alform system

alform system
procedures manual
 Alform System Sdn Bhd
User Information
Alform System Procedures Manual
Instructions for assembly and use (Methodology)

Revision 3. Date October 20, 2016

Introduction
The Alform System Formwork is precisely-engineered system fabricated in aluminium. Using this system, all the
elements of a building namely, load bearing walls, columns, beams, floor slabs, stairs, balconies etc. can be constructed
with cast in situ concrete. The resulting structure has a good quality surface finish and accurate dimensional tolerances.
Further, the construction speed is high and the work can be done in a cost effective manner.
The modular nature of the formwork system allows easy fixing and removal of formwork and the construction
can proceed speedily with very little deviation in dimensional tolerances. Further, the system is quite flexible and can
be easily adapted for any variations in the layout.
Structurally speaking, the adoption of the closed box system using monolithic concrete construction has been
found to be the most efficient alternatives. The stresses in both the concrete and steel are observed to be much lower
even when horizontal forces due to wind or earthquake are taken into consideration.
The formwork system can be used for construction for all types of concrete systems, that is, for a framed
structure involving column beam-slab elements or for box-type structure involving slab-walls combination.
CONTENTS
Isometric profile of the aluminium formwork system Page
SECTION (1) PRE CONCRETE ACTIVITIES
1 Receipt of aluminium formwork 1
2 Level surveys 1
3 Setting out points 1
4 Control and corrections of deviations 1
5 Assembly of wall formwork 2
6 Assembly of slab formwork 2-3
7 Setting kickers 3
8 Pre-concrete checklist 4

SECTION (2) DURING CONCRETE WORKS

9 Standby during concrete work 5

SECTION (3) POST CONCRETE ACTIVITIES

10 Dis-assemble wall formwork 6
11 Dis-assemble slab formwork 7
12 Clean 8
13 Transport & store the formwork 9
14 Remove kicker formwork 9
15 Dis-assemble the wall mounted working platform 10
16 Assemble the wall mounted working platform 11
17 Working platform sequence 12-14

SECTION (4) MISCELLANEOUS

18 Instructions 15
19 Details 16-33
20 Setting out 34
21 Form oil 35
22 Steel adjustable props 35
23 Placing the concrete in the formwork 35
 SECTION (1) PRE CONCRETE ACTIVITIES

1. RECEIPT OF THE FORMWORK EQUIPMENT TO THE PROJECT

Unload the components from transport and where possible, store by code and size. Standard panels can normally be stored
safely up to 25 panels high on wooden skids or pallets. When stored, holing in the formwork should be aligned allowing
easy identification by the code. Ensure the first panel at the bottom of the stack has the contact face upwards. All pins,
wedges, wall ties, P.E. sleeves, polythene sheet and special tools are to be put into proper storage and only distributed as
required. A check requires to be carried out against the packing list to ensure all the items stated are received.

2. LEVELS
A concrete level survey should be taken on all sites and remedial work carried out prior to the assembling of formwork. All
survey levels should be taken from a T.B.M. (temporary bench mark).
A record of all surveys should be kept on file by the allocated site manager, supervisor or main contractor. It is good working
practice to mark the concrete slabs with paint indicating a plus (+) or minus (-) as the survey is being conducted. This
eliminates unnecessary circulation of paper copies to site personnel, and the Supervisor can identify at a glance any remedial
work required. High spots along the wall line to be chipped off to the proper level. Low spots along the wall line should be
packed to the required level, using plywood, timber or metal. Packing the corner and the centre of the wall length to the
required level will normally be adequate, as the formwork when pinned together will bridge across low spots. Concrete
(+5mm) and above must be chipped/hacked off to the (correct level). After concreting, survey levels should also be carried
out on the top of the kickers. One reason for structural deviation from the centre line can be on a - level kicker. This in turn
means the formwork is not plumb.
Kickers are manufactured with a 26mm slotted hole on the contact face to allow for adjustment after concreting.
As with the concrete survey level, proper records of the kicker survey should be kept on file by the allocated site Manager,
supervisor or main contractor. Also a deviation survey requires to be carried out and kept on file for future records.

3. SETTING OUT LINES

Only the approved shell drawings supplied by the Formwork Design Department should be used for setting out. Setting out
lines should continue through openings, corners where possible etc., by a minimum of 150mm. This makes it easier to fix
the formwork in position prior to concreting. It is very important that the reference points and the setting out points are
protected against accidental movement or damage. Transferring of reference points from the level below requires to be done
quite accurately. Incorrect reference points give incorrect deviations therefore creating unnecessary work for the formwork
erection. It is suggested a lazer be used for transferring the points through openings provided in the slab.

