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Weilaicheng aluminium concrete formwork design project
● Project Description
In construction projects, concrete formwork serves as a crucial turnover materials that has a significant impact on cost control, construction progress, and project quality. There are numerous options available in the market for suitable concrete formwork materials, such as concrete formwork timber, concrete formwork steel, concrete formwork plywood, and concrete formwork aluminium. In the Weilaicheng project, all the townhouses are constructed as passive houses, which have strict requirements for quality.
The accuracy of the shape, size, and positioning of the components after concrete molding is crucial to prevent any adverse effects on subsequent works such as insulation, doors/windows installation, ventilation systems, and interior finishing. Therefore, it is necessary for the type of concrete formwork to possess sufficient strength, rigidity, and stability. Considering the practicality of the project, there are 11 townhouses with a total of 48 identical units, And the house type is consistent. Therefore, it was decided to use an aluminium concrete formwork design approach. Phase 1 of the Weilaicheng project is located on the west side of Line 32 in Huangdao District, Qingdao City. The total construction area of the project is 114,808.07 square meters, with an above-ground area of 76,089.54 square meters and an underground area of 38,718.53 square meters.
● Aluminium concrete formwork design
★how to design concrete formwork?
In the aluminium formwork design, both parties' technical personnel should participate jointly. The concrete formwork experts will establish the structure and concrete formwork 3D model based on the project drawings, taking into account various factors such as formwork design concrete pressure, concrete formwork estimating, and concrete slab formwork removal time.
Once the aluminium concrete formwork design is reviewed and approved by the project technical personnel, we will create a drawing issue review form, which will serve as an important reference for any changes to the drawings and construction operations. Then, the design team from the aluminium concrete formwork vendors will further develop the design and create an aluminium concrete formwork diagram of the assembly based on the construction drawings, design specifications, and the records from the drawing issue review.
★Aluminium concrete wall formwork design
1. For this project, the aluminium concrete wall formwork design utilizes wall formworks of 2700mm in height with an additional 300mm in the horizontal direction for concrete formwork kickers and makes partial adjustments to the aluminium concrete formwork based on the actual circumstances.
2. concrete wall formwork design includes the installation of T18 high-strength concrete formwork tie rods along both horizontal and vertical directions. The standard spacing between concrete formwork tie rods in the horizontal direction is 800mm. In the vertical direction, starting from the ground, the concrete formwork tie rods are divided into 5 rows. The first row is 250mm above the ground, the second row is 850mm above the ground, the third row is 1450mm above the ground, the fourth row is 2250mm above the ground, and the fifth row is 2720mm above the ground. Additionally, two concrete formwork clamps (measuring 60*40mm) are installed along the horizontal direction at each bolt location.
3. To ensure accurate and convenient adjustment of the verticality of the wall, at least 2 push-pull props are installed on one side of the aluminium concrete wall formwork design. The distance between the push-pull props should not exceed 1500mm. Additionally, mortar is added at the base of the columns to prevent column displacement and leakage of grout.
● Aluminium concrete formwork design
★Aluminium beamformwork design
1. The aluminium concrete formwork beam is configured according to the actual structural dimensions. The profile has a height of 65mm and the aluminium sheet is 4mm thick.
2. When the width of the beam section is equal to or less than 400mm, single-row supports are placed at the bottom of the beam. The maximum spacing between the bottom supports is 1200mm. A concrete formwork for slabs is installed on the bottom of the beam, and support heads with a width of 100mm are used for support.
3. When the width of the beam section is more than 400mm, two-row supports are placed at the bottom of the beam. The maximum spacing between the bottom supports is 1200mm. A concrete formwork for slabs is installed on the bottom of the beam, and support heads with a width of 100mm are used for support.
4. The concrete formwork details for the beam are depicted in the attached illustration.
★ Aluminium slab design formwork for concrete
1. The standard size of the aluminium house concrete slab formwork is 400×1200mm, and it can be adjusted locally according to the actual structural dimensions. The profile has a height of 65mm and a thickness of 4mm.
