KNEST ALUFORM

KNEST MANUFACTURERS LLP

METHODOLOGY
 About Us
• Knest Aluform Solutions LLP was established in the year 2014.
• The promoters of the company having a wide range of
experience in various other industries started research &
development on aluminum formwork by assembling a team of
technical experts with years of experience in aluminum
formwork.
• Modular Aluminum Formwork is prefabricated aluminum
extrusion formwork panels customized to suit the
requirement of the project as per GFC Architectural &
Structural Drawings. It facilitates faster monolithic
construction.
• Basic element of Modular Aluminum Formwork is a panel
which is a framework of extruded aluminum sections welded
to an aluminum sheet.
• It is a lightweight panel with an excellent stiffness to weight
ratio, yielding minimal deflections under concrete loading. 2
 Aluform Components FR

Wall Panel (W) Deck Panel (D) Beam Side Panel Kicker (K) Rocker (RK)

Beam Prop Head SBE/PCE (Plate Cover) Deck Prop (DP) Mid Beam (MB)
(BP) WRB 3
 Aluform Components FR

SC

Slab Length (SL) Joint Bar/ Beam Bar (JB) Slab Corner External

Staircase Accessories
Kicker LS Internal Corner (IC)

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 MS - Components FR

Wall Tie Pin & Wedge Long Pin Transfer Box

Wingnut VS Tube L Bracket Tie Rod

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Note : Only items mentioned in Agreement is in Knest Scope rest all essential Items to be arranged by client
 MS - Components FR

Alu form Bracket Type A Alu form Bracket Type B Alu form Bracket Type C

Push Pull Prop Alignment Waller/ Square Tube

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Note : Only items mentioned in Agreement is in Knest Scope rest all essential Items to be arranged by client
 Fixing & Removing Tools FR

Panel Puller Wall Tie Remover Nose Plier Adjustable Wrench

Hole Bari Panel Cleaner Ring Spanner

Note : Only items mentioned in Agreement is in Knest Scope rest all essential Items to be arranged by client 7
 Consumable Items FR

Kicker Nut & Bolt Wall Tie Sleeve Wall Tie (PVC Sleeve) PVC Sleeve Cover
With Washer & Cover

Tie Rod Tube Tie Rod Cone

(PVC) (PVC)

Note : Only items mentioned in Agreement is in Knest Scope rest all essential Items to be arranged by client 8
 Consumable Items FR

Permanent Marker/ Pencil Line Dori Marking Powder

Multi Purpose Roller Brush Shuttering Oil Sprayer Shuttering Release Agent
Grease

Cotton Clothes
(Waste)

Note : Only items mentioned in Agreement is in Knest Scope rest all essential Items to be arranged by client 9
 Power Tools FR

Sr. No. Item Specification

1 Spanner 18*19 D/E & Ring
2 Spanner 20*22 D/E & Ring
3 Spanner 24*27 D/E & Ring
Ring Spanner Drilling Machine Double End Spanner
4 Spanner 30*32 D/E & Ring
5 Drilling Bit 6 MM
6 Drilling Bit 16.5 MM
7 Drilling Bit 20 MM
8 Drilling 13 MM
M/C
Drilling Bits 9 Holsa 16.5 MM
High Pressure Cutter & 20 MM
Water Jet Bits Size
Cleaner Step Drill Bit 10 High
Pressure
Water Jet
Note : Only items mentioned in Agreement is in Knest Scope rest all essential Items to be arranged by client Cleaner 10
 Safety Items FR

