Formwork Modification

Refurbishment & Modification Process Detail

1. Evaluation & Sorting

We will evaluate the available formwork as Per the Packing list and verify it against the Physical Inventory on Site. The same is done to check for any sort of flaw or damage that may need repair. We assess the formwork and categorize basis below elements:

Formwork is in good condition – Only cleaning required
Formwork is damaged – Minimal repair required
Panel Needs Modification- Major Repair required
Panel/Non Panels is unusable – Scrap the Panels/Non Panels that needs to be disposed

2. Washing & Cleaning

Lumps of Concrete on Formwork face is removed using Single Phase Concrete Chipper & Hacking tools.
Once the Formwork is free from Lumps of Concrete the same is dipped in the chemical Tanks containing Special Aluminium Shuttering Cleaning Chemical.
Post dipping & following timelines Panels are removed and Sprayed with a 250 bar Pressure Water Pump to remove the chemical from the Panels.
Once the Aluminium formwork Panel is Clean & Free from Chemical the same is kept for drying up naturally and thus taken for Modification.

3. Cutting & Drilling

Methodology for Cutting

The Panels to be cut is inspected and Post Checking the same to be free from Concrete, Jig Fixture is attached
with the help of C Clamps to Table Saw Machine.
The Panel is moved freely along length on the bed and Cutting blade of Table Saw Machine with two persons holding the same so as to get the smooth finish.
The Machine motor is stopped once the cutting from one end to other is completed & Small Pieces/Burr too are removed.

Methodology for Drilling

The Point where drilling is to be done is marked manually with help of Measuring Tape & Permanent CD marker.
The Point is embossed with Center Punch & the embossed point is drilled with 5 mm Drill Bit using Table Drill Machine.
The 5 mm drilled hole is re-drilled with 16.5 mm drill bit using Table drill machine.

4. Welding & Routing

Methodology of Welding:

The Surfaces to be welded will be initially grinded using the 4” Grinder to make the surface free from foreign impurity or chemical deposits if any.
The Machine used in Welding operation will be High Quality that ensures quality & Finish.
The High Quality welding wire of 5356 Grade of Well Known brand is used for Welding to ensure life of the Panel.
The Shielding Gas Used in welding too would be from Grade 1 Suppliers to ensure best Quality for Modification.

Methodology of Routing:

The routing will be done using professional routing machine & 19 mm Carbide Bit.

5. Buffing & Lacquer

Methodology for Buffing

Once the Chemical Treatment & Modification of Aluminium formwork is complete, the same is cooled down naturally after fabrication.
Formwork Panels are dried and cooled down naturally and then taken for buffing.
Buffing is done on Concrete face using the Buffing Machine & Buffing Paper so as to remove any leftover concrete surface & to get slightly rough Surface for Lacquer to get proper adhesion.

Methodology for Lacquer

Once the Buffing & Cleaning operation is completed to PU Lacquer is Prepared Using 3:1 ratio of Hardner & PU Thinner.
The PU Lacquer applied to Aluminium formwork is kept for drying naturally at least for 2.5 to 3 Hrs before using the same for erection.

6. Mockup & Erection

Aluminium Formwork Modified Panels & Non Panels ready with Cleaning, Cutting, Routing,Welding, Drilling, Buffing & Lacquer is handed over for Mockup & Successful Erection of formwork System on site.