DESIGN DETAILING AND MANAGEMENT FOR ALUFORM SHUTTERING IN HIGH RISE TOWERS.pdf

A
Elective Report
On
Design Detailing and Management for Aluform
Shuttering in High Rise Towers
In Partial fulfillment of requirement for the degree of
Master of Architecture
In
Construction Management
Of
Savitribai Phule Pune University, Pune
Submitted by:
Ms. PALLAVI.S. BHOSAREKAR
Under the guidance of
Mrs. MADHAVI KHANDAR- KARANGALE
Assistant Professor
Dr. D Y Patil College of Architecture, Akurdi, Pune.
April 2021

CERTIFICATE
Academic Year: 2020 - 2021
Name of Student: Miss. Pallavi Satish Bhosarekar
Class: F.Y. M. Arch (Construction Management)
College Roll No.: 1MA109
Exam Seat No.: 1MA10210009
Name of the Subject: Electives II
This is to certify that Miss. Pallavi Satish Bhosarekar
is allowed to appear for the Sessional Assessment to
be conducted in April / May 2020- 2021.
Internal Examiner College Stamp Principal
External Examiner Date: 29-07-2021
DR. D.Y. PATIL COLLEGE OF ARCHITECTURE
AKURDI, PUNE- 411 044

INDEX OF CONTENTS
Chapter I
1.0 Introduction ..........................................................3
1.1 Problem Statement........................................................................................... 4
1.2 Aim, Objective and Scope of Study................................................................. 5
1.3 Innovations in Construction…......................................................................... 5
1.4 Present Technologies Available in India… ..................................................... 7
Chapter II
2.0. Research Methodology ........................................11
Chapter III
3.0. Formwork ............................................................13
3.1. Definition of Formwork................................................................................. 13
3.2. Loads acting on a Formwork… ......................................................................16
3.3. Design Aspects................................................................................................17
3.4. Aluminium Formwork ....................................................................................18
3.5. Merits of Aluminum Formwork…..................................................................19
3.6. Comparison of Aluminium Formwork ...........................................................20
Chapter IV
4.0. Literature Review ............................................24
4.0.1. Research Paper 1............................................................................................ 24
4.0.2. Research Paper 2............................................................................................ 27
4.0.3. Research Paper 3............................................................................................ 29

Chapter V
5.0. Mivan: A Versatile Formwork.............................32
5.1. Background….................................................................................................33
5.2. Modular Formwork…......................................................................................33
5.3. Formwork Components................................................................................... 34
5.4. Formwork Assembly…...................................................................................52
5.5. Simplicity- Pin and Wedge System ................................................................60
5.6. Efficient- Quick Strip Prop Head.................................................................... 60
5.7. Construction Activities with MIVAN as Formwork ......................................61
5.8. Illustrations of Assembly and Dismantling…................................................. 69
5.9. Software Application to Formwork Design…................................................ 72
5.10. Site Management .............................................................................................73
5.11. Speed of Construction......................................................................................73
5.12. Economics…....................................................................................................75
5.13. Quality…..........................................................................................................78
5.14. Advantages and Disadvantages of MIVAN Formwork…...............................80
5.15. Remedies…......................................................................................................81
5.16. Components … ................................................................................................81
Chapter VI
1. Case Study- Avon Vista........................................ 85
6.1. Introduction…......................................................................................................85
6.2. Building Description….........................................................................................85
6.3. Shell Drawing Design….......................................................................................91
6.4. Preparatory Work…..............................................................................................94
6.5. Assembly Work… ................................................................................................96
6.6. Worksite Management…....................................................................................112
6.7. Logistics…..........................................................................................................113
6.8. Manpower….......................................................................................................114
6.9. Safety… ..............................................................................................................114
6.10. Accessories and Tools… ..................................................................................115

6.11. Conclusion… ....................................................................................................... 115
6.12. References…........................................................................................................ 116
6.13. Appendix….......................................................................................................... 117
List of figures:
Page
Fig 1.1 Prefabricated Technology................................................................................. 8
Fig 1.2 Tunnel Technology........................................................................................... 8
Fig 1.3 Outinard Technology........................................................................................ 8
Fig 1.4 Mascon Technology ..........................................................................................9
Fig.1.5 Plastic Formwork Technology...........................................................................9
Fig 2.1 Staircase under Traditional formwork arrangement…...................................15
Fig 2.2 Typical steel formwork system…....................................................................15
Fig 2.3 Aluminum formwork for wall .........................................................................15
Fig 2.4 Formwork system ............................................................................................16
Fig 2.5 Example of a self-climbing….......................................................................... 16
Fig 2.6 VSL formwork…............................................................................................. 16
Fig 3.1 Wall Section… .................................................................................................18
Fig 3.2 Rocker….......................................................................................................... 36
Fig 3.3 Kicker… ...........................................................................................................36
Fig 3.4 Kicker Fixation…............................................................................................. 38
Fig 3.5 Wedge with Pin… ............................................................................................ 38
Fig 3.6 Wedge with Pin… ............................................................................................39
Fig 3.7 Long Pin… ....................................................................................................... 39
Fig 3.8 Stub Pin…......................................................................................................... 39
Fig 3.9 Tie Rod… ......................................................................................................... 40
Fig 3.10 Beam Side Panel….........................................................................................40
Fig 3.11 Prop Head for Soffit Beam….........................................................................41
Fig 3.12 Beam Soffit Panel............................................................................................41
Fig 3.13 Beam Soffit Bulk Head…...............................................................................42
Fig 3.14 Deck Panel......................................................................................................43
Fig 3.15 Deck Prop… ...................................................................................................44
Fig 3.16 Deck Prop Length…........................................................................................44
Fig 3.17 Deck Mid Beam...............................................................................................45

Fig 3.18 Soffit Length....................................................................................................46
Fig 3.19 Deck Beam Bar…...........................................................................................47
Fig 3.20 Internal Soffit Corner ….................................................................................48
Fig 3.21. External Soffit Corner… .............................................................................. 49
Fig 3.22. External Corner….........................................................................................50
Fig 3.23. Internal Corner…..........................................................................................51
Fig 3.24. Typical Aluform Assembly… ......................................................................52
Fig.3.25. Typical Wall Formwork Assembly… ..........................................................53
Fig. 3.26. Typical Beam Formwork Assembly…........................................................54
Fig. 3.27. Beam Assembly Details…...........................................................................55
Fig. 3.28. Assemble all formwork on 2nd floor in preparation for conc. work….......55
Fig. 3.29. Striking of Formwork…..............................................................................56
Fig. 3.30. Positioning of Formwork….........................................................................56
Fig. 3.31. Erection of External Working Platform…...................................................57
Fig. 3.32. Removal of Kicker…...................................................................................57
Fig. 3.33 Removal of Platform Brackets… .................................................................58
Fig. 3.34. Striking of Formwork…..............................................................................58
Fig. 3.35. Assembly Process 1: Formwork coating with Form oil… ..........................69
Fig. 3.36. Assembly Process 2….................................................................................69
Fig. 3.43. Dismantling Process 1… .............................................................................71
Fig. 4.1. Overview of Building…................................................................................85
Fig. 4.2. Location of Building…..................................................................................86
Fig. 4.3. Google Earth Building Location View…......................................................87
Fig. 4.4. Bird’s Eye View Building Location…..........................................................87
Fig. 4.5. Bird’s Eye View Building Location…..........................................................88

Fig. 4.6. Project Location….........................................................................................88
Fig. 4.7. General Building Information… ...................................................................89
Fig. 4.8. Residential floor typical Plan… ....................................................................90
Fig. 4.9. Deck Plan of Typical Floors…......................................................................91
Fig. 4.10. Deck Panel Drawings… ..............................................................................92
Fig. 4.11. Staircase Deck Panel Plan… .......................................................................92
Fig. 4.12. Wall Panel Drawing….................................................................................92
Fig. 4.13. Safety Formwork Drawing… ......................................................................93
Fig. 4.14. Kicker Drawing… .......................................................................................93
Fig. 4.15. Kicker Drawing… .......................................................................................93
Fig. 4.16. Guided Chart…............................................................................................95
Fig. 4.17. Coding Chart…............................................................................................95
Fig. 4.18. Lifting tools… .............................................................................................96
Fig. 4.19. Positioning Rebar… ....................................................................................97
Fig. 4.20. Vertical Rebar and ME works… .................................................................98
Fig. 4.21. Internal and External Work Formwork… .................................................100
Fig. 4.22. Installation of Pins and Wedges… ............................................................100
Fig. 4.23. Setting out and Timber Stay Fitting… ......................................................100
Fig. 4.24. Spacing of wall Pins… ..............................................................................101
Fig. 4.25. Spacing of Pins of Slab panels… ..............................................................101
Fig. 4.26. Spacing of Kicker Pins… ..........................................................................101
Fig. 4.27. Wall Formwork Erection….......................................................................102
Fig. 4.28. Beam and Slab Assembly…......................................................................104
Fig. 4.29. Kicker Assembly… ...................................................................................104
Fig. 4.30. Working Platform…..................................................................................106
Fig. 4.31. Working Platform Brackets…...................................................................106
Fig. 4.32. Wall Formwork Stripping and Lifting through Openings….....................108

