Value Addition Through Engineering Expertise

By: Shailesh Mirkar

MIVAN SHUTTERING
Definition of formwork

It is the total system of support for freshly placed concrete

including the mould or sheathing which contacts the
concrete as well as all supporting members, hardware and
bracings.

Sometimes also called as falsework or shuttering.

Types of formwork

Type of material used

By the concrete element supported

Construction Technique

Removable or permanent
Types of formwork (Materials)

Steel Aluminum Timber

Fabric Plastic
Types of formwork(Member)

Foundation Column Beam

Slab Wall
Types of formwork(Construction Technique)

Precast Tunnel Table

Slipform

Jumpform Metal Deck

Types of formwork(Permanent or Removeable)

Permanent Insulated Pile liner

Concept of formwork
The pressure exerted by the concrete on the facing material.

Spacing of studs will depend on strength of facing material.

Studs will span between walings.

Studs must be designed for the loads imposed on them by the

facing material.

Spacing of walings should be chosen to suit studs of a convenient

size.

Walings will span between ties which go through to the opposite

face.

Walings must be designed for the loads imposed on them by the

studs.

Spacing of the ties should be chosen to enable walings of a

convenient size to be used.

Load in the ties is determined from this.

Economy in Formwork
Economical design will result when spacing between
studs, wales and ties increase progressively.
The plan of the building should imply a minimum number
of variations in the size of rooms, floor area, etc. to permit
reuse of the formwork repeatedly.
Design should be perfect to use slender sections only in
the most economical way.
Minimum changes to be made to enable reuse of the
material many times. The quantity of surface finish
depends on the quality of the formwork.
Formwork requirements

To obtain required size, shape, finish, position and

alignment of concrete members.
Enough load carrying/transferring capacity to take
pressure or weight of fresh concrete at any other loads,
without distortion, deflection, leakage, failure or danger to
workmen.
Design for quick erection and removal.
Should be Tight & rigid to prevent loss of mortar.
Should be appropriate to method of placing/compacting.
Formwork requirements

Should be made of made of suitable material to suit

thermal requirements.
Should provide concrete of the correct shape and surface
finish.
Should withstand without excessive deflection, worst
combination of self weight, rebar & concrete weight
besides all loads.
Should be capable of easily striking without damaging
concrete.
Formwork requirements

Construction of formwork should permit removal of

various parts in desired sequences without damage to the
concrete.
The material of the formwork should be cheap, readily
available, and should be suitable for reuse
Capable of being cleaned or coated if necessary,
immediately prior to casting.
Able to provide temporary openings where required.
It should be as light as possible
Importance of Formwork

Design Team To ensure final form as per design intent

Planning team To plan timelines as per type of formwork
QS & Budgeting team To estimate precise quantity and cost
Contracts & procurement team To procure optimum sets of formwork
Quality control team To achieve desired quality
Execution team To achieve minimum slab cycle
Safety team To implement safety measures
Bill certification team To measure actual progress
History & development of Aluminum Formwork

W.J. Malone developed aluminum formwork system in 1970

for developing countries
Used gulf countries like Iraq & Iran
Later in 1990, the Mivan Company Ltd, a Malaysian firm
started manufacturing these formworks, hence giving the
name 'Mivan Technology’.
Mivan technology got introduced in India in 2001-02
L&T was the first company to use it in 2003
History & development of Aluminum Formwork

MIVAN

KUMKANG

S FORM

DURAND

KNEST

MFE
‘What’ & ‘Why’ of Aluform or Mivan Formwork
Cost effective cast in situ or cast in place construction
Casting the whole slab, beam, wall, column at one go
Easily withstand high pressure from freshly poured concrete.
Load carrying capacity – 7-8 Tonnes/Sqm(60KN/Sqm-safe
working load)
Highly suitable for load bearing wall construction
Fulfills increased demands of rapid urbanization
Controls speed and quality of construction
‘What’ & ‘Why’ of Aluform or Mivan Formwork

Increases usable floor space(Carpet area)

