FORMWORK TECHNOLOGY IN HIGH-RISE BUILDING ITS COST AND QUALITY ANALYSIS

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 05 | May 2023 www.irjet.net p-ISSN: 2395-0072
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 1749
FORMWORK TECHNOLOGY IN HIGH-RISE BUILDING ITS COST AND
QUALITY ANALYSIS
Ar. Swetha. D1, Ar. Radhika2
1 Post Graduate Student, M. Arch – Construction Project Management, Faculty of Architecture, Dr. MGR
Educational and Research Institute, Maduravoyal, Chennai
2 Head of the department, M. Arch – Construction Project Management, Faculty of Architecture, Dr. MGR
Educational and Research Institute, Maduravoyal, Chennai
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - This paper describes about the formwork
technology used in high- rise building suitable for Indian
construction. By utilizing new technologies in formwork,
construction can now achieve the casting oflargerelements in
a single pour. This advancement not only minimizes time and
labor needed but also outperforms conventional methods.
Formwork technology is based on the cost, time, andqualityof
project delivery. The study is about advantages of aluminium
formwork and tunnel formwork with conventional system in
terms of cost and quality analysis. Traditional approaches
can’t keep up the demand of infrastructuralfacilitieswith high
degree of quality control & assurance. Case studies with two
different technology is done, its cost and duration are
compared. This study is focusses on the two different
conducted on a construction site in Chennai. Further, the real
time cost duration and labor savings in the use of aluminium
formwork is demonstrated in a G+21, 8 tower building.
Key Words: Aluminium formwork, cost, tunnel formwork,
comparison of quality analysis, economy, time saving.
1. INTRODUCTION
Formwork in construction refers to the utilization of
supportive structures and molds to shape concrete into
desired structures. Concrete is poured into these molds,
which can be constructed from various materials such as
steel, wood, aluminum, or pre-made forms. A range of
material options is available for constructing the formwork.
The selection of formwork material is based on various
factors, including cost, project requirements, and the type of
structure involved. This study is to compare conventional
with aluminium and tunnel specifically related to high rise
building
1.1 TYPES OF FORMWORKS:
Timber has been the prevailing choice of material for
formwork thus far. Nonetheless, due to diminishing forest
reserves and escalating timber costs, the adoption of
alternative materials like plywood and steel has gained
prominence. Moreover, plastics and fiberglass haverecently
emerged as viable options for prefabricating formwork. The
selection of material depends on factors such as the
construction's characteristics, material availability,andcost.
Additionally, project constraints such as overall cost and
completion time significantlyinfluencethechoiceofmaterial
for formwork. Timber, Steel Aluminum, Plastics, Fabric are
common materials used in formwork. The formwork used in
high-rise construction are timber, aluminiumformwork and
tunnel formwork.
1.2 ALUMINIUM FORMWORK:
The utilization of an aluminum formwork system enhances
the construction's quality while simultaneously reducing
both time and costs. The cost-effectiveness of the formwork
becomes evident when it is utilized for numerous
construction cycles. As aluminium can be used around 250
repetations. The primary drawback of aluminum
forms is that once the formwork is manufactured, no
changes can be made. The system typically operates on a
four-day cycle, as outlined below:
Day 1 - The initial task involves erecting vertical
reinforcement bars and one side ofthevertical formwork for
either an entire floor or a portion of a floor.
Day 2 - The subsequent step entails erecting the secondside
of the vertical formwork and installing formwork for the
floor.
Day 3 - Involves the placement of reinforcementbarsforthe
floor slab and the casting of walls and the slab.
Day 4 - The vertical formwork panels are removed after 24
hours, while the support props remain in place for seven
days, and the floor slabs formwork remains in place for 2.5
days.
1.3 TUNNEL FORMWORK:
A tunnel is a specially fabricatedstructure madeofstructural
steel, designed in the shape of an L and resembling a half-
room in size. Its primary function is to facilitatetheseamless
pouring of reinforced concrete (RCC) walls and floor slabs,
allowing them to form a unifiedanduninterruptedstructure.
Two half tunnels are combined to create a full tunnel with
dimensions equivalent to that of a room. This innovative
approach ensures efficient construction with a focus on
speed, quality, and precision whileofferingtheadvantagesof

