“MIVAN – AN ALUMINUM FORMWORK CONSTRUCTION TECHNIQUE”

Presentation By :Sandeep Jain (2014CET2226)

Course - Construction Methods and Equipment (CEL778)Course by - Prof. A.K. Jain

© Sandeep Jain

Image Courtesy: Google

What is MIVAN Formwork..? History & Background When it is Suitable ..? Modular Aluminum Formwork Formwork Assembly

Simplicity – Pin and Wedge system Efficient – Quick Strip Prop Head

Construction with MIVAN Pre – Concrete activities On Concrete activities Post – Concrete activities

OUTLINE OF PRESENTATION

Components of MIVAN Formwork Beam Components Deck Components Other Components Wall Components

Software Application to Formwork Design Site Management Speed of Construction Design Aspects of MIVAN Quality Advantage of MIVAN Other Advantage of MIVAN Limitations of MIVAN Formwork

Remedial Measures Video on – Aluminum Formwork Construction Technique

OUTLINE OF PRESENTATION

WHAT IS MIVAN 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, 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 tailor–made aluminum formwork for cast–in–situ fully concrete structure.

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.

WHAT IS MIVAN FORMWORK Aluminum Formwork system is a comparatively a new technology

in India. It saves cost ,time and improves the quality of construction. It was used by L&T for the first time in India in its projects in

Mumbai, Delhi & South India (South city, Bangalore) in 2003 for the construction of both low and high rises apartments and buildings.

aluminum formwork is very cost effective for repetitive Buildings layouts and for above the plinth work.

aluminum formwork panels can be designed for any condition/components of buildings such as bay windows, stairs , balconies and special architectural features. This system is very unique as all the components in a buildings , including slabs, beams, walls, columns, staircases, balconies and special window hood are of concrete and there is no need for block works or brick works.

HISTORY & BACKGROUND Mivan is basically an aluminum 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. 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.

WHEN IT IS SUITABLE ..? Mass Housing

Typical Floors

Fast Construction Required

No. of Repetitions Are More

High Quality

Column Less Structure

Highly Suitable To Load Bearing Structure (Shear wall)

MODULAR ALUMINUM FORMWORK Precisely-engineered system fabricated in aluminum. 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.

In India and the willingness to use mechanized means of transport and placing of concrete, the use of aluminum 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 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.1 – Wall Assembly DetailsImage Courtesy: Google

FORMWORK ASSEMBLY

Fig.2 – Beam Assembly Details Image Courtesy: Google

SIMPLICITY – PIN AND WEDGE SYSTEMThe 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.

FORMWORK ASSEMBLYBuildings 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. 

EFFICIENT – QUICK STRIP PROP HEADOne 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.

CONSTRUCTION WITH MIVANA) PRE – CONCRETE ACTIVITIES Receipt of Equipment on Site – The equipment is received in the site

as ordered. Level Surveys – Level checking are made to maintain horizontal

level check. Setting Out – The setting out of the formwork is done. Control / Correction of Deviation – Deviation or any correction are

carried out. Erect Formwork – The formwork is erected on site. Erect Deck Formwork – Deck is erected for labours to work. Setting Kickers – kickers are provided over the beam.

CONSTRUCTION WITH MIVAN After the above activities have been completed it is necessary to

check the following. All formwork should be cleaned and coated with approved realize

agent. Ensure wall formwork is erected to the setting out lines. Check all openings are of correct dimensions, not twist. Check all horizontal formwork (deck soffit, and beam soffit etc.) in

level. Ensure deck and beam props are vertical and there is vertical

movement in the prop lengths. Check wall ties, pins and wedges are all in position and secure. Any surplus material or items to be cleared from the area to be cast. Ensure working platform brackets are securely fastened to the

concrete. 

CONSTRUCTION WITH MIVANB). 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: Dislodging of pins / wedges due to vibration. Beam / deck props adjacent to drop areas slipping due to vibration. Ensure all bracing at special areas slipping due to vibration. Overspill of concrete at window opening etc.

CONSTRUCTION WITH MIVANC). POST – CONCRETE ACTIVITIES Strike Wall Form- It is required to strike down the wall form. Strike Deck Form- The deck form is then removed. Clean, Transport and stack formwork Strike Kicker Formwork – The kicker are removed. Strike wall – Mounted on a Working Platform the wall are fitted on

next floor. Erect Wall – Mount Working Platform and the wall is erected.Normally all formwork can be struck after 12 hours. The post-concreting activities includes:I. 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.

ERECTING FORMWORK 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 Image Courtesy: Google

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 PlatformImage Courtesy: Google

POSITIONING OF FORMWORK

Fig.5 – Positioning of PlatformImage Courtesy: Google

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

REMOVAL OF KICKER

Fig.6 – Positioning of PlatformImage Courtesy: Google

Removing of kicker from one floor level and erecting all formwork on next level.

CONSTRUCTION WITH MIVANB). 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: Dislodging of pins / wedges due to vibration. Beam / deck props adjacent to drop areas slipping due to vibration. Ensure all bracing at special areas slipping due to vibration. Overspill of concrete at window opening etc.

