Mivan-A Versatile Formwork

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.
2.1.1 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).

2.1.2 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.

2.2 Classification of Formwork

Formwork can be classified according to a variety of categories, relating to the differences
in 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, there has been a strong

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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.
2.5:- 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.
Since the equipment is made of aluminium, it has sections that are large enough to
be 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.
2.5.1 MERITS OF ALUMINIUM FORMWORK:-

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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 angles at
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 sacrificing

the 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 work or
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 structure is

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.

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.

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2.5.2: -Comparison of Aluminum Form Construction Technique Over

Conventional Forms:
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.

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Table 2.1:- RELATIVE COMPARISON OF IN SITU ALUMINIUM FORM

SYSTEM WITH CONVENTIONAL CONSTRUCTION.
Sr.
No

FACTOR

Quality

CONVENTIONAL

IN SITU ALUMINIUM
FORM SYSTEM

Normal

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.
Speed
of
Erection of formwork,
construction.
concreting
and
deshuttering forms is a two

week
cycle.
The
plastering
and
other
finishing activities can
commence only thereafter.

Aesthetics.

External
finishes.

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.
Cement
plastered
brickwork, painted with
cement based paint.
Finishing needs painting

REMARKS

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
In this system, the walls and
floors are cast together in one
continuous operation in matter
of few hours and in built
accelerated curing overnight
enable removal and re-use of
forms on daily cycle basis.

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
Textured / pattern coloured
concrete facia can be provided.
This will need no frequent
repainting.

Superior quality
in System
housing

System
construction is
much faster.

Permanent facia
finishes feasible
with
minor
extra initial cost

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every in three years.

Useful carpet Efficiency around 83.5%

area as % of
plinth area.

Efficiency around 87.5%

More efficient
utilization
of
land for useful
living space.

Consumption
of basic raw
materials
Normal
Cement.

6
Reinforcing
Steel

Maintenance

Consumption somewhat more Although

than that used in conventional greater
structures.
consumption
strength
and
durability
is
also more
Reinforcing steel required
is less as compared to the
in situ construction as RCC
framework uses brick wall
as alternative

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.

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.

The walls and ceiling being

smooth and high quality concrete
repairs for plastering and
leakages are not at all required
frequently.

Steel
requirement is
more, as it is
required for the
shear
wall
construction.
But shear wall
construction
increases safety
against
earthquake.
It
can
be
concluded that
maintenance
cost
is
negligible.

3.0 MIVAN: - A Versatile Formwork

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The system of aluminum forms (MIVAN) has been used widely in the
construction of residential units and mass housing projects. It is fast, simple, adaptable
and cost effective. It produces total quality work which requires minimum maintenance
and when durability is the prime consideration. This system is most suitable for Indian
condition as a tailormade aluminum formwork for castinsitu fully concrete structure.

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, faade 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 superstructure is constructed
using MIVAN techniques. The integrated use the technology results in a durable
structure.
3.2.1: -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

FIG 3.1: WALL PANEL

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

allotment holes for stub pin.

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FIG 3.2: ROCKER

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

FIG 3.3: KICKER

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

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FIG 3.4: STUB PIN

3.2.2:

- 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

FIG 3.5: BEAM SIDE PANEL

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2) Prop Head for Soffit Beam: - It forms the soffit beam. It is a V-shaped head
for easy dislodging of the formwork.

FIG 3.6: PROP HEAD FOR SOFFIT BEAM.

3) Beam Soffit Panel: - It supports the soffit beam. It is a plain rectangular
structure of aluminium.

FIG 3.7: BEAM SOFFIT-PANEL

4) Beam Soffit Bulkhead: - It is the bulkhead for beam. It carries most of the bulk
load.

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FIG 3.8: - BEAM SOFFIT BULKHEAD

3.2.3: DECK COMPONENT:

1) Deck Panel: - It forms the horizontal surface for casting of slabs. It is built for
proper safety of workers.

FIG 3.9: - DECK PANEL

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

FIG 3.10: -DECK PROP

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

FIG 3.11: - DECK PROP LENGTH

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

FIG 3.12: - DECK MID-BEAM

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

FIG 3.13: - SOFFIT LENGTH

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

FIG 3.14: -DECK BEAM BAR

3.2.4: 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.