Eliminates need for external and internal plaster
Flexible, lightweight and easy to install.
Easy to assemble, safety in built system
A semi-skilled labour force is adequate
Less joints so less leakage
Comparison of Aluminum Formwork vs Conventional Formwork
Sl. Aluminum
Characteristics Conventional Formwork
No. Formwork(Mivan)
1 Speed of construction 4-6 days cycle time Min. 21 days cycle time
Excellent. Plastering not
2 Quality of surface finish Ok. Plastering required
Required
Pre-planning of
3 Required Not required
formwork
4 Type of construction Cast in situ cellular Simple RCC frame
5 Wastage of formwork Very less Relatively more
6 Accuracy More accurate Relatively less accurate
Coordination with other
7 Essential Not necessarily required
agencies
Comparison of Aluminum Formwork vs Conventional Formwork

Sl. Aluminum
Characteristics Conventional Formwork
No. Formwork(Mivan)
Resistance to
8 Good Relatively less
earthquake
Removing of slab forms
9 Possible Not possible
without removing props
10 Re-use value 250-300 times Max 50-60 times
Sustainability for high
11 Suitable Not suitable
rise
12 Initial Investment High Less
Economical for mass
13 Economy Economical on small scale
housing
‘Physical properties of Mivan Formwork

Basic element is the panel

Extruded Aluminum rail section, welded to Aluminum
sheet confirming to IS 733 - 1983
6061(T6) - heat-treated aluminum alloy that has good
strength and corrosion resistance
Thickness – 4mm thk.
Weight – 18-20 Kg per Sqm.
Colour – Silver white
‘Components of Mivan Formwork

Wall Components

Beam Components

Slab Components
‘Wall Components

Rocker Wall tie

Wall panel
It forms the face of It is a supporting It connects
the wall. External Corner component of internal and
20 -25 Kg wall. It is L-shaped external wall panel
It forms the external panel having and maintains
corner of the allotment holes width in between
formwork system. for stub pin.
 ‘Wall Components

Wedge & Pins, Long pin

Internal Corner
Kicker Bolt It helps in joining two wall
It connects two pieces of
vertical formwork pieces at It forms the wall face at the top of the panels. It helps in joining two
their exterior intersections. panels and acts as a ledge to support. joints.
‘Beam Components

Beam panel Beam prop head Beam soffit Panel Beam soffit Bulkhead
It forms the side of
It forms the soffit
the beams. It is a It supports the soffit It is the bulkhead
beam. It is a V-shaped
rectangular beam. It is a plain for beam. It carries
head for easy
structure and is cut rectangular structure of most of the bulk
dislodging of the
according to the size aluminum. load.
formwork.
of the beam.
‘Slab/deck Components

Slab panel Slab prop Prop Length Middle Beam

It forms the It is the length of the It supports the

horizontal surface It forms a V-shaped
prop head. It supports prop. length of the middle portion
for casting of slabs. slab. of the beam. It
It is built for proper the deck and bears
the load coming on holds the
safety of workers. concrete 9 kg
13Kg the deck panel. 2kg
 ‘Slab/deck Components

Soffit Length Slab Beam Bar External Soffit Corner Internal Soffit Corner
It forms the vertical
It provides support to the internal corner between
It is the deck for the beam. It forms the external corner
edge of the deck panels at the walls and the beams,
This component supports between the components
their perimeter of the room slabs, and the horizontal
the deck and beam. 0.8 Kg
15 Kg. internal cornice between
the walls and the beam
slabs and the beam
soffit.
‘Staircase Components

Special Step Panel Step Angle Panel

Step Cap Panel
staircase step
panel
‘Tools and accessories

Working Bench
Panel puller
Claw Hammer
Tie rod
Hole bar
Tie puller, Tie ejector,Tie
Breaker
Measuring tape
‘Tools and accessories

Al-New clamp
Bracing
Adjustable Bracket
Water barrier
‘Construction using MIVAN

Design & Manufacturing

Factory Inspection

Dispatch & receipt

Drawing reading and installation of Dry Mock up

Concreting

De-shuttering and shifting

‘Design of MIVAN shuttering
Design based on - IS 14687 -1999 – Clause 5.2

IS 800-2007 & IS 2075- 1964

IS 456
‘Design of MIVAN shuttering

Annex B of IS 14687 - 1999 mentions about information to be

supplied by manufacturer of proprietary formwork systems.

