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Cheng Ji Xin Yuan Aluminium Concrete Formwork Systems Project
● Project Overview
The aluminium formwork is one of the concrete formwork, it has the advantages of the improve the construction quality and reducing the construction time. Our project consists of four 34-story high-rise residential buildings and adopts the aluminium formwork.The total construction area of 102,945.49 square meters. The above-ground area is 86,307.72 square meters, while the basement area is 16,637.77 square meters. The building's reference elevation is set at ±0.000, with an absolute elevation of ±38.300 meters. For buildings 9-12, the construction will utilize aluminium concrete formwork systems from floors 2 to 34. The excavation pit has been classified as Level 3 in terms of safety, and the environmental protection level is also set at Level 3.
Why use the aluminium formwork in this construction project?
1. Because this project has a requirement for short construction time, we need to improve the construction speed and construction quality. So, our team decided to adopt the aluminium formwork system. This system has the advantages of high efficiency and precision. It can help us to finish this project with high speed and high quality.
2. This project has four high-rise residential buildings and we can use the advantages of the aluminium formwork slab cycle to reduce the construction costs.
3. The high-end residential project adopts the aluminium formwork technology to improve the quality of construction and optimise the construction site environment. And the most important is to improve the satisfaction and recognition of the customers.
4. The aluminium formwork profile has a high load capacity and is important in high-rise building construction. It can not only improve the structural safety and effective optimization of the overall design but also improve the safety performance and aesthetics of the building.
● Preparatory work:
The most important parts of the aluminium formwork shuttering are design and production. So, we should keep the accuracy of the aluminium formwork panels, and ensure that all problems will be solved in the factory. So, it needs the aluminium formwork system manufacturer to design and produce, the following is aluminium formwork manufacturing process.
1. The aluminium formwork design should take into account the requirements of the design drawings, as well as the structural and architectural plans, and detailed construction specifications.
2. After careful verification by the concrete formwork manufacturers to ensure the accuracy of the design drawings, production and manufacturing can commence.
3. The concrete formwork dimensions are very accurate, so, after production, we need to install them in the factory. Before delivery, they undergo the inspections listed in the table below:
| Num | Aluminium concrete formwork systems project | tool |
|---|---|---|
| 1 | height:±3mm | Steel tape |
| 2 | Length:±2mm | Steel tape |
| 3 | Diagonal difference:≤3mm | Steel tape |
| 4 | Flatness:±2mm | Measuring and feeler gauges |
| 5 | seam level difference:≤1mm | 2m Measuring and feeler gauges |
| 6 | seam gap:≤2mm | Square and feeler gauges |
4. After aluminium formwork installation, they are assigned individual identification numbers, and detailed assembly diagrams are created.
5. After the numbering is completed, the aluminium for formwork is disassembled, packed, and transported to the construction site. The quantities are counted, and each concrete formwork panel's dimensions and flatness are checked to ensure they meet the design requirements.
6. Arrange for our construction managers and some workers to attend a concrete formwork training program at the factory to learn about the techniques for aluminium formwork installation and dismantling, as well as the steps involved in the construction process.
● Concrete formwork systems installation
The aluminium formwork construction is similar to other concrete formwork construction, the worker can use the components of aluminium formwork even if they are using it for the first time.
★ Concrete wall formwork systems installation
1. All pins on the concrete formwork wall must be fully inserted according to the hole requirements, with the direction of the pin heads consistent and all pin tips facing downwards.
2. The distance between two concrete formwork pins should not exceed 300mm.
3. The holes for the tie rods on both sides of the concrete formwork wall should be straight and aligned.
4. It is necessary to install concrete formwork wall ties at the ends of the concrete formwork wall for better stability.
5. The concrete formwork wall ties used should have a diameter of 16mm and the length should not be too long, preferably about 25mm away from the nut.
6. Ensure that the screws for the concrete formwork wall are firmly embedded in the concrete layer beforehand. Keep in mind that the spacing between two screws should not exceed 1200mm, and there should be at least 2 screws in place.
★ concrete formwork beam systems installation
1. After the installation of concrete formwork beams, the inspection of the concrete formwork wall for verticality and flatness begins.
