Raghav-Building Construction

PREFABRICATION
STRUCTURES
ALUMINUM IN PREFABRICATION
RAGHV RAJ 4-C
PREFABRICATION IN ALUMINIUM | 2014
CONTENTS
CONTENTS .................................................................................................................................................................... 2
3.3. PREFABRICATION : ALUMINIUM ..................................................................................................................... 3
3.3.1. INTRODUCTION 3
3.3.2. METHADOLOGY .............................................................................................................................................. 4
3.3.3. LIMITATIONS..................................................................................................................................................... 4
3.3.4. FORMS OF ALUMINUM 4
3.3.5. ALUMINIUM EXTRUSION 10
3.3.6. ALUMINIUM LADDERS 12
3.3.7. ACP (ALUMINIUM COMPSITE PANEL) 14
3.3.8. ALUMINIUM FORMWORK...16
3.3.9 MODULAR ALUMINIUM FRAMEWORK 20
3.3.10 APPENDIX ..22
BIBLIOGRAPHY ......................................................................................................................................................... 25
Page 2 of 25
LIST OF FIGURES
Figure 1 ......................................................................................................................................................................... 4
Figure 2 ......................................................................................................................................................................... 6
Figure 3 ......................................................................................................................................................................... 7
Figure 4 ......................................................................................................................................................................... 7
Figure 5 ......................................................................................................................................................................... 8
Figure 6 ......................................................................................................................................................................... 8
Figure 7 ......................................................................................................................................................................... 9
Figure 8 ......................................................................................................................................................................... 9
Figure 9 ...................................................................................................................................................................... 12
Figure 10 .................................................................................................................................................................... 13
Figure 11 .................................................................................................................................................................... 13
Figure 12 .................................................................................................................................................................... 14
Figure 13 .................................................................................................................................................................... 15
Figure 14 .................................................................................................................................................................... 15
Figure 15 .................................................................................................................................................................... 19
Figure 16 .................................................................................................................................................................... 20
Figure 17 .................................................................................................................................................................... 22
Page 3 of 25
3.3.1. Introduction
1.1Why choosing Aluminium?
Aluminium is a very light material with reduced specific weight.
Thats why production costs of the raw material in this phase are
Very affordable. Its resistance is very high and it can be
calculated with precision.
Ideal material for the production of windows, doors and glass
faade of big dimensions. It can be endless re-melted with a
limited energy consumption. More Aluminium is recycled, more
cheaper is its price.
Features facilitating easy jointing are often incorporated into
profile design.
Fusion welding, Friction Stir Welding, bonding and taping are
also used for joining
1.2 Use of Aluminium in a Building
Figure 1
Source: http://www.engineeringcivil.com/use-of-aluminium-in-building-construction.html
Page 4 of 25
3.3.2. METHADOLOGY
3.3.3. LIMITATIONS
No direct contact with the manufacturers
The cost given on the net might not be the actual cost in field.
In forms of aluminium only extrusion based and casting based are covered due to
lack of time and resources.
3.3.4. FORMS OF ALUMINIUM
Extrusion based
Casting based
Foil and powder based
Sheet based
2.1EXTRUSION BASED
Doors
Single sliding
Double sliding
Single and double
Windows
Fixture
Side hung
Tilt and turn
Page 5 of 25
Folding stacking
Single top hung and Double top hung
2.2 CASTING BASED

Baluster head
Add elegance to the interior of buildings
Complicated figures can be developed.
Figure 2
Source:http://www.manaksia.com/images/product/aluminum/aluminium-prefabricated-stairs-
2.3 ROOFING BASED

