Common Problems With Aluminum Formwork And How To Fix Them

Formwork systems made of high-grade aluminum are now widely used in large-scale construction projects. It is way better than traditional (timber, steel) formworks in several ways, compelling construction businesses to choose it. Aside from its high reusability and lightweight aspect, aluminum formwork contributes significantly to the efficiency of a project.

But, similar to other construction-related systems, alu-form also has its own set of challenges. It is essential to have a clear understanding of the common problems with these shuttering systems and the best solutions. Completing a construction project on time is possible because of the several beneficial aspects of aluminum-based formworks.

Deformation and Warping

Aluminum panels often warp and sustain deformation due to excess heat, insufficient support when casting, and improper handling. Expensive rework is certain when builders use warped aluminum panels. The reason is that these formworks can’t create a flat, flawless concrete surface. So, it is essential to handle these aluminum shuttering systems in a meticulous manner and store them in a proper place.

To combat wet concrete’s pressure during casting, ensuring the formwork is appropriately braced and supported is imperative. It’s advisable to opt for using wall ties and adjustable props. If a panel warps, a qualified technician may be able to rectify small deformations using light pressure and heat. But, to preserve the final structure, replacing the panels that sustain extreme damage is a must.

Leaking Seams and Joints

One of the common problems with aluminum shuttering systems is leaking seams and joints. Therefore, the issue of finning happens — seeping of wet concrete through gaps. That’s the reason the final concrete surface has ridges. Improper fit right between panels, as well as loose fasteners or clamps, cause these typical leaks.

Performing a thorough check is necessary before every pour. Builders must look for damage signs in all panels and properly seat the sealing gaskets. In addition, making sure a secure connection between the aluminum panels is a must. Applying a foam strip or sealant to each joint can help make a watertight barrier.

Rough Concrete Surface

Typical issues like rough or powdery concrete surfaces often arise when builders work with aluminum formwork systems. This problem occurs due to the inadequate application of the release agent, preventing the wet concrete from properly sticking to the panels. The concrete tends to stick to the formwork made of aluminum if builders apply it thinly or unevenly.

The answer is to use a sprayer to evenly and sparingly apply a premium, non-staining, releasing agent. Air cavities in the concrete surface are another frequent problem. These happen usually because of insufficient concrete vibration. To remedy this, using a poker vibrator can help remove the air trapped thoroughly and methodically.

Final Words

Proactive problem-solving and attention to detail are critical to the effectiveness of formwork systems made of aluminum. Construction businesses can fully utilize the advantages of this cutting-edge approach by resolving typical problems. It’s advisable to harness the potential of sturdy, reusable, modular plastic shuttering systems that Nova Formworks manufactures. These formworks are instrumental in speeding up a construction project and protecting the environment.