MIVAN – A Versatile Aluminum Formwork Construction Technique”R.S.PANCHAL Assistant Engineer, R&B Design Circle, Gandhinagar

What is MIVAN Formwork..? History & Background When it is Suitable ..? Formwork Assembly Components of MIVAN Formwork Design Aspects of MIVAN Work cycle (Speed of Construction) Comparison between Aluminium formwork &

Conventional formwork system Quality Advantage of MIVAN Other Advantage of MIVAN Limitations of MIVAN Formwork Remedial measures Conclusion Video on – Aluminum Formwork Construction Technique

OUTLINE OF PRESENTATION

Mivan is the Brand name from far East,Malaysia. It is Alluminium Alloy Formwork. The system of Aluminium 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.

Aluminum Formwork system is a comparatively a new technology in India.

WHAT IS MIVAN FORMWORK?

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.

HISTORY & BACKGROUND

WHEN IT IS SUITABLE ..? Mass Housing

No. of Repetitions Are More

Typical Floors

Fast Construction Required

High Quality

Column Less Structure

Highly Suitable To Load Bearing Structure (Shear wall)

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 Details Image 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 ASSEMBLY

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 minimum 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 within three months after they are ordered. Following are the components that are regularly used in the construction.

BEAM COMPONENTS

Prop Head Beam Side Panel

Beam Soffit PanelBeam Soffit Bulkhead

Image Courtesy: Google

DECK COMPONENTS

DeckPanel

Deck Prop

Prop Length

Deck Mid –Beam

Soffit Length

Image Courtesy: Google

OTHER COMPONENTS

Internal Soffit Corner

External Soffit Corner

External Corner

Internal Corner

WALL COMPONENTS

Wall Panel

Rocker

Kicker

Image Courtesy: Google

PIN AND WEDGE SYSTEM

Pin

Stub

Image Courtesy: Google

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 -WORK CYCLE

SPEED OF CONSTRUCTION – WORK CYCLE

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.

SPEED OF CONSTRUCTION – WORK CYCLE

System for scheduling & controlling the work of other connected construction tradesDeshuttering of the panels – 12 to 15 hrsPositioning brackets & platforms on the level- 10 to 15 hrsDeshuttered panels lifted & fixed on floor-7 to 10 hrsKicker & external shutters fixed in -7 hrsShutters are erected in 6-8 hrs Reinforcement – 10 to 12 hrsElectrical fittings -10 hrsPouring concrete

COMPARISON BETWEEN ALUMINIUM FORMWORK & CONVENTIONAL FORMWORK SYSTEM

Sr No Characteristic Aluminium formwork system

Conventional Formwork system

1 Speed of construction Four days cycle per floor

Ten days cycle per floor

2 Quality of surface finish Excellent plastering is not required

Bad

3 Pre-planning of form work system

Required Not Required

4 Type of construction Cast in situ cellular construction

Simple RCC framed construction

5 Wastage of form work material Very less In great amount6 Accuracy in construction Accurate

constructionLess than Aluform

7 Coordination between different agencies

Essential Not necessrily required

8 Resistance to earthquake Good resistance Less than Aluform9 Reusage value 250-300 50

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.

QUALITY ADVANTAGE OF MIVAN

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.

OTHER ADVANTAGE OF MIVAN 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. Doesn’t require timber or plywood for construction activities

so, it saves the environment. Casting of walls and slabs possible simultaneously. Doesn’t require skilled labour. 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: -

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.

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

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

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.

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.

CONCLUSION The intension of this paper is not provide a detailed

comparison or explain the technical features of Mivan formwork system in depth. Instead of it aims to show the overview, condition & constraints governing the use of Mivan formwork system under the typical local circumstances.

It can be concluded that the modern methods of construction such as 'Mivan formwork system' are the key to meeting the demand for efficient, sustainable housing. Also the quality and speed must be given due consideration with regards to economy.

ALUMINUM FORMWORK CONSTRUCTION TECHNIQUE

THANK YOU !SPECIAL THANKS TO SHRI.S.K.PATEL SIR, SUPERINTENDING ENGINEER, R&B DESIGN CIRCLE, GANDHINAGAR