FORMWORK SYSTEMS

MIVAN OUTLINE OF PRESENTATION

⁄ Modular Aluminium Formwork

⁄ Formwork Assembly
⁄ Simplicity – Pin and Wedge system
⁄ Efficient – Quick Strip Prop Head

⁄ Components of MIVAN Formwork

⁄ Beam Components
⁄ Deck Components
⁄ Other Components

⁄ Wall Components Site Management

⁄ Speed of Construction Quality Advantage of MIVAN
⁄ Other Advantage of MIVAN
⁄ Limitations of MIVAN Formwork

⁄ Video on – Aluminium Formwork Construction Technique

 MIVAN MODULAR ALUMINUM FORMWORK

 Precisely-engineered system fabricated in aluminium.

 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.
 System is quite flexible and can be easily adapted for any variations in the layout.
 The availability of concrete from ready mix concrete facility has augured well for the use of this work
system.
 Asian countries and the willingness to use mechanized means of transport and placing of concrete, the use
of aluminium formwork system has received a boost.
 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.
 FORMWORK ASSEMBLY
MIVAN aims in using modern construction techniques and
equipment in all its projects. On leaving the MIVAN factory all
panels are clearly labelled to ensure that they are easily
identifiable on site and can be smoothly fitted together using the
formwork modulation drawings. All formwork begins at a corner
and proceeds from there.

Fig.1 – Wall Assembly Details

SIMPLICITY – PIN AND WEDGE SYSTEM

Fig.2 – Beam Assembly Details
The panels are held in position by a simple pin and wedge system that
passes through holes in the outside rib of each panel. 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.
 FORMWORK ASSEMBLY AND ERECTING

 EFFICIENT – QUICK STRIP PROP HEAD

One of the principal technical features which enables this aped to be attained 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.

 The formwork is designed using the most

economical assortment of panel sizes with the
help of the state-of-the art design software which
ensures an efficient construction process by
incorporating the optimum assembly procedures,
economical panel selection and ultimately
minimizing capital and operational costs.
 Sequence for erecting and striking the wall
mounted on working platform:

Fig.3 – Erection of Platform

 FORMWORK ASSEMBLY AND ERECTING

STRIKING OF PLATFORM
Striking of all forms can be done within 10-15 hours. The only tool
required for dismantling is hammer.

Fig.4 – Striking of Platform

POSITIONING OF FORMWORK
Positioning of working platform bracket and securing nuts on tie
rod on inside the building.

REMOVAL OF KICKER
Positioning of working platform bracket and securing nuts on tie rod on
inside the building.

Fig.6 – Positioning of Platform

COMPONENTS OF MIVAN FORMWORK
 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 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.
 A. BEAM COMPONENTS

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.

3. Beam Soffit Panel: It supports the soffit beam. It is a plain rectangular

structure of aluminum.

4. Beam Soffit Bulkhead: It is the bulkhead for beam. It carries most of 2

the bulk load.

4 3 1
 B. DECK COMPONENTS
1) Deck Panel: It forms the horizontal surface for casting of slabs. It is built for proper
safety of workers.

2) Deck Prop: It forms a V-shaped prop head. It supports the deck and bears the load
coming on the deck panel. 1

3) Prop Length: It is the length of the prop. It depends upon the length of the slab.

4) Deck Mid – Beam: It supports the middle portion of the beam. It holds the 2
concrete.

5) Soffit Length: It provides support to the edge of the deck panels at their perimeter
of the room.

6) Deck Beam Bar: It is the deck for the beam. This component supports the deck and
beam.

6 5 4
 C. OTHER COMPONENTS

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. 1
2) External Soffit Corner: It forms the external corner between the
components

3) External Corner: It forms the external corner of the formwork system.

4) Internal Corner: It connects two pieces of vertical formwork pieces at

their exterior intersections 2

3 4
 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.

2) Rocker: It is a supporting component of wall. It is L-shaped

panel having allotment holes for stub pin.

3) Kicker: It forms the wall face at the top of the panels and acts 1
as a ledge to support.

4) Stub Pin: It helps in joining two wall panels. It helps in joining

two joints.

3
SOFTWARE APPLICATION TO FORMWORK DESIGN
 The formwork is designed using the most economical assortment of panel sizes with the help of the state-of-the art
design software. The use of the software along with the experience and skill of the designers ensures an efficient
construction process by incorporating the optimum assembly procedures, economical panel selection and ultimately
minimizing capital and operational costs.
 Using design software, the formwork is designed using the most economical assortment of panel sizes.
✓ Most efficient construction process incorporating the optimum assembly procedures.
✓ Economical panel section.
✓ Ultimately minimizing capital and operational cost.

