Sei sulla pagina 1di 28

CIVIL4M

Aluminium Formwork
Introduction
Formwork Drawings

Site will be provided with a set of formwork drawings which entailed the
followings: -
Shell Plan Layout
Formwork layout drawings,
 Wall panel Layout,
 Slab Panel Layout,
 Starter Block Layout,
 Corner Layouts,
 Beam Panel Layout,
 Soffit Layout,
 Staircase Layout,
 Bracket and Soldier layout,
 Miscellaneous Layout which includes sunken portion, upstand portion
etc,
Elevations and sections drawings indicating the location of formwork
panels and component,
Typical Fixing Detail drawings,
Location of Box outs and Transfer Box out drawings for transfer of
Formwork, etc.

Worksite Management
Logistic
Prior to the arrival of the containers from the disembarking point to the
project work site; a Stock Yard is to be properly allocated and set up for
the unloading of the formwork material and accessories.
This Stock Yard should preferably be located at close proximity or within
the compound of the project work site, properly fenced up and security

SRINIVASAN[Type text]
CIVIL4M

shall be of up most priority due to the high residue value in the secondary
market for aluminum formwork material.
A Workshop area for maintenance of formwork material is recommended
to be set up at the project site to minimize the downtime in requisition of
replacement panels.
the proposed Stock Yard and Workshop area shall be flexible and re-
adjustable to suit the working environment and project work site. As a
result of the far away Stock Yard or Workshop area the project progress
will affect the targeted construction cycle time. (Ref Layout Drg No.: )
Upon arrival of formwork panels at Project Site, Site personnel shall ensure
that the panels are stacked and stored according to sizes and marking using
proper separator such as pallets for easy identification and allocation for
subsequent distribution. (Dry Mockup will be assembled as per schemes
at factory; this will eliminate the usual problematic discrepancies of odd
size panels which need to be fabricated at project site).

Manpower
BSCC - HQ shall provide the estimated manpower requirement for the
Project based on the quantity of formwork panels to be supplied to achieve
the required cycle time. This manpower requirement shall vary according
to the size of formwork use on the building.
However, the manpower requirement for other supplementary trades which
complement the formwork installation such as Mechanical & Electrical
(M&E) services and rebar works need to be taken into consideration also.
A joint effort of all operations from formwork installer, rebar, plumbing,
electrical and concreting workers need to be synchronized to achieve the
required cycle time.
Segregation and systematically allocation of duties for each formwork team
are required in ensuring optimization of productivity. Hence, each team
shall be delegated or assigned to do specific job tasks on a daily basis to
resemble a manufacturing production line. However, due consideration
should be used in determining the level of experience and compatibility of
persons when allocating tasks to minimize the risks.

SRINIVASAN[Type text]
CIVIL4M

Safety
Control measures should be taken to identify and minimize the hazards
associated with work involving the assembly and dismantling of formwork
equipment such as falls from height, slips, falling objects, noise, dust and
manual tasks.
Minimize the working heights for persons performing the assembly and
dismantling formwork.
Mixing of formwork components should be avoided to prevent unsafe
installation such as mixing pins and braces which may lead to collapse of
the formwork.
Do not allow drop stripping of formwork as it is an unsafe practice.
Partially assembled or dismantled formwork should be secured during
break time to prevent against overturning or collapsing due to strong wind
or accidentally / unintentionally knock over by workers.
Electrical safety should be implemented for the safe use of electrical
equipment.
Protruding flat ties or projecting nails should be removed immediately
with appropriate tools at dismantling stage.
Use of personal protective equipment by all persons working at work
areas (such as safety hardness, safety helmets, eye protection etc) should
be strictly implemented.

Accessories & Tools


Accessories (10%) extra will be supplied for the assembly and dismantling
of the formwork panels.
Sufficient tools required for assembling and dismantling will also be
supplied as per the attached list.

SRINIVASAN[Type text]
CIVIL4M

Assembly Process
Setting Up Level & Marking Of Position
The project surveyor shall mark based on the approved construction drawings
to ensure that the gridline and level of the foundation level is properly set up,
marked for walls, column etc. Leveling must be checked prior to commencement
of formwork installation to ensure accurate positioning.
Formwork Panels
Cleaning of the surface and side panel of the formwork after each usage
shall be done immediately using proper tools.
Ensure that all front and side panel of formwork is properly coated with
recommended Form release agent that prevents from sticking and concrete
buildup aluminium form surfaces. It protects and prolongs the useful lives
of the aluminium formwork.
The following precautions shall be taken when applying the Formoil on
the aluminium panels.
 The best results are obtained when a uniform application of Formoil is
applied immediately following stripping and subsequent cleaning of
the panels. Always ensure that the coated form surfaces are allowed
to dry prior to placing concrete.
 Do not over apply. Excess Formoil can adversely affect performance
and should be picked up promptly with rags.
 Prevent Formoil overspray from contacting reinforcing steel bars and/
or tensioning cables.
Installation Works of Rebar, M&E & Plumbing
The support works such as rebar, Mechanical & Electrical (M&E) and
plumbing are to commence immediately once the set up is done. The
same is to be ensured before installing the Aluminium formwork.
The support works for the slab section commence after the slab formwork
panels are assembled.
Cover Blocks should be fixed on both sides of the rebar section for
positioning and eliminate the rebar from resting on the surface of the
formwork panels.
SRINIVASAN[Type text]
CIVIL4M