List of Tables
Page
Table 1- Comparison of inner aluminium form system with conventional
construction ….......................................................................................... 20
Table 2.- Cost Comparison between Conventional and Mivan .................................. 75
Table 3. - Comparison of Aluminium formwork with Conventional type ..................77
Table 4. – Slump Cone Test Result .............................................................................79
Table 5. – Comparative Strength Testing Result …................................................... 79
Table 6. – Components Code…...................................................................................81

Design Detailing and Management for Aluform Shuttering in High Rise Towers
PALLAVI BHOSAREKAR
D.Y. PATIL COLLEGE OF ARCHITECTURE 2
Chapter I

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1.0 INTRODUCTION
Besides, food and clothing, shelter is a basic human need. India has been successful in
meeting the food and clothing requirements of its vast population; however, the
problem of providing shelter of all is defying solutions. “While there has been an
impressive growth in the total housing stock from 65 million in 1947 to 187.05
million in 2001, a large gap still exists between the demand and supply of housing
units. The Working Group on Housing for the 12th five-year plan estimated the
housing shortage in 2018 at 19.4 million units- 12.76 million in rural area and 6.64
million in urban area. The shortage of housing is acutely felt in urban areas –more
so in the 35 Indian cities, which according to the 2011 census have a population of
more than a million”. (Carol., 2015).
In metro cities, particularly in Mumbai, Delhi and Kolkata- each having a
population in excess of 10 million- the problem is still aggravated. A host of factors are
responsible such as the phenomenal growth in population- mainly due to relentless rise
inmigration- non availability of land, legal hurdles in the form of Land Ceiling and Rent
Control (LCRC) acts, paucity of funds, absence of cost-effective construction
techniques-to mention only a few. Barring a few exceptions, no serious attempts were
made in the past to find meaningful solutions to these problems. As a result, we are
witnessing a large-scale proliferation of slums and squatter settlements in the metros.
The National Urban Housing and Habitat Policy, announced in July 2007, laid
stress on the creation of an enabling environment, wherein government assumed the
role of a facilitator and the private sector was expected to play a vital role in providing
large-scale housing. In the recent years, a number of fiscal measures initiated by the
government have given a boost to the housing sector. The easy availability of finance,
coupled with lower interest rates and a variety of tax incentives announced by the
government in the successive union budgets have triggered massive housing
construction in urban and semi urban areas, especially in the middle- and higher-
income groups.
IN A DEMOCRATIC SET-UP OF INDIA, one would agree that this section of
the population cannot be ignored and that they also need to be provided with affordable
housing; but how this can be achieved remains a permanent question. In this context,
the recent affords made in Mumbai under the aegis of the Metropolitan Urban Transport
Project (MUTP), Metropolitan Urban Infrastructure Project (MUIP), and the Slum

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Rehabilitation Authority (SRA) of the government of Maharashtra can provide some
guidance. “It is reported that under MUTP and the MUIP schemes nearly 50,000
tenements are being constructed presently and about 20,000 families have already
shifted to new flats”. Editor (Indian Concrete Journal).
This report deals with all the aspects of MIVAN technology, an aluminium
formwork developed by the company MIVAN itself. The salient features of this
formwork are its ‘speed of construction, quality of construction, seismic resistivity and
its economy.’ All these features are elaborately described in this report.
1.1 PROBLEM STATEMENT
Construction is one of the significant sectors of Indian economy and is an
integral part of the development. Today, India’s urban population is the second largest
in the world and its future development leads to increased demand for housing. To
cope with this problem, India should desperately need to plan for acquisition of land
and rapid creation of dwelling units. Construction is a complex process involving
basically the areas of Architectural planning, Engineering & Construction.
Despite of the boom in construction activities in urban centers in recent years
across the country, the scenario on the housing front remains far from satisfactory.
“Latest statistics indicate that the total housing shortage in the urban sector
was 7.75 million in 2011. An additional demand of 9.7 million units is expected to
be generated in this sector during the period 2012–2017. According to the
Federationof Indian Chamber of Commerce and Industries (FICCI), keeping in
view the existing housing crisis, the country shall need addition of more 2.5 million
new dwelling units annually” (Kulkarni, 2018). The recent years voiced the active
participation private sectors in finding the solution over the prevailing situation on
housing front.
Keeping in view the gigantic task of providing affordable shelter to masses,
adoption of a cost – effective technology assumes greater significance. The present
strain on Indian economy and the overgrowing demands for housing calls for adoptions
of appropriate building technology which could lead to economy and speed in
construction. As a result of experimentation of innovate construction techniques and
modern construction management it is now possible to achieve an overall saving to the
extent of 10% in the total cost of housing construction compared to the cost of

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traditional housing.
There is growing realization today that speed of construction needs to be given
greater importance especially for large housing projects. This is not only essential for
the faster turnover of equipment and investment – leading possible to the reduction in
the housing cost – but also for achieving the national objective of creating a large
stock to overcome shortest possible time. Fortunately, some of the advanced
technologies catering to faster speed of construction are already available in the
country. For e.g., prefabrication, autoclaved blocks, tunnel formwork, aluminum
formwork (MIVAN Technology) of construction etc.
1.2 AIM, OBJECTIVES AND SCOPE OF STUDY
The advancement of technology, increase of population and the space limitation
led the way to construct high-rise buildings.
The aim of this report is to achieve the design aspects and management needed
for Aluform or Mivan shuttering in high rise buildings.
This can simply be achieved by
- understanding the Mivan formwork
- analyzing its merits and demerits
- studying its productivity rate, cost analysis, time optimization and safety.
The most important factor in terms of cost, quality and speed in a high-rise building
construction project is the type of the formwork used in the project. The first formwork
type used is the conventional type formwork where the timber planks were supported
on timber columns.
The scope of this study has been narrowed down or focused to simplify the process of
information gathered in order to conduct the analysis within an appropriate time frame.
The scope of the study is limited to:
• Only high-rise buildings;
• One building case studies only, being a project of Naiknavare Developers, Avon Vista;
• The design aspects and Site Management in high-rise buildings only.
1.3 INNOVATIONS IN CONSTRUCTION
The traditional mode of construction for individual houses comprising load
bearing walls with an appropriate roof above or reinforced concrete (RC) framed

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structure construction with infill masonry walls would be totally inadequate for mass
housing construction industry in view of the rapid rate of construction. Further, such
constructions are prone to poor quality control even in case of contractors with
substantial resources and experience.
“For undertaking mass housing works, it is necessary to have innovative
technologies which are capable of fast rate construction and are able to deliver
good quality and durable structure in cost effective manner”. (R. Kalbhor,2018)
Several systems are adopted at different places in the world; eventually the
systems which are reasonably economical and easy for operation with skilled labour
are useful in India. Certain systems are in vogue and more and more contractors are
trying to bring in new technologies. These are essentially based on the basis of mode
of construction, namely, pre-cast construction or in-situ construction.
1.3.1. CAST IN SITU CONSTRUCTION
Pre-cast and cast-in-situ are techniques that are used for quick construction. Pre-
cast includes the wall-panel units and slab units directly added to building structure.
The use of aluminium also evolved as one of the techniques for quick construction by
and steel (tunnel) formwork. As a matter of fact, the cost of the formwork may be up
to 25% of cost of the structure in building work, and even higher in bridges, it is
thus essential that the forms are properly designed to effect economy without
sacrificing strength and efficiency.
Certain patented systems based on imported technologies such as ‘Mascon
System’ (Canada), ‘Mivan System’ (Malaysia) have come on the Indian scene in recent
years. In these systems, traditional column and beam construction is eliminated and
instead walls and slabs are cast in one operation at site by use of specially designed,
easy to handle (with minimum labour and without use of any equipment) light weight
pre-engineered aluminum forms. Rapid construction of multiple units of a repetitive
type can be achieved with a sort of assembly line production by deployment of a few
semi- skilled labours.
The entire operation essentially comprises fitting and erecting the portion of
shuttering as already determined (the optimization in use is determined by appropriate
planning) and then carrying out concreting of the walls and slabs. Props are so designed
that they stay in position while de-shuttering of slabs and/or takes place. The
dimensional accuracy of the formwork is of high order. Therefore, any possibility of

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errors does not rise.
1.3.2. ‘3-S’ SYSTEM OF PRECAST CONSTRUCTION
An engineered system of building construction, namely ‘3-S’ system was
developed by B.G. SHIRKE CONSTRUCTION TECH LTD., for achieving, speed,
strength, safety and economy in construction practices. The system involves structural
elements such as pre-cast hollow column, shells, pre-cast concrete beams, light weighed
reinforced cellular autoclaved concrete slabs for floor and roofs constituting the basic
structural formwork. The ‘3-S’ system involves activities for construction of building
such as:
 Cast in-situ sub-structure including foundations, stem columns, plinth beams, plinth
masonry.
 Erection of partial pre-cast components, jointing of these components using castin-
situ concrete with appropriate reinforcement.
 Lying of reinforced cast in-situ screed over slab panels, construction of panels,
construction of walling, flooring, plastering, water proofing etc.
Achieving the ‘3-S’ system in the MIVAN formwork is quite easy. MIVAN
formwork has got the unsurpassed speed of construction due to saving time for
required time in masonry and plastering. The strength of raw aluminium is very less
but when alloyed with other materials prove to be strong enough to use as a formwork.
To ensure safety in the site, an integrated safety/ working platform is developed which
ensureslabor safety during erection and striking of the formwork. Economy is also
one of the main factors of any system. The MIVAN formwork proves to cost efficient
as it can be used efficiently for 250 times.
1.4. PRESENT TECHNOLOGIES AVAILABLE IN INDIA
Some of the advanced technologies of formwork catering to the speed of
construction are given below:
To name a few: -
1) The Prefabrication Technology: - The Pre-cast concrete elements in roofs,
floors and in walls have become more common as these eliminate shuttering;
centering & plastering labor and saves material cost.