FIG 3.15: -INTERNAL SOFFIT CORNER

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

FIG 3.16: -EXTERNAL SOFFIT CORNER

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

FIG 3.17: - EXTENAL CORNER

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

exterior intersections. Fig 3.18

FIG 3.18: - INTERNAL CORNERS

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3.2.5: 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 a corner and proceeds from there. (Fig.
No.3.19, Fig no 3.20).

FIG 3.19: - WALL ASSEMBLY DETAILS

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FIG 3.20: - BEAM ASSEMBLY DETAILS

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3.2.6: 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.
3.2.7 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. (Fig.No.3.22).
3.3 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:
3.3.1 PRE CONCRETE ACTIVITIES:
a) Receipt of Equipment on Site The equipments 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 the
following.
i.

All formwork should be cleaned and coated with approved realize agent.

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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.

3.3.2 ON CONCRETE ACTIVITIES:

At least two operatives should be on stand by during concreting for checking pins,
wedges and wall ties as the pour is in progress. Pins, wedges or wall ties missing could
lead to a movement of the formwork and possibility of the formwork being damaged.
This effected area will then required remedial work after striking of the formwork.
Things to look for during concreting:

i.
ii.

Dislodging of pins / wedges due to vibration.

Beam / deck props adjacent to drop areas slipping due to vibration.

iii.

Ensure all bracing at special areas slipping due to vibration.

iv.

Overspill of concrete at window opening etc.

3.3.3 POST CONCRETE ACTIVITIES:

i) Strike Wall Form- It is required to strike down the wall form.
ii) Strike Deck Form- The deck form is then removed.
iii) Clean, Transport and stack formwork
iv) Strike Kicker Formwork The kicker are removed.
v) Strike wall Mounted on a Working Platform the wall are fitted on next
floor.
vi) Erect Wall Mount Working Platform and the wall is erected.
Normally all formwork can be struck after 12 hours.

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The post concreting activities includes:

3.3.4 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.
3.3.5 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.

3.3.6 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.

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Fig 3.1: - Erection of Platform

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Fig 3.2:- Striking of formwork

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Fig 3.3: - Positioning of Platform

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Fig 3.4: - Removal of kicker

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3.6.1 Work cycle

MIVAN is a system for scheduling & controlling the work of other connected
construction trades such as steel reinforcement, concrete placements & electrical inserts.
The work at site hence follows a particular sequence. The work cycle begins with the
deshuttering of the panels. It takes about 12-15hrs. It is followed by positioning of the
brackets & platforms on the level. It takes about 10-15hrs simultaneously.
The deshuttered panels are lifted & fixed on the floor .The activity requires 7-10
hrs.Kicker & External shutters are fixed in 7 hrs. The wall shutters are erected in 6-8 hrs
One of the major activity reinforcement requires 10-12 hrs. The fixing of the electrical
conduits takes about 10 hrs and finally pouring of concrete takes place in these.
This is a well synchronized work cycle for a period of 7 days. A period of 10-12
hrs is left after concreting for the concrete to gain strength before the beginning of the
next cycle. This work schedule has been planned for 1010-1080 sq m of formwork with
72-25cu m of concreting & approximate reinforcement.
The formwork assembling at the site is a quick & easy process. 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 formwork modulation drawings. All
formwork begins from corners and proceeds from there.
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.
3.7 Design Aspects
The comparison is done between buildings constructed by: -

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i)

Conventional RC columns, beams, and slab construction (RC moment

resisting framed structure)
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.

3.8 Economics
It can be seen that the total cost of ground-plus-seven building using MIVAN
System is Rs.5344/m which is lower than that in conventional system is Rs.6034/m.( As
calculated by Srinivaschar.P.H, July 2005).
The cost per flat (or per m 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

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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 no.3.8.2.
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.
4.1 The Advantages of this system are: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.

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4.2 LIMITATION 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: 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.

4.3 REMIDIES
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 boxtype 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 flyash.
6.1 CONCLUSION:
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

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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.

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