2. The concrete formwork wall must be checked and adjusted to the correct height. If there is any portion that exceeds the designated height, the excess concrete at the bottom should be chiseled off to match the specified height. If there is any section that falls below the designated height, it needs to be raised with proper shimming to ensure that the concrete formwork wall is level with the desired height.
★ Concrete slab formwork systems installation
1. For concrete formwork for slabs, there should be a minimum of 2 concrete formwork pins used for connections, with a spacing not exceeding 300mm.
2. The spacing between concrete formwork supports should meet the design requirements and should not exceed 1300mm x 1300mm.
3. The concrete formwork for slabs should be laid out in parallel, temporarily secured with pins, and finally tightened.
4. Once the concrete formwork for slabs is installed, it is important to use an infrared level to systematically inspect and measure each piece for its flatness and alignment. If there are any discrepancies, adjustments can be made using concrete formwork supports until the overall surface is even and aligned with the desired elevation.
5. The concrete formwork supports should be vertical and not tilted, and they must not bear any eccentric loads.
● Correction of concrete formwork
Correction of concrete formwork walls: After the installation of concrete formwork walls, it is necessary to check their verticality and make corrections if needed. For exterior wall columns, a hand-operated hoist and a push-pull prop can be used. One end of the push-pull prop is fixed onto the concrete formwork clamps, while the other end is secured to the floor slab using pre-embedded bolts. This ensures that the verticality of the wall columns remains unaffected during concrete pouring. The allowed tolerance for verticality deviation of the wall columns is within 5mm.
Correction of concrete formwork for beam and slab:
Based on the floor elevation, use an infrared level to check the horizontal alignment of the concrete formwork for beam and slab. Adjust the concrete formwork supports to ensure they are level, keeping the maximum difference within a range of 5mm.
● Pouring concrete with concrete formwork
1. Once the installation is completed and approved, concrete pouring can proceed. It is essential to have the concrete formwork construction crew present on-site during the pouring process.
2. It is prohibited to directly place the advanced concrete pumping on top of the concrete formwork.
3. After pouring, it is necessary to immediately level the surface. The floor must not exceed a maximum height difference of 10mm and a thickness deviation of 5mm from the dimensions specified in the drawings. For shear walls, the control range should be within 5mm both above and below the specified measurements.
4. While pouring concrete, it is important to promptly rinse any areas where the concrete formwork is leaking with clean water.
5. It is not allowed to directly impact the concrete formwork components during concrete pouring to prevent them from becoming loose or shifting.
● Concrete formwork removal
★ Concrete formwork wall removal
1. Begin by removing all wall supports and neatly arranging concrete formwork parts in the designated area for subsequent use.
2. Use specialized tools to pry open the concrete formwork wall and transfer it to the upper level. Clean and brush mold release agent on it before neatly arranging it. Hammering is strictly prohibited.
3. During the removal of concrete formwork wall, avoid hitting the steel supports.
★concrete formwork beam removal
1. During the removal of concrete formwork beam, the bottom supports must remain in place to bear the load.
★formwork under concrete slab removal
When removing formwork under concrete slab, start from the fkeels. First, open the adjacent connectors and ensure that the support heads and supports, which bear the load, are not dismantled or moved. Minimize impact and clean up while dismantling, and neatly arrange the components.
● Concrete formwork removal precautions
1. Small concrete formwork that are not supported can be dismantled simultaneously during the removal of concrete formwork wall.
2. For challenging concrete formwork such as railing openings and chimney openings, plastic film can be used to wrap the components, and they can be removed immediately after the concrete has partially set.
3. There are numerous junctions in the concrete formwork, it is necessary to thoroughly review them after pouring each floor. Any missed areas should be improved upon.
4. For certain connecting concrete formwork, it is possible to install them in different directions during the installation process. Once the initial concrete pouring is completed, it is important to conduct a comprehensive inspection of the grooves. To address similar situations, it is crucial to clearly mark the installation direction on the board.
5. Using oil-based release agents or applying machine oil can help reduce the difficulty of removing concrete formwork kickers screws.
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