RUDRA ALUMINIUM FORMWORK SYSTEM

RAFS ENGINEERS PVT. LTD.

ALL WORK ACTIVITY

Rudra Nom s,
Site representative will start the pallet opening in the presence of customer’s authorized person and both will
jointly verify the material by checking the ONE-BY-ONE label barcode of panels. Customer will give their
acceptance at the same time after checking the scanning panel & packing list of any pallet

All the pallets coming to the site are scanned and sent to the site so that there is no problem in working on the site.

The scanning process is the most important process for us. After scanning, our site problems are completely solved.

Like

the complete material reaches the site. By scanning the pallet, we and you confirm that our material has reached the
site completely.

There is no confusion about sort and extras.

The mobile scanner will be in our scope on the site for scanning and you have to provide Wi Fi network on the site
 DO’S & DONT’S While using Aluminum Formwork System
(A) Do’s: -

* Check the materials supplied at site as per attached packing list.

* Segregate components as per code list & size and highlight or mark each item in drawing.

* In case of any discrepancy observed while verifying quantity with supplied packing list & drawing, immediately inform to RAFS aluminum
formwork System staff.

* Use approved drawing supplied by RAFS for the erection of material.

* Ensure the area is properly clear is clean and free from obstruction for setting out of Formwork.

* Ensure the layout & Floor level is correct as par Drawing.

-* The concrete face and side rails must be clean and coated with an approved releasing agent prior to erection for each repetition of
formwork.

* Wall ties should be coated with releasing agent provided before being fixed to formwork.

* All component should be used as per drawing & unit wise otherwise chances of error.

* Ensure the supporting MS fixers are used properly in formwork like Waller, Door spacer, Vertical soldiers, Sunk angle etc.

* Ensure all necessary fixers like Tie-rod, Kicker Bolt, Kicker pvc cone, anchor nut s are used properly.

* Ensure wall and column formwork are erected are per the layout lines.

* Ensure the bottom of columns and wall formwork is properly braced to ensure correct alignment.

* Check all the opening for correct dimensions. It should not be twisted.

* Check all horizontal formwork (Deck, Beam, Soffits, and Kicker etc.) are leveled.

* Check all vertical formwork (wall & column) are in plumb.

* Ensure verticality of deck and beam props.

* Check wall ties, pins and wedges are all in position and properly tight.

* Ensure stop-ends (stoppers) are secured in position.

* Ensure RAFS working platforms are securely fastened to the concrete structure.

* A client staff shall lead and oversee the work to ensure safety, proper handling of materials and in systematic manner while stripping the formwork.

* Before removing the formwork ensure the area is free from nails, rubbish scraps & unwanted material like steel scrap & debris, as it can damage
surface of formwork.

* Removal of wall panels should start 12 hours after the casting and deck panels should be removed after 48 hours or upon the approval of the concrete
cube test without disturbing the props.

* Thicker wall should be stripped first to allow early extraction of wall ties (otherwise wall ties may get sticked) while another group is stripping the
external formwork.

* Dismantled panels should be stacked according to the numbering of wall & deck and should be cleaned and coated by releasing agent before
transferring onto the next level of work.

* Steel and aluminum drop frames, transfer hole boxes, slab opening boxes and other accessories should be cleaned, oiled and put in one particular
place ready for the next level of work.

* Prop lengths should be removed only on the approval of the site engineer. RAFS provides 2 sets of prop lengths to be used for 2 floor level.

* It is advised to place different color buckets on the floor where de-shuttering is carried out.

* Scattered Accessories like Pins/Wedges, wall Ties etc. found by any site personnel shall be picked and placed into these buckets. This may be helpful
in maintaining the loss of accessories.

Only approved shell plan should be referred for dimensions of structures

(B) DONT’S: -

* If found any component incorrect in any terms (Design or Fabrication.) Do not use the same for
erection.

* Do not cut or modify any components to replaces wrong components at site without permission
from Aluminum Formwork System.

* Do not use any drawing other than the approved shell plan to erect the materials.

* Do not work at site without safely shoes, safety belts & helmets.

* In case of adjustable props, inner and outer member should not be separated.

* Materials should not be used for the area for which it is not designed for like typical floor materials
should not be in basement, stilts & other floors apart from typical floors.

* No component should be erected without proper cleaning & without proper coating of approved
releasing agent.

* Location of components should not be changed even if it is of same size.

The Site Working Method for Aluminum Formwork
The following steps outline the only site working method for aluminum formwork:

1. Site Preparation
1. Inspect the site to ensure it is level and compact.
2. Clean the site to prevent debris from interfering with formwork.