2. The distance between the aluminium house concrete slab formwork does not exceed 1200mm horizontally, a keel with a width of 100mm is installed for support. Similarly, the vertical spacing between the keels should also not exceed 1200mm.
3. The aluminium slab formwork design is shown in the following figure: (an example of a local area is shown)
★ Aluminium concrete stair formwork design
The aluminium concrete stair formwork design consists of concrete formwork for steps, bottom formwork, base beam formwork, wall formwork, and side formwork.
★Support design of concrete formwork 1. A total of 3 sets of floor supports and 3 sets of beam bottom supports are installed in this project. 2. The standard floor height in this project is 3.0m, and the support system adopts adjustable shoring props. The main physical characteristics are shown in the table below:
| project | outer diameter(mm) | inner diameter(mm) | Thickness(mm) | Cross-sectional area(mm2) | Sectional moment of inertiaⅠ(mm4) | Bending section coefficientWx (mm3) | Radius of gyration(mm) |
|---|---|---|---|---|---|---|---|
| Insert shoring props | 48 | 42 | 3.0 | 424.1 | 107831 | 4492 | 15.9 |
| Nested shoring props | 60 | 55 | 2.5 | 451.6 | 186992 | 6233 | 20.3 |
● Aluminium concrete formwork process construction arrangement
According to the aluminium concrete formwork process, the site is divided into 12 construction teams, with each unit floor having a dedicated construction team consisting of 6 to 8 people. The teams are scheduled to enter the site in batches. After the aluminium concrete formwork products arrive, the first batch of 12-14 construction workers enter the site to mainly work on the installation of two sets of aluminium concrete formwork on the first floor. After removing the aluminium concrete formwork on the first floor, the second batch of workers enters to install the aluminium concrete formwork on the unit floor of the second story, and so on up to the installation of the aluminium concrete formwork. In total, 72 to 96 workers will be needed to complete the task.
● Aluminium concrete formwork products preparation
The concrete formwork companies refine the aluminium concrete formwork design and proceed with production. Entry will be divided into 6 batches according to the actual construction progress on site. Prior to entry, pre-assembly is carried out, and once the assembly passes inspection, the components are numbered and packaged. Then, technicians from the manufacturer are dispatched to guide the on-site assembly of the aluminium concrete formwork. Aluminium concrete formwork products configuration: Based on the actual requirements at the construction site, we need to provide twelve units of aluminium concrete formwork products. Each unit floor will have 1 set of standard formworks, 2 sets of kicker-formworks, 3 sets of slab supports, 3 sets of beam supports, and 4 sets of supports for stairs, bay windows, cantilevered slabs, and other elements.
● Construction Phase
There are a total of 11 buildings on-site, each with 48 identical unit layouts. This project requires a total of 12 sets of concrete formwork products.Considering that all the buildings in the construction are passive houses with airtightness requirements, the aluminium concrete formwork products will utilize a flat tie system, which helps reduce the need to seal screw holes. This reduces the risk during the later stages of passive house inspection.
Installation process: Measurement and layout → Installation of steel reinforcement for walls and columns (including electrical conduiting work) → Installation of aluminium concrete formwork for round columns and concrete formwork for walls → Installation of aluminium concrete formwork for beams → Installation of formwork materials for concrete slab → Installation of steel reinforcement for beams and slabs (including electrical conduiting work) → Final inspection and reinforcement → Pouring concrete into the formwork → Transfer aluminium concrete formwork to the next unit.
Aluminium formwork for concrete is widely used in construction. This construction process is suitable for multi-story buildings with consistent and numerous identical units. Through careful planning and detailed aluminium concrete formwork design, we ensure safety, quality, and progress, making on-site construction more reasonable, efficient, and time-saving. It significantly reduces manual labor, improves work efficiency, and achieves win-win cooperation between the project and the construction team. This construction process provides a valuable reference for similar projects in the future, resulting in positive economic and social benefits.
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