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Fig 1.1: - Prefabricated Technology
2) Tunnel Formwork Technology: - It is a technology constructing large no of
housing within short time using steel forms to construct walls & slabs in one continuous
pour.
Fig 1.2: - Tunnel formwork
3) Outinard Technology: - Outinard’s superior engineering, the use of high-quality
steel and High-Performance quality control result in a vastly superior Wall Form
system.
Fig 1.3: -Outinard Technology

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4) Mascon Technology: -The Mascon Construction System is a system for forming
the cast in-place concrete structure of a building. It is also a system for scheduling and
controlling the work of other construction trades such as; steel reinforcement, concrete
placement, and mechanical and electrical trades.
Fig 1.4: - Mascon Technology.
5) Plastic Formwork Technology: - These forms have become increasingly popular
for casting unique shapes and patterns being designed in concrete because of the
excellent finish obtained requiring minimum or no surface treatment and repairs.
Different types of plastic forms are available like glass reinforced plastic, fiber
reinforced plastic and thermoplastics etc. The material allows greater freedom of design.
Unusual textures and designs can be molded into the form. It allows the contractor to
pour structural and finished concrete simultaneously. Because sections can be joined on
the job site in such a way so as to eliminate joints, there is no size limitation. If carefully
handled, a number of reuses are possible making it highly & Economical. It is
lightweight and easily stripped. The disadvantage of using plastic forms is that it does
not lend itself to field fabrication hence, the design and planning of this form must be
carefully carried out. Also, care must take not to damage the plastic by the heat applied
for accelerated curing of the concrete. Trough and waffle units in fiberglass are used in
construction of large floor areas and multistoried office buildings.
Fig 1.5: - Plastic Formwork Technology.

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Chapter II

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2.0. RESEARCH METHODOLOGY
GENERAL:
Literature review consists of an overview, a summary, and an evaluation of the current
state of knowledge about a specific area of research. It may also include discussion of
methodological issues.
DATA COLLECTION:
Data collection includes primary data and secondary data from preparation to execution.
It includes literature survey, observation methods, telephonic interactions.
DATA ANALYSIS AND COMPARISON:
Data collected is analyzed whether it satisfies the requirement of the project. Data should
be relevant to the project work in order to get necessary inputs.

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Chapter III

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3.0. FORMWORK
When concrete is placed, it is in plastic state. It requires to be supported by
temporary supports and castings of desired shape till it becomes sufficiently strong to
support its own weight. This temporary casing is known as the formwork or forms or
shuttering. The term moulds are sometimes used to indicate formwork of relatively
small units such as lintels, cornices etc.
3.1. DEFINITION OF FORMWORK
“Forms or moulds or shutters are the receptacles in which concrete is
placed,so that it will have desired shape or outline when hardened. Once concrete
develops the adequate strength to support its own weight they can be taken out”.
(ACC).
“Formwork is the term given to either temporary or permanent moulds
into which concrete or similar materials are poured”. (Wikipedia Encyclopedia).
3.1.1. REQUIREMENTS OF GOOD FORMWORK
The essential requirements of formwork or shuttering are: -
a) It should be strong enough to take the dead and live loads during construction.
b) The joints in the formwork should be rigid so that the bulging, twisting, or
sagging due to dead and live load is as small as possible. Excessive deformation
may disfigure the surface of concrete.
c) The construction lines in the formwork should be true and the surface plane
sothat the cost finishing the surface of concrete on removing the shuttering is the
least.
d) The formwork should be easily removable without damage to itself so that it
could be used repeatedly.
3.1.2. CLASSIFICATION OF FORMWORK
Formwork can be classified according to a variety of categories, relating to the
differencesin sizes, the location of use, construction materials, nature of operation, or
simply by the brand name of the products. However, the huge amount of tropical
wood being consumed each year for formwork has resulted in criticism from
environmentalists, as well as the continual escalation of timber prices. As a result,

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there has been a strong tendency to use other formwork materials or systems to replace
timber. The different categories in which formwork can be classified are:
a) According to size.
b) According to location of use.
c) According to materials of construction.
d) According to nature of operation.
e) According to brand name of the product.
3.1.2.1. CLASSIFICATION ACCORDING TO SIZE
Classification according to the size of formwork can be very straightforward. In
practice, there are only two sizes for formwork; small-sized and large-sized. Any size
which is designed for operation by workers manually is small-sized. Very often, the
erection process is preferably handled by a single worker, with site work best done
independently to avoid possible waiting times. Due to reasons of size and weight, the
materials and construction of small-sized formwork are thus limited. At present, the
most common systems are made of timber and aluminium, and are usually in the form
of small panels. There is seldom medium-sized formwork. In cases in which large-sized
formwork is used, the size of the form can be designed as large as practicable to reduce
the amount of jointing and to minimize the amount of lift. The stiffness required by
large-sized formwork can be dealt with by the introduction of more stiffening
components such as studs and soldiers. The increase in the weight of the formwork
panels is insignificant as a crane will be used in most cases.
3.1.2.2. CLASSIFICATION ACCORDING TO LOCATION OF USE
There are not many effective formwork systems for stairs and staircases. The
complicated three-dimensional nature of an element involving suspended panels and
riser boards, as well as the need to cope with very different spatial and dimensional
variances as required by individual design situations, cannot be achieved by a
universally adaptable formwork system (fig 2.1).

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Fig 2.1 - Staircase under traditional formwork arrangement using timber
3.1.2.3. CLASSIFICATION ACCORDING TO MATERIAL OF
CONSTRUCTION
Materials used for formwork are traditionally quite limited due to finding the
difficult balance between cost and performance. Timber in general is still the most
popular formwork material for its relatively low initial cost and adaptability. Steel, in
the form of either hot-rolled or cold-formed sections and in combination with other
sheeting materials, is another popular choice for formwork materials. In the past two to
three years,full aluminium formwork systems have been used in some cases but the
performance is still being questioned by many users, especially in concern to cost and
labor control (fig 2.2 & 2.3).
Fig 2.2 - Typical steel form system to construct a core Fig 2.3 - Aluminium formwork for wall, floor wall.
and other architectural features
3.1.2.4. CLASSIFICATION ACCORDING TO NATURE OF
OPERATION
Formwork can be operated manually or by other power-lifted methods. Some
systems are equipped with a certain degree of mobility to ease the erection and
striking processes, or to allow horizontal moment using rollers, rails or tracks.
Timber and aluminium forms are the only manually-operable types of
formworks. They are designed and constructed in ways that they can be completely
handled independently without the aid of any lifting appliances. On the other end of
the scale, such systems are used in very large-sized and horizontally-spread buildings
with complicated layout designs which require the systems' flexibility. Fig 2.4 & 2.5

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shows the formwork system allowing the incorporation of pre-cast elements and self-
climbing form with hydraulic jack devices respectively.
Photo 2.4 - formwork system Photo 2.5 - example of a self-climbing
3.1.2.5. CLASSIFICATION ACCORDING TO BRAND NAME OF
PRODUCT
Several patented or branded formwork systems have successfully entered the local
construction market in the past decade. These include products from brands SGB,
RMD, VSL, MIVAN, Thyssen and Cantilever. Each of these firms offers its own
specialized products, while some can even provide a very wide range of services
including design support or tender estimating advice. As the use of innovative building
methods is gaining more attention from various sectors in the community, advanced
formwork systems are obviously a promising solution. The input through research and
development by the well- established formwork manufacturers is of no doubt
contributing to efforts in these areas. (fig. 2.6)
Fig 2.6: - VSL FORMWORK
3.2. LOADS ACTING ON FORMWORK
In Construction, the formwork has to bear, besides its own weight, the weight
of wet concrete, the live load due to labor, and the impact due to pouring concrete

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and workmen on it. The vibration caused due to vibrators used to compact the
concrete should also be taken care off. Thus, the design of the formwork is an essential part
duringthe construction of the building.
For the design of planks and joists in bending & shear, a live load including the
impact may be taken as 370kg/m². It is however, usual to work with a small factor of
safety in the design of formwork. The surfaces of formwork should be dressed in such
a manner that after deflection due to weight of concrete and reinforcement, the surface
remains horizontal, or as desired by the designer. The sheathing with full live load of
370 kg/m² should not deflect more than 0.25 cm and the joists with 200kg/m² of live
load should not deflect more than 0.25cm.
In the design of formwork for columns or walls, the hydrostatic pressure of
the concrete should be taken into account. This pressure depends upon the quantity of
water in the concrete, rate of pouring and the temperature.
The hydrostatic pressure of the concrete increases with the following cases: -
 Increase in quantity of water in the mix.
 The smaller size of the aggregate.
 The lower temperature.
 The higher rate of pouring concrete.
If the concrete is poured in layers at an interval such that concrete has time to
set, there will be very little chance of bulging.
Aluminium as usual is not a very strong material. So, the basic elements of the
formwork system are the panel which is a framework of extruded aluminium sections
welded to an aluminium sheet. It consists of high strength special aluminium
components. This produces a light weight panel with an excellent stiffness-to-weight
ratio, yielding minimal deflections when subjected to the load of weight concrete. The
panels are manufactured in standard sizes with non-standard elements produced to the
required size and size to suit the project requirements.
3.3. DESIGN ASPECTS
In MIVAN formwork, we give stress on shear wall rather than conventional
framed structure of columns and beams. In general, the design of a wall formwork is
described as under.
Consider designing a wall for 30 cm thick and 5 m high. The concrete is poured