4. CONTROL AND CORRECTIONS OF DEVIATIONS

A study of the deviation and kicker survey level should confirm what, if any, corrective action is required. If the kicker
requires adjustment for level, loosen the holding - in bolt by turning anti-clockwise, adjust kicker to the required position
and retighten the bolt. Once the vertical formwork is fixed in position, the external corners should be checked for plumbness.
This will determine if further action is required to control the deviation. In addition to the kicker levels, if the formwork
requires to be pushed, then adjustable props can be used.

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5. ASSEMBLING THE FORMWORK
For the initial set up 100mm metal studs, wooden or plywood battens can be fixed to the concrete slab at the corners and at
intermediate centres to keep the formwork in position during assembly as this will ensure the formwork is in the correct
position to the setting out lines.
Note: Ensure when fixing the metal studs, wooden or plywood battens to the concrete slab, take care not to puncture any
imbedded conduits during the process. All formwork begins at a corner and proceeds from there. This is to provide
temporary lateral stability. A single panel at a corner will give sufficient lateral support to a very long section of wall. Ensure
all edges of the formwork and contact face are properly cleaned and oiled prior to fixing in place.
When satisfied the corner is stable and the internal corner is positioned to the setting out lines continue erecting the formwork
to one wall. Use only 2 no pins and wedges to connect the formwork at this stage as the pins and wedges will have to be
removed later to insert the wall ties or tie rods. Alternatively the wall ties or tie rods can be positioned as the formwork is
erected. For ease of stripping, pin the wall panels to the internal corners with the head of the pin to the inside of the internal
corner if possible.
Wall ties should be coated with form oil before being fixed to the formwork, and tie rods must have the PVC sleeve and
cone fitted. Fit the wall ties through the slots in the wall formwork or the marked holes seen on the contact face of the wall
panels and secure in position with pins and wedges or wing nut. Prior to closing the formwork, pre-wrapped corrugated
PVC sleeves are placed over the wall ties or PVC sleeve and cone are inserted over the tie rod. Please ensure, since
preparation of the sleeves they have not been damaged in any way before installing, as this can have an adverse effect on
the removal of the wall tie or tie rod after concreting. Also, ensure they are located properly to the contact face of the
formwork on each side of the wall. Sleeves installed with one end fixed between the side rails of two adjoining panels,
exposes the wall tie at the opposite end, therefore making it difficult to retrieve the wall tie after concreting.
When deviations of external walls occur, they must be brought back to the correct plan location as quickly as possible. This
is done by slightly tilting the external wall forms in one plane. If a deviation from plumb has occurred in two directions,
then this should be improved over two floors, one for each direction. Realignment in two directions should not be attempted
on a single lift. A maximum of 8mm in vertically improvement in one lift is sufficient.
Method of assembling the formwork
It is important maximum efficiency to define a sequence of erection is followed by each team. One side is erected using
only an upper and lower pin and wedge connection. Later, ties are inserted at the other connections and fixed with pin and
wedge. Then the previously installed pins are removed and those ties inserted and pinned. Subsequently, panels for the other
side are inserted between the existing ties and fixed with pins and wedges.
The advantages of this assembly method are as follows:-
1. Rooms can be closed and squared by assembling only one side of wall panels. If misaligned, it is easier to shift
rows of single panels.
2. If steel reinforcement is likely to interfere with the placement of the ties, it can be seen and corrected without
delaying the panel erection.
3. Enables fast start up of deck teams as the first rooms can be closed quickly.
4. Continuous steel reinforcement for the walls creates a barrier between the two sides of the
Formwork, so the work proceeds at the pace of single erector.
Special care must be taken at the lift shafts. The interior panels will align properly on their own because they are set on the
kicker from the formwork below. Ensure the kickers are level and will not affect the verticality of the lift shaft. However,
the matching panels are set on the concrete that may not be level. If the concrete is too high in place, it can distort the
alignment of the four sides of the lift shaft and must be broken out to allow a level base. Care must be taken so that the
concrete and in particular the reinforcement does not become contaminated due to excessive or negligent application of the
releasing agent.
The ends of walls and door openings should be secured in position by nailing plywood supports or timber wedges to the
concrete slab. Walls require to be straightened by using a string line and securing in place by nailing timber supports to the
concrete slab. During this operation verticality of door openings also requires to be checked for plumbness. Where possible,
door spacers should be fitted.
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6. ASSEMBLING THE SLAB FORMWORK
Before fixing in position, the slab joint (SJ) and slab corners (SC) should be coated on the contact face plus the top and
bottom rails with a form oil.
When connecting the slab joints and slab corners to the vertical formwork, the pins should be inserted from the top
preventing the possibility of the pin falling out during concreting. After fixing the slab joints, the slab panels can be pinned
at the corners, again ensuring form oil has been applied to the edges only.
In most cases the slab links to support the slab formwork, can be assembled on the existing concrete slab. Lay the link
components on the floor as per the deck layout drawing. Components are held together by pinning link bars 350, through
two adjoining beams with a link head 200 located between using the 132mm pin.
Fit the prop lengths to the preassembled beam with the shoe of the prop facing in the direction of the beam. This protects
the bottom of the prop length when striking the prop. Using the prop lengths lift the beam into position. The beam is held
in place by inserting a pin from the beam, through the end of the slab panel already fixed to the corner. Ensure the side rails
of the slab beam has been oiled prior to fixing.
The first panel in a row has to be pinned to the slab joint and the slab link. The second panel should be pinned to the first
slab panel only, (two pins are normally enough). Ensuring the second panel is not fixed to the slab link will leave sufficient
movement in the link to place the third panel of that row. Fix the third panel to the second panel, and then pin the second
panel to the slab link. Place the remaining panels in the row using the same method. A numbers of rows can be fixed
simultaneously. The face of the slab panels on completion can be oiled prior to the placing of the slab reinforcement.
On the completion of fitting the slab panels a survey team is required to check the level of all soffit formwork and adjust
accordingly if required, by shimming the bottom of the fixed props (PL's) or adjusting the screw handle on the steel
adjustable props.

