Improving Formwork Productivity by Using Aluminium Formwork for Sub-structure Works

Formwork system accounts for approximately 15–20% of the construction cost in a typical residential project and is a major driver to ensure the anticipated project margin. While analysing the Formwork performance of residential projects, especially in sub-structures, it was evident that lower labour output, moderate material utilization, and lower efficiency levels and inferior concrete surface finish were the major problems affecting the overall performance. Major factors for the low productivity being the weight of shutters, having too many Formwork systems (Conventional, Alufo, Aluminium) within a site, low plywood durability, etc. Given the light weight, better load bearing capacity, excellent reusable properties and the ability to produce a good concrete finish, Aluminium Formwork system was believed to be a promising alternative for the existing Conventional system. Traditionally, the standard Aluminium panels were scrapped-off after completing the planned cycle of typical floors. But as per the intended strategy of utilizing the used Aluminium panels, the panels were systematically refurbished with multiple scheme drawings to ascertain the feasibility of using standard Aluminium panels for elements of varying sizes. The implementation has shown improvement in labour productivity, material reusability and faster execution by a factor of around 20%.