2. Formwork Assembly

1. Assemble aluminum forms according to manufacturer's instructions.

2. Use clamps and ties & hole bare, panel puller , tie puller to secure forms in place

3. Concrete Pouring

1. Pour concrete into assembled forms.

2. Vibrate and finish concrete to desired texture.
4. Striking and Reusing Forms

1. Allow concrete to set and cure.

2. Remove forms carefully to prevent damage.
3. Clean and store forms for reuse.

Benefits of Aluminum Formwork

1. Faster construction times

2. Improved concrete finish
3. Reduced labor costs
4. Reusable forms reduce waste and costs
5. Lightweight and easy to handle

Important Considerations

1. Ensure proper training for site personnel.

2. Follow instructions for formwork assembly and use.
3. Regularly inspect forms for damage and wear.

By following the site working method for aluminum formwork, contractors can efficiently and effectively create high-quality
concrete structures while minimizing costs and waste.
 QUICK STRIP PROP HEAD
One of the principal technical features which enables this speed to be attained using a
single set of formwork panels is the unique V shaped prop head which allows the 'quick
strip' to take place whilst leaving the propping undisturbed. The deck panels can therefore
be reused immediately.

Major important factors affecting the final finish of concrete through Aluminum
Formwork:
The concrete used is produced in RMC batching plants under strict quality control and
conveyed to the site with transit mixers.
Poor workmanship and lack of attention to details while installing formwork leads to
concrete leakage, offsets and rough finishes.
➢ For Aluminum Material ➢ For MS Accessories
1. Aluminum material is dispatched on 1. MS material is dispatched on Pallets, Bundles & sometimes
Pallets & Bundles from our Factory. loose from our Factory.

2. All the Pallets & Bundles must be 2. All the Pallets, Bundles & Speciale Loose material must be
properly verified at the time of properly verified at the time of unloading.
unloading.
3. The Pallets/ bundles must be opened in presence of Rudra
3. The Pallets/ bundles must be alu. formwork Representative.
opened in presence of Rudra alu.
formwork Representative. 4. How ever if pallets are opened in absence of our
representative & material is found short. we bear no
4. How ever if pallets are opened in responsibility for same
absence of our representative &
material is found short. we bear no
responsibility for same.
Alu. form sequence
1.Initial preparation from jobsite
2.Setting drawing
3.Man power analysis
4. Monolithic Construction
5.Sequence of Activities on Site
6.Checklist before concrete casting.
7.Concrete pouring
8.Dismantling
9.Do’s & Don’ts
10.Some common workman ship issues
Preparation , Material & Division of labor

Preparation Materials Verification Division of labor

1. Setting out drawings ✓ Checklist
2. Packing list 1. Accessories Division of labor
3. Setting of nearest Alu . 2.Corners (I/C, hunch) 1. Erection team
form Materials 3.ECA, ECT,ECB, ECX 2. Dismantling team
4. Standard wall panels
4. Setting Do’ & Don’t order 3. Flat-tie puller team
5. Non-standard wall panels
5. Fixing & removing Tools 6.Deck panel
4. Formwork lifting team
6. Consumables 7.Beam panel 5. Panel oiling
7. Form oil user manual 8.IC, ICI,ICE application team
8. Cover Blocks 9.EB, MB, DP
9. Checklist before & After 10.Plate Covers (UD, PC) 6. Collector , House
concrete casting 11.Stoppers (DCRB,WRB,WX) Keeper
10. Concrete pouring 12.Standard slab panels
13.Non-standard slab panels
Staff presence during the material
unloading

Unloading in unit wise Receiving on delivery Jointly verification with dispatch

sequence. invoice. packing list.
MATERIAL SCANING
Sequence of Activities
1. Stacking the material .
2. Marking of wall lines.
3. Tying of Wall Rebar
4. Cover Blocks
5. Form Oil User Manual
6. Fixing of Electrical conduit a) Door / Window openings at wall
7. Fixing of Plumbing Grooves
8. Fixing of internal wall form
9. Correcting Levels of Wall Panels & Maintaining Plumb
10. Guidelines for fixing Pin-Wedges
11. Erection of T- Panels
12. Erection of slab formwork
13. Fixing of external wall form
14. Erection of Lift Formwork
15. Erection of Staircase Formwork
16. Tying of Slab rebar
17. Fixing of Conduits at slab a)Sunken, Transfer box out in position & Cutouts
18. Final Aligning & checking & Fixing of Push Pull Prop
 Marking of Wall Lines
 Levelling Activities
1. Setting out line and Slab level /
kicker level survey.
2. Adjustment if any and Theci
(Timber stay/ Wooden support) 300mm
offset line
fixing along the setting out line.
3. Theci must be provided on both
Side sin case of internal walls.
4. In case of external wall, Theci must
be provided on the inner wall.
5. A theci of 295mm with minimum
25mm thickness must be fixed. The
distance between 2 consecutive
Theci must be less than 1000mm.
6. Nails must be fitted on both
ends of theci for best support fix
nails diagonally on theci.
FORMWORK EXECUTION