COMPONENTS OF MIVAN FORMWORK The basic element of the formwork is the panel, which is an

extruded aluminum rail section, welded to an aluminum 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 aluminum 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.

Fig.7 – Beam Side PanelImage Courtesy: Google

BEAM COMPONENTS 2). Prop Head for Soffit Beam: It forms the soffit beam. It is a V-

shaped head for easy dislodging of the formwork.

Fig.8 – Prop Head for Soffit BeamImage Courtesy: Google

BEAM COMPONENTS 3) Beam Soffit Panel: It supports the soffit beam. It is a plain

rectangular structure of aluminum.

Fig.9 – Beam Soffit PanelImage Courtesy: Google

BEAM COMPONENTS 4) Beam Soffit Bulkhead: It is the bulkhead for beam. It carries most

of the bulk load.

Fig.10 – Beam Soffit BulkheadImage Courtesy: Google

B. DECK COMPONENTS 1) Deck Panel: It forms the horizontal surface for casting of slabs. It

is built for proper safety of workers.

Fig.11 – Deck PanelImage Courtesy: Google

DECK COMPONENTS 2) Deck Prop: It forms a V-shaped prop head. It supports the deck

and bears the load coming on the deck panel.

Fig.12 – Deck PanelImage Courtesy: Google

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

length of the slab.

Fig.13 – Prop LengthImage Courtesy: Google

DECK COMPONENTS 4) Deck Mid – Beam: It supports the middle portion of the beam. It

holds the concrete.

Fig.14 – Deck Mid–BeamImage Courtesy: Google

DECK COMPONENTS 5) Soffit Length: It provides support to the edge of the deck panels at

their perimeter of the room.

Fig.15 – Soffit LengthImage Courtesy: Google

DECK COMPONENTS 6) Deck Beam Bar: It is the deck for the beam. This component

supports the deck and beam.

Fig.16 – Deck Beam BarImage Courtesy: Google

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.

Fig.17 – Internal Soffit CornerImage Courtesy: Google

OTHER COMPONENTS 2) External Soffit Corner: It forms the external corner between the

components

Fig.18 – Internal Soffit CornerImage Courtesy: Google

OTHER COMPONENTS 3) External Corner: It forms the external corner of the formwork

system.

Fig.19 – External CornerImage Courtesy: Google

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

pieces at their exterior intersections

Fig.20 – Internal CornerImage Courtesy: Google

D. WALL COMPONENTS 1) Wall Panel: It forms the face of the wall. It is an aluminum sheet

properly cut to fit the exact size of the wall.

Fig.21 – Wall PanelImage Courtesy: Google

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

having allotment holes for stub pin.

Fig.22 – RockerImage Courtesy: Google

WALL COMPONENTS 3) Kicker: It forms the wall face at the top of the panels and acts as a

ledge to support.

Fig.23 – KickerImage Courtesy: Google

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

two joints.

Fig.24 – Stub PinImage Courtesy: Google

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. The combination of bespoke software and the experience of MIVAN designer’s guarantees :-

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 CONSTRUCTIONThe 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.

DESIGN ASPECTS OF MIVAN Buildings are compared as:1). Conventional RC columns, beams, and slab construction (RC moment resisting framed structure) 2).  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.

DESIGN ASPECTS OF MIVAN On evaluating above alternatives, it is seen that the beam column

frame system in the following.

1). 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.

2). The sizing and detailing of columns needed to be –that they are 20% stronger than beams they support.

QUALITY ADVANTAGE OF MIVANThe 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.

OTHER ADVANTAGE OF MIVANThe Advantages of this system are :-

▶ Easy to handle.▶ aluminum does not rust like steel; therefore, the aluminium

formwork can be reused hundreds of times.▶ Formwork is made with an aluminium alloy, which has high

tensile strength and is also very hard.▶ Saving on overhead expenses due to speedy construction.▶ Monolithic crack free structures.▶ Doesn’t require timber or plywood for construction activities so,

it saves the environment.

OTHER ADVANTAGE OF MIVANThe Advantages of this system are :-

▶ Casting of walls and slabs possible simultaneously.▶ Doesn’t require skilled labour.▶ For the marking purpose there is no need of starter.▶ Floor slabs forms removed without moving props.▶ Earthquake resistance of resulting structures increases manifold.▶ Less debris generation. ▶ Higher scrap value.▶ Carpet area will increase.▶ 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: -

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.

LIMITATIONS OF MIVAN FORMWORK 6) Architectural changes not possible on the structure (but

some walls can be of brick work or openings can be entertained).

7) 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.

8) Due to tremendous speed of construction, working capital finance needs to be planned in advance.

9) 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.

LIMITATIONS OF MIVAN FORMWORK 10)     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.

11)      Due to box-type construction shrinkage cracks are likely to appear.

12)      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.

ALUMINUM FORMWORK CONSTRUCTION TECHNIQUE

Video Courtesy: YouTube

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