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1. INTRODUCTION
Formwork is defined as temporary structure whose purpose is to provide support and
containment for fresh concrete until it can support itself. It moulds the concrete to the desired shape
and size and controls its position and alignment. The development of formworks is parallel with the
growth of concrete construction throughout the 20th century. The advancement of technology,
increase of population and the space limitation lead the way to construct high-rise buildings. But the
task was not very easy at the beginning but now the man made the task easy by inventing new
machinery and new techniques. 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 to be used is the conventional type formwork where the timber planks were supported
on timber columns. With the advancement of technology it developed gradually and people used ply
wood sheets instead of timber planks and steel pipes with jacks were used to support the ply wood.
Then people invented small units of formworks and connect the repeating units in the construction.
The larger units were invented like formworks for slab panels, formworks for columns, beams etc.
when the same elements are repeating. Then finally the whole system of formwork is made and
initially the material used to it was steel and it was very heavy. Then the aim was to reduce the weight
of the system and the materials for formwork have extended to aluminium, plastic, fibre glass etc.
Aluminium formwork system provides aluminium formwork for RCC load bearing or RCC
framed multi-storied buildings and enables the walls and slabs to be poured in same operation. These
increases efficiency and also produces an extraordinarily strong structure with excellent concrete
finish. Due to the fine tolerance achieved in the machined metal formwork components, consistent
concrete shapes and finishes are obtained floor after floor. This allows plumbing and electrical fittings
to be prefabricated with the certain knowledge that there will be an exact fit when assembled. As
described by the manufacturers a low-cost system for housing using aluminium formwork. Aluminium
formwork system is construction system for forming cast in place concrete structure of building. It is
also a system for scheduling and controlling the work of other construction trends such as steel
reinforcement, concrete placement and mechanical and electrical conduits. This type of construction
requires a restructuring of the entire conventional construction process to enable interaction between
the design phase and production planning in order to improve and speed up the construction. The
speed of construction by this system will surpass speed of most of the other construction method.
2. INNOVATION IN CONSTRUCTION
The traditional mode of construction for individual houses comprising load bearing walls with
an appropriate roof above or reinforced concrete (RC) framed 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.
Several systems are adopted at different places in the world; eventually the systems which
are reasonably economical and easy for operation with skilled labor 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.
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 ensures labor 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.
3. 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 is
sometimes used to indicate formwork of relatively small units such as lintels, cornices etc.
“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”.
“Formwork is the term given to either temporary or permanent moulds into
which concrete or similar materials are poured”.
3.2 Requirements of a 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 so that 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.
a) TIMBER FORMWORK
Timber is required for practically all jobs of formwork. The timber bring used for formwork
must satisfy the following requirements. It should be durable and treatable. It should have sufficient
strength characteristics. It should be light weight and well seasoned without warping. It should hold
nails well. It is economical for small construction jobs. It is design flexible and easy to erect. It has
good thermal insulation which makes it useful to be used in colder Regions. It can easily be made into
any shape or size. And it is easy for transporting purpose for in between sites.
b) STEEL FORMWORK
Mostly used in large construction projects or in situations where large number of re-uses of
the same shuttering is possible. It is Suitable for circular or curved shaped structures such as tanks,
columns, chimneys etc. and also used for structures like sewer tunnel and retaining wall. Strong,
durable & have longer life. Reuses can be assumed to vary from 100 to 120 wares timber varies from
10 to 12.Steel can be installed & dismantled with greater ease & speed resulting in saving in labour
cost. Excellent quality of exposed concrete surface obtained. No danger of formwork absorbing water
from the concrete and minimizing honeycombing.
d) ALUMINIUM FORMWORK
Forms made from aluminum are in many respects similar to those made of steel. However,
because of their lower density, aluminum forms are lighter than steel forms, and this is their primary
advantage when compared to steel. As the strength of aluminum in handling, tension and
compression is less than the strength of steel, it is necessary to use large sections. The formwork
turns out to be economical if large numbers of reuses are made in construction. The major
disadvantage of aluminum forms is that no changes can be made once the formwork is fabricated.
4.1 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 and sturdy, 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, facade 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.
The method of construction adopted is no difference except for that the sub – structure is
constructed using conventional techniques. The super–structure is constructed using MIVAN
techniques. The integrated use the technology results in a durable structure.
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
2) Rocker: - It is a supporting component of wall. It is L-shaped panel having allotment holes for stub
pin
FIG 4.2 ROCKER
3) Kicker: - It forms the wall face at the top of the panels and acts as a ledge to support.
