Friction stir welding, a game-changer in formwork solutions

This interaction explores I-Form’s innovative aluminium formwork products for the construction industry and explains why they are best suited for this sector.

What are the latest advancements in formwork materials offered by your company to improve the durability and performance at construction sites? 
We use the 6061T6 grade aluminium alloy, which offers excellent mechanical strength and chemical properties, making it suitable for fast-paced monolithic construction projects that are most prominent in the construction industry. As the material is subject to frequent movement by workers across floors and multiple buildings or projects, wear and tear is inevitable. To address this, we have adopted friction stir welding technology, which increases weld strength by 40 per cent compared to the regular MIG welding process. Additionally, we use thicker profiles and sections after detailed design and die development to ensure the product’s longevity. We also pay attention to small details, such as adding extra reinforcement to components at critical sections which are critical for the quality, integrated workplace safety, and durability of our products.

Could you elaborate on how your formwork solutions contribute to cost efficiency throughout the construction lifecycle, from set-up to dismantling? 
Aluminium formwork systems offer several advantages, including cost-effectiveness, time saving, and improved quality. For example, while conventional construction methods allow us to complete 1 to 1.5 slabs a month, at least 3 floors can be completed in a month using aluminium formwork; the construction speed is three times accelerated. This faster pace not only enhances the builder’s profitability but also benefits all internal and external stakeholders involved in the project by ensuring timely handover. Switching over from conventional construction processes to monolithic casting using aluminium formwork helps complete a higher number of projects in a fixed timespan.

How do your formwork systems cater to the complete construction of complex sectors such as high-rise buildings, ensuring efficiency and structural integrity? 
Almost 90 per cent of high-rise buildings in India are constructed using aluminium formwork systems, as it is a proven technology. We provide on-site guidance for the installation procedures for the first two floors. Once the panels are installed according to the drawings, we permanently mark them to ensure easy handling and positioning by workers. This reduces the need for highly skilled labour; also, as these formwork systems are lightweight, it eliminates the need for tower cranes or heavy lifting equipment, making the construction process more efficient. Another advantage is the ability to create complex structures with ease. The technology is a boon for architects, who can propose innovative designs and collaborate with aluminium formwork suppliers to bring those to life. We aim to expand our reach beyond India in supplying high-quality aluminium formworks.

In what ways do you leverage digital technologies to streamline design and execution processes? 
The manufacturing of aluminium formwork systems is in itself a complex process, with design at its core. We ensure that the design and the drawings are well-coordinated, especially since architects and structural consultants already use automated software. Dealing with large-scale projects is a challenge, as they require hundreds of thousands of panels, and matching holes in these panels is a critical step. Both these issues are currently being addressed with automated software, and we hope to see more advancements in this area soon. We have also streamlined the planning and production control phase using software that tracks raw material receipts from day 1, which helps us reduce raw material wastage.

Can you guide us through the steps your company takes to promote sustainable practices? 
In India, traditional construction systems have relied on wood and bricks, which hurt the environment. Aluminium, however, is 100 percent recyclable and therefore sustainable. We focus on sustainability by using friction welding to manufacture nearly 85 percent of our panels, which produces zero-carbon emissions. We are proud to be the first in South India to adopt this method. We are committed to transitioning to 100 percent friction welding within the next year. This effort aligns with global sustainability goals, including those set by the United Nations ESC (Environmental Sustainability Criteria).

For more details, visit: https://iform.co.in/