SITE MANAGEMENT

 The essence of the system is that it provides a production line approach in the construction industry. The laborers are
grouped together to form small teams to carry out various tasks within a certain time frame such as, reinforcement,
fabrication and erection, formwork erection, concreting etc.
 Scheduling involves the design and development of the work cycle required to maximize efficiency in the field. The
establishment of a daily cycle of work, which when fully coordinated with different trades.
 Optimum use of the labour force is made by ensuring that each trade has sufficient work on each working day.
 The improved coordination and construction management enables the equipment to be used at optimum speed and
efficiency and speed of the output are outstanding. Thus a disciplined and systemized approach to construction is
achieved.
 SPEED OF CONSTRUCTION
The system usually follows a four day cycle: -

 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.
 QUALITY ADVANTAGE OF MIVAN
The Advantages of this system are :-

o The MIVAN formwork is specifically designed to allow rapid construction of all types of architectural
layouts.
o Total system forms the complete concrete structure.
o Custom designed to suit project requirements.
o Unsurpassed construction speed.
o High quality finish.
o Cost effective.
o Panels can be reused up to 250 times.
o Erected using unskilled labor.
o Easy to handle.
o Aluminum does not rust like steel; therefore, the aluminium formwork can be reused hundreds of times.
o Formwork is made with an aluminium alloy, which has high tensile strength and is also very hard.
o Saving on overhead expenses due to speedy construction.
o Monolithic crack free structures.
o Doesn’t require timber or plywood for construction activities so, it saves the environment.
 OTHER ADVANTAGE OF MIVAN

o Casting of walls and slabs possible simultaneously.

o Doesn’t require skilled labour.
o For the marking purpose there is no need of starter.
o Floor slabs forms removed without moving props.
o Earthquake resistance of resulting structures increases
manifold.
o Less debris generation.
o Higher scrap value.
o Carpet area will increase.
o Collect the best premium from the customer,
because of 100% RCC buildings.
 LIMITATIONS OF MIVAN FORMWORK
Even though there are so many advantages of MIVAN formwork the limitations cannot be ignored. However the
limitations do not pose any serious problems. They are as follows: -

 Because of small sizes finishing lines are seen on the concrete surfaces.
 Concealed services become difficult due to small thickness of components.
 It requires uniform planning as well as uniform elevations to be cost effective.
 Modifications are not possible as all members are caste in RCC.
 Large volume of work is necessary to be cost effective i.e. at least 200 repetitions of the forms should be possible at
work.
 Architectural changes not possible on the structure (but some walls can be of brick work or openings can be
entertained).
 The reinforcement will be congested in the lower floors up to 4th floor thus max. slump (200mm) is required, so
cement content will be increased.
 Due to tremendous speed of construction, working capital finance needs to be planned in advance.
 Number of holes will be more in the vertical wall, outer wall which is in direct contact with the rain, hole should be
grouted by Non Shrink compound.
 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.
 Due to box-type construction shrinkage cracks are likely to appear.
 Heat of Hydration is high due to shear walls.
 Remedial Measures

In external walls, ties used in shutter connection create holes in wall after deshuttering. These may become a source of
leakage if care is not taken to grout the holes. Due to box-type construction shrinkage cracks are likely to appear around
door and window openings in the walls. It is possible to minimize these cracks by providing control strips in the structure
which could be concreted after a delay of about 3 to 7 days after major concreting. The problem of cracking can be avoided
by minimizing the heat of hydration by using fly ash.

Video on – Aluminium Formwork Construction

Technique

Link-01
Link-02
RAPIDCLIMB
 Introduction
Rapidclimb equipment provides a crane lifted jump
formwork system providing safe, self contained
working levels for economical core construction and
multi-lift wall structures.
The platforms and formwork are moved by crane as a
single assembly from pour to pour.
A rack & pinion operation trolley enables fast and
controlled pull back of the shutters from the poured
wall by up to 700mm to enable cleaning of the form
face and steelfixing.
The trolley is safely secured with a wedge locking
system. All form types can be accommodated for
straight, curved or inclined walls and forms can be
adjusted readily in level and side to side by +/- 25mm
Suspended platforms are designed with hinged
connections so that components can be attached at
low level to reduce work at height. Also, suspended
uprights are offset to facilitate anchor removal.
 Rapid climb System

Pouring Platform
Rapidclimb Turnbuckle

Wall
Rapidclimb Bracket Main Platform (constructed
Guardrail Post using Aluminium Beam and
GTX & Plywood or
Rapidclimb Frame Customers Scaffold Boards
Assembly

Wind Restraint

Suspension Tube

Hanging Platform (Optional)

Used for concrete finishing
and removing low level
anchors prior to climbing
Rapidclimb Frame Assembly
(RCX10003)
Rapidclimb Rack &
Pinion Trolley