on-site construction, flexibility, and cost-effectiveness. The
slab cycle for this system is 24 hours. However, it should be
noted that each tunnel is custom-made and highly modular,
limiting the possibility of design changes.
Figure 1 Tunnel Formwork Process
2. METHODOLOGY:
The study is to identify the different types of formworks
used in high-rise building. The literature and net study are
done to collect data about the most efficiently used
formwork in high-rise. Comparative study is done between
aluminium, tunnel and conventional formwork. For the
proposed site aluminium formwork is implemented,itscost,
quality and time schedule analysis are done and the end
results are compared with conventional formwork
technology.
3. LITERATURE REVIEW:
The review of journal papers involves a comparison of
different types of formwork for high-rise buildings. The
study suggests that, in terms of cost and availability,
aluminium formwork is well-suited for construction sites in
India. This is due to its design flexibility, minimal machinery
usage, and the ability to utilize unskilled labor, despite
having fewer repetitions compared to tunnel formwork. In
contrast, tunnel formwork necessitates heavy machinery, a
significant initial investment, and skilled labor.
Consequently, the aluminium formwork is economically
advantageous for high-rise building projects in India.
ACTIVITY CONVENTIONAL ALUMINIUM TUNNEL
Capital cost less
Cost of
shuttering
material is
high
Cost of
shuttering
material and
other related
machinery is
very high
Speed of
work
slow fast fast
Accuracy and
Quality of
construction
less Good
accuracy
Good
accuracy
Internal/exte
rnal
Plastering
required
required Not required Not required
Cycle time of
RCC work
20 days 10-15 days 1 day with
proper
infrastructur
e and other
ancillary
machineries
No of
repetition of
shuttering
material
12-15 200-250 500
Cost of
shuttering
Around Rs 400
to 500 / Sq.ft of
shuttering floor
area
Around Rs
8000 to
10000 /Sq.ft
of shuttering
floor area
Around Rs
12,000 to
14,000 / Sq.ft
of shuttering
floor area
3.1 CASE STUDY 1:
The project involves the construction of a high-rise
residential building on a 3.88-acre site, consisting of 6
towers, 2 basements, stilt, and G+21 floors. The total project
cost amounts to 218.72 crores, employing an aluminium
formwork system.
For this project, the shear walls are 200 mm thick, while the
non-shear walls are 10 mm thick.Theformwork isfilledwith
self-compacting concrete to fill the voids [4]. By utilizing
thinner wall sections, the usable area is increased by
approximately 5% through the adoption of shear wall
systems. Additionally, maintenance costs arereduceddueto
improved quality and the elimination of brickwork and
plaster [5]. All services are pre-planned, and the cost of
construction for one floor, includingtheprovisionandlaying
of RCC M-30, self-compacting concrete, steel reinforcement,
and aluminium formwork, amounts to 44,00,258
The construction time schedule for each floor using the
aluminium formwork system is 620 days. The floorcycle is4
days per floor, employing a box-type framework structure.
The dimensional accuracy is high, and the surface finish
allows for direct painting after putty application. From an
economic perspective, the fund flow associated with the
aluminium formwork system is favorable. The waste
production when using aluminium formwork is moderate,
and the formwork can be repeated up to 200 times.

Figure 2 Site Map
3.2 CASE STUDY 2:
The project entails the construction of a high-rise residential
building on a 3.88-acre site, comprising 3 towers with G+18
floors. The total project cost amounts to Rs. 117,32,17,750,
employing the tunnel formwork system.
Considering the project's location in the bustling premium
residential hub of Chennai metropolitan city, three distinct
unconventional formwork technologies have been adopted
to leverage their specific advantages [11]. While tunnel
formwork allows for the construction of large, multi-story,
and cellular structures [9],theproject'scostincreaseddueto
the utilization of expensive equipment and skilled labor.
However, tunnel formwork lacks the design flexibility
necessary for incorporating basement floors in the towers,
making it less preferable for efficient high-rise building
construction when compared to aluminium formwork.
4. PROJECT PROPOSAL: DOSHI RISINGTON:
The proposal for Phase 2 construction in DOSHI RISETON
suggests the utilization of aluminium formwork, as outlined
in the provided table. The conventional construction
approach for Phase 2 involves approximately 10 towers,
encompassing 2 basements, stilt, and G+21 floors.
By adopting the aluminium formwork system, different
design phases within each tower can be efficiently executed.
The estimated time duration for the conventional method is
around 3 years, whereasaluminiumformconstructionoffers
the advantagesofhigh-qualityconstruction,increasedspeed,
and reasonable cost [5]. This technology holds significant
potential for addressing India's growing population's need
for affordable housing.
Moreover, the number of repetitions with aluminium
formwork increases, making the initial investment more
profitable [5]. Unlike the conventional method where the
number of repetitions is lower, leading to an increase incost
per square meter after the 16th floor slab cycle. This
includes rising costs for shuttering formwork, brickwork,
and plastering. The break point forthe aluminiumformwork
occurs after the 16th floor of the tower, and repetitions
continue for the remaining part of the tower, ensuring a
profitable initial investment..
Figure 3 Cost Analysis
Time schedule for 1 floor using aluminum formwork:
INSTALLATION OF ALUMINIUM OF PRE-CONCRETE
ACTIVITIES
SI.NO PROCESS
DURATION
(HOURS)
1 level surveys 5
2 setting out data 5
3 control of deviations 5
4 enforcement wall panel 15
5
enforcement column
panel 5
6
enforcement staircase
panel 3
7 enforcement beam level 10
8 enforcement slab level 20
9 setting kickers 10
10
lay oil at the panel &
kickers 9
ERECTION OF ALUMINIUM OF POST-CONCRETE
ACTIVITIES
11
erection wall and column
panel 10
12
erection beam and slab
panel 15
13
clean, transport and stack
panel 10
14 erection of kickers 10
TOTAL DURATION 132