7. SETTING THE KICKERS

Where there is a continuous vertical wall, e.g. lift shaft, external face of the building etc., a kicker forms the perimeter of
the slab and also acts as the connecting component for the vertical formwork on the next level.
After casting of the first level of formwork, two levels of kicker are required, one coming off the previous floor to which
the formwork is fixed and the other fixed to the top of the wall formwork which forms the perimeter of the slab. This kicker
remains in place after concreting and is used to start the wall form on the next level.
Connecting the kickers to the wall panels
Ensure kickers are properly cleaned and oiled prior to fixing in position. To prevent the pin being dislodged during
concreting, pins should be inserted in a downward direction through the bottom rail of the kicker and top rail of the wall
panel.
Kickers are manufactured with a 26mm x 16.5m vertical slotted hole. Prior to concreting, a 16mm diameter mild steel 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 an adjustment if required for improvement on the level
of the kicker, which also controls the verticality of the formwork.
Aligning the kickers
Kickers should be checked for alignment using a string line: A straight kicker will ensure the wall on the next level is also
straight.
The method used to align the kickers.
Steel vertical soldiers are fixed in place using a tie-rod, through the cast in PVC sleeve, which will be used later for the
fixing of the wall mounted scaffold brackets. Where the ends of two kickers meet, a BKS (alignment extrusion) should be
fixed across the top of the kickers, keeping the two adjoining components flush.

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8. PRE-CONCRETE CHECKLIST

Project: Date:
Work Area
1.Building 2.Floor 3.Area
Pre-concrete formwork checklist items
Workmanship acceptable Yes No
No. Description of Work
1 Formwork has been cleaned and coated with an approved form oil. Contact face & sides
2 All flat wall ties / tie rods installed
3 All P.E. wall tie sleeves / tie rod sleeves correctly installed. Along with PVC cones
4 External & internal walls vertically adjusted accordingly
5 Verticality and alignment of window & door openings
6 Alignment of all internal walls
7 Check all required pins and wedges are installed and secure
8 Verticality of all prop lengths / adjustable props
9 Ensure there is no vertical movement in the prop lengths / adjustable prop handles
10 Slab soffit formwork level
11 Door spacers installed as per drawings issued
12 Alignment walers installed as per drawings issued
13 Vertical Soldiers installed as per drawings issued
14 All kickers have been lined and adjusted accordingly
15 All kicker bolts installed correctly
16 All wall heels have been installed
All excessive spaces between wall heel and floor level have been sealed.
17
Note: By others
18 Ensure all working platform brackets are securely fastened to the structure
Remarks:

Inspected By: (Name)

Signature:
Company:
Date:

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 SECTION (2) - DURING CONCRETE WORK

9. STAND BY DURING CONCRETE WORK

At least two workers should be on standby during concreting, to cover both sides of the wall being casted. During concreting,
the ideal position is slightly in front of the pour, checking pins, wedges and wall ties as the pour is in progress.
Pins, wedges or wall ties missing could lead to a movement on the formwork and the possibility of the formwork being
damaged. This effected area will then require remedial work after striking of the formwork.

Things to look for during the concreting

(a) Dislodging of pins / wedges due to vibration.
(b) Beam / slab heads adjacent to drop areas slipping due to vibration.
(c) Ensure all bracing at special areas stays intact.
(d) Overspill of concrete at the window openings etc.

Workers on standby should have the following equipment (at hand)

(a) Pins and wedges
(b) Adjustable steel props
(c) Masonary nails
(d) Carpenters saw and hammer
(e) Lengths of steel / timber for additional bracing, (if required).