Positioning of outlets for electrical switch boxes to its correct alignment can
be done by riveting the appropriate fit size mould to the formwork panels.
The electrical switch boxes are then securely cap to the fit size mould and
fasten by way of wiring to the formwork panels. Ensure that it is properly
secured to prevent grouting from building up in the switch boxes.

Assembly of Wall Formworks


The formwork panels wall positioning is securely placed on the marked
gridlines and level by way of fixing timber stoppers at the base of the
outer side of the formwork panels at interval of one (1) meter. This would
ensure that the formwork panels are not disposition during the concreting
process.
Once the initial wall corner panels are assembled, place the wall corner
panels on the allotted set up position.
Commence to erect simultaneously the balance of the wall panels from
either side of the external wall panel.
Proceed to assemble the internal wall corner. Place these panels into the
correct position on the lines which were set up by the surveyor. Proceed to
assemble the balance of the internal wall at both sides.
The internal and external walls are to be held together by flat wall tie with
wall tie sleeve and PVC cover. These wall tie sleeve and PVC cover are
to be cut for the exact length of the wall thickness. Flat wall tie are to be
coated with the Form Oil before each usage.
To determine and achieve the vertical accuracy of the formwork panels
assembled before concreting process, several methods such as plumb
bob, spirit level, theodolite equipment etc can be used. The simplified
method of using a plumb bob with a string attached to it which is then
suspended from the upper part of the formwork panels is used as a guide
to determine the deviation from the vertical alignment of the panels.
Additional wall panels or starter blocks (kickers) are fixed on the external
wall panels in accordance to the required height for the formation of the

SRINIVASAN[Type text]
CIVIL4M

slab concrete. Check to ensure that the verticality of the Starter Blocks
(kickers) is correctly aligned.
The Starter Blocks (kickers) shall remain at its position for the subsequent
forming of next level wall.

Assembly of Beam & Slab Formworks


Fix the slab corner on top of the wall panels with round pins and wedges.
The position of the pins should be from top down to ease the dislodging
process.
The prop length and prop head is to be connected together for beam and
slab support.
Alu span mid beam and Alu span cantilever end beam are connected to
the Slab prop head using Beam Splice Bars. They are connected together
by long pins and wedges at bottom section.
The Aluspan mid beam sections are accurately position to enable the slab
panels to be connected systematically.
Commence to assemble the slab panels from the corner section of the
slab. Subsequently, fixed the whole slab area by pinning the slab panels
together with the Aluspan mid beam.

Assembly of External Working Brackets


External working platform brackets are used to provide a work area at the
external wall section.
Once the first level is completed and external formwork panels are
removed, fix the external working brackets to the first floor level at position
slightly below the kickers which are fixed on first floor external slab.
The external working brackets are secured to the external wall section
from the inside using tie rods, nuts and bolts.
Once all the external working brackets are put in place, timber planks
and strips are placed on the floors and railings respectively to create an
external working platform for the assembly of the subsequent level of the
external formwork panels and kickers.
Another set of external working brackets are later fixed on the subsequent
level using the method as prescribed above.
Once the subsequent level of external formwork panels are fixed, the
SRINIVASAN[Type text]
CIVIL4M

external working brackets at one level below are removed and moved to
the subsequent level. This process is repeated until the completion of the
subsequent floors.
Identification of Formwork Assembled
A numbering sequence / stenciling shall be given for each panel and is
identified in accordance to unit area such as living rooms, Kitchens, Bed
rooms, bathrooms, common areas etc.
Color identification scheme while numbering on each section or area will
also eliminate the confusion that may arise due to the size. It can be
identified such that Blue is for Room 1, Red is for Room 2, Green is for
Living area etc.,
By practicing the use of numbering system in combination with the color
identification scheme, it have been proven to avoid confusion and assist
in the process of identification of panels position once they are transferred
to the next level/floor.
CONCRETING PROCESS
Pre-Check Before Concreting
Ensure that the position of the walls and column formwork are in
accordance with the set up marking.
Check to ensure correct spacing of props for slab formwork.
Check the verticality and horizontality level of the wall and slab panels
respectively.
Ensure that all pins, wedges and ties are properly secured and tightened.
Re-check the opening such as door and window panels are correct.
Re-check all propping stands to ensure its height are in accordance to
drawings.
Adequate bracing (if necessary) to ensure stability.
Ensure cover blocks are placed correctly.
Monitoring During Concreting Process
Ensure site coordinators are available and on stand-by during the
concreting process.
Always ensure that concrete pouring is distributed evenly throughout the