PALLAVI BHOSAREKAR
at shifts of 1.5 m each. The sheathing is placed horizontally and spans between vertical
studs are under horizontal pressure due to wet concrete. These Studs are backed by the
horizontal pieces called Wales which are tied by bolts, passing through the wall. Thus,
pressure on either side of the wall is self-balanced as shown fig 2.7.
The pressure exerted by concrete will be 2300 equivalent weight of fluid at a
depth of h meters. Taking lowest portion of the sheathing, the pressure is equal to 2300
x 1.5 =3450 kg/ sq.m. If the sheathing is 25 cm thick, the spacing x of the studs is given
by M=bd²/6 x σ;
σ = 102 kg/ sq cm where σ is safe fiber-stress.
Or, 3450 x x² = 1 x 2.5²/6 x 102
100² x 10
Or, x = 55.5 cm.
Adopt the spacing of 55 cm apart.
If the spacing of Wales is 68cm, the average
pressure on the studs between two bolts will
be2300(1.5-68/2) x .55 =1468 kg per meter
run, assuming concrete pouring is started at
level ofa low bolts.
Max S.F. at edges of clear span = 1468 x
0.6/2 = 440 kg.Assume studs to be 7.5 cm x 10 cm,
Shear stress = 3/2 x 440/ (7.5 x 10) = 8.8 kg/ sq cm.
Maximum fiber stress = 6785 x 10/2 = 54.3 kg/ sq cm.
7.5 x 10³/12
So, the section adopted is satisfactory.
3.4. ALUMINIUM FORMWORK
The panels of aluminium formwork are made from high strength aluminium
alloy, with the face or contact surface of the panel, made up of 4mm thick plate, which
is welded to a formwork of specially designed extruded sections, to form a robust
component. The panels are held in position by a simple pin and wedge arrangement
system that passes through holes in the outside rib of each panel. The panel fits
precisely, securely and requires no bracing. The walls are held together with high
strength wall ties,while the decks are supported by beams and props.
Fig 2.7: - Wall Section

PALLAVI BHOSAREKAR
Since the equipment is made of aluminium, it has sections that are large enough
tobe effective, yet light enough in the weight to be handled by a single worker.
Individual workers can handle all the elements necessary for forming the system with
no requirement for heavy lifting equipment or skilled labor. By ensuring repetition of
work tasks on daily basis it is possible for the system to bring assembly line techniques
to construction site and to ensure quality work, by unskilled or semi-skilled workers.
Trial erection of the formwork is carried out in factory conditions which ensure
that all components are correctly manufactured and no components are missed out.
Also, they are numbered and packed in such a manner so as to enable easy site erection
and dismantling.
3.5. MERITS OF ALUMINIUM FORMWORK
i. In contrast to most of the modern construction systems, which are machine and
equipment oriented, the formwork does not depend upon heavy lifting equipment and
can be handled by unskilled labors.
ii. Fast construction is assured and is particularly suitable for large magnitude
construction of respective nature at one project site.
iii.Construction carried out by this system has exceptionally good quality with accurate
dimensions for all openings to receive windows and doors, right anglesat meeting
points of wall to wall, wall to floor, wall to ceiling, etc., concrete surface finishes are
good to receive painting directly without plaster.
iv. System components are durable and can be used several times without sacrificingthe
quality or correctness of dimensions and surface.
v. Monolithic construction of load bearing walls and slabs in concrete produces
structurally superior quality with very few constructions joined compared to the
conventional column and beam slabs construction combined with filter brick workor
block work subsequently covered by plaster.
vi. In view of the four – day cycle of casting the floor together with all slabs as against
14 to 20 – day cycle in the conventional method, completed RCC structureis available
for subsequent finish trades much faster, resulting in a saving of 10 to 15 days per floor
in the overall completion period.
vii. As all the walls are cast monolithic and simultaneously with floor slabs requiring
no further plasters finish. Therefore, the time required in the conventional method for
construction of walls and plastering is saved.

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viii. As fully completed structural frame is made available in one stretch for subsequent
– finishing items, uninterrupted progress can be planned ensuring, continuity in each
trade, thereby providing as cope for employing increased labor force on finishing item.
ix. As the system establishes a kind of ‘Assembly line production’ phase – wise
completion in desired groups of buildings can be planned to achieve early utilization of
the buildings.
3.6. COMPARISON OF ALUMINIUM FORMWORK
CONSTRUCTION TECHNIQUES OVER CONVENTIONAL
FORMWORK CONSTRUCTION
Advantages of aluminium formwork over conventional construction
i. More seismic resistance: - The box type construction provides more seismic
resistance to the structure.
ii. Increased durability: - The durability of a complete concrete structure is more
than conventional brick bat masonry.
iii.Lesser number of joints thereby reducing the leakages and enhancing the
durability.
iv. Higher carpet area- Due to shear walls the walls are thin thus increasing area.
v. Integral and smooth finishing of wall and slab- Smooth finish of aluminium can
be seen vividly on walls.
vi. Uniform quality of construction – Uniform grade of concrete is used.
vii. Negligible maintenance – Strong built up of concrete needs no maintenance.
viii. Faster completion – Unsurpassed construction speed can be achieved due to light
weight of forms
ix. Lesser manual labour- Less labour is required for carrying formworks.
x. Simplified foundation design due to consistent load distribution.
xi. The natural density of concrete wall result in better sound transmission
coefficient.
Table 1. RELATIVE COMPARISON OF IN – SITU ‘ALUMINIUM
FORM’ SYSTEM WITH CONVENTIONAL CONSTRUCTION.
Sr.
No
FACTOR CONVENTIO
NAL
IN – SITU
ALUMINIUM
FORM SYSTEM
REMARKS

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1 Quality Normal
Superior.
In – Situ casting of whole
structure and transverse
walls done in a continuous
operation, using controlled
concrete mixers obtained
from central batching,
mixing plants and
mechanically placed through
concrete buckets using crane
and compacted in leak proof
moulds using high frequency
vibrators
Superior quality
in ‘System
housing’
2
Speed of
construction.
The pace of
construction is slow
due to step – by – step
completion of
different stages of
activity the masonry is
required to be laid
brick by brick.
Erection of formwork,
concreting and
deshuttering forms is a
two– week cycle. The
plastering and other
finishing activities can
commence only
thereafter.
In this system, the walls and
floors are cast together in
one continuous operation in
matter offew hours and in-
b u i l t accelerated curing
overnight enable removal
and re-use of forms on daily
cycle basis.
System
construction is
much faster.
3 Aesthetics.
In the case of RCC
structural framework
of column and beams
with partition brick
walls is used for
construction, the
columns and beams
show unsightly
projections in room
interiors.
The Room – Sized wall
panels and the ceiling
elements cast against steel
plates have smooth finishing
and the interiors have neat
and clean lines without
unsightly projections in
various corners. The walls
and ceilings also have
smooth even surfaces, which
only need colour/white
Wash
4
External
finishes.
Cement plastered
brickwork, painted with
cement – based paint.
Finishing needs painting
every in three years.
Textured / pattern
colored concrete facia
can be provided. This
will need no frequent
repainting.
Permanent facia
finishes feasible
with minorextra
initial cost

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5
Useful carpet
area as % of
plinth area.
Efficiency around 83.5% Efficiency around 87.5% More efficient
utilization of
land for useful
living space.
6
Consumption
of basic raw
materials:
Cement.
Reinforcem
ent Steel
Normal
Reinforcement steel
required is less as
compared to the in situ
construction as RCC
framework uses brick
wall as alternative
Consumption somewhat
more than that used in
conventional structures.
It may, however will be
slightly more than
corresponding load –
bearing brick wall
construction for which,
requirements of IS
456 have to be followed
for system housing.
Although
greater
consumption
strength and
durability is
also more
Steel
requirement is
more, as it is
required for the
shear wall
construction.
But shear wall
construction
increases safety
against
earthquake.
7
Maintenance In maintenance cost, the
major expenditure is
involved due to:
 Repairs and
maintenance of plaster
of walls / ceiling etc.
 Painting of outer and
inner walls.
Leakages due to
plumbing and sanitation
installation.
The walls and ceiling
being smooth and high-
quality concrete repairs
for plastering and
leakages are not at all
required frequently.
It can be
concluded that
maintenance
cost is
negligible.