The duration for 1 floor of 870 Sq.m is 132 hrs. using
aluminium formwork.Ittakesabout126daysapproximately
to complete tower A.
Time schedule for 1 floor using conventional formwork:
INSTALLATION OF CONVENTIONAL
FORMWORK OF PRE-CONCRETE ACTIVITIES
SI.NO PROCESS
DURATION
(HOURS)
1 level surveys 15
2 setting out data 5
3 control of deviations 10
4
enforcement wall
wood 150
5
enforcement column
wood 80
6
enforcement staircase
wood 60
7
enforcement beam
wood 75
8
enforcement slab
wood 75
9
setting- up other
components 100
10
lay oil at the panel &
kickers 25
ERECTION OF CONVENTIONAL FORMWORK OF
POST-CONCRETE ACTIVITIES
11
dismantle wood
column 15
12 dismantle wood wall 50
13 dismantle wood beam 20
14 dismantle wood slab 40
15
dismantle other
components 25
16 clean up leftovers 20
TOTAL DURATION 765
The duration for 1 floor of 870 Sq.m is 765 hrs. using
conventional formwork. It takes about 651 days
approximately to complete tower
5. CONCLUSIONS
The aluminium formwork presents a favorable option for
achieving timely completion of construction with maximum
efficiency. Gathering information from literature and case
studies will prove beneficial for selecting the appropriate
formwork in future projects. Additionally, this approach
helps minimize construction waste associated with
formwork usage.
Although the aluminium system formwork incurs a higher
initial cost, it demonstrates its cost-effectiveness when the
number of repetitions falls between 150 and 200 in the
construction of high-rise buildings. In contrast, employing
contemporary conventional formwork, which is the least
expensive type and requires moretime,resultsinthehighest
total expenditure. For the proposed site, utilizing
conventional formwork leads to a 25% reduction in both
cost and time.
6. REFERENCES
[1] Prof. Zen Raut, Mayur S. Meshram Analysis and
Comparison of Mivan Formwork System with Conventional
Formwork System
[2] Mayur Sanjay Lodha Comparative Analysis of
Conventional Formwork and Mivan Formwork based on
Duration and Cost
[3] Jaya Surya R Evaluation of Different Kinds of Formwork
Systems in Indian Construction Industry
[4] Danish Sadruddin Ansari, COMPARATIVE STUDIES OF
CONSTRUCTION TECHNIQUES (CONVENTIONAL
TECHNIQUE VS ALUMINIUM FORMWORK TECHNIQUES)
[5] Ar. Sowndharya ANALYISING ADVANCED FORMWORK
SYSTEM FOR HIGH RISE BUILDING CONSTRUCTION
[6] Loganathan ALUMINIUMFORMWORKSYSTEMUSINGIN
HIGHRISE BUILDINGS CONSTRUCTION
[7] Miss Manik Moholkar Productivity Analysis of Building
Construction Using Mivan Formwork June 2019 | IJIRT |
Volume 6 Issue 1 | ISSN: 2349-6002
[8] Miss. Renuka Hangarge Comparison of Conventional,
Aluminium and Tunnel Formwork
[9] Vallabhy .S Advanced Technology for Speedy
Construction (Tunnel Formwork)
[10] Asst. Prof. A. R. Chavan A REVIEW ON FAST TRACK
CONSTRUCTION USING MODERN FORMWORK SYSTEMS
[11] Mr. Manas A. Shalgar IntroductiontoadvancedTUNNEL
Formwork system: Case study of ‘Rohan - Abhilasha’

FORMWORK TECHNOLOGY IN HIGH-RISE BUILDING ITS COST AND QUALITY ANALYSIS

More Related Content

Similar to FORMWORK TECHNOLOGY IN HIGH-RISE BUILDING ITS COST AND QUALITY ANALYSIS (20)

More from IRJET Journal (20)

Recently uploaded (20)

FORMWORK TECHNOLOGY IN HIGH-RISE BUILDING ITS COST AND QUALITY ANALYSIS