Identification, description and intended use of components

Drawings of major components giving dimensions, weight, locating
& fixing arrangements
Details of material used
Modifications for extended or additional uses and limitations for
every use
‘Design of MIVAN shuttering
Strength details of components and assemblies as given below:
Characteristic failure load
Maximum working load for different conditions
Deflections and camber at maximum working load
Conditions of limiting deflection
Assumed working stresses and material properties
Section properties
Design of bracing against lateral load

Maximum allowable wear and tear and defects due to long usage
and life
‘Design of MIVAN shuttering

Erection method, erection stages, erection tools, precautions and

test on complete structure
Method of stripping and releasing system
Suggested method of stacking and maintenance of system
‘Manufacturing of MIVAN
Melting
Billets
Billets Cutting
Moulding
Extruding
Cutting
Punching
Auto welding
Coating
‘Manufacturing of MIVAN
‘Factory Inspection of MIVAN
Pre-dispatch activity
Straightness

Sizes

Joints and welding of panels

Joinery slots (side faces and wedge slots)

Right angles of fixing edges
Surface uniformity

Coding as per design

Wall tie slots locations and sizes

Fixing rigidity

Uniformity of installed panels

‘Receipt of MIVAN
Demarcation of Stock Yard and set up for the unloading of the formwork material
and accessories
This Stock Yard location close proximity or within the compound of the project
work site, properly fenced up and secured.
Upon arrival of formwork panels at Project Site, Site personnel shall ensure that
the panels are stacked and stored according to sizes and marking using proper
separator such as pallets for easy identification and allocation for subsequent
distribution.
Dry Mockup should be assembled as per schemes at factory; this will eliminate
the usual problematic discrepancies of odd size panels which need to be
fabricated at project site
‘Dispatch and receipt of MIVAN
‘Dispatch and receipt of MIVAN
‘Drawings of MIVAN & Assembly
Wall panel Layout,
Slab Panel Layout,

Starter Block Layout,

Corner Layouts,
Beam Panel Layout,

Soffit Layout,
Staircase Layout,

Bracket and Soldier layout,

Miscellaneous Layout which includes sunken portion, upstand portion etc,

Elevations and sections drawings indicating the location of formwork panels and
component, Typical Fixing Detail drawings, Location of Box outs and Transfer Box out
drawings for transfer of Formwork, etc.
‘MIVAN Drawings
Mivan Unit Layout
MIVAN Drawings
Mivan Sub-unit Layout
MIVAN Drawings
Deck Layout
‘MIVAN Drawings

Prop Layout
‘MIVAN Drawings
Mivan drawings

Wall Layout

Beam Layout
Mivan drawings

Beam Soffit Layout

Beam side Layout

Mivan drawings

Kicker Layout

Corner Layout
Mivan drawings

Wall elevation Layout

Miscellaneous Layout
Mivan drawings

Wall elevation Layout

‘Assembly of MIVAN
Setting Up Level & Marking of Position
Checking on form panels( Cleaning of form)
Applying form release agent. For best results
Uniform application
Immediately after stripping
Prevent contact with rebar
Installing rebar and MEP fixtures( not necessary for dry
mock up)
Fixing cover blocks
Positioning of outlets for electrical switch boxes
‘Assembly of MIVAN
Install external corner

Install external wall panels as per sequence

Install internal corner

Install internal wall panels as per sequence

Install wall tie with sleeve and PVC cover

Install slab corner

Connect prop length and prop head together for

beam and slab support.(Beam splice bar)

Install beam side panel

Commence to assemble the slab panels

Install beam bottoms panel

Follow sequence of pins installation

‘Assembly of MIVAN
Install kicker
Install drop frame, transfer box
Assemble external working bracket
Number all panels as per sequence
Check verticality
‘Assembly of MIVAN
‘Assembly of MIVAN
‘Assembly of MIVAN

Slab corner
Internal
‘Typical MIVAN Assembly
‘Typical MIVAN Assembly
‘Assembly of Staircase

Installation of kicker Installation of soffit length

Installation of Step Panel & SSP Installation of step angles

‘Typical MIVAN Assembly
‘Concreting
Pre-pour check

Ensure that the position of the walls and column formwork are in accordance
with the set up marking.

