Aluminum Shuttering for High-Rise Buildings
Learn how aluminum formwork revolutionizes high-rise construction. Discover parts, casting precautions, cost, and leading companies providing aluminum shuttering systems. For project quotations or expert advice, contact us on WhatsApp +91-9860109440.
Overview — What Is Aluminum Shuttering?
Aluminum shuttering, also known as Aluminum Formwork System, is a reusable casting mold used to construct the structural elements of high-rise buildings — such as walls, slabs, columns, beams, and staircases. Unlike conventional plywood or steel shuttering, aluminum systems are lightweight, precise, and easy to handle, enabling faster floor cycles and superior concrete finishes.
The entire building design must be tailored for this system — ensuring all floor heights, wall thicknesses, and beam sizes are repetitive and modular. This design uniformity minimizes re-fabrication, reduces cost, and speeds up work cycles — often achieving one floor in 5–7 days.
Parts of Aluminum Shuttering & Their Uses
| Component | Function / Use |
|---|---|
| Wall Panel | Vertical shutter for walls and columns — forms the concrete face. |
| Deck Panel | Horizontal panel for slab bottom casting. |
| Beam Soffit | Supports the bottom surface of beams. |
| Beam Side Panel | Holds the vertical sides of beams during casting. |
| Soffit Corner / Wall Corner | Provides alignment at wall junctions. |
| Prop Head & Drop Head | Support system for beams and slabs during early removal. |
| Pins and Wedges | Used for locking adjacent panels securely. |
| Kicker | Base component ensuring correct wall alignment. |
| External Corner | Forms outer junctions of walls at 90°. |
| Deck Prop | Adjustable steel/aluminum support for slab formwork. |
Care During Casting — Especially on Top Surfaces
- Ensure all aluminum panels are tightened properly before pouring concrete.
- Apply shuttering oil evenly — avoid pooling or dry spots.
- Check slab soffits and beam levels before concreting.
- For top surfaces, vibrate carefully with needle and surface vibrators to avoid honeycombing.
- Cover exposed areas with plastic sheets after finishing to prevent rapid evaporation.
- Ensure correct alignment to prevent offsets between successive floors.
- Always clean and oil panels after every cycle for smooth finishes.
Pros and Cons of Aluminum Shuttering
Advantages:
- Lightweight and easy to assemble/disassemble.
- High precision leads to excellent concrete finish — plaster not required.
- Reusable for up to 200–250 cycles, reducing long-term costs.
- Rapid floor cycle — ideal for high-rise residential and commercial towers.
- Compatible with mechanized construction methods.
Disadvantages:
- High initial investment — requires volume to be economical.
- Not suitable for irregular or varying architectural designs.
- Repair and welding require skilled labor and special tools.
- Prone to surface scratches or dents if mishandled.
Cost and Leading Companies in Aluminum Shuttering
The price of aluminum shuttering varies depending on the manufacturer, design complexity, and project scale. Below is an approximate cost guide:
| Item | Approx. Cost (INR) |
|---|---|
| New Aluminum Formwork (Purchase) | ₹1,200–₹1,800 per sq.ft |
| Rental System (Cycle basis) | ₹120–₹200 per sq.ft |
| Repair & Refurbishing | ₹30–₹50 per sq.ft |
Top Aluminum Formwork Companies:
- PERI India Pvt. Ltd.
- Doka India Pvt. Ltd.
- Nova Formwork Systems
- Forsa Aluminum Systems
- MFE Formwork Technology
- Aluform India Pvt. Ltd.
Labour, Welding & Spare Parts
Repair and maintenance of aluminum shuttering require TIG or MIG welding machines. Welders should be trained for aluminum joints, as improper heating causes panel distortion.
- Welding Machine: TIG/MIG 250A or above with argon gas setup.
- Spare Parts: Pins, wedges, wall ties, prop heads, corner angles, and alignment clamps are available through authorized suppliers.
- Labour Cost: Skilled shuttering carpenter ₹800–₹1,200/day; fitter ₹1,200/day; helper ₹600/day.
Repair services are available from formwork manufacturers or specialized local workshops. For maintenance quotations, contact us directly on WhatsApp +91-9860109440.
Conclusion
Aluminum shuttering has transformed the construction industry by improving speed, precision, and surface quality in high-rise projects. While the system requires high initial investment, its long-term durability and superior concrete finish make it ideal for repetitive designs and large housing projects.
For detailed design consultation, repair work, or project quotation, contact our experts anytime on π WhatsApp +91-9860109440.
Design Principles for Buildings Using Aluminum Shuttering
When adopting aluminum shuttering technology, the design of the structure must be kept modular and repetitive. This ensures all formwork panels can be reused for several floors without major modifications. The following design rules help in achieving speed and economy:
- Uniform Structural Grid: Columns and beams should follow a consistent spacing (typically 3m to 6m) for easier panel repetition.
- Standard Wall Thickness: All internal and external walls should be of similar thickness, usually 150mm or 200mm RCC walls for structural consistency.
- Flat Slab or Beam-Slab System: Flat slabs reduce the number of beam side panels, simplifying the shuttering layout.
- Integrated Staircase & Balcony Panels: These should be included in the formwork design for monolithic concrete casting.
- Service Ducts and Shafts: Keep aligned vertically through all floors for easy repetition of shutter panels.
In short, the building should be “formwork-driven” rather than “architecture-driven”. This approach not only accelerates project timelines but also enhances uniformity, reduces material wastage, and simplifies labor operations.
Workflow of Aluminum Shuttering in High-Rise Construction
The following is the typical workflow followed for each floor cycle when using aluminum formwork:
- Stage 1 – Layout and Survey: Leveling and marking of the grid lines on the slab are done using total station or laser devices.