Aluminium Prefabricated Shelter
Manaksias prefab shelters are uniquely pre-engineered using special
Aluminium Alloy profiled roofing sheet for roof & side wall anchored on column
and roof beam also made of preformed Aluminium alloy plain sheet.
LIGHT WEIGHT
DURABLE
FIRE RESISTANCE
RESALE VALUE
ALUMINIUM ROOFING SHEET APPLICATIONS
INDUSTRIAL BUILDINGS
COLD STORAGE SHEDS
RURAL HOUSING
POULTRY CAGES
Page 6 of 25
FALSE CEILINGS FOR LARGE HALLS etc.
Figure 3
Source:http://www.manaksia.com/images/product/aluminum/aluminium-prefabricated-shelterl.jpg?phpMyAdmin=3d0089490d12bc8f2e6f3093aa1276fa&phpMyAdmin=2d0b18ba60f6091a92aa08d62d00ca25
MULTI COLOR
ROOF PROFILES
SCREW LESS ROOF SYSTEM
MULTI ZIP
Standing Seam Roof Systems
Figure 4
Source: http://www.multicolorsteel.com/images/Products/Roof%20Profiles/Screw%20Less%20Roof%20Systems/MultiZip/Multi_zip_a_big.jpg
Page 7 of 25
430 mm Standard
Figure 5
Source: http://www.multicolorsteel.com/images/Products/Roof%20Profiles/Screw%20Less%20Roof%20Systems/MultiZip/Multi_zip_a2_big.jpg
Tapered Profile
Figure 6
Source:http://www.multicolorsteel.com/images/Products/Roof%20Profiles/Screw%20Less%20Roof%20Systems/MultiZip/Multi_zip_a3_big
.jpg
Advantages
A versatile roofing system that can adopt all creative architectural design
flexibility
Different shapes of Convex Curve, Concave Curve, Taper, Taper Convex and
Taper Concave, opens up a whole variety of fascinating options for creating
stunning architectural designs
Lightweight Screw less roofing system, outstanding durability.
The special design of Clip Connecter allows for the expansion movements of
seamed panel.
Various clip connector heights are available to accommodate insulation materials
Page 8 of 25
Profiles available in 300, 400, 430 & 500 mm width in steel and in Aluminium.
Figure 7
Source:http://www.multicolorsteel.com/images/Products/Roof%20Profiles/Screw%20Less%20Roof%20Systems/MultiZip/Multi_zip_a4_big.jpg
http://www.multicolorsteel.com/images/Products/Roof%20Profiles/Screw%20Less%20Roof%20Systems/Multi-Zip/Multi_zip_a4_big.jpg
Figure 8
Page 9 of 25
Material:
Aluminium, Colour Coated Steel, Galvalume, or other metallic materials.
Material Thickness
(Post production): Aluminium 0.5 to 1.0, Steel 0.5 to 0.8
Maximum Length:
100m per single panel
Minimum Radius:
Concave Curve- Aluminium 4m and Steel Curve 6m
Convex Curve-Aluminium 2m and Steel Curve 4m
Colour Coating/ Finish:

All standard RAL- colours special colours on request; minimum order may apply.
Stucco or mill finish. Colour finishes of multi-coat PVDF or Polyester.
Insulation Options:
Glass, Fibre / Mineral Wool Blanket insulation.
Accessories:
We provide full range of customizable accessories such as clips, clamps, safety
systems and equipment.
Usage:
Airports, Exhibition halls, Sports Facilities, Industrial Buildings etc.
2.4 STRUCTURAL GLAZING FRAMES

Structural glazing is a system of bonding glass to an aluminium frame of
curtain wall utilizing a high-strength, high-performance silicone sealant.
aluminium members are not visible from outside
Page 10 of 25
3.3.5. ALUMINIUM EXTRUSION
Page 11 of 25
Figure 9
Page 12 of 25
Figure 10
3.3.6. Aluminium Ladders
Figure 11
Page 13 of 25
Figure 12
Page 14 of 25
3.3.7. ACP (Aluminium Composite Panel)

These sheets are made from non-combustible polyethylene core that
is laminated and then sandwiched between two aluminium sheets. The noncombustible polyethylene core is a rubber like paste that is compressed and
pressed between two aluminium sheets. The compression process is same as
that of compression process of laminates.
Figure 13
Source: http://www.contractorbhai.com/wp-content/uploads/2015/02/Aluminum-Composite-Panels1.jpg
Branded ACPs offer architects and builders an exciting dimension for

expansion in planning and designing structures. ACPs are available in wide
and attractive surface finish.
Figure 14
Source: http://www.contractorbhai.com/wp-content/uploads/2015/02/Different-finish-ACP-Sheets.jpg
The most preferred brands of ACP sheets are Eurobond, Alto-bond and Viva.
The manufacturing units of these brands are in India itself. Youll not find any
Page 15 of 25
other local ACP sheet manufacturer as setting up a unit is a heavy investment