ERECTION OF WALL FORMWORK

Concrete level survey
Detail layout.
Required hacking /
chipping.
Reinforcement binding.
Electrical conducting.
Service sleeves.
Shuttering panels
cleaning and oiling.
 RK Grooves

Wherever the building is in height restriction zone, We cannot increase or decrease the slab level by kicker
adjustment. Also if the client is not allowing chipping, In this case the RK panel can be fixed by creating
grooves (at the time of concreting) as shown in above photograph to help us finish the building within
restricted Height limits.
4
(B
Tying Of Wall Rebar tying
 Cover Blocks
Cover block spacing requirement

Sr. No. Member Requirement Remarks

1 Slab Min 2 Nos. / Sq. m.
2 Wall 4 Nos. / Sq. m.
3 Column 4 Nos. @every 1.0 m c/c
4 Beam Min 3 Nos. @every 1.50 m c/c Nos. Depends upon
the beam Size

Column
Reinforcement

Slab Wall
Reinforcement Reinforcement
 Form Oil User Manual
 Recommended Shuttering oil

 Reebol
 Sika®-form oil

A coverage between 40 to 60 m² per liter is possible The coverage rate for Sika-Form oil is 40 to 50m²
per liter depending upon application
depending upon application

Rheo finish® 202  SETRELEASE RTU Mould release agent

The coverage rate for RHEOFINISH 202 is 30 to The coverage rate for SETRELEASE RTU covers 22 to
70m² per liter depending upon application. 30 m² per liter depending upon application
 Form Oil User Manual
Notes on Application/Limitations

• The molds should be dry and clean.

• Any residues of rust and concrete must be removed.
• Form oil is applied in thin layers, covering the complete
surface (a second application may be necessary incase of
highly absorbent formwork).
• We recommend the use of a special spray gun with an operating
pressure of 3-6 bar and a flat spraying nozzle.
• After application the concrete can be placed immediately without any
waiting time.
• Before concreting preliminary test are recommended to
optimize the procedure for each project.
 Fixing of Electrical Conduit
 M&E Fixed & Door / Window openings in Wall Formwork with the Reinforcement
 ERECTION OF INNER SIDE WALL

 The inner wall consists of 4 parts

 ROCKER(RK)
 WALL PANEL (W)
 WALL TOP PANEL (WT)
 SOFFIT LENGTH (SL)

 Rocker is connected with bottom side of wall

panel (w) with nut and bolt.

 Inner side wall panel first W – panel then T-

panel and then SL, row by
row is to be erected and connected with pin and
wedges.
 After checking, beam soffit has to be provided
with beam props in
certain distance as per drawing given by Mach
one.
 One side of beam is to be erected including
soffit length and soffit
corner with pins and wedges.
 This will form a rectangular shape on top of wall
and below the slab
concrete
ERECTION OF DECK FORM WORK

*After fixing of the soffit lengths the

deck panels can be pinned

*at the covers again ensuring oil has

been applied to the edge

*of every panels.

*The deck beams to support the
deck form work are
*assembled on the concrete floor as
per Mach one drawing.

*EB - DP–MB–DP–EB is placed on

concrete surface and this

• is held together by the ST

350mm using 127mm pin and
wedges
The beam is held in place by inserting a pin from the beam through the end of deck panel already fixed to the corner.

Ensure side rails of the deck beam have been oiled prior to fixing.

The first panel in a row has to be pinned to the soffit length and the deck beam.

The second panel should be pinned with first panel (3 no’s pin) and with soffit length (2 no’s pin).

Ensure the second panel is not fixed to the deck beam, which will leave sufficient movement in the beam
to place the third panel of that row.

Place the remaining panels in the row using the same method as per drawing and fix all the pins and
wedges with
deck beam.
 Setting of Kickers

Prior to concreting a Ø16mm MS bolt is

fixed to the kicker located tight to the

bottom of the slot.

This bolt remains fixed to the casted

concrete with a flat washer and nut to act as
anchor.