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Chapter IV

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4.0. LITERATURE REVIEW
4.0.1. RESEARCH PAPER I:
Analysis of Productivity by Comparing Mivan and
Conventional Formwork
THIS PAPER IS PUBLISHED IN THE JOURNAL OF EMERGING TECHNOLOGIES
AND INNOVATIVE RESEARCH, PUBLISHED IN VOLUME 2, ISSUE 4, APRIL 2018.
Presented by:
1. Prathul U, PG student, Department of Civil Engineering
2. Leeladhar Pammar, Assistant Professor, NMAMIT, Nitte
I. INTRODUCTION
Productivity is the important factor affecting the overall efficiency in Construction site. At
site level productivity can be grouped under various departments like productivity in concrete,
steel work and shuttering. With advancement in cost industry, it has become necessary to keep
account of expenditure made in the process. The view of this productivity has become a major
concern to delt with.
High productivity refers to doing the work in a shortest possible time with least expenditure
on inputs without sacrificing quality and with minimum wastage of resources. Productivity
measurement at construction site level enables companies to monitor their own performance
against their site performance.
Formwork is a total system of support required before placing of concrete. It includes the
molder, sheathing which contacts the concrete as well as all supporting members, hardware
and necessary bracing. It is used to shape and support concrete until it attains sufficient
strength to carry its own weight. Formwork should be able to carry all imposed dead and live
loads apart from its own weight. As Formwork governs quality, cost and time, it is essential
to choose a right scheme of formwork for project.
II. AIM
The main aim of the study is to analyze the productivity by comparing conventional and

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Mivan formwork.
III. SCOPE AND OBJECTIVE
A.Scope
The main scope of the study is to analyze the productivity of Mivan and Conventional
formwork and their suitability under different circumstances.
B.Objective
The main objectives are
 To determine the productivity of Mivan and conventional formwork for
different months.
 To track the variation of productivity from target productivity.
 To calculate shuttering usage ratio for conventional formwork.
 Cost comparison between Mivan and conventional formwork.
IV. OBSERVATIONS AND OUTCOMES
It was estimated that 30 to 70 percent of cast-in-place concrete cost is attributed to the
assembly and stripping of formwork. A comparative analysis of concrete formwork
productivity influencing other factors and analysis of labour productivity in buildings was
studied. It was found that the Concrete formwork labour costs constituted to over 1/3 of total
concrete construction costs which is nearly about 35% of the total cost of vertical concrete
work. Thus, proper system selection, repetitive design dimensions, efficient scheduling, and
careful activity coordination can yield significant productivity savings. Productivity depends
on form type, panel size, formed surface shape, form height, method of assembly and
placement.
Also, a Neural network model was used to study a number of factors considered to impact
labour productivity on daily basis. These included temperature, relativehumidity, wind speed,
precipitation, gang size, crew composition, height of work, type of work and construction
method employed.The data were then analyzed to determine the influence of these parameters
on site labour productivity.

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A case study was done Brigade Cosmopolis site, undertaken by Shapoorji Pallonji & Co. Ltd
in Whitefield, Bangalore. Collection of data was done for 16 months. The project consisted of
12 towers, construction was done in 2 Phase, each phase had 6 towers. Study was done for
Phase1 (Tower F, G, H, I, J, K, L) Comprising 2 Basement, Ground floor and 18 upper floors.
Total built up area of Phase 1 is 11, 22,000 Square feet. Mivan and conventional formwork
were used for Construction.
Productivity for Mivan and formwork were calculated separately and they are tracked against
target productivity which is obtained from company norms. For Brigade Cosmopolis project
target productivity for conventional formwork is 2.5 Sqm/man-day’s and for Mivan formwork
is 10 Sqm/man-days.
Productivity of conventional formwork mainly depends on the element for which it is used as
mould. Formwork used for column as shuttering has higher no of repetitions when compared
with shuttering material used for beams and slabs. Since the Deshuttering time for column is
24 hours where as in slab its 28 days although it covers large area. Increase in no of repetition
results in increase in quantity of work done per month which in turn increases the productivity.
Constraints such as rain, failure of tower crane also lowers the productivity.
At the beginning, productivity of Mivan formwork is low because it takes time for setting out
and aligning. As number of floors increases there is increase in productivity because of
repetition of same job. In this project all 6 towers have different date of start hence the overall
productivity get affected.
In Mivan formwork system materials are shifted manually from one floor to another, use of
tower crane for shifting of Mivan panel is almost nil but for transferring reinforcement bars
tower cranes are used. Failure in tower will delay the 7-day slab cycle.
Initial cost of Mivan formwork is high when compared with conventional formwork. Rate of
Aluminium formwork varies from Rs. 7000 / sq.m to Rs. 10000 / sq.m. Mivan formwork is
economical when floors are typical and also labour cost for Mivan is slightly less when
compared with conventional formwork. Aluminium formworks are more durable, maximum
repetition of 300 can be achieved where as in conventional maximum repetition of 10 can be
achieved which makes aluminium formwork more economical.

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4.0.2. RESEARCH PAPER II
Mivan Technology
THIS PAPER IS PUBLISHED IN THE INTERNATIONAL JOURNAL OF
ENGINEERING AND TECHNICAL RESEARCH, PUBLISHED IN VOLUME 3, ISSUE
6, JUNE 2018.
Presented by:
1. Kushal Patil
2. Ajitkumar Jadhav
3. Nikhil Shingate
1. INTRODUCTION
The Mivan Technology System was developed by MivanCompany Ltd from Malaysia late
1990s as a system for constructing mass housing project in developing countries. The units
were to be of cast-in-place concrete, with load bearing walls using a formwork of aluminum
panels. To be erected by the hundreds, of a repetitive design, the system ensured a fast and
economical method of construction. The concrete surface finish produced with the
aluminum forms allows achievement of a high-quality wall finish without the need for
extensive plastering. 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 athigh
level. The speed of construction by this system will surpass speed of most of the other
construction methods/technologies.
2. AIM
This paper aims to discuss cost comparison of Mivan technology with conventional
construction technology. It also reviews from the people who are occupying the houses
constructed by Mivan technology to get the feedback from occupant on Mivan technology.

PALLAVI BHOSAREKAR
3. SCOPE AND OBJECTIVE
Scope:
The scope of the study is limited to the cost comparison, reviews and remedies.
Objectives:
To find a solution to the defect found in Mivan technology and future scope of Mivan
technology.
4. OBSERVATIONS AND OUTCOMES:
It states that the Mivan formwork is made up of an aluminium alloy. While Construction is in
process, the formwork is supposed to bear, besides its own weight, the weight of wet concrete,
the live load due to labour, and the impact due to pouring concrete and workmen on it. The
vibration caused due to vibrators used to compact the concrete should also be taken care off.
Thus, the design of the formwork considering its requirements is an essential part during the
construction of the building. The Mivan Formwork should be able to take a live load including
the impact about 370kg/m². The formwork components are durable they can be used repetitively
up to 200 times. It is light weighted so heavy lifting is eliminated, the heaviest components is
of 25 kg, a labor can easily lift it. It was observed that honeycombing and cracks were developed
in the shear walls. In Mivan Technology of construction the concrete is placed from height of 3
meter in shear wall and compacted using vibrator, now as height of placing concrete is more
there are chances of segregation in concrete resulting in honeycombing and cracks in wall. In
Mivan construction, it is generally happened that after removing formwork there is
honeycombing in shear wall, in this project we had tried to fix the problem of honeycombing in
shear wall. It was suggested us to use the MasterGlenium ACE 30JP as admixture to concrete
so as to increase the workability of concrete to reduce honeycombing and increase the strength
of concrete. One of the measures to check the workability of concrete is its slump and to check
the strength is compressive strength. Thus, it can be concluded that quality and speed must be
given due consideration with regards to economy. Good quality construction will never deter to
projects speed nor will it be uneconomical. In fact, time consuming repairs and modification
due to poor quality work generally delay the job and cause additional financial impact on the
project.

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4.0.3. RESEARCH PAPER III
Time and Cost Optimization of Construction Project
Using MivanTechnology
THIS PAPER IS PUBLISHED IN THE JOURNAL OF ENGINEERING RESEARCH
AND APPLICATION, PUBLISHED IN VOLUME 8, ISSUE 8 (PART II), AUGUST 2018.
Presented by:
1. Akshay Gulghane
2. Nikhil Pitale
3. Sanket Sanghai
1. INTRODUCTION
Mivan is one of the sophisticated- engineered formwork fabricated in Aluminium Monolithic
pouring. Walls, columns, slabs & beam are poured together in particular system. The
utilization of Mivan formwork in the construction industry of India is comparatively very less
as to the other developing or developed countries around the globe. The utilization of Mivan
formwork technology in construction industry has the greater potential. This formwork as a
sophisticated construction material but it is also economical inheavy type of construction.
This recent method of construction by this technology can appreciably increase the
productivity of construction, built quality and durability of construction work through the use
of efficient construction tools, construction materials, and time for construction saving
compared to conventional technologies or methods. This technology is one of the recent
construction technologies upcoming at the greater speed for the successful completion various
construction project across Indian construction industry, especially mass housing project.
2. AIM
The basic ideology is to reach a sturdy conclusion regarding the superiority of the two
techniques over another that is conventional technology and Mivan Technology.
3. SCOPE AND OBJECTIVES

PALLAVI BHOSAREKAR
Scope: The scope is limited to time, cost and speed of construction through Mivan
Technology.
Objectives:
a. Quantity estimation of construction material required for building by both MIVAN
formwork and Conventional formwork.
b. To determine complete time required for completion of the building by both the above
methods.
c. To compare the cost of buildings based on the cost of materials required in each of them.
d. To carry out the comparative analysis between the mentioned two methods of construction
and define suitability difference between them.
4. OBSERVATIONS AND OUTCOMES
The basic elements included in Mivan Formwork are the sets of panels, which are a shear
extruded aluminium rail section, fully welded to an aluminium metal sheet. Cubic Contents
Method is particularly used to find the complete volume of the construction activities. In this
precise method the length, width and the depth of the construction elements is multiplied to
obtain the total quantity of that particular element. In the case of plastering of the surfaces
and other surfacing works the complete surface area is found by multiplying the length with
the width for which the work is to be done. The rate per unit of the construction work is then
multiplied with the total quantity of the work to get the amount required to do the particular
work. It is more accurate that the other two methods viz., plinth area method and unit base
method of computing. The cost of a construction facility is computed approximately as the
total cubical contents i.e., Volume of structure multiplied by the available Local Cubic Rate.
The complete Formwork planning process is categorized into 3 main stages:
In First stage all the necessary information and limiting conditions must be efficiently
collected and appropriately defined. When construction projects of the similar nature are
being executed, a proper and formatted checklist can be of immense help in obtaining
complete information required to prepare a complete pre-plan.
In second stage, the formwork system which has to be used in the building the construction
facility can be properly selected. In addition to total cost of the materials which has to be
used, the choice of the efficient system will be influenced by the experience of the planning
team. A complete database that particularly captures the complete experience collected over
the number of years can contribute in cost effective system selection.