that not all can afford.
STRUCTURAL GLAZING AND ALUMINIUM COMPOSITE PANEL
Providing and supplying aluminium extruded tubular and other aluminium sections as per the
architectural drawings and approved shop drawings , the aluminium quality as per grade
6063 T5 or T6 as per BS 1474,including super durable powder coating of 60-80 microns
conforming to AAMA 2604 of required colour and shade as approved by the Engineer-inCharge. ( The item includes cost of material such as cleats, sleeves, screws etc. necessary for
fabrication of extruded aluminium frame work. Nothing extra shall be paid on this account).
Cost Kg 363.85
The cost of providing extruded aluminium frames, shadow boxes, fire stop (barrier)- cumsmoke seals, extruded aluminium section capping for fixing in the grooves of the curtain
glazing and vermin proof stainless steel wire mesh shall be paid for separately under relevant
items under this sub-head. However, for the purpose of payment, only the actual area of
structural glazing (including width of grooves ) on the external face shall be measured in sqm.
up to two decimal places.
Cost sqm 2282.65
Page 16 of 25
3.3.8. Aluminium Formwork

The Aluminium Formwork System was developed by W. J. Malone, a Canadian
Engineer in the late 1970s as a system for constructing lowcost housing unit in
developing countries. The units were to be of cast-in-place concrete, with load
bearing walls using a formwork of aluminium panels. To be erected by the
hundreds, of a repetitive design, the system ensured a fast and economical
method of construction.
This is one of the systems identified to be very much suitable for Indian
conditions for mass construction, where quality and speed can be achieved
at high level.
The speed of construction by this system will surpass speed of most of the
other construction methods/technologies.
The labour handles this method effectively to speed up the construction, to
assure quality control and durability. Adoption of this system reduces
overall cost of the structure.
TECHNOLOGY
Aluminium Formwork System is highly suited to load bearing wall
construction whereas traditional formwork consisting of plywood and
timber is not suitable to the high pressures of fresh concrete on the wall.
COST: Use of this formwork in load bearing design gives an average of
15 per cent cost saving in the structure of the building and increased
usable floor space of 8 per cent over RCC design.
TIME: For 100 per cent work, construction through slab beam wall
construction takes X time and through Aluminium Formwork technology the
time required is 1/6th of the X time.
ENVIRONMENT FRIENDLY: The technology is environment friendly as
there is no use of timber. The formwork gives the box or cellular design
resulting in the walls giving support to the super structure in two directions.
As a result, the structures are more resistant to earthquakes than the
traditional RCC column and beam designs.
LIFTING: As the Aluminium Formwork is lightweight, no tower cranes are
required for the same unlike in tunnel framework.
LABOURS: Due to simplicity of the assembly, only unskilled labours are
required with minimal supervision.
REPETITIONS: The Aluminium Formwork System is removable and can be
reused hundreds of times with little maintenance.
SCRAP VALUE: Moreover, the requirement of steel is also reduced in this
technology as aluminium has a higher scrap value.
Page 17 of 25
SIMPLE ASSEMBLY SYSTEMS

PIN AND WEDGE SYSTEM The panels are held in position by a simple
pin and wedge system that passes through holes in the outside rib of each
panel.
QUICK STRIP PROP HEAD One of the principal technical features
which enables this speed to be attained using a single set of formwork
panels is the unique V shaped prop head which allows the 'quick strip' to
take place whilst leaving the propping undisturbed. The deck panels can
therefore be reused immediately.
Aluminium Formwork - Project cycle
Page 18 of 25
Figure 15
Source:http://files.hostgator.co.in/hostgator181958/file/aluminiumformworksystemintro.pdf
Page 19 of 25
Figure 16
http://files.hostgator.co.in/hostgator181958/file/aluminiumformworksystemintro.pdf
Page 20 of 25
3.3.9. MODULAR ALUMINUM FRAMING SYSTEM
Page 21 of 25
Figure 17
Source:http://www.apricot123.com/modular-aluminium-framing-system.html
Manufacturers in India
Grand Edifice Developers
Century Extrusion Limited