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 SECTION (3) POST CONCRETE ACTIVITIES

10. DIS-ASSEMBLE THE WALL FORMWORK

Normally wall formwork can be removed after 12 hours. Striking times are confirmed on a project, to project basis. Approval
must be agreed by the on-site resident engineer.
Before striking wall formwork ensure the following are removed:
(a) All plywood supports nailed to the concrete slab.
(b) Walers (if any).
(c) Vertical soldiers.
(d) All pins and wedges from the panels identified for striking.
(e) Care must be taken when removing pins and wedges on the external and void areas, especially on the safety
issue. Also, considerable amount of pins and wedges can be lost over a short period of time due to
inadequate care taken when removing.
Ensure commencement of work on the thickest walls first, therefore enabling commencement of extracting the wall ties as
soon as possible. The wall ties can be removed before the removal of the formwork. The sooner they are extracted from the
wall, less force required and less time consuming.
External walls are also critical to enable the progress of installing the scaffold bracket for placing of the formwork on the
next level. While removal of the wall ties is in progress ensure they are kept neatly in an appropriate area where they can
be prepared for the next level.
As soon as the removal of the wall ties is progressing then removal of the wall formwork can proceed.
The removal of the wall panels starts from the top of the wall panel. Insert the 16mm lug on the panel puller into the top
hole of the standard wall panel. Apply downward pressure on the side rail of the wall panel and it will start to break free.
Move to the opposite side of the wall panel and apply pressure. The wall panel will break free from the concrete face
allowing the panel to pivot away from the concrete face. This procedure ensures the wall panel will break free from the wall
with minimum of ease. Do not open the wall panel from the middle or bottom areas as this can damage the wall panels.
All components must be cleaned as soon as they are removed. The longer the cleaning process is delayed, the more difficult
it will be. Wall panels, are designed to be removed by pulling the top of the panel away from the concrete where a rocker is
fitted.
The wall heel at the bottom of a panel enables the panel to pivot about a point against the concrete slab. Where the wall
formwork is pinned to a kicker, the panels are removed by pulling the bottom away first.
The first panel in a row is the most difficult to remove as it is also held by the adjacent panels. If properly cleaned and oiled
prior to concreting and using the panel pullers provided, the panels will come away with ease. The remainder of the wall
panels on this wall will strike easily by breaking the bond to the adjacent panel using the panel puller as mentioned above.
To strike internal corners the wall ties are removed first as the wall ties prevent the removal of the internal corner.
As the wall panels are being removed, removal of the wall ties will have commenced. The same situation applies to the
sleeves as the removal of the wall ties, the sooner they are extracted from the wall the less time consumed. Also less damage
will occur therefore maximum uses can be achieved per sleeve.
Sleeves are removed by using long nose pinch pliers. Ensure the sleeves are being stored in a proper container when removed
and returned to the preparation location as they can be prepared for the next use.
When moving the formwork to the next area, proper stacking of panels is a clear sign of a well-run operation. Stacking at
the right place and in the right order greatly benefits the following erection work, and prevents clutter that impedes all
activities.
Striking of the external walls also requires urgent attention to enable the installation of the working platform bracket.

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11. DIS-ASSEMBLE THE SLAB FORMWORK

Normally slab panels can be removed after 36 to 48 hours but in any event, concrete test cubes must be taken to ensure
concrete strength requirement is met. Striking times should be confirmed on a project, to project basis. The striking begins
with the removal of slab link. Remove the 132mm pairs of pins and the link bars from the link head, which has been
identified for removal. This is followed by removing the pins and wedges from the slab panels adjacent to the slab link to
be removed. The slab link can now be taken out.
As the first panel in a row rests on the support lip of the soffit length, the adjacent panel should be removed first. After
removing the pins and wedges from the panel to be removed, a panel puller can be used to break the bond from the adjacent
formwork.
Where there is no link beam supports and the panels, span from wall to wall, one wall will have the supporting lip of the
slab joint removed. Pins and wedges only to be removed on the identified component that is to be struck. Slab panels remain
in place longer than wall panels and will not come away easily unless proper cleaning and oiling is done during the erection
process. Panels should be cleaned immediately after striking. Consequently the sequence of striking should confirm to the
sequence of erection.
Prop lengths
Whenever the PL's are to be removed, use a heavy hammer to strike the bottom of the PL in the same direction as the beam,
while holding the PL with your other hand to prevent from falling.

Steel Adjustable Props

Whenever the steel props are to be removed, turn the handle clockwise by striking the ring of the handle. For quick release,
insert the podgier into the ring and turn clockwise along with the hinged handle and pull. At no time should you strike the
handle connected to the threaded ring with heavy tools as this may cause damage.

