HOW WE USE ALUMINIUM FORMWORK TO CAST-IN-PLACE YOUR HOME.

‘Aluminium Formwork’, ‘Cast-in-place Construction’, ‘Shear Wall Construction’. I’m sure you’ve had your fair share of hearing these technical words being used across the Real Estate industry. They all refer to the same thing. But exactly what does this construction technology mean for you and your family? This article is geared towards giving you clarity on the subject.

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What is Cast-in-Place Construction?

‘Cast-in-place Construction’ is a construction technique that involves Aluminium Moulds that are custom manufactured to fit together in the shape of an apartment. Like a complex puzzle, these moulds are first assembled on site (hence the term ‘Cast-in-place’). The panels of aluminium formwork are made from a high strength aluminium alloy. The panels fit precisely, and securely with extremely efficient clearances.

During this assembly process, steel reinforcements, electrical conduits, galvanised metal switch boxes, plumbing sleeves are embedded within the mould. During each stage of the assembly process, engineers run quality checks to make sure that all parts are assembled according to plan. When this is done, Concrete is poured into the mould. Once the concrete sets, the moulds are removed and you are left with an entire apartment literally moulded in concrete. A lot like water in an ice tray, the concrete takes the shape of the predesigned mould and therefore gives us the ability to repeatedly create forms with the accuracy of an assembly-line process.

The excavation, foundation and basements are time-consuming and dependent on many site conditions as they dont follow this factory-style process. After the building reaches the ground floor stage, under ideal site conditions, to structurally complete one floor of approx. ten flats, “Cast-in-place construction” gives us the ability to complete this task in about 40% lesser time.

Superior Strength

The primary benefit of cast-in-place construction is its high level of strength. You’ve probably grown up seeing buildings constructed in a conventional manner. During which a series of columns and slabs are first erected, like a skeletal structure and later fleshed out with brickwork. Cast-in-place Construction uses the same principles involved in casting a beam or a column, to build an entire house. So if I were to stretch the analogy of flesh and bones; in this case, you are building the entire body out of bone. In other words, these structures are extremely strong.

After we layer each apartment of concrete one on top of the other, we’re left with a monolithic, multi-storey concrete structure which is not just stronger than a conventional building, but is also more resistant to earthquakes and has a longer life.

Factory-Like Finish

The Aluminium Formwork is custom manufactured in a factory and is designed to fit together with precision clearances. This accuracy renders a similar degree of precision in the outcome of these moulds. The concrete surfaces produced through this process are smooth, accurate and predictable. Human error is mitigated to a great extent.

Since this equipment is made of aluminium, it has sections that are large enough to be effective, yet light enough to be handled by a single worker. Individual workers can handle all the elements necessary for forming the system with no requirement for heavy lifting equipment. By ensuring repetition of work tasks on a daily basis it is possible for the system to bring assembly line techniques to the construction site.

The cast walls are so perfect, that it eliminates the need for any plastering. After they are fully cured, with minimal putty work, these walls can be primed and painted.

The ‘cast-in-place’ process essentially resembles an industrial production line. At every stage, quality checks are conducted by engineers. This build-and-check process drastically increases the efficiency of the build.

Increase in Carpet Area

Since every wall is concrete, the requirement for conventional beams and columns ceases to exist. Every wall is a load-bearing wall. This enables us to construct thinner walls that effectively increase the carpet area in the apartment when compared to conventional construction.

Also, the lack of columns and beams creates flat, functionally and aesthetically pleasing walls that are devoid of any protrusions. In a conventionally constructed building, you will notice that beams and columns cause highly inefficient and unattractive niches in a straight wall.

Accurate openings for windows & doors

This is a very important aspect. Window and door frames are installed after the main structure is finished, if the clearances are not perfect, you will have inconsistencies in the finish of how a door or a window is installed. Contractors will be forced to plaster in large gaps if the openings are too big or saw sections of the frames if the openings are too small. Not only does this affect the finish and functionality of the door or window, it also slows down the process of installation. The exacting clearances that “Cast-in-place construction” gives us, allows for a great degree of accuracy and speed in the installation of doors and windows.

Speed of Construction

This form of construction speeds up the entire process by a factor of at least 30%. Why does the speed of construction matter to an end-user?

Firstly, the amount of EMI’s you pay when a purchase is made at the beginning of the construction process is reduced, as the total time of construction is lesser.

Secondly, delays in construction are mitigated. Faster construction times and efficient processes enable us to predict timelines accurately and thereby reduce the chances of any delays in construction.

Insulation

Another advantage of cast-in-place concrete is the high degree of insulation it provides. This includes thermal insulation, so the buildings are cooler, and sound insulation. These insulation properties all extend to resistance from insects, mould, and mildew, none of which can penetrate cast-in-place concrete easily since there are no natural cracks or gaps between sections of building material.

Conclusion

Cast-in-place Construction has a range of benefits that begin during the construction process but are more exponentially experienced during the life of the building.