Jindal Aluminium Limited
Product
Aluminium Formwork
Industrial Application based

Aluminium extrusions of all types
Aluminium ladders
Page 22 of 25
3.3.10. APPENDIX
COST
a) Two Track Aluminum Sliding Window (with powder Coating) :
The aluminum fabrication rates in bangalore for windows are given below.
Material Used : 61.5mmx45.5mmx1.2mm thickness aluminum Section for outer
Frame.40mmx1.8mmx1.2mm thickness aluminum Section for window Shutters
4mm Plain Glass, TPI wheel TVS or EPDM gasket, Star lock, weather Proof Silicon
Sealant.
Per Square Feet Rs.180/.
1.5mm aluminum thickness per square feet Rs.195/-.
Jindal make aluminum Section .Extra 20% Per square Feet.
Color 1 way glass Extra Rs25/- to 40/- Per Square Feet.
Without Powder Coating less Rs 20/- Per square feet.
.
b) Three Track Aluminum Sliding Window RATES.
Material Used : 90mmx45.5mmx1.2mm thickness aluminum Section for outer
frame, 40mmx1.8mmx1.2mm thickness aluminum Section for window Shutters,
4mm Plain glass, TPI wheel, TVS or EPDM gasket, Star lock, weather proof
Silicon Sealant, Stainless Steel Mesh or aluminum mesh..
Per Square Feet Rs 220/.
1.5mm aluminum thickness Rs 240/- Per Square feet.
Jindal make aluminum Section, Extra Rs 30/- Per Square Feet.
Colour 1 Way glass, Extra Rs 25/- to Rs 40/- Per Square Feet.
Without Powder Coating, Less Rs 20/- Per Square Feet.
.
2 : ALUMINUM PARTITION (with Powder Coating)
Material Used : The aluminum partition rates 60mmx40mmx1.2mm thickness
Single groove & Double groove Locking Clip TVS & EPDM gasket, 4mm Plain
glass, 9mm Novo pan sheet, Silicon Sealant.
Per Square Feet Rs 180/.
Without Powder Coating Rs 160/1.5mm aluminum thickness Rs 200/Jindal make aluminum Section. Extra Rs20/- Per Square Feet.
Colour 1 way glass Extra Rs 25/- to Rs 40/-.
.
3 : ALUMINUM OPEN DOOR (with powder coating)
Material Used : Aluminum door rates Bangalore 50mmx50mmx1.2mm thickness
door vertical, 100mmx50mmx1.2mm thickness door bottom,
50mmx50mmx1.2mm thickness door top & centre, TVS gasket, door lock, door
handle, Pivot, Locking clip, door stopper, 9mm NOVO sheet, 4mm plain glass or
Page 23 of 25
pinned glass, door rod.