7
 SECTION (3) POST CONCRETE ACTIVITIES

12. CLEANING

Cleaning the formwork prior to the formwork assembly

Cleaning Form oil

During and after the concrete pouring During formwork assembly
Remove any concrete slurry from the back face of
Apply the form oil to the contact face and side rails of the
the formwork panels, using water.
formwork during each assembly. Take care not to contaminate
Immediately after stripping the formwork the reinforcement, M&E services and surrounding concrete slab.
Clean the formwork contact surface & side rails
with metal scrapers.

Function of long handle scraper

clean the contact face clean the side rail

Long handle scraper & small scraper

Important note:
Do not use wire brushes, rotating grinding disks,
or any type of abrasive material on the contact face
of the formwork during the assembly.

Do not use

8
13. TRANSPORTING
There are 3 basic methods recommended when transporting to the next floor level:-
(a) The heaviest and longest which is full height wall panels can be carried up the nearest stairway, or
(b) Passed up through void areas, or
(c) Raised through slots specially formed in the floor slab for this purpose. Once they have served their purpose they
are closed by casting in the concrete to close the opening.
Striking
Once cleaned and transported to the next point of erection, panels should be stored at the right place and in the right order.
Proper storing is a clear sign of a well-managed operation and greatly aids the next sequence of erection as well as preventing
clutter and impeding other activities.
14. REMOVING THE KICKER FORMWORK

Only the kicker pinned to the bottom of the wall panels should be removed. The top kicker will be used for starting the
wall formwork on the next floor level.

Once the wall panels are removed, disconnect the lower kicker by removing the cast in bolt. This leaves the kicker free to
be taken off and prepared for reuse i.e. cleaned and oiled. Ensure the cast in bolts are also cleaned by wire brush after each
use.
Each level of "kicker leap-frogs" up the building to the next level

9
 SECTION (3) POST CONCRETE ACTIVITIES

15. DIS-ASSEMBLE THE WALL MOUNTED WORKING PLATFORM BRACKET

The lower level of scaffold must be struck on the day of casting the floor above, and prepare for fixing the following day.

Safety should be the priority in everyone's mind during this operation; first principle is to ensure the working platform is
free from any debris.

One member of the team should be on the working level above to receive the material from the level below. Another team
member should be on the lower level and it is COMPULSORY this person wears an approved SAFETY HARNESS

The Safety Harness is attached to the bracket above, using a quick release shackle. The Safety Harness will be moved to its
next fixing point by the helper on the level above.

Remove the toe-board and decking, passing them to the helper above. This is followed by the removal of the handrail.

The scaffolders must ensure that no part or parts are left partially removed, as this will endanger themselves and their fellow
workers.

Another section of the team will follow behind to remove the scaffold brackets and the same crew will be responsible for
fitting the scaffold bracket on the next level.

As there are two complete levels of scaffold brackets, one team member will be on the upper level and another inside the
building on the level below. The worker on the upper level will require a rope attached to an S type steel hook which he
will hook to the scaffold bracket below.

The worker inside the building will then commence to unscrew and remove the tie nut, thus releasing the scaffold bracket,
and allowing the worker holding the rope on the upper level, to gently raise the rope while the tie rod is being gently knocked
through from the inside, until the bracket is completely free from the building. At this stage, the safety bracket is pulled to
the next level in preparation for fixing to the level above.

10
 SECTION (3) POST CONCRETE ACTIVITIES

16. ASSEMBLE THE WALL MOUNTED WORKING PLATFORM BRACKET

Before commencing the operation, ensure the following equipment has been procured:-

(a) Scaffold brackets and all the necessary fixings.

(b) Scaffold bracket, vertical safety post.
(c) Safety harness.
(d) Timber and all materials for the platform decking and handrails.

For the initial set up of the formwork and when using the wall mounted scaffold brackets, 20mm diameter holes require to
be drilled through the formwork to position the PVC sleeves, which when cast in the concrete, should be used for fixing the
scaffold brackets. This hole also accommodates the bolting up of the formwork to control the alignment at the kicker level.

As the external formwork is being removed, a team of allocated people working in pairs will commence erecting the working
platform. With the tie-rod through the hole provided in the working platform bracket, and using a small ladder, fix the
bracket by pushing the tie rod through the PVC sleeve, which is cast in the concrete. A helper inside the building can fix
and tighten the locking nut.

During this operation, the person on the external must have his safety belt secured to the kicker above. As this operation
progresses along the building, another pair of the team should follow, placing the decking, toe-board and handrails. One
person should remain on the lower platform and pass the decking to his helper on the upper level.

When working on the outside edge, safety equipment MUST be worn at all times.