700mm max
Roll-back Rapidclimb
Trolley Jack

Rapidclimb Frame Assembly

(RCX10003) Weight = 163 Kg
 Typical Erection Sequence
First Lift First Lift
Place the concrete and Remove the ties from the
allow curing. formwork the morning after
concreting. Leave 2 ties loosely
in place at the top of the forms.
If bolts have been used to fix the
anchors to the form face remove
them. Strike the formwork from
the side remote to the alignment
props, clean, oil and store ready
for reuse.
Second Lift
Fix the Rapidclimb Wall Brackets
to the anchors as shown. The
grade strength of the bolt is
indicated on the bolt head and is
important. Check that the grade
of each bolt during installation
matches with the requirements
of the RMDK drawing. Straighten
each wall bracket and tighten
the bolt with a spanner.
 Typical Erection
Sequence

Second Lift Second Lift Second Lift

Assemble the platforms and Fit wind ties as shown. Ratchet Remove the formwork from the
mount on the wall. Insert and lashing wind ties should be lightly other side of the wall clean, oil
secure the safety pins through tensioned. Avoid over-tightening as and store ready for reuse.
the holes in the wall brackets to this can apply excessive force to
prevent accidental removal of components and anchorages.
the platforms. Platforms may
either be prefabricated off the
wall in modules or built in situ
on the wall
 Typical Erection Sequence
Second Lift
Engage the wedge brakes on all Rapidclimb
Trolleys. Crane in the formwork to one side of
the wall and bolt to the plumbing jacks. Add
the plumbing turnbuckles ensuring that all are
orientated with the right hand thread end at
the bottom. Plumb the formwork and release
the crane.
Second Lift
Release the wedge brakes and advance the
formwork to contact the wall by rotating the
pinion spindle. Drive the wedge brakes into
position to lock the trolleys.
Adjust the level of the formwork by rotating the
spindle on the trolley jack. Adjust the sideways
transit of the forms by slackening the bolted
connection to the trolley jack and using a podger
bar (spud wrench) to slide the formwork in the
slots. Re-tighten the fixings. Check the form for
plumb and adjust if necessary.
 CONVENTIONAL FORMWORK

6.1.4 Formwork for Slabs & beams

It consists of
• Sole plates
• Wedges
• Props
• Head tree
• Planks
• Batten
• Ledgers

• Beam formwork rests on head tree

• Slab form work rests on battens and joists

DOKA FORMWORK
FLEX SYSTEM FOR RCC SLAB (Upto 4.5m Height)

FOUR WAY
HEAD
 3
1

1. H BEAM (H-16 / 2.CT

H – 20) Types PROP
CT 250, CT 300, CT 340,
CT 410

4
3.FOUR WAY 4.FOLDING
I HEAD TRIPOD
FLEX TABLE TABLE FORMWORK SYSTEM
 4

1. BASIC FRAME 2. HORIZONTAL BRACING AND DIAGONAL

Sizes 1 BRACING
0.90,1.20,1.50,1.80
M

3
 HD COUPLER
BEAM SPAN 1525
6.BEAM SPAN 2230
5.TOWER SPINDLE WITH LEVER LOAD BEARING MEMBER FOR
NUT BEAM
TO ADJUST THE HEIGHT OF TOWER 7

7.SHORT PROP
8.LTS-WHEEL B
IT IS USED IN SLAB AND BEAM
FORMWORK FOR TRANSFERRING TO BE FIXED WITH 8
THE SLAB LOAD TO THE BEARING BOTTOM FRAME OF STAIR
TOWERS THROUGH STANDARD TOWER / HDT TO SHIFT ONE
WALERS PLACE TO ANOTHER PLACE
Peri form materials are available in

1. Plywood as well as in
2. Steel
 Cup-lock

Threaded Anchor Plate

Wing Nut
 Steel Waller

Steel
Tension
Rod
▪ Tripod is the main basic
component of the system.

▪ It needs hard and

▪ good resting surface.

▪ All the loads coming through

the slab, beam and column
is transferred to the Tripod
through the CT Props.
Height should be adjust
by this jacking system
through threads.
Four Way Head CT- Prop
Slab Formwork
Trio

Secondary Girder

Main Girder
GT-24 Girder

Main Props

Intermediate Props
Peri Sky Deck Alluminium Forms
Arrangement of Wall Wall Formwork
Panels Before Concreting

Joining of four
panels through Cup
- lock, Steel Rod,
and Steel Waller
Column Panel

Supports

Column Formwork
Beam Head

Cross Head

CT Prop

Locker

Tripod

Beam Formwork
Comparison of different kinds of Formworks used
with in Construction Industry