Per Square Feet Rs 250/1.5mm aluminum thickness Per square feet Rs 275/Jindal make aluminum Section Extra Rs 20/- Per square feet.
Colour 1 way glass. Extra Rs 25/- to Rs 40/- Per square feet.
Without Powder Coating less Rs 20/- Per square feet.
Door Closer changes extra.
4 : ALUMINUM SLIDING DOORS (with Powder Coating)
Material Used : The sliding door rates 50mmx50mmx1.2mm thickness door
vertical,100mmx50mmx1.2mm Thickness door Bottom, 50mmx50mmx1.2mm
thickness door top & centre, TVS gasket, door lock, door handle, pivot, locking
clip, door stopper, 9mm NOVO per sheet, 4mm plain glass, or pinned glass,
door rod, C Gear Wheel, C Gear, C Gear Channel.
Per Square Feet Rs 280/1.5mm aluminum thickness per square feet Rs 350/Jindal make aluminum Section Extra Rs 20/- per square feet.
Colour 1 way glass. Extra RS 25/- to Rs 40/- per square feet.
Without Powder Coating Less Rs 20/- per square feet.
5 : ALUMINUM GRILLED MESH WORK
Material Used : The aluminum grilled mesh work rates for
50mmx25mmx1.2mm thickness aluminum plain section, 4x4 aluminum Grilled
mesh, grilled locking clip.
Per square feet Rs 180/Per Running Feet (RFT)
6: ALUMINUM GLASS WORK.
a)Aluminum Fish Bottom glass work. (12mm tough glass).
Material Used : Fish bottom or fish mouth aluminum powder coating section,
12mm Toughened glass, weather proof silicon Sealant.
Per Square Feet Rs 350/-.
b) Aluminum fish bottom glass work.(10mm tough glass).
Material Used : Fish bottom or fish mouth aluminum powder coating section.
10mm Tough glass, weather proof silicon sealant.
c) Aluminum fish bottom glass work (12mm plain section).
Material used : Fish bottom or fish mouth aluminum powder coating section,
12mm plain glass weather Proof Silicon sealant.
d) Aluminum Bottom glass work (10mm plain section).
Fish bottom or fish mouth aluminum powder coating section, 10mm plain glass,
weather proof silicon sealant.
Page 24 of 25
BIBLIOGRAPHY
http://www.engineeringcivil.com/use-of-aluminium-in-building-construction.html
http://www.manaksia.com/images/product/aluminum/aluminium-prefabricated-shelterl.jpg?phpMyAdmin=3d0089490d12bc8f2e6f3093aa1276fa&phpMyAdmin=2d0b18ba60f6091a92aa08d62d00ca25
http://www.multicolorsteel.com/images/Products/Roof%20Profiles/Screw%20Less%20Roof%20Systems/Multi-Zip/Multi_zip_a_big.jpg
http://files.hostgator.co.in/hostgator181958/file/aluminiumformworksystemintro.pdf
http://ecocomb.in/aluminium-honeycomb-panels-manufacturers.html
Page 25 of 25

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PREFABRICATION

PREFABRICATION IN ALUMINIUM | 2014

PREFABRICATION IN ALUMINIUM | 2014

PREFABRICATION IN ALUMINIUM | 2014

1.2 Use of Aluminium in a Building

PREFABRICATION IN ALUMINIUM | 2014

No direct contact with the manufacturers

3.3.4. FORMS OF ALUMINIUM

PREFABRICATION IN ALUMINIUM | 2014

Single top hung and Double top hung

2.2 CASTING BASED

2.3 ROOFING BASED

ALUMINIUM ROOFING SHEET APPLICATIONS

PREFABRICATION IN ALUMINIUM | 2014

FALSE CEILINGS FOR LARGE HALLS etc.

PREFABRICATION IN ALUMINIUM | 2014

PREFABRICATION IN ALUMINIUM | 2014

PREFABRICATION IN ALUMINIUM | 2014

Colour Coating/ Finish:

2.4 STRUCTURAL GLAZING FRAMES

PREFABRICATION IN ALUMINIUM | 2014

3.3.5. ALUMINIUM EXTRUSION

PREFABRICATION IN ALUMINIUM | 2014

PREFABRICATION IN ALUMINIUM | 2014

3.3.6. Aluminium Ladders

PREFABRICATION IN ALUMINIUM | 2014

PREFABRICATION IN ALUMINIUM | 2014

3.3.7. ACP (Aluminium Composite Panel)

Branded ACPs offer architects and builders an exciting dimension for

PREFABRICATION IN ALUMINIUM | 2014

other local ACP sheet manufacturer as setting up a unit is a heavy investment

PREFABRICATION IN ALUMINIUM | 2014

3.3.8. Aluminium Formwork

PREFABRICATION IN ALUMINIUM | 2014

SIMPLE ASSEMBLY SYSTEMS

PREFABRICATION IN ALUMINIUM | 2014

PREFABRICATION IN ALUMINIUM | 2014

PREFABRICATION IN ALUMINIUM | 2014

3.3.9. MODULAR ALUMINUM FRAMING SYSTEM

PREFABRICATION IN ALUMINIUM | 2014

Grand Edifice Developers

Century Extrusion Limited

Industrial Application based

PREFABRICATION IN ALUMINIUM | 2014

PREFABRICATION IN ALUMINIUM | 2014

pinned glass, door rod.

PREFABRICATION IN ALUMINIUM | 2014

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