SRINIVASAN[Type text]
CIVIL4M

wall sections before commencing to cast the slab level areas. This is to
prevent loading pressure on the formwork panels due to uneven casting.
Recheck the areas whenever cement slurry leakage is noted to determine
the cause of it. Remedy work should be done immediately to ensure the
concreting process is not affected.
During concreting, always ensure that immediate step is taken to remove
/ clean all the excess concrete that is stuck on the back of the formwork
panels. Non removal will result in the formwork panels getting too heavy
and also the scrapping task after the concrete has dried up becomes more
tedious.

SRINIVASAN[Type text]
CIVIL4M

Dismantling Process
Dismantling of Wall, Column & Beam Formwork
Formwork panels shall be removed without damaging the concrete.
Reinforcement Bars or other tools shall not be used as a lever against the
concrete in removing the formwork panels. Only panel puller shall be
used for removing the wall panels.
The appropriate time for the stripping of formwork panels will vary
according to the environment and type of concrete used. The formwork
panels of the wall, column and beam section can be usually dismantled
after 12 hours. However, this process shall subject to approval of the
project structural engineer after taking into consideration the grade of
concrete used, additional props stand ordered, etc.
Always ensure that the wall section panels are removed first follow by the
column and beam sections.
For precautionary step, ensure that formwork panels are removed
systematically and due care is to be taken to prevent any damages to the
formwork panels and also finish surface of the concrete whenever possible.
For safety reason, ensure that no workers are facing the pin and wedges
when removing using hammer. Pin and wedges removed are to be
collected and placed in containers to minimize lost and replacement.
The dismantle formwork panels shall be transferred to the next level/floor
for subsequent assembly process via the slab opening or staircase areas
in an orderly manner and to the appropriate section/area immediately.
This will eliminate the confusion and congestion in the dismantling area
or level as a result of too many dismantled formwork panels lying on the
floor area.
As the formwork panels are pre-numbered and if color identification
scheme is implemented, the transfer of panels can be determined and
planned ahead according to the various sections / areas of one level/floor
to the subsequent level/floor.
Always ensure that all the formwork panels are to be properly cleaned
and applied with the Form release agent to protect the surface of the
formworks before re-used.

SRINIVASAN[Type text]
CIVIL4M

For the external wall section, the Starter Blocks (kickers) on the upper
portion of the floor level shall remain intact to support and align the
next level/floor of formwork panels that are going to be assembled.
The assembly of the external formwork panels can be done by using the
external working platforms that are fixed to the wall areas.

Dismantling of Slab Formwork


The appropriate time for the stripping of formwork panels will vary
according to the environment and type of concrete used. The formwork
panels of the slabs section are usually dismantled after 36 hours. However,
this process shall subject to approval of the project structural engineer
after taking into consideration the grade of concrete used, additional
props stand ordered, etc.
The Aluspans mid beams / end beams have to be removed first after
dismantling the wall panels. Proceed by removing the long pins and
wedges on the joint bars for the end and middle beams. However, the
prop lengths are to remain undisturbed during this process to lend support
for the weight of the concrete slab.
There shall be 2 sets of prop lengths to support the concrete slab. The first
set of the prop stands will only be removed when the assembly of the third
level/floor commences and also upon approval and consultation with the
project structural engineer.
Proceed to dismantle the slab panels by commencing from the end of the
slab area. Once the slab panels are dismantled, continue to remove the
slab corners.

Removal of Flat Wall Tie & Wall Tie Sleeve

Flat wall Ties are used for the purpose of ensuring the thickness of the walls
and column are consistent. Flat wall ties are to be removed by using special
called Wall tie remover / extractor.

Subsequently, proceed to remove the wall tie sleeve which is embedded in the
walls and columns section by using nose player.

SRINIVASAN[Type text]
CIVIL4M

Form Release agent (Solvent based) to be applied on the surface of all the
panels before the assembly process.

SRINIVASAN[Type text]
CIVIL4M

Outer Corner is fixed to External Wall Corner panel by round pin and
wedge.

SRINIVASAN[Type text]
CIVIL4M

Inner Corner is fixed to the Internal Wall panels by round pin & wedge. The
Internal and External Wall Panels are hold by Flat Tie with Tie Bar Shield in
between the panels.

VERTICAL CORNER INTERNAL

SRINIVASAN[Type text]
CIVIL4M

Repeat Sequence No. 3 to complete the assembly of both the Internal and
External Wall Panels.