- Stage 2 – Wall Panel Fixing: Panels are assembled for external and internal walls using pins and wedges.
- Stage 3 – Beam and Slab Deck Installation: Soffit panels and deck panels are supported with props and head systems.
- Stage 4 – Reinforcement & Services: Rebar, conduits, sleeves, and boxes are placed within the formwork cavities.
- Stage 5 – Inspection: Engineers verify alignment, plumb, and form tightness before concreting.
- Stage 6 – Concreting: Concrete is poured monolithically (walls + slab) using pumps and vibrators.
- Stage 7 – Curing & De-shuttering: After 12–16 hours, side panels are removed; slab panels after 2–3 days using drop-head system.
- Stage 8 – Cleaning & Oiling: All panels are cleaned with wire brush and coated with releasing oil for the next cycle.
This repetitive cycle allows projects to achieve one floor per week. Many developers in Mumbai, Dubai, and Singapore have standardized this 7-day floor cycle for efficient mass housing.
Common Problems in Aluminum Shuttering and Their Solutions
Even though aluminum shuttering ensures high quality, site-level challenges can affect the outcome if not managed properly. Here’s a summary of common problems and solutions:
| Problem | Cause | Solution |
|---|---|---|
| Honeycombing on walls | Improper vibration or leakage at joints | Seal joints properly and use internal vibrators uniformly. |
| Panel misalignment | Unleveled props or loose wedges | Use laser levels and tighten locking systems before pour. |
| Form leakage | Inadequate sealing or worn-out joints | Use aluminum tape or joint sealer before casting. |
| Uneven slab surface | Over-vibration or improper leveling | Check surface with straight edge and re-vibrate evenly. |
| Panel denting / damage | Improper handling or hammering | Use plastic/rubber mallets; store panels vertically. |
Maintenance and Storage of Aluminum Formwork
Proper maintenance extends the life of aluminum shuttering beyond 200 cycles. The following precautions should be practiced:
- Store cleaned panels on wooden pallets under covered sheds.
- Apply shuttering oil before stacking to prevent oxidation.
- Repair bent or dented panels immediately using hydraulic straighteners or TIG welding.
- Label panels by floor and location to ensure efficient reuse cycle.
- Always clean concrete residue with soft nylon brushes — never hammer or grind the surface.
For professional refurbishment, panels can be sent to certified workshops that offer alignment, panel welding, and surface polishing. You can contact Aluform India, PERI, or Nova Formwork for refurbishment services, or request local workshop support via WhatsApp +91-9860109440.
Productivity, Economics, and Cost-Benefit Analysis
The biggest advantage of aluminum shuttering is its speed. When used efficiently, it allows one complete floor cycle every 5 to 7 days. For a 25-floor residential tower, this results in time savings of nearly 5–6 months compared to conventional methods. Labor productivity improves drastically as fewer materials are needed and setup times are shorter.
Here’s a comparative cost and cycle analysis:
| Parameter | Conventional Plywood | Aluminum Formwork |
|---|---|---|
| Reusability | 10–15 cycles | 200+ cycles |
| Floor Cycle Time | 12–15 days | 5–7 days |
| Surface Finish | Needs plastering | No plastering required |
| Initial Investment | Low | High (₹1,200–₹1,800/sq.ft) |
| Total Project Cost (per sq.ft) | Higher due to time & labor | Lower in long term |
Future of Aluminum Shuttering in India and Abroad
Globally, aluminum formwork is gaining traction in mass housing, infrastructure, and urban development projects. Countries like UAE, Singapore, and Malaysia have already standardized it for high-rise and mid-rise towers due to its high-quality output and low maintenance needs. In India, major developers such as Tata Housing, Lodha Group, and Godrej Properties have adopted it for their residential projects.
Future innovations include:
- Hybrid Formwork Systems — Combination of aluminum panels and steel frames for strength.
- Robotic Erection & Dismantling — To improve safety and reduce dependency on labor.
- 3D Scanning for Alignment Checks — Ensures perfect plumb and level before concrete pour.
- AI-driven Project Monitoring — For real-time progress, scheduling, and quality tracking.
Sustainability and Environmental Benefits
Aluminum shuttering is highly sustainable compared to timber or plywood systems. Since the panels can be reused hundreds of times, it saves thousands of cubic meters of wood and reduces deforestation. Furthermore, the surface finish eliminates the need for plaster, cutting down cement and sand usage. The recycling value of aluminum after its lifecycle adds an extra environmental advantage.
Developers seeking Green Building Certification (LEED or GRIHA) can earn sustainability credits by using aluminum formwork, as it reduces material wastage and energy consumption during construction.
Expert Advice and Consultation
Choosing the right aluminum formwork supplier and ensuring proper installation technique are crucial. Many small contractors purchase low-quality systems that bend or warp after few cycles. Always verify the material thickness (2.5mm–3mm grade aluminum) and weld quality. For professional consultation, design compatibility, or quotation, contact our expert on WhatsApp +91-9860109440.
Final Summary
Aluminum shuttering is transforming modern construction by combining speed, precision, and sustainability. With proper planning, standardization, and trained workforce, it can reduce project timelines by up to 40%. It is particularly ideal for affordable housing and high-rise structures where uniformity is key. The technology continues to evolve, paving the way for smarter, greener, and faster buildings across the world.
Whether you’re a developer, engineer, or contractor, adopting aluminum shuttering is a strategic investment in long-term efficiency. For inquiries, designs, or project quotations, reach out on π WhatsApp +91-9860109440.