PALLAVI BHOSAREKAR
The third stage involves all engineering related designing tasks. This is most time-consuming
part of the particular process. One of the important thing is to have the flexibility in the
working of system in later stages of the project. The complete emphasis should be on
maximum reuse of available materials and procuring minimum materials that to Just-In-
Time.
It also states that excellent seismic resistant construction facility with considerably greater
efficiency and appreciably smooth finish is achieved by using Aluform formwork system.
Analysis of cost is worked out as below.
 Total Analysis Of Cost Using Mivan technology
Cost of foundation of building = Rs. 50,00,000
Cost of P+7 floor of area 771.92 Sqm= Rs. 4,22,50,000
Total cost of building=Rs. 4,27,50,000
 Using Conventional technology
Cost of foundation of building =Rs. 50,00,000
Cost of P+7 floor of area 771.92 Sqm=Rs. 4,82,50,000
Total cost of building=Rs. 4,87,50,000
5. CONCLUSION
It is concluded that construction facilities built by using the Mivan formwork technology is
quite cheaper than the Conventional Method and total cost saving is nearly about 12.5
percent. This technology also enables us in saving considerable amount of time in
construction of high-rise building. Also, many of the finishing works is saved in using Mivan
technology which includes plastering (both internal and external), brickwork etc. Monolithic
casting of the structural members at one pour saves appreciable time and increases strength
and durability of the structure. The advantages of Mivan technology include higher durability
of material, uniform quality of construction, low maintenance of formwork system and faster
completion of activities. Whereas the drawbacks are high initial cost, structural symmetry is
required and requirement of skilled labour at every stage of construction.

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Chapter V

PALLAVI BHOSAREKAR
5.0. MIVAN: A VERSATILE FORMWORK
The system of aluminum forms (MIVAN) has been used widely in the
construction of residential units and mass housing projects. It is fast, simple,
adaptableand cost – effective. It produces total quality work which requires minimum
maintenanceand when durability is the prime consideration. This system is most
suitable for Indian condition as a tailor–made aluminum formwork for cast–in–situ
fully concrete structure.
5.1. BACKGROUND
Mivan is basically an aluminium formwork system developed by one of the
construction company from Europe. In 1990, the Mivan Company Ltd from Malaysia
started the manufacturing of such formwork systems. Now a days more than 30,000 sq
m of formwork used in the world are under their operation. In Mumbai, India there are
number of buildings constructed with the help of the above system which has been
proved to be very economical and satisfactory for Indian Construction Environment.
The technology has been used extensively in other countries such as Europe,
Gulf Countries, Asia and all other parts of the world. MIVAN technology is suitable
for constructing large number of houses within short time using room size forms to
construct walls and slabs in one continuous pour on concrete. Early removal of forms
can be achieved by hot air curing / curing compounds. This facilitates fast construction,
say two flats per day. All the activities are planned in assembly line manner and hence
result into more accurate, well – controlled and high-quality production at optimum
cost and in shortest possible time.
In this system of formwork construction, cast – in – situ concrete wall and floor
slabs cast monolithic provides the structural system in one continuous pour. Large room
sized forms for walls and floors slabs are erected at site. These forms are made strong
andsturdy, fabricated with accuracy and easy to handle. They afford large number of
repetitions (around 250). The concrete is produced in RMC batching plants under strict
quality control and convey it to site with transit mixers.
The frames for windows and door as well as ducts for services are placed in the
form before concreting. Staircase flights, façade panels, chajjas and jails etc. and other
pre-fabricated items are also integrated into the structure. This proves to be a major
advantage as compared to other modern construction techniques.

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The method of construction adopted is no difference except for that the sub –
structure is constructed using conventional techniques. The super–structure is
constructedusing MIVAN techniques. The integrated use the technology results in a
durable structure.
5.2. MODULAR FORMWORK
The formwork system is precisely-engineered system fabricated in aluminium.
Using this system, all the elements of a building namely, load bearing walls, columns,
beams, floor slabs, stairs, balconies etc. can be constructed with cast in place concrete.
The resulting structure has a good quality surface finish and accurate dimensional
tolerances. Further, the construction speed is high and the work can be done in a cost-
effective manner.
The modular nature of the formwork system allows easy fixing and removal of
formwork and the construction can proceed speedily with very little deviation in
dimensional tolerances. Further, the system is quite flexible and can be easily adapted
forany variations in the layout.
The availability of concrete from ready mix concrete facility has augured well
for the use of this work system. However, the proliferation of RMC facilities in the
cities in India and the willingness to use mechanized means of transport and placing of
concrete, the use of aluminium formwork system has received a boost. The quality of
the resulting concrete is found to be superior.
Structurally speaking, the adoption of the closed box system using monolithic
concrete construction has been found to be the most efficient alternatives. The stresses
in both the concrete and steel are observed to be much lower even when horizontal
forces due to wind or earthquake are taken into consideration.
The formwork system can be used for construction for all types of concrete
systems, that is, for a framed structure involving column beam –slab elements or for
box- type structure involving slab-walls combination.
5.3. FORMWORK – COMPONENTS
The basic element of the formwork is the panel, which is an extruded aluminium
rail section, welded to an aluminium sheet. This produces a lightweight panel with an
excellent stiffness to weight ratio, yielding minimal deflection under concrete loading.
Panels are manufactured in the size and shape to suit the requirements of specific

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projects.
The panels are made from high strength aluminium alloy with a 4 mm thick skin
plate and 6mm thick ribbing behind to stiffen the panels. The panels are manufactured
in MIVAN’S dedicated factories in Europe and South East Asia. Once they are
assembled, they are subjected to a trial erection in order to eliminate any dimensional
or on-site problems.
All the formwork components are received at the site whining three months after
they are ordered. Following are the components that are regularly used in the
construction.
Aluminium Extrusion Components:
 Modulus of Elasticity (E) = 68,900 N/mm2
 Yield Strength (Fy) = 240 N/mm2
 Allowable Bending Stress (0.6 x Fy) = 144 N/mm2
Aluminium Flat Sheet:
 Modulus of Elasticity (E) = 68,900 N/mm2
Wall Tie and Waling:
 Mild Steel Grade = 250 N/mm2
 Modulus of Elasticity (E) = 2,00,000 N/mm2
 Allowable Axial Tension (0.6 x Fy) = 150 N/mm2
Stub Pin:
 Allowable Axial Tension = 153 N/mm2
 Allowable Shear Stress = 102 N/mm2
5.3.1. WALL COMPONENTS
1) Wall Panel: - It forms the face of the wall. It is an Aluminium sheet
properly cut to fit the exact size of the wall.

PALLAVI BHOSAREKAR
FIG 3.1: WALL PANEL
2) Pivot Block / Rocker: - It is a supporting component of wall. It is L-
shaped panel having allotment holes for stub pin.
FIG 3.2: ROCKER
 4mm thick Al sheet as sheathing
member and the stiffeners with
Edge Frames.
 Forms the face the wall from the
top of the kicker to the bottom of
the kicker.
 Wall panel and top panels if
needed.

