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Tian Xiwan Aluminium concrete formwork panels project
● Project overview
The Tian Xiwan project is located in the Donghai area of Quanzhou, specifically in the reclamation area of Donghai Beach in the Fengze district. The site is bordered by Jing16 Road on the east, Wei5 Road on the north, Donghai Comprehensive Avenue Street on the west, and Dongbin Avenue on the south. The transportation conditions are convenient in this area. The total construction area for this project is 92,000 square meters and includes one basement level with a total area of 27,000 square meters. It currently has five main buildings numbered as Building 7 to Building 11, each containing 33 stories. The first floors of Building 7 to 9 have a height of 4.01 meters, while the first floors of Building 10 and 11 are 4.36 meters high. Standard floors from the second to the thirty-second level have a height of 3 meters. The height of the 33rd level is 3.04 meters. The whole building has a height of 106.40 meters, with the main building height of 4.05 meters for the underground floor and the group building height of 3.7 meters. After considering factors such as construction quality, project duration, and economic benefits, it was decided to use aluminium concrete formwork panels for the construction.
In this project, aluminium concrete formwork systems will be used to mold structural walls, columns, floor slabs, lintels, door jambs, pressure grooves, and structural pillars in one go. This approach ensures the overall quality of the buildings to the maximum extent and significantly reduces the procedures for secondary structural construction. Based on the characteristics of the concrete formwork panels, concrete formwork timber will be used for construction for parts of the standard floor structure where protruding lines are present, and for structures that appear three times or less. Aluminium concrete formwork panels are an advanced concrete technology that can achieve optimal construction results. Unlike traditional systems relying on unloading platforms and tower cranes for transportation, aluminium concrete formwork panels are lightweight both in terms of their own weight and the supporting system. They can be easily transported by hand, either through material transfer openings (one per unit, measuring 200mm*800mm) on the floor slabs or via scaffolding and stairwells.
● Construction area division
Due to the large volume of aluminium concrete formwork panels in this project, the main structure is divided into 7 construction phases for sequential construction. Specifically, Building 7 and Building 8 are each divided into two construction phases for sequential construction. Building 9, Building 10, and Building 11 are each divided into three construction phases for sequential construction.
| Construction area | Number of construction workers |
|---|---|
| Building 11# | 45 |
| Building 10# | |
| Building 9# | |
| Area A, Building 8# | 30 |
| Area B, Building 8# | |
| Area A, Building 7# | 30 |
| Area B, Building 7# |
● Construction preparation
1. The management personnel need to be familiar with the aluminium concrete formwork shop drawings and have an understanding of the architectural structure characteristics and component dimensions. They will conduct a thorough review of the drawings, focusing on identifying potential issues and providing suggestions for improvements during the construction process.
2. Organize technical and management personnel to study relevant specifications, regulations, and standards. Based on the concrete formwork diagram and the construction capabilities of the company, a targeted special construction plan will be developed, taking into account the practical circumstances.
3. Inspect the concrete and formwork quantity and, according to the construction schedule, organize the entry of labor, materials, and machinery equipment in batches.
4. Before the aluminium concrete formwork construction, technical personnel, quality personnel, and foremen will hold a full discussion and study on the key parts, difficult points, quality and safety requirements,concrete formwork guide, and precautions of the construction. Workers will also be organized to learn the advanced concrete technology of aluminium formwork in a serious manner.
| Aluminium concrete formwork standards configuration | ||||
|---|---|---|---|---|
| Num | Concrete formwork name | Unit | Quantity | Remark |
| 1 | concrete formwork wall | layer | 1 | |
| 2 | concrete formwork beam | layer | 1 | |
| 3 | concrete formwork for slabs | layer | 1 | |
| 4 | Support head | layer | 3 | Equipped with 6 sets for the cantilevered area |
| 5 | concrete formwork supports | layer | 3 | |
| Aluminium concrete formwork specifications | |
|---|---|
| concrete formwork thickness | 4( mm); |
| concrete formwork width | 50~600(mm); |
| concrete formwork rib height | 65(mm); |
| concrete formwork weight | 18～25(kg /m°); |
| concrete formwork holes diameter | 16.5(mm); |
| Weld length and height | L:50 (mm) H:5 (mm) |
| concrete formwork clamps | Material: Q235A, main specification model: 60×40×3.0; |
| concrete formwork tie bars | Material: Q235A, diameter: T18, nut material: Q235A, specification: T18×25; |
| concrete formwork kickers | Width: 400mm, length: depending on the actual needs; |
| concrete formwork braces | Format:Φ48×900/Φ48×2000; |
| concrete formwork supports | Size: outer diameter of casing: Φ60 (mm), outer diameter of cannula: Φ48 (mm), wall thickness: 3±0.5 (mm), shape: round tube. |
● On-site preparation
1.Construction technicians will carefully cross-check the on-site control lines and benchmark control lines in advance to ensure accuracy and correctness.