After concreting the slotted hole allows for a

adjustment if required.

The level of the kicker also controls the

verticality of the formwork
Alignment of Kicker

The steel vertical solders are fixed in place

using tie rods through a PVC sleeve, which will
later be used to fix the work platform
brackets.

Where the ends of two kickers meet, a BKS

should be used to keep the two adjacent
components level.

A straight kicker will ensure that the wall at

the next level is also straight.
 De-shuttering of Deck Form panel
One end wall form & soffit length to be removed first
where there is no deck beam supports and the panels
span from wall to wall.

De-shuttering of deck form panels

First the length of one end wall form and soffit

should be removed where there is no deck beam
support and the panels extend from wall to wall.

Pins and wedges should be removed from the

identified component which is to be struck.
Unplanned and irregular removal of wedges and
pins will create safety hazards.

Panels should be cleaned and stacked room-wise

immediately prior to stacking.
 Adjustable  Stub
Pin
Props

 Panel
 hole bare
puller

 Alignment
 Wall Tie
bracket
Tie
Wing
puller
Nut

 Tie Rod Vertical

With Nut Soldier

d
 Wall
Alignment
Attached Pipe
Bracket
Components :-
2. Slab Deck (D)
1. Wall panel with rocker (W)

Day 4
Formwork Erection

3. Soffit Length Corner (ICI) 4. Soffit Length (IC)

5. (MB) - (D)100(H)125(L)600/900/1,000 6. End Beam (EB)

7.Deck Prop (DP) 8. Beam Bar/ Shoulder Tie (ST)

(L)350mm
(D)100*(L)200*(H)125
I. Staircase Tread Riser Connector (STR)
Accessories
Pins and ties are used to hold the formwork firmly while pouring the concrete, and they are the most essential components for our strategi can advance d form work system

I. Stub Pin /Wedge Pin / Long Pin

Stub pin and wedge pin are used to inter lock wall panel sand slab panels together.
Beam pin and wedge pin are used to interlock deck prop (DP) with end beam (EB) and middle beam (MB)

II. Reusable Flat Tie / Embedded Flat Tie

I.Prop Jack • Wall Bracket / Slab Bracket / Elevator Bracket/ Each bracket works on
exterior walls, slabs and lifts.
• Each bracket will be mounted and fixed to the concrete surface when in use.

Type Lengt Weight(kg)

h(M)

V1 1,500 11-12
~3,00
0
V2 2,000 12-13
~3,50
0
Installation & Dismantlement
•Installation of Wall and Slab Panels

We use IC (Internal corner), end beam(EB), and middle beam(MB) components to connect wall and slab components
together firmly
•Installation of wall panels
•Installation of Internal Corner (IC) and (ICI)
•Installation of standard deck panels
•Installation of end beams (EB)and middle beams (MB)
 ■ Dismantle of Wall and Slab Panels
Dismantling processer enquire the wall panels to be disassembled first , the n beams , slabs ,and IC

1. Dismantlement of wall panels

2. Dismantlement of beams
3. Dismantlement of Slab Panel
4. Dismantlement of Soffit Length
 • Installation of Staircase Formworks
We create the basic frame guideline with IC for stairs ,and step panels (Staircase cover), special step panels
(STR),and staircase step are installed accordingly
Installation of kickers
Installation of soffit length for stairs
Installation of step panels (Step cover) and special step panels (STR)
Installation of stair case step
7TH and 8TH DAYS WORK
With our advanced Aluminum formwork system, the construction phase for one floor can be achieved in 8 days

1ST and 2ND Days

Lining up structure all in es and
installation of reinforcing bars.

3RD and 4TH Days

Installation of wall panels.

4THand 5TH Days

Installation of deck panel.

6TH DAY
Installation of reinforcing bars on the
slab panels before casting the
concrete.
7TH and 8TH DAYS
Final Checking & Casting and curing of
the concrete.
* Where wall ties are not provided due to falling of reinforcement at exactly same location, do provide walers from outer face of wall.

•Kicker bolts are supreme important thing and need to be checked without failed for correct location .
•Once the formwork is erected, do check for stub pins at all holes before concrete, this ensures no damages to shutters due to concrete pressure
and also concrete
• does not get waste as all pins keeps shutter in place and does not allow to get deform under pressure.

•Transfer box should be installed at correct location along with additional extra reinforcement bars to make cutout stronger.
* Tightening of chuck nut from other face also need to be checked to ensure the safety of people working at huge

* De-shuttering of panel and shifting should be done properly without rough handling, this ensures better concrete finish and more repetitions
of form.
Thank You