Safety Shoes Safety Belt Gloves

Safety Helmet

PPE Ladder
Stand
Note : Only items mentioned in Agreement is in Knest Scope rest all essential Items to be arranged by client 11
 Material Required Quantity FR
Sr. Accessory Name Unit Quantity
No.
1 Round Pin Nos. 12 Numbers /Square Meters Typical
One Floor
+ Extra 10%
2 Wedge - 70 X 3 mm Nos. 12 Numbers /Square Meters Typical
One Floor
+ Extra 10%
3 Long Pin Nos. Typical One Floor (As per design)
4 Reusable Wall Tie Nos. Typical One Floor (As per design)
5 Reusable PVC Sleeve (Supplies to be Nos. Typical One Floor
made in form of Corrugated (As per design) + Extra 10%
Polypropylene Sheet)
6 Polythene Roll Nos. Typical One Floor
(As per design) + Extra 10%
7 Kicker Bolt Nos. Typical One Floor (As per design)
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 Material Required Quantity FR

Sr. Accessory Name Unit Quantity

No.
8 Kicker Nut (GI Coated) Nos. Typical One Floor (As per Design)
9 RK Bolt (GI Coated) Nos. Typical One Floor (As per Design)
10 RK Bolt (GI Coated) Nos. Typical One Floor (As per Design)
11 Adjustable Waler Bracket Nos. Typical One Floor (One Level)
12 Alignment Waler (Square Tube) Nos. Typical One Floor (As per design)
13 Kicker Soldier Nos. Typical One Floor
(As per design) (One Level)
14 Wall Tie Puller Nos. 1 Piece/ 400 Square meter
15 Panel Puller Nos. 1 Piece/ 400 Square meter
16 Hole Bari Nos. 1 Piece/ 400 Square Meter.

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 Material Required Quantity FR

Sr. Accessory Name Unit Quantity

No.
17 Slab Transfer Box Nos. 1 Piece/ Flat

18 Adjustable MS Prop Nos. Typical Two Floor (As per Design)

19 Push Pull Prop Nos. 1 Piece/ 10 Square Meters
20 External Bracket Nos. Typical two Floor (As per Design)

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 FR
Material Unloading on Site
1. MS material is dispatched on Pallets,
1. Aluminum material is dispatched on Bundles & sometimes loose from our
Pallets & Bundles from our Factory. Factory.
2. All the Pallets & Bundles must be 2. All the Pallets, Bundles & specially
properly verified at the time of Loose material must be properly
unloading. verified at the time of unloading.
3. The Pallets/ bundles must be opened 3. The Pallets/ bundles must be opened
in presence of Knest Representative. in presence of Knest Representative.
4. However if pallets are opened in 4. However if pallets are opened in
absence of our representative & absence of our representative &
material is found short we bear no material is found short we bear no
responsibility for same. responsibility for same.
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 Aluform sequence FR

1. Initial preparation from jobsite 12. Monolithic Construction

2. Alu-formwork - man power analysis a) Walls
3. Rebar fabrication manpower analysis b) Columns
4. Form oil c) Beams
5. Plastic and concrete cover block. d) Slabs
6. Do’s & Don’ts e) Central Core
7. Master drawing list – code f) Staircase
8. Checklist before concrete casting 13. Sequence of Activities on Site
9. Concrete pouring 14. Dismantling
10. Panel cleaning 15. Refurbishment
11. Setting drawing 16. Refurbishment - Before & After

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 Materials , Preparation , Division of FR
labor
Materials Verification Preparation Division of labor

✓ Checklist
1. Accessories 1. Setting out drawings 1. Erection team
2. Corners (I/C, hunch) 2. Packing list 2. Dismantling team
3. EC, ECH, ECX 3. Setting of nearest Aluform Materials 3. Flat-tie puller team
4. Standard wall panels 4. Setting Do’ & Don’t order 4. Formwork lifting team
5. Non-standard wall panels 5. Fixing & removing Tools 5. Panel oiling application team
6. Consumables 6. Collector , House Keeper
6. Deck panel 7. Form oil user manual
7. Beam panel 8. Cover Blocks
8. SC,SCE 9. Checklist before & After
9. EB, MB, CC concrete casting
10. Plate Covers (SBE, PCE) 10. Concrete pouring
11. Stoppers (WXSE, WRB) 11. Refurbishment – Tools
12. Standard slab panels
13. Non-standard slab panels