PALLAVI BHOSAREKAR
3) Kicker: - It forms the wall face at the top of the panels and acts as a
ledge to support.
FIG 3.3: KICKER
Specifications:
- 65 mm wide x 125 mm deep.
- Forms the wall face at the top of the wall panels.
- Anchored to the concrete and acts as a ledge for the wall panels on the next floor to sit
on.
Specifications:
 Size: 65x50x8mm
 Material: Aluminium t 6-
6061/6063
 Application: Use at the bottom
of the wall panels at the
internal wall. Helps in
facilitate striking.
 Special feature: One meter =
1.74 kg


PALLAVI BHOSAREKAR
FIG 3.4: KICKER FIXATION USING KICKER BOLT AND STARTER BLOCK /KICKER
BOLT
4) Wedge With Pin: - It helps in joining two wall panels. It helps in joining two
joints.
FIG 3.5: WEDGE WITH PIN

PALLAVI BHOSAREKAR
FIG 3.6: WEDGE WITH PIN
5) Long Pin: - It helps in joining two wall panels. It helps in joining two joints
FIG 3.7: LONG PIN
6) Stub Pin: - It helps in joining two wall panels. It helps in joining two joints
FIG 3.8: STUB PIN
SPECIFICATION
Material Mild Steel
Size 50 - 56 mm
Packaging Type Box
Brand Mahalaxmi Traders
Surface Finish Brass Coated, Electro Zinc Plated
Specifications:
 Size: 132mm
 Material: Mild Steel
 Application: Use in
aluminium formwork's
system
 Available Size: 127mm,
132mm,140mm,190mm
 Colour Coating: Silver and
Gold coated, zinc electro
plated
SPECIFICATION:
 56mm long
 Electro Zinc Plated

PALLAVI BHOSAREKAR
7) Tie Rod: - It helps in joining two wall panels. It helps in joining two joints
FIG 3.9: TIE ROD
5.3.2. BEAM COMPONENTS:
1) Beam Side Panel: - It forms the side of the beams. It is a rectangular structureand
is cut according to the size of the beam
FIG 3.10: BEAM SIDE PANEL
SPECIFICATION:
Brand VIP ALUFORM
Shape Rectangular
Finishing SMOOTH
Material Steel
Length 6 feet
Panel Thickness 6-8 mm
SPECIFICATION:
 Dywidag Tie Rod 3mtr Long

PALLAVI BHOSAREKAR
2) Prop Head for Soffit Beam: - It forms the soffit beam. It is a V-shaped head
for easy dislodging of the formwork.
FIG 3.11: PROP HEAD FOR SOFFIT BEAM.
3) Beam Soffit Panel: - It supports the soffit beam. It is a plain
rectangularstructure of aluminium.
FIG 3.12: BEAM SOFFIT-PANEL

PALLAVI BHOSAREKAR
SPECIFICATION
Material Aluminium
Color Black
4) Beam Soffit Bulkhead: - It is the bulkhead for beam. It carries most of the bulk
load.
FIG 3.13: - BEAM SOFFIT BULKHEAD

PALLAVI BHOSAREKAR
SPECIFICATION
Material Aluminium
Color Black
5.3.3. DECK COMPONENT
1) Deck Panel: - It forms the horizontal surface for casting of slabs. It is built for
proper safety of workers.
FIG 3.14: - DECK PANEL
2) Deck Prop: - It forms a V-shaped prop head. It supports the deck and bears theload
coming on the deck panel.

PALLAVI BHOSAREKAR
FIG 3.15: -DECK PROP
SPECIFICATION
Material Aluminium
Color Black
3) Prop Length: - It is the length of the prop. It depends upon the length of
theslab.
FIG 3.16: - DECK PROP LENGTH

PALLAVI BHOSAREKAR
SPECIFICATION
Material Aluminium
Color Black
4) Deck Mid – Beam: - It supports the middle portion of the beam. It holds the
concrete.
FIG 3.17: - DECK MID-BEAM

PALLAVI BHOSAREKAR
SPECIFICATION
Material Aluminium
Color Black
5) Soffit Length: - It provides support to the edge of the deck panels at
theirperimeter of the room.
FIG 3.18: - SOFFIT LENGTH

PALLAVI BHOSAREKAR
6) Deck Beam Bar: - It is the deck for the beam. This component supports thedeck
and beam.
FIG 3.19: -DECK BEAM BAR

PALLAVI BHOSAREKAR
5.3.4. OTHER COMPONENTS
1. Internal Soffit Corner: - It forms the vertical internal corner between
thewalls and the beams, slabs, and the horizontal internal cornice
between thewalls and the beam slabs and the beam soffit.
FIG 3.20: -INTERNAL SOFFIT CORNER

PALLAVI BHOSAREKAR
2. External Soffit Corner: - It forms the external corner between the components
FIG 3.21: -EXTERNAL SOFFIT CORNER
3. External Corner: - It forms the external corner of the formwork system.

PALLAVI BHOSAREKAR
FIG 3.22: - EXTENAL CORNER
4. Internal Corner: - It connects two pieces of vertical formwork pieces at
theirexterior intersections. Fig 3.18

PALLAVI BHOSAREKAR
FIG 3.23: - INTERNAL CORNERS

PALLAVI BHOSAREKAR
5.4. FORMWORKS ASSEMBLE
MIVAN aims in using modern construction techniques and equipment in all its
projects. On leaving the MIVAN factory all panels are clearly labeled to ensure that
they are easily identifiable on site and can be smoothly fitted together using the
formwork modulation drawings. All formwork begins at corner and proceeds from
there. (Fig. No.3.19, Fig no 3.20, Fig. no. 3.21)
FIG 3.24: - TYPICAL ALUFORM ASSEMBLY

PALLAVI BHOSAREKAR
5.4.1. WALL FORMWORK ASSEMBLY
FIG 3.25: - TYPICAL WALL FORMWORK ASSEMBLY

PALLAVI BHOSAREKAR
5.4.2. BEAM FORMWORK ASSEMBLY
FIG 3.26: - TYPICAL BEAM FORMWORK ASSEMBLY

PALLAVI BHOSAREKAR
FIG 3.27: - BEAM ASSEMBLY DETAILS
5.4.3. GRAPHICAL REPRESENTATION: WORKING PLATFORM
ASSEMBLY
SEQUENCE FOR STRIKING AND
ERECTING THE WALL
MOUNTED PANELS ON
WORKING PLATFORM FOR 2ND
FLOOR

PALLAVI BHOSAREKAR
Fig 3.28: - Assemble all formwork on the 2nd
floor in preparation for the concrete works
Fig 3.29: - Striking of formwork
Fig 3.30: - Positioning of formwork
STRIKING OR REMOVAL OF
ALL FORMWORK AFTER
CONCRETE WORK CAN BE
DONE WITHIN 10-15 HOURS.
THE ONLY TOOL REQUIRED
FOR DISMANTLING IS
HAMMER
POSITIONING OF WORKING
PLATFORM BRACKET ON 3RD
FLOOR LEVEL AND SECURING
POSITION WITH TIE ROD AND
SECURING NUTS ON INSIDE
THE BUILDING

PALLAVI BHOSAREKAR
Fig 3.31: - Erection of external working platform
Fig 3.32: - Removal of Kicker
FIX THE HANDRAIL SUPPORTS,
PLYWOOD WALKWAY & TOE
BOARD TO THE 3RD FLOOR
PLATFORM. NOTE: SAFETY
HARNESS MUST BE WORN
DURING THE OPERATION
REPEAT THE PROCESS AGAIN
BY ASSEMBLING THE
VERTICAL FORMWORK ON THE
3RD FLOOR. REMOVE KICKERS
FROM THE 2ND FLOOR LEVEL
AND FIX TO THE TOP OF THE
3RD FLOOR LEVEL.

PALLAVI BHOSAREKAR
Fig 3.33: - Removal of platform brackets
Fig 3.34: - Striking of formwork
REMOVE THE WORKING
PLATFORM BRACKET AND
SUPPORTS FROM THE 2ND
FLOOR AND PASS UP TO BE
STORED ON LEVEL 3
PLATFORMS.
THIS OPERATION IS TO BE
CARRIED OUT ON THE DAY OF
THE CONCRETING – LEVEL 3
WALL AND LEVEL 4 SLAB.
REMOVE ALL VERTICAL
FORMWORK ON THE 3RD
FLOOR. (CONCRETE WAS
POURED ON THE PREVIOUS
DAY)

PALLAVI BHOSAREKAR
REMOVE NUTS FROM THE TIE
ROD ON THE 2ND FLOOR
WORKING PLATFORM
BRACKET.
HOIST THE WORKING
PLATFORM BRACKET FROM
THE 2ND FLOOR UP TO THE
3RD FLOOR.

PALLAVI BHOSAREKAR
5.5. SIMPLICITY – 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. (Fig.No.3.21) The panels
fit precisely, simply and securely and require no bracing. Buildings can be constructed
quickly and easily by unskilled labour with hammer being the only tool required. Once
the panels have been numbered, measuring is not necessary. As the erection process is
manually, tower cranes are not required. The result is a typical 4-to-5-day cycle for floor
– to – floor construction.
5.6. EFFICIENT – QUICK STRIP PROP HEAD
One of the principal technical features which enables this aped to beattained using
a single set of formwork panel is the unique V shaped a prop head which allows the ‘quick
strip’ to take place whilst leaving the propping undisturbed. The deck panels can therefore
be resumed immediately.
POSITION THE WORKING
PLATFORM BRACKET ON THE
4TH FLOOR LEVEL AND
SECURE USING THE TIE ROD
AND SECURING NUT ON THE
INSIDE OF THE BUILDING.

PALLAVI BHOSAREKAR
5.7. CONSTRUCTION ACTIVITIES WITH MIVAN AS FORMWORK
The construction activities are divided as pre – concrete activities, during concreting and
post – concrete activities. They are as follows:
5.7.1. PRE – CONCRETE ACTIVITIES:
a) Receipt of Equipment on Site – The equipment’s is received in the site as ordered.
b) Level Surveys – Level checking are made to maintain horizontal level check.
c) Setting Out – The setting out of the formwork is done.
d) Control / Correction of Deviation – Deviation or any correction are carried out.
e) Erect Formwork – The formwork is erected on site.
f) Erect Deck Formwork – Deck is erected for labours to work.
g) Setting Kickers – kickers are provided over the beam.
After the above activities have been completed it is necessary to check thefollowing.
i. All formwork should be cleaned and coated with approved realize agent.
ii. Ensure wall formwork is erected to the setting out lines.
iii. Check all openings are of correct dimensions, not twist.
iv. Check all horizontal formwork (deck soffit, and beam soffit etc.) in level.
v. Ensure deck and beam props are vertical and there is vertical movement inthe prop
lengths.
vi. Check wall ties, pins and wedges are all in position and secure.
vii. Any surplus material or items to be cleared from the area to be cast.
viii. Ensure working platform brackets are securely fastened to the concrete.
i) RECEIPT OF EQUIPMENT ON SITE:
a) Unload components from transport and where possible, stack by code and size panels
can normally be stacked safely up to 25 panels high on skids or pallets.
b) When stacked, holing in the formwork should be aligned allowing easy identification
by code.