207
 Type of
Advantages Dis-advantages
formwork
• Durable, light weight, economical, flexible for easy erection.
• It exhibits good thermal insulation so it can be used in cold • High labor cost.Usually varies from 30 to 40%
climates. ofvtotal cost of concrete slab per floor.
• Its reusability varies from 10 to 12 times. • High waste generation.5% of waste is produced for
Unique advantages of timber formwork: a single use of formwork.
Timber formwork • It can be built piece by piece so capable enough to form any • Erection and dismantling is to be done piece by
concrete shape as per architectural design. piece.
• This system is economical for small scale projects • Very highly skilled labor force is needed.
• with limited potential reuse. • Spans are limited as timber has low strength
• It has low initial cost and make up cost. compared to metal formworks.
• Good for restricted site conditions less storage area and use
of crane is difficult.
• Lighter in weight compared to steel formwork due to its low
density.
• Large section can be made because the strength of
aluminum in handling tension and compression is more than
that of steel.
• No changes can be made if ones fabricated.
Aluminum • It can be easily handled by unskilled labor.
• Initial cost is very high.
Formwork • Reusability is more. Varies from 100-250.
• Not economical for small and non-recitative
• In case of high magnitude constructions where need of rapid
works.
erection, this system creates
exceptionally fine quality finish and precise dimension
good enough to receive painting directly without plastering
in a very short time.
• Monolithic construction with few construction joints can be
easily made.
 Type of
Advantages Dis-advantages
formwork
• Does not provide field fabrication by itself so
• Unique shapes and patterns can be designed with
design and planning must be carefully done.
• excellent finishing with less or no surfacetreatment.
• It is not suitable for heat applied curing of
• No size limits
Plastic concrete.
• More reuses making it highly economical
formwork • Strengthening material (fiber glass) is to be
• Light weight
used to increase stiffness in construction of
• Easy to strip and handle.
large and higher floor areas of multi storied
• No need of skilled labor.
buildings.
• Simple, fast, easily adaptable.
• High quality work with minimum maintains cost.
• It is a completely pre-engineered system where
MIVAN methodology is planned to its finniest details. • Pre- engineering is needed for
formwork • Early removal of formwork with air curing • planning and execution.
• components are made with aluminum so they are
light in weight number of reputations is very high it is
around 250-300.
• It is Australian based company that produces timber, • Preside planning is need before execution
DOKA form
aluminum, and steel forms which has a wide • Skilled labor is need to handle the form work
works
application in all fields of construction sector. system.
 Type of
Advantages Dis-advantages
formwork
• Uses mostly in huge construction projects where
large number of repetitions of same shuttering is
possible.
• It is good for curved structures like columns,
chimneys, tanks. • Heavy to carry and handle.
Steel
• It is strong, durable in nature. • Not suitable for curved and new architectural
formwork
• Its reusability varies from 100 to 120. shapes.
• Instillation and dismantled with greater speed can be
achieved with results in higher savings in labor cost.
• Water absorption is very less, so formation of honey
combs can be minimized.
Factors Affecting Conventional Mivan Coffor Peri Doka

Initial Cost
Weight

Re-use

Maintenance cost

Scrap Value

Construction speed

Volume of Required
material
Seismic Resistance

Formwork Material
Pilferage
Formwork Material
Shrinkage
Possibility of Damage

Handling of Equipment 20
9
Factors Affecting Conventional Mivan Coffor Peri Doka

Finishing

No. of labour’s required

Reinforcement
Requirement
Monolithic Structure

Allied Accessories

Supply & Availability of

Formwork
During Concreting Quality
Check
On site assembly of
formwork
Labour Skill set required

No of post concrete
procedures

BEST GOOD MEDIUM 21

0
Parameters considered for analysis of MIVAN, DOKA and Conventional system
 Cost Comparison of Formwork
Type of formwork Unit Rate(INR)
Wooden Sqm 3500
Steel Sqm 5000
Aluminium Sqm 8000

Scrap Value of Formwork

Type of formwork Scrap Value in %
Wooden 10%
Steel 30%
Aluminium 50%
CONCLUSIONS
Based upon the survey and comparison from live project key contributing factors that plays a significant role
in selection of formwork are cost, quality, cycle time, Number of reputations, safety, administration of change
orders, performance of concrete. By comparing the above parameters through study and graphs from
questioner, the fallowing conclusions can be made
▪ Cost adopted for MIVAN formwork is highest among the all formwork systems this is because of use of
aluminium in making of formwork even though cost of MIVAN is high due to higher number of
reputations the overall cost reduces which makes it favorable in repetitive kind of works.
▪ MIVAN gives highest Number of reputations compared with conventional formwork.
▪ Faster construction can be achieved with MIVAN formwork as cycle time of MIVAN is less compared to
conventional formwork.