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 Manpower Analysis FR

Aluform System
Productivity per Man Day – 8 Sq. m / For 1st slab Productivity per Man Day - 4 Sqm

Rebar fabrication manpower

Productivity per Man Day – 80 Kg/ Man day

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 Form Oil User Manual FR

➢ Recommended Form Oil

✓ REEBOL ✓ Sika®-Form Oil

A coverage between 40 to 60m² per The coverage rate for Sika- Form Oil is
liter is possible depending upon 40 to 50 m² per liter . The consumption
application. is dependent on application.
✓ RHEOFINISH® 202 ✓ SETRELEASE RTU MOULD RELEASE
The coverage rate for RHEOFINISH 202 AGENT
is 30 to 70m² per liter when spray The coverage rate for SETRELEASE RTU
applied depending on application. covers 22 to 30m² per liter.

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 Form Oil User Manual FR

➢ Notes on Application / Limitations

• The molds should be dry and clean. • After application the concrete can be
• Any residues of rust and concrete placed immediately without any
must be removed. waiting time.
• Form oil is applied in thin layers, • Before concreting preliminary test
covering the complete surface (a are recommended to optimize the
second application may be necessary procedure for each project.
incase of highly absorbent
formwork).
• We recommend the use of a special
spray gun with an operating pressure
of 3-6 bar and a flat spraying nozzle

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 Cover Blocks FR

➢ Cover blocks Spacing Requirement

Sr. No. Member Requirement Remarks

1 Slab Min 2 Nos. / Sq. m.
2 Wall 4 Nos. / Sq. m.
3 Column 4 Nos. @every 1.0 m c/c
4 Beam Min 3 Nos. @every 1.50 Nos. Depends
m c/c upon the beam
Size Column
Reinforcement

Slab Wall
Reinforcement Reinforcement

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 Do’s & Don’ts (For Casting) FR

Do’s Don’ts

✓ Proper placing of cover blocks. × Without Proper placing of cover blocks

✓ Proper rebar tying. × Without Proper rebar tying in
✓ Proper Layer wise concrete pouring & × Without Proper Layer wise concrete
placement. pouring & placement.
✓ Wooden malting during concrete × Without Wooden malting during
operation. concrete operation.
✓ No slurry leakage – Apply proper × Without mortar at base (Slurry
mortar at base. leakage)
✓ Proper curing in next level.

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 Master drawing list – Code FR

• RK • SP-IC • CC • PC
• W • ICB • SX • PLB
• WRB • EC • SL • K
• WRBS • B • SC • KC
• T • SB • SLWL • JL
• TS • BP • LS • JR
• WX • CP • LSC • MB
• IC • DP • LSCE • EB

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 Checklist before Concrete Casting FR

➢ Before pouring concrete, Ensure that the Jobsite Engineer

& Foremen will apply following checks:

✓ 1. Check for straightness and verticality of the wall.

✓ 2. Check for Wedge-pin and Wall-ties has been installed correctly.
✓ 3. Check for external working platforms as per the formwork layout.
✓ 4. Check for shuttering oil has been applied on the slab panels.
✓ 5. Check for interlocking with all components.
✓ 6. Check for all Wooden Stopper, Door Spacers, Sunk Angle, Kicker Spacers,
alignment Waller whether fixed as per accessories layout.
✓ 7. Check for BKS Patti, Kicker Nut Bolts, Prop Spacing VS Tube whether fixed as
per accessories layout.

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 Checklist While Pouring Concrete FR

➢ When pouring concrete:

✓ Vertical rate of rise of concrete should not exceed 1.8 m/hr (height of
liquid concrete in any wall should not exceed 1.8 metre at any given point
of time – so if wall is of 3 metre height – 1.5 metre to be poured first –
then after it hardens, remaining 1.5 metre to be poured)
✓ Don’t dump or heap of concrete at one area.
✓ In order to avoid honeycombing on the concrete surface give gentle blows
with wooden mallet.
✓ Monitoring with skilled person while pouring the concrete.
✓ We recommend the use of Self Compacting Concrete(SCC) on site for best
results.