4) Stub Pin: - It helps in joining two wall panels. It helps in joining two joints
1) Beam Side Panel: - It forms the side of the beams. It is a rectangular structure and is cut
according to the size of the beam
2) Prop Head for Soffit Beam: - It forms the soffit beam. It is a V-shaped head for easy dislodging of
the formwork.
FIG 4.6 PROP HEAD FOR SOFFIT BEAM.
3) Beam Soffit Panel: - It supports the soffit beam. It is a plain rectangular structure of aluminium.
4) Beam Soffit Bulkhead: - It is the bulkhead for beam. It carries most of the bulk load.
1) Deck Panel: - It forms the horizontal surface for casting of slabs. It is built for proper safety of
workers.
FIG 4.9: - DECK PANEL
2) Deck Prop: - It forms a V-shaped prop head. It supports the deck and bears the load coming on
the deck panel.
3) Prop Length: - It is the length of the prop. It depends upon the length of the slab.
FIG 4.11 DECK PROP LENGTH
4) Deck Mid – Beam: - It supports the middle portion of the beam. It holds the concrete.
5) Soffit Length: - It provides support to the edge of the deck panels at their perimeter of the room.
1) Internal Soffit Corner: - It forms the vertical internal corner between the walls and the beams,
slabs, and the horizontal internal cornice between the walls and the beam slabs and the beam soffit.
2) External Soffit Corner: - It forms the external corner between the components
3) External Corner: - It forms the external corner of the formwork system.
FIG 4.17 EXTENAL CORNER
4) Internal Corner: - It connects two pieces of vertical formwork pieces at their exterior intersections.
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 in the 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.
4.4.4 CLEANING:
All components should be cleaned with scrapers and wire brushes as soon as they are struck.
Wire brush is to be used on side rails only. The longer cleaning is delayed, the more difficult the task
will be. It is usually best to clean panels in the area where they are struck.
4.4.5 TRANSPORTING:
There are basic three methods recommended when transporting to the next floor:
i. The heaviest and the longest, which is a full height wall panel, can be carried up the nearest
stairway.
ii. Passes through void areas.
iii. Rose through slots specially formed in the floor slab for this purpose. Once they have served their
purpose they are closed by casting in concrete filter
4.4.6 STRIKING:
Once cleaned and transported to the next point of erection, panels should be stacked at right
place and in right order. Proper stacking is a clean sign of a wall – managed operation greatly aids the
next sequence of erection as well as prevents clutters and impend other activities
Fig 4.21: - Erection of Platform
Day 1: -The first activity consists of erection of vertical reinforcement bars and one side of the vertical
formwork for the entire floor or a part of one floor.
Day 2: -The second activity involves erection of the second side of the vertical formwork and
formwork for the floor
Day 3: - Fixing reinforcement bars for floor slabs and casting of walls and slabs.
Day 4: -Removal of vertical form work panels after 24hours, leaving the props in place for 7 days and
floor slab formwork in place for 2.5 days.
3) Cycle Time
High speed of construction can be achieved by this system that means faster completion of
project. 7 Days per floor.
4) Striking time
• Vertical (Wall) Formwork – 12 hours after concreting or when concrete strength has reached
2N/mm2.
• Horizontal (Deck) Formwork – 36 hours after concreting or when concrete strength has reached
10N/mm2.
5) Pouring System
Monolithic pouring for:
• Slabs
• Walls
• Columns
• Beams
6) Durability
OR
ii) RC load-bearing walls and slabs.
In the case of RC moment-resisting framed structures, the horizontal forces due to wind or
earthquake are resisted by the frames resulting in the bending moments in columns to resist bending
moment and vertical loads would be more than that required to resist vertical loads without bending
moment. Similarly, additional reinforcement will be required in beams at supports. In the case of RC
load-bearing walls, monolithic casting of slab along with RC walls results in a box type structure,
which is very strong in resisting horizontal forces due to wind or earthquake. In view of large depth of
shear walls, the resulting stresses due to bending moment and vertical loads are smaller and in many
cases, concrete alone is capable of resisting these forces.
On evaluating these alternatives, it is seen that the beam column frame system in
i) Performs poorly against earthquake forces compared to RCC wall and slab construction.
Recent changes in the IS Codes, as well as recommended good practice demand provision of
additional reinforcement comply with ductility requirements.
ii) The sizing and detailing of columns needed to be –that they are 20% stronger than beams
they support.