SRINIVASAN[Type text]
CIVIL4M

Install Slab Corner on the top portion of the Wall Panels with round pin &
wedge.

Slab Corner Internal

SRINIVASAN[Type text]
Aluspans mid beams / end beams and Prop head are combined by Beam
splice bar with long pin and wedge at the bottom section.

BEAM SPLICE BAR


Aluspan cantilever

BEAM SPLICE BAR

Aluspan

SRINIVASAN[Type text]
Start the assembly of the Slab Panels from the Slab corner Internal.
Subsequently, fill out the whole slab area by pinning the slab panels together
with the Aluspans (Comprises of Aluspans and cantilevers). Mid Beams / End
Beams

Slab corner Internal

SRINIVASAN[Type text]
Additional Wall Panels (or Kickers) are fixed to the external Wall Panels to raise
to the appropriate height to contain the slab concrete when it is poured.

SRINIVASAN[Type text]
Upon completion of the installation and fixing of the Wall and Slab Panels,
a numbering sequence will be made for each of these panels with colour
identification scheme to differentiate each of the unit area such as bedrooms,
living room, bathroom etc. This numbering and colour identification scheme
will ensure that each panels can be determined as to their exact location once
they are tansferred to the next level for installation.

Sequence No. 10

Always ensure that wall ties, pins and wedges are properly installed and
secured before pouring concrete into the forms. Ensure that concrete pouring
is distribute evenly throughout the Wall Panels section before commencing to
cast the slabs level area.

SRINIVASAN[Type text]
After 12 hours, remove the Internal Wall panels by knocking out the wedges
and pins. The Wall Panels are to be moved to upper floor through the slab
opening as shown. The transferring of the panels should be done in a
systematically and orderly manner to ensure that the next cycle or level is not
affected. Since all the panels are numbered with different colour identification
scheme, these transfer process can be determined and planned in advance
according to section of the building such as Room 1, Room 2, Bathroom are
etc.

SRINIVASAN[Type text]
After removing the External Wall Forms (the starter Block (kicker) should
remain undisturbed), the dismantled wall forms are moved to upper floor.
Access Scaffolding is use for transferring of external wall panels from the
ground floor level. For level 1 and above, an external working platform is
fixed to the external wall. The external wall forms from level 1onward shall
be supported by the kickers. (These steps are to be repeated from one floor
to another floor.)

Starter Block

Super plate

SRINIVASAN[Type text]
After removing the Wall Panels, proceed to the Slab Panels after 36 hours
by removing the long pins and wedges on the joint bars the end and middle
beam section.

SRINIVASAN[Type text]
Upon removing the Aluspans Mid Beams and Aluspan cantilevers End Beams,
the prop shall remained undisturbed during this process to support the
concrete slab.

SRINIVASAN[Type text]
Proceed to strip the Slab Panels and transfer to the next level according to the
designated area and installation sequence.

SRINIVASAN[Type text]
Strip the Slab Corner.

Pull out Wall flat Tie using Wall Tie puller and remove the Wall tie sleeve using
SRINIVASAN[Type text]
Nose player.

Sequence No. 8

When the cube tests show that the slab concrete is sufficiently strong, the prop
together with the prop heads are removed and transferred to the next level.

SRINIVASAN[Type text]
Aluform Work at Site

1 1a, 1b, 1c

If not suitable

2a, 2b 2 3 3a

If suitable If not suitable

5 4 4a

7 7a
`
8

If work front is not ready


9 12

If work front is ready 10

11

13

14 15 15a

16a 16 17 18

19a, 19b, 19c, 19d 19

23 22 21 20

SRINIVASAN[Type text]
cc

Chart Numbers
1. Receive Aluform materials.
1a. Packing list, BOQ, and Formwork layout.
1b. Tools.
1c. Additional accessories.
2. Visual inspection.
2a. Packing list & schemes.
2b. Acceptance criteria.
3. Inform concern for any defects
3a. Details of report.
4. Collect modification details.
4a. Fabrication drawings.
5. Stock the material as per packing list.
6. Room wise segregation.
7. Dry mock-up.
7a. Schemes.
8. Room wise numbering for identification.
9. Dismantling of mock-up.
10. Setting out.
11. Shift to work location.
12. Shift to stock yard.
13. Actual assembly at work location.
14. Slab rebars & M&E works.
15. Final checking (Pre pour check)
15a. Check list.
16. Concreting.
16a. Pour card.
17. Post pour check.
18. Leveling and finishing.
19. De-shuttering
19a. Removing pins and wedges.
19b. Removing wall ties.
19c. Removal of wall panels.
19d. Removal of deck panels.
20. Cleaning of panels.
21. Fixing of working platforms with brackets.
22. Erection of Safety posts / rails.
23. Applying Form release agent.
SRINIVASAN[Type text]