Check to ensure correct spacing of props for slab formwork.

Check the verticality and horizontality level of the wall and slab panels
respectively.

Ensure that all pins, wedges and ties are properly secured and tightened.

Re-check the opening such as door and window panels are correct.

Re-check all propping stands to ensure its height are in accordance to

drawings.

Adequate bracing (if necessary) to ensure stability. Ensure cover blocks are
placed correctly.

Check for room dimensions.

‘Concreting
During pour check
Ensure site coordinators are available and on stand-by
during the concreting process
Ensure that concrete pouring is distributed evenly
throughout the wall sections before commencing to
cast the slab level areas.
Recheck the areas whenever cement slurry leakage is
noted to determine the cause of it. Remedy work
should be done immediately to ensure the concreting
process is not affected.
During concreting, always ensure that immediate step is
taken to remove / clean all the excess concrete that is
stuck on the back of the formwork panels.
Deshuttering and shifting
After 12 hours, remove the Internal Wall panels by
knocking out the wedges and pins.
After removing the External Wall Forms (kicker should Starter

remain undisturbed), the dismantled wall forms are

Block

moved to upper floor.

After removing the Wall Panels, proceed to the Slab Super

Panels after 36 hours by removing the long pins and

plate

wedges on the joint bars the end and middle beam

section.
Upon removing the Aluspans Mid Beams and Alu span
cantilevers End Beams, the prop shall remain
undisturbed during this process to support the concrete
slab.
Deshuttering and shifting

Proceed to strip the Slab Panels and transfer to the next

level according to the designated area and installation
sequence.
Strip the Slab Corner.
Pull out Wall flat Tie using Wall Tie puller and remove
the Wall tie sleeve using Nose player.
When the cube tests show that the slab concrete is
sufficiently strong, the prop together with the prophets
are removed and transferred to the next level.
Safety Measures

The external working brackets/platforms or scaffoldings

should not be used to stack materials or equipment.
Minimize the working heights for persons performing the
assembly and dismantling formwork.
Mixing of formwork components should be avoided to
prevent unsafe installation such as mixing pins and braces
which may lead to collapse of the formwork.
Do not allow drop stripping of formwork as it is an unsafe
practice.
Safety Measures

Partially assembled or dismantled formwork should be

secured during break time to prevent against overturning or
collapsing due to strong wind or accidentally /
unintentionally knock over by workers.
Protruding flat ties or projecting nails should be removed
immediately with appropriate tools at dismantling stage.
Use of personal protective equipment by all persons working
at work areas (such as safety hardness, safety helmets, eye
protection etc) should be strictly implemented.
‘Team structure

Engineering team
Formwork & material shifting team
Surveyor
Foreman and formwork team
Rebar & MEP team
Concreting
Quality & safety team as per requirement
Daywise activities

Day 1 Grid Line marking, Thesi work, rebar of

column & walls
Day 2 MEP fixures installation, Column & Wall
panel erection
Day 3
Column & Wall panel erection, deck slab
Day 4 installation
Rebar of beam and slab,
Day 5
Leveling work Electrical conduting work,
Day 6
Grid line checking, verticality check,
Day 7 Quality check, Concreting work
Typical Slab cycle
TIME >>> DAYS 0 1 2 3 4 5 6 7
TIME >>> HOURS 0 12 24 36 48 60 72 84 96 108 120 132 144 156 168
1 Concrete of previous pour

2 Dismantling