4.8 ECONOMY
The cost per flat (or per m² built up area) using MIVAN shuttering system depends upon the
number of repetition and period of completion of the project. As the formwork can be reused over 250
times, the initial cost per unit of forming area is less when compared to traditional methods. The
reduction of cost is also due to the elimination of brickwork and plaster and also due to reduction in
time. The cost of the project gets substantially reduced due to shear wall construction. These are due
to the reduced consumption of steel, masonry, and plaster even though the use of concrete
decreases. For the same number of repetition, the cost will be less if the period of completion is
longer. This is because for a shorter completion period, the area of formwork is more than required for
longer completion period. Cost of formwork is illustrated in Table 4.1.
The aluminium formwork provides an integrated scaffolding system which reduces the cost of
scaffolding requirements. The mechanical and electrical installation is simplified as conduits are
embedded in the structure by precise engineering of outlets and service ducts. Thus, we can conclude
that the overall cost of the project is lesser when compared to project using traditional methods of
formwork.
By using admixture the workability of concrete is increased by 120 % whereas the strength of
concrete is increased by 13 %
6.1 Advantages:
The MIVAN formwork is specifically designed to allow rapid construction of all types of
architectural layouts.
1) Total system forms the complete concrete structure.
2) Custom designed to suit project requirements.
3) Unsurpassed construction speed.
4) High quality finish.
5) Cost effective.
6) Panels can be reused up to 250 times.
7) Erected using unskilled labor.
Quality and speed must be given due consideration along with economy. Good quality
construction will never deter to projects speed nor should it be uneconomical. In fact, time consuming
repairs and modifications due to poor quality work generally delay the job and cause additional
financial impact on the project. Some experts feel that housing alternatives with low maintenance
requirements may be preferred even if the initial cost is high.
1) Because of small sizes finishing lines are seen on the concrete surfaces.
2) Concealed services become difficult due to small thickness of components.
3) It requires uniform planning as well as uniform elevations to be cost effective.
4) Modifications are not possible as all members are caste in RCC.
5) Large volume of work is necessary to be cost effective i.e. at least 200 repetitions of the forms
should be possible at work.
6) The formwork requires number of spacer, wall ties etc. which are placed @ 2 feet c/c; these create
problems such as seepage, leakages during monsoon.
7) Due to box-type construction shrinkage cracks are likely to appear.
8) Heat of Hydration is high due to shear walls.
7. CONCLUSION
The task of housing due to the rising population of the country is becoming increasingly
monumental. In terms of technical capabilities to face this challenge, the potential is enormous; it only
needs to be judiciously exploited.
Civil engineers not only build but also enhance the quality of life. Their creativity and technical
skill help to plan, design, construct and operate the facilities essential to life. It is important for civil
engineers to gain and harness the potent and versatile construction tools.
Traditionally, construction firms all over the world have been slow to adopt the innovation and
changes. Contractors are a conservative lot. It is the need of time to analyze the depth of the problem
and find effective solutions. MIVAN serves as a cost effective and efficient tool to solve the problems
of the mega housing project all over the world. MIVAN aims to maximize the use of modern
construction techniques and equipments on its entire project.
We have tried to cover each and every aspect related to aluminium (MIVAN) form
construction. We thus infer that MIVAN form construction is able to provide high quality construction at
unbelievable speed and at reasonable cost. This technology has great potential for application in India
to provide affordable housing to its rising population.
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. Some experts feel that housing
alternatives with low maintenance requirements may be preferred even if at the slightly may preferred
even if at the higher initial cost.
REFERENCES
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), Miss. Patil Dhanashri Suryakant1 ,
Prof. Desai D B
2. International Journal of Innovative Research in Science, Engineering and Technology Vol. 3, Issue 6,
June 2014, Patel Abhiyan S, Neeraj Sharma D, Bhavin K Kashiyani.
3. International Journal of Innovations In Engineering Research And Technology [IJERT] issn: 2394-
3696 volume 2, issue 3 march2015, Mr. Shankar Bimal Banerjee.
4 Jain and Jain., “(1993)”. “Design of Formwork”. “Design of Concrete Structures.”, Edition 1993, pp 595-
606.
5. Kulkarni., D., V., “(2001)”. “ First Rate Forms”. “Times Journal Construction and Design”. Oct-Dec
2001, pp 22-23.
6. International Journal of Engineering and Technical Research, Kushal Patil, Ajitkumar Jadhav, Nikhil
Shingate
Posted by Visit n' Tech at 4:41 AM
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