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 Panel cleaning FR

➢ Before re-installing the panels, the panels must

be cleaned :

✓Use Jet Spray to keep panels clean while concreting.

✓After removing concrete scraps, apply form oil on the panels using a Spray
/ roller, gently remove the smaller concrete blocks.

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FR

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 Setting drawings FR

➢ Aluform formwork system usage at site with Setting drawing

layout
1. Wall Layout
2. Beam Bottom Layout
3. Rocker Layout
4. Internal Corner Layout
5. Deck Panel layout
6. SL Layout
7. B Panel Layout
8. Elevation Layout

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 Wall Panel Layout FR

Note : all dimension are in mm 29

 Beam Bottom Panel Layout FR

Note : all dimension are in mm 30

 Rocker Layout FR

Note : all dimension are in mm 31

 Internal Corner Layout FR

Note : all dimension are in mm 32

 Deck Panel Layout FR

Note : all dimension are in mm 33

 SL Layout FR

Note : all dimension are in mm 34

 B Panel Layout FR

Note : all dimension are in mm 35

 Elevation Layout FR

Note : all dimension are in mm 36

 Elevation Layout FR

Note : all dimension are in mm 37

 FR
➢ Monolithic Construction

Staircase

Central
Core

Slabs

Beams

Columns

Wall 38
 Sequence of Activities FR

1. Stacking the material 10 . Fixing of Conduits at slab

2. Marking of wall lines. a) Sunken, Transfer box out in position &
3. Tying of Wall Rebar Cutouts
4. Fixing of Electrical conduit 11 . Final Aligning & checking
a) Door / Window openings at wall 12. Concreting
5. Fixing of internal wall form 13. Stripping of wall form
6. Guidelines for fixing Pin-Wedges 14. Quality concrete Finish
7. Erection of slab formwork 15. Lifting to the next level
8. Fixing of external wall form 16. After regular refurbishment
9. Tying of Slab rebar.
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 Stacking the Material FR

1. Joint verification of all Pallets.

2. Segregate material Item wise.

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 Marking of Wall Lines FR
➢ Levelling Activities

1. Setting out line and Slab level /

kicker level survey.
2. Adjustment if any and Theci
(Timber stay/ Wooden support)
fixing along the setting out line.
3. Theci must be provided on both
sides in case of internal walls.
4. In case of external wall, Theci must
be provided on the inner wall.
5. The distance between 2
consecutive Theci must be less than
1000mm.
6. Nails must be fitted on both ends
of theci for best support fix nails
diagonally on theci.
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Tying Of Wall Rebar tying FR

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 Fixing of Electrical Conduit FR
➢ M & E F i xe d & D o o r / W i n d o w o p e n i n g s i n Wa l l
Formwork with the Reinforcement

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 Fixing Of Internal Wall Form FR
➢ Timber Stay to be provided for ➢ Internal wall erection to be start first as per
periphery in start-up level. the scheme drawings & level must be
maintained. (Before erection make sure all
panels are properly oiled with approved
shuttering oil)

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 Fixing Of Internal Wall Form FR
➢ E x te r n a l Wa l l e re c t i o n to b e ➢ Wa l l t i e a n d P i n & we d ge s to b e
done as per the scheme drawing provided in all connections.
( i n c l u d i n g V S Tu b e s e t c . )

Wingnuts must be
fixed (On the outer
side for VS Tube &
On the inner
Concrete surface
while fixing for
bracket) using
Adjustable spanner/
Ring Spanner.

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Fixing Of Internal Wall Form FR

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Fixing Of Internal Wall Form FR

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Guidelines for Fixing Pin-Wedges FR

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Guidelines for Fixing Pin-Wedges FR

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 FR
Push Pull Prop Fixing

1. Wooden stopper must be there on both sides.

2. Alignment Waller must be fixed as per design.
3. Push Pull Jack should be fixed at the ends of Alignment Waller &
in between the span of fixed Alignment Waller where the Waller
is not touching the Rail of Panels.
4. Push pull props are to be used for minor adjustments up to 5 mm
& not more than that.