2. Check if the previous process has been completed and if the conditions for setting up concrete formwork are met. For the processes that have been completed, conduct timely inspections for acceptance.
3. Prepare the necessary construction tools for concrete formwork, including a hammer, pry bar, concrete formwork vibrator, power drill, adjustable wrench, cutting machine, electric hammer, plumb bob, and step ladder.
● Aluminium concrete formwork method statement
Place the wall column line → level the elevation → install the aluminium concrete formwork wall → install the aluminium concrete formwork beam → install formwork under concrete slab → check the verticality → leveling concrete formwork → check whether the pins are correctly → binding steel bars→ reinforcement of wall columns → pouring concrete into formwork.
● Aluminium concrete formwork installation
★Aluminium concrete formwork wall installation
The installation of aluminium concrete formwork walls should follow the sequence of installing the inner walls first, followed by the outer walls. Once the installation is complete, vertical and horizontal adjustments should be made to ensure proper elevation.
1）First, place the one-sided concrete formwork along the control line and temporarily secure it with supports. Then, simultaneously begin installing the aluminium concrete formwork walls on both sides.
2）Before installing the aluminium concrete formwork walls, it is necessary to install concrete formwork kickers and anchor them into the concrete structure using fixed screws. The weight of the exterior aluminium concrete formwork walls is supported by the concrete formwork kickers. During installation, a crane can be used to lift and position as a whole.
3）When installing concrete formwork shutters, it is important to ensure a secure connection between the four sides of the opening and the aluminium concrete formwork walls.
4）After the installation of the aluminium concrete formwork walls, it is necessary to install four flat tie rods, four steel walers, and concrete wall formwork spacers. This is done to prevent any twisting or misalignment of the aluminium concrete formwork walls and ensure a straight and smooth structure.
5）To avoid any grout leakage at the base of the columns and walls, after reinforcing and installing the aluminium concrete formwork walls and ensuring they are perfectly vertical and smooth, it is important to fill the column and wall bases with cement mortar to prevent any grout from leaking out.
6) To reduce concrete pressure on wall formwork, it is necessary to install diagonal bracing, which will contribute to improved construction quality and ensure the stability and smoothness of the wall structure.
★Aluminium concrete formwork beam installation
1. Once all formwork for concrete retaining wall has been adjusted, the installation of concrete formwork beams and floor joists can begin. It is important to apply form release agent on the surfaces of concrete formwork elements that come into contact with the concrete.
When connecting concrete edging formwork to formwork for concrete retaining wall, pins should be inserted from the top to prevent the pins from falling off during pouring.
For concrete formwork beams, in addition to meeting the requirements for load-bearing capacity and deformation calculations, the following criteria should be satisfied:
For beam heights of 800mm ≤ H ≤ 1200mm, at least one steel walers should be added to the beam.
For beam heights H > 1200mm, steel walers should be installed in accordance with formwork for concrete retaining wall and secured with flat tie rods. The spacing between the flat tie rods should be ≤ 900mm.
In this project, there are no beams exceeding a height of 1200mm.
★Aluminium formwork under concrete slab installation
When installing formwork under concrete slab, it should be done piece by piece along the wall in a parallel manner. It is temporarily secured using pins and then finally fixed uniformly. Once installed, the elevation of the formwork is checked using a level to ensure a flat and even surface. Adjustments are made if needed before moving on to the next construction phase. You can click our blog "alumnium formwork installation and dismanting" for more details about installation of concrete formwork.
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