PALLAVI BHOSAREKAR
c) Ensure the first panel at the bottom of the stack has the contact face upwards.
d) All pins, wedges, wall ties, P.E sleeves, L.D.P.E sheet and special tools to be put into
proper storage and only distributed as required.
e) A check requires to be carried out against the packing list ensuring all items stated are
received.
ii) LEVEL SURVEYS:
a) A concrete level survey should be taken on all sites and remedial work carried out prior
to the erecting of formwork.
b) All level surveys should be taken from T.B.M (Temporary Bench Mark).
c) In certain cases, it is good practice to mark the slabs with paint indicating a plus (+) or
minus (-) as the survey is being conducted. The eliminates unnecessary circulation of
paper copies to site personnel, and supervisor can identify at a glance any remedial work
required.
d) High spots along the wall line to be chipped off to the proper level.
Low spots along the wall line should be packed to the required level, using plywood or
timber.
Packing the corner and the centre of the wall length to the required level will be normally
be adequate, as the formwork when pinned together will bridge across low spots.
e) Concrete (+8mm) and above must be chipped to the correct level.
After concreting, level surveys should also be carried out on the top of the kickers. One
reason for structural deviation from the centre line can be on a – level kicker. This in turn
means the formwork is not in plumb.
f) Kickers are manufactured with a 26mm slotted hole on the face to allow for adjustment
after concreting.
g) As with the concrete level survey, proper records of the kicker survey should be kept
on file by the allocated supervisor.
h) Also, a deviation survey requires to be carrying out and keeping on fire.
iii) SETTING OUT:
a) Only approved shell drawings supplied by Mivan Formwork Design should be used

PALLAVI BHOSAREKAR
for setting out.
b) Setting out lines should continue through openings, external corners etc., by a
minimum of 150mm. This makes it easier to fix formwork in position prior to concreting.
c) It is very important that the reference points and the setting out points are protected
against accidental movement or damage.
d) Transferring of reference points from the level below requires to be done quite
accurately. Incorrect reference points give incorrect deviations therefore creating
unnecessary work for the formwork erection. It is suggested a theodolite be used for
transferring the points through openings provided in the slab.
iv) CONTROL / CORRECTING OF DEVIATIONS:
a) A study of the deviation and kicker level survey should confirm what, if any, corrective
action is required.
b) If the kicker requires adjustment for level, loosen the holding- in bolt by turning anti-
clockwise, adjust kicker to the required position and retighten the bolt.
c) Once the vertical formwork is fixed in position, the external corners should be checked
for plumbness. This will determine if further action is required to control the deviation.
d) In addition to the kicker levels, the formwork can be pulled by using bottle screws and
chain blocks; if the formwork requires to be pushed adjustable props can be used.
v) ERECT FORMWORK:
For the initial set up only 50mm*25mm timber stays can be nailed to the concrete slab,
close to the internal and external corners, to ensure the formwork is erected to the setting
out lines.
All formwork begins at corner and proceeds from there. This is to provide temporary
lateral stability. A single panel at a corner will give sufficient lateral support to a very
long section of wall.
Ensure all edges of the formwork and contact face are properly cleaned and oiled prior to
fixing in place.
When satisfied the corner is stable and the internal corner is positioned to the setting
out lines continue erecting the formwork to one wall. Use only 2 no of pins and wedges
to connect the formwork at this stage the pins and wedges will have to be removed later

PALLAVI BHOSAREKAR
to insert the wall ties. Alternatively, the wall ties can be positioned as the formwork is
erected. For ease of striping, pin the wall panels to the internal corners with the head of
pin to the inside of the internal corner if possible.
Wall ties should be coated with the releasing agent provided before being fixed to the
formwork. Fit the wall ties through slots in the wall formwork and secure in position with
pins and wedges.
Prior to closing the formwork, pre-wrapped corrugated PVC sleeves are placed over the
wall ties. Please ensure, since preparation of the sleeves they have not been abused in any
way before installing, as this can have an adverse effect in the removal of the wall tie after
concreting. Also, ensure they are located properly to the contact face of the formwork on
each side of the wall. Sleeves installed with one end fixed between the side rails of two
adjoining panels, exposes the wall tie at the opposite end, therefore impossible to retrieve
the wall tie after concreting.
When deviation of external walls occurs, they must be brought back to the correct plan
location as quickly as possible. This is done by slightly tilting the external wall forms in
one plane. If a deviation from plumb has occurred in two directions, then this should be
improved over two floors, one for each direction. Realignment in two directions should
not attempted on a single lift.
A maximum of 8mm in vertically improvement in one lift is sufficient.
METHOD OF ERECTING FORMWORK:
It is important maximum efficiency to define a sequence of erection to be followed by
each team. One side is erected using only on upper and lower pin and wedge connection.
Later, ties are inserted at the connection and fixing with pin and wedge. Then previously
installed pins are removed and those ties inserted and pinned. Subsequently, panels for
the other side are inserted between the existing ties and fixed with pins and wedges.
The advantages of this Erection Method are as Follows: -
1) Rooms can be closed and squared by assembling only one side of wall panels. If
misaligned, it is easier to shift rows of single panels.
2) If steel reinforcement is likely to interfere with the placement of the ties, it can be
seen and corrected without delaying the pane erection.
3) Enables fast start up of deck teams as the first rooms can be closed quickly.

PALLAVI BHOSAREKAR
4) Continuous steel reinforcement for the walls, creates a barrier between the two sides
of the formwork, so the work proceeds at the pace of single erector.
Special care must be taken at the lift shafts. The interior panels will align properly on
their own because they are set of the kicker from the formwork below. Ensure the kickers
are level and will not affect the vertically of the lift shaft. However, the matching panels
are set on the concrete that may not be level. If the concrete is too high in place, it can
distort the alignment of the four sides of the lift shaft and must be broken out to allow a
level base.
Care must be taken so that the concrete and in particular the reinforcement does not
become contaminated due to excessive or negligent application of the releasing agent.
The ends of walls and door openings should be secured in position by nailing timber
stays to the concrete slab. Walls require to be straightened by using a string line and
securing in place by nailing timber stays to concrete slab. During this poperation
vertically of door openings also require to be checked for plumb. Where possible, door
spacers should be lifted.
vi) ERECT DECK FORMWORK:
Normally deck panels can be struck after 36 hours. Striking times should be confirmed
on a project-to-project basis.
The striking begins with the removal of deck beam. Remove the 132mm pin and the beam
bars from the beam which has been identified for removal.
This is followed by removing the pins and wedges from the deck panels adjacent to the
deck beam to be removed.
The deck beam can now be taken out.
As the first panel in are rests on the support lip of the soffit length, the adjacent panel
should be removed first. After removing the pins and wedges from the panel to be
removed, a panel puller can be used to beak the bond from the adjacent formwork.
Where there is no deck beam support and the panels span from wall to wall, one wall
will have the supporting lip of the soffit length removed.
Pins and wedges only to be removed on the identified component that is to be struck.
Deck panel's remains in place longer than wall panels and will not come away easily

PALLAVI BHOSAREKAR
unless proper cleaning and oiling is done during the erection process. Panels should
confirm to the sequence of erection.
PROP LENGTHS:
Whenever the PL's is to be removed, use a wooden mallet to strike the bottom of the PL
in the same direction as the beam and holding the PL with your other hand.
Before commencing the operation, ensure the following equipment has been procured: -
a) Scaffold brackets and all the necessary fixings.
b) Scaffolding bracket, vertical safety post.
c) Safety harness and all materials for the platform decking and handrails.
d) Timber and all materials for the platform decking and handrails.
For the initial set up of the formwork and when using the wall mounted scaffold
brackets, 20mm diameter holes require to be drilled through the formwork to position the
PVC sleeves, which when cast in the concrete should be used for fixing the scaffold
brackets. This hole also accommodates the bolting up of the formwork to control the
alignment at the kicker level.
As the external formwork is being removed, a team of allocated people working in pairs
will commence erecting the working platform. With the tie-rod through the hole provided
in the working platform. With the tie-rod through the hole providing in the working
platform bracket, and using a small ladder, fix the bracket by pushing the tie rod through
the PVC sleeve which is cast in the concrete. A helper inside the building can fix and
tighten the locking nut.
During this operation, the person on the external must have his safety belt secured to the
kicker above. As this operation progresses along the building, another pair of the team
should follow, placing the decking, toe-board and handrails. One person should remain
on the lower platform and pass the decking to his helper in the upper level.
When working on the outside edge, safety equipment MUST be worn at all times.
INSTRUCTIONS:
To be imposed on every worker, are the following things not to be done:
· Do not lay bottom panel contact face down, when starting a stack

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