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Erection of lift formwork FR

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Erection of Staircase formwork FR

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 Erection of slab formwork FR
➢ Erect the deck panels with proper accessories
and alu-span as per the scheme drawings

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Fixing of external wall form FR

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Tying of Slab Rebar FR

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Fixing of Conduits at slab FR

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 Fixing of Conduits & Sunken, Transfer FR
box out in position & Cutouts in slab
➢ Check the Sunken assembly in ➢ C h e c k t h e Tr a n s f e r b o x o u t i n
position position & Cut outs in Slab

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 Final Aligning & checking FR
➢ C h e c k t h e Ve r t i c a l a l i g n m e n t p l u m b f o r b o t h
internal and external walls

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 Concreting FR

➢ Monolithic Concrete placement for different

elements

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 Simple Interlocking removing system FR

➢ Dismantling process

1. Dismantling of inside wall, column ,beam & slab formwork.

2. Dismantling of outside wall.
3. Removal of flat wall tie, wall tie sleeve / Cover & grouting.

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 Easy removing & Stripping FR

➢ Dismantling of outside wall, & Fixing of

external working platform

Removal of Wall formwork Place the working platform bracket on the Floor
Erect the formwork for the floor 2 and tighten the nuts on the tie-rod from the
(Next day of pouring of Concrete)
inside of the building. 61
 Easy removing & Stripping FR
➢ Dismantling of outside wall, & Fixing of
external working platform

Fix the plywood/ walkway Jali, railings, toe boards Strike the kicker form Floor 1 and Remove the plywood/ walkway jali/
on the platform to make it workable. Safety should erect the formwork on Floor 2 timber plank, side rails, toe boars from
be paramount throughout the operation and the platform on floor 1 and shift the
hence it is mandatory to use required safety gears same to floor 2. This exercise is to be
like safety belt during the process. carried our during the day of concreting
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of walls of floor 2 and slab of floor 3.
 Easy removing & Stripping FR
➢ Dismantling of outside wall, & Fixing of
external working platform

Remove the plywood/ walkway Jali/

De shutter the timber plank, side rails, toe boars Erect the working
Remove the nuts from
formwork on Floor 2. from the platform on floor 1 and platform bracket on
the tie rods from the
(Concreting was done shift the same to floor 2. This Floor 3 and tighten
Floor 1 working platform.
on the previous day) exercise is to be carried our during the nuts from inside
This is to be done from
the day of concreting of walls of of the building. 63
inside of the building.
floor 2 and slab of floor 3.
 Easy removing & Stripping FR

➢ Lifting of wall panels to the next floor

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 Stripping of wall form FR

➢ Easy handling

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 Stripping of wall form FR

➢ Simple Interlocking removing system

✓ Consult with Consultancy before removal of any element
after casting.
✓ Easy wall tie & wall tie pvc sleeve removing

Panel Puller Nose Plier

Wall Tie Remover
(PVC Sleeve & Cover Remover)
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Quality Concrete Finish FR

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Lifting to the Next Level FR

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Integrated Scaffolding System FR

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 After Regular Refurbishment FR
➢ Environment Friendly

✓ Knest Aluform Formwork can be

recycled at the end of its lifespan.
✓ Timber requirement is nil in
aluminum formwork, hence it is
environment friendly

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 Refurbishment FR
➢ What is Refurbishment? Why is it Necessary?

✓ It is nothing but correcting the Formwork panel repairs like bend, dent,
widening of holes, crack in welding etc.
✓ To effectively utilize the available resources.
✓ To reduce the high initial investment that leads to overall cost reduction.
✓ To achieve more/specified repetitions.

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 Refurbishment FR

➢ Before Refurbishment ➢ After Refurbishment

Add a footer 72
 FR Thank You.
Knest Manufacturers LLP 8600400895
sales@knestaluform.in
www.knestaluform.com