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17. STEP BY STEP WORKING PLATFORM ASSEMBLY SEQUENCE
Step 1. Step 2.
Assemble all formwork on the 2nd floor in preparation for the Remove all vertical formwork on the 2nd floor after concrete
concrete works work has been completed. Approximately 24hrs

Step 3. Step 4.
Position the working platform bracket on the 3rd floor level and Fix the handrail supports, plywood walkway & toe board to the 3rd
secure in position with the tie rod and securing nut floor platform. Note: Safety harness must be worn during the
operation

Continued page.13

12
 Step 5. Step 6.
Repeat the process again by assembling the vertical formwork Remove the working platform bracket and supports from the 2nd
on the 3rd floor. Remove kickers from the 2nd floor level and floor and pass up to be stored on level 3 platforms. This operation
fix to the top of the 3rd floor level is to be carried out on the day of the concreting level 3 wall and
level 4 slab

Continued page.14
13
 Step 7. Step 8.
Remove all vertical formwork on the 3rd floor. (Concrete was Remove nuts from the tie rod on the 2nd floor working platform
poured on the previous day) bracket

Continued page.15
14
 Step 9. Step 10.
nd
Hoist the working platform bracket from the 2 floor up to the Position the working platform bracket on the 4 th floor level and
3rd floor (each bracket is approximately 16kg in weight) secure using the tie rod and securing nut on the inside of the
building.

15
 SECTION (4) MISCELLANEOUS

18. INSTRUCTIONS

Health and Safety

a. Do not carry out the following

Do not lay the bottom panel contact face down, when starting a stack
Do not drop the aluminium formwork from a height
Do not use wall panels as ramps, working platforms, bridges, ladders or scaffold
Do not use hammer and wedge to forcefully pull panels together
Do not drive the steel wedge until full length of panels are butted together
Do not use extreme hammer force when installing wedges
Do not erect formwork elements that are not properly cleaned and oiled (The slab panel contact faces are oiled after
assembling the formwork)

b. Health & Safety

1. Ensure all scaffold brackets are in good condition and have not been damaged since the last installation.
2. Ensure the working platform is fully decked out and the toe-board and handrail is properly installed.
3. Penetration holes in the slab for transferring panels must be covered when not in use until cast back with concrete.
4. Any workers working above the platform level must wear his safety harness attached to a secured life line.
5. When removing the timber supports from the concrete slab ensure no concrete nails have been left exposed.
6. Steel Pins and wedges are to be removed with care especially on the external of the building.
7. Take care when handling of the aluminium formwork equipment, components and accessories.
8. The formwork is not to be stored on the working platform.

16
19. DETAILS

On site activity teams

The work involved in using the aluminium system formwork is segregated into duties for specified teams of workers as
listed below. Each team is responsible for following the correct procedures as laid out in the previous sections.

a Formwork erection team (section 6 & 8)

b Formwork striking team (section 12 & 14)
c Working platform / safety team (section 17 & 18)
d Alignment team (section 5 & 9)
e Kicker team (section 9 & 16)
f Survey team (section 3 & 4)

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SLAB COMPONENTS

Slab panel
The slab panel rests between pairs of mid & end link
beams and provides a horizontal surface for concreting the
slabs.

Link head
The link head fits between the mid & end link beams. It
transmits the load through to the adjustable prop. The link
head and adjustable prop stay in position when the slab
panels and mid-link beams are removed. This provides
undisturbed back propping.

Mid-link beam
The mid-link beam fits onto the end of the link head using
2 No. link bars & 2 No. 132mm pins and wedges. The mid-
link beam provides support to the deck panels.

End-link beam
The end-link beam fits onto the end of the link head using
2 No. link bars, pins and wedges. The end-link beam
provides support to the deck panels at the perimeter of the
rooms.

Continued.page 18

18
 Slab joint
The slab joint fits on top of the wall panels and beam sides.
It provides support to the edge of the slab panels at the
perimeter of the rooms.

Link bar
The link bar(s) are used in pairs to fix the link heads, end-
link beam and mid link beam together. The link-bar is
removed after concrete work, this allows the quick drop
down removal of the slab formwork.

132mm long pin

The long pin is used in pairs with the link bars which
secures the link head, mid & end link beams together.

Standard 50mm stud pin

The standard 50mm pin is used to fix one component to
another.

Continued.page 19

19
 Slab corner internal
The internal soffit corner forms the vertical internal corner
between walls and / or beam faces and horizontal internal
corners between wall / beam face and soffit of slabs.

Slab external corner

The external soffit corner forms the vertical external
corner between walls and / or beam faces and horizontal
external corners between wall / beam faces and soffit of
slabs.

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WALL COMPONENTS

Wall panel
The wall panel forms the face of the wall from the top of
the wall heel to the bottom of the top panels.

