly
Good quality
Excellent Plastering
is
Not required
Excellent;
Plastering is not
Required
Reuse value
Wood - 20
Steel- 100
H-beams - 80
Steel-150
800
300
Rs. 6500 / m
Of shuttering area
Rs. 10,000/ m
Of shuttering
Area
Rs. 5.64
Rs. 3.80
Rs 1.50
Minor
Construction
works
e.g. residential
buildings
For repetitive
Architectural
layouts e.g mass
housing
Rs. 3.25
Mostly useful
For mass
Housing
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Because of small sizes finishing lines are seen on the concrete surfaces.
Large volume of work is necessary to be cost effective i.e. at least 200 repetitions of the forms
should be possible at work.
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The formwork requires number of spacer, wall ties etc. which are placed @ 2 feet c/c; these create
problems such as seepage, leakages during monsoon.
Due to box-type construction shrinkage cracks are likely to appear.
Heat of Hydration is high due to shear walls.
In external walls, ties used in shutter connection create holes in wall after deshuttering. These may
become a source of leakage if care is not taken to grout the holes.
Due to box-type construction shrinkage cracks are likely to appear around door and window
openings in the walls. It is possible to minimize these cracks by providing control strips in the
structure which could be concreted after a delay of about 3 to 7 days after major concreting.
The problem of cracking can be avoided by minimizing the heat of hydration by using flyash.
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PHOTOGRAPHS
WALL REINFORCEMENT
WALL FORMWORK
DECK REINFORCEMENT
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DECK FORMWORK
KICKER FORMWORK
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STAIRCASE REINFORCEMENT
STAIRCASE FORMWORK
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SURFACE FINISHING
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