Wall top panel

The wall top panel is used to form the wall face above the
standard wall panels.

Wall heel
The wall heel forms the wall face at the bottom of the wall
panels and helps to facilitate striking. The wall heel is
designed for the wall panel to pivot away from the concrete
wall.

Kicker
The kicker forms the wall face at the top of the wall top
panels. It is temporally anchored to the concrete and acts
as a ledge support for the wall panels on the next floor to
sit on. The kickers are manufactured with a 26mm slotted
hole on the contact face to allow for adjusting levels after
concreting.

Column neck
The column neck is used on columns and walls. It forms
part of the beam soffit. It connects to the column and wall
panels, and to the beam soffit formwork.

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BEAM COMPONENTS

Beam side panel

The beam side panel is used to form the beam sides.

Prop head for beam soffit

The prop head is used on the beam soffit and forms part of
the beam soffit. It connects to the steel prop and to the
beam bottom plate formwork.

Beam bottom plate

The beam bottom plate is used to form the soffit of the
beams.

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INTERNAL AND EXTERNAL CORNER WALL & SLAB COMPONENTS

Slab corner
The internal slab corner forms the vertical internal corner
between walls and / or beam faces and horizontal internal
corners between wall / beam face and soffit of slabs.

Slab external corner

The slab external corner forms the vertical external corner
between walls and / or beam faces and horizontal external
corners between wall / beam faces and soffit of slabs.

Corner joint
The internal corner joint connects 2 pieces of vertical wall
panels together at their internal intersection.

Continued.page 23

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 External angle vertical
The external angle connects 2 pieces of vertical formwork
together at their external intersection.

External angle horizontal

The external angle connects 2 pieces of horizontal
formwork together at their external intersection to form
right angles.

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 TYPICAL WALL AND SLAB ASSEMBLY DETAIL

The drawing below shows the layout of formwork at the top of the wall. The slab panels rest on the lip on the soffit joint
and span onto the end-links. The opposite sides of the wall and the end-links have been omitted for clarity.

SLAB CORNER
SLAB PANEL

SLAB JOINT WALL PANEL

TOP PANEL

CORNER JOINT

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PANEL PULLER OPERATION FOR STANDARD WALL PANEL HEIGHT
2100 AND 2600

PANEL PULLER

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 DROP DOWN SLAB SOFFIT REMOVAL DETAIL

The components shown here are the link heads, pins and wedges, link bar and mid-links. The pins and wedges are removed,
which in turn release the link bars. Once these have been removed, the mid-link and panel can drop down be leaving the
link head undisturbed and secure as back propping.

LINK BAR MID LINK LINK BAR

LINK HEAD LINK HEAD

BEFORE REMOVAL

LINK BAR MID LINK LINK BAR

LINK HEAD LINK HEAD

AFTER REMOVAL
Early removal of the slab formwork can take place when the concrete has reached a strength of 10N/mm2

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STAGE 1 TO 4 OF THE BEAM ASSEMBLY DETAIL

The first stage of erecting the beam and slab formwork is to connect the link head to the steel prop. The beam bottom plate
panels are then connected to the prop head using the pins and wedges.
Step 1. Step 2.
Adjust the steel prop to the desired height and Connect the internal and external beam side panels to the
connect the beam bottom plate beam bottom plate

Step 3. Step 4.
Connect the external kicker component and the slab Secure the slab panels to the slab joint component
joint component onto the external & internal beam
side panels

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FORMWORK SLAB TRANSFER BOX DETAIL

This detail shows a typical slab box used at the slab area. The box-out is used to form an opening in the slab to allow easy
handling of formwork components and accessories to the next floor. Similar boxes can be fabricated to any dimension to
form other openings in the slab.
Note: In some countries this method cannot be used due to the environment. Also, the slab box-out method can only be
used on the approval of the Resident Engineer.

Step 1. Step 2.
Box fixed to the slab formwork Box removed after the concrete work

Step 3.
Passing formwork components up through the
opening in the concrete slab Technical information for transfer box

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DELIVERY OF FORMWORK EQUIPMENT TO THE PROJECT

All Alform System components are delivered to the project, palletized, project coded, banded & plastic wrapped

30
FORMWORK ASSEMBLY DETAILS
Alform aims in using modern construction techniques and equipment in all its projects. On leaving the factory all panels are
clearly labeled to ensure that they are easily identifiable on site and can be smoothly fitted together using the formwork
modulation drawings. All formwork begins at a corner and proceeds from there. Refer to fig 1.

EFFICIENT QUICK DROP DOWN SLAB BEAM SYSTEM

One of the principal technical features which enables this aped to be attained using a single set of formwork panel 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 resumed immediately. Refer to fig 2.

Fig 1. Fig 2.
Wall assembly Drop down slab beam assembly

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THE SLAB PANELS AND DROP DOWN BEAM WITH SUPPORTS DETAILS

End links, mid links, link heads & beam length components Completed slab
Assembly of fixed prop lengths supporting the aluminium formwork panel made from high strength aluminium alloy, with the face
or contact surface of the panel, made up of 4mm thick plate, which is welded to a formwork of specially designed extruded sections,
to form a robust component

Slab with slopped beams Steel prop supports giving clear access

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SIMPLICITY USING THE QUICK RELEASE PIN AND WEDGE SYSTEM

The panels are held in position by a simple pin and wedge system that passes through holes in the outside rib of each panel.
The panels fit precisely, simply and securely and require no bracing. Buildings can be constructed quickly and easily by
unskilled labour with hammer being the only tool required. Once the panels have been numbered, measuring is not
necessary. As the erection process is manually, tower cranes are not required. The result is a typical 6 8 - 10 day cycle for
floor-to-floor construction.

Pin & wedge at wall panel intersection Pins & wedges at various points

50mm STUB PIN 132mm LONG PIN

The pin is used to fix one component to another. The long pin is used in pairs to connect the link head, end link &
mid link beams.

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METHOD OF ASSEMBLING THE WALL FORMWORK
It is important maximum efficiency to define a sequence of erection is followed by each team. One side is erected using
only an upper and lower pin and wedge connection. Later, ties are inserted at the other connections and fixed with pin and
wedge. Then the previously installed pins are removed and those ties inserted and pinned. Subsequently, panels for the other
side are inserted between the existing ties and fixed with pins and wedges.
WALL ASSEMBLY OF SIDE 1 & SIDE 2 CLOSED

Typical one side wall setup during assembly Typical completed wall after assembly

20. SETTING OUT GUIDELINE

Setting out lines should continue through openings, corners where possible etc., by a minimum of 150mm. Metal studs can be used
to keep the walls or columns in position during assembly as this ensures the walls or columns are in the correct position prior to
concrete work. Note: in some case metal studs may have to be treated with a non-rust treatment.

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21. FORM OIL

BASIC INFORMATION FOR THE APPLICATION OF FORM OIL (OIL BASED)

Aluminium form contact surfaces that are to be made bond free should be clean before applying the form oil. Remove any
previous buildup of concrete laitance, residue, scale, rust and dirt, and repair any dents from previous use before applying
the form oil. The form oil is ready to use direct form its container. Do not dilute. It can be applied by brush, roller or spray
onto the forms. The form oil must be applied to the contact face and side rails of the wall components prior to assembly and
applied to the slab and beam formwork prior to the installation of the reinforcement. However the form oil must be kept off
the reinforcement and any other embedments, spray application must be done with care when forms and rebar are already
in place. Form oil can be effective for up to 24 hours before concrete is poured. Apply uniformly and ensure you leave no
gaps. The aluminium forms must not be dry prior to pouring concrete.

NOTE: Alform do not recommend the use of water based form oil applied on the Alform formwork system.

22. STEEL ADJUSTABLE PROPS

a) Steel adjustable props can be seen on many construction sites and are used to support a structure or transfer a load. Steel
props are typically used to support concrete formwork while the concrete is curing. They are easy to position and are fully
adjustable with in the height range of the prop.
b) Steel props consist of two circular steel tubes, an inner tube with a top plate that slides up and down freely inside an outer
tube which is attached to the base plate. The inner tube has holes down its length so that you can quickly extend the inner
tube to just below the desired height and insert a steel pin to lock in that length. To extend the prop to the correct height the
top of the outer tube has a threaded collar, which is similar to a nut on a bolt, this supports the steel pin. So by rotating the
collar and moving it up it extends the inner prop. This allows you to achieve the exact height required.

PLACING THE CONCRETE IN THE FORMWORK

Maximum strength and durability and better appearance result in the situation where concrete, after placing, is homogeneous
throughout its mass. To bring this situation about it is necessary that the people on the job know the following proven and
simple principles of placing, and they ensure they dont depart from them.
Mixes, when placed, should contain the minimum amount of water necessary for workability.
Concrete should not be dropped free more than 1.5 metres.
Baffles should be placed to direct the flow of concrete coming from tipped buggies, or chutes, into downpipes at
least 600mm long (except where extended truck chutes are discharging concrete directly into shallow forms).
Concrete should be placed directly into corners and ends of forms and generally any flow of concrete should be
from the corners and ends rather than towards them.
In slab construction, concrete being poured into a form should be poured against the concrete already in place, not
away from it.
In wide but deeper forms, place concrete so that the forms are filled in fairly shallow layers, compacting each layer
carefully.

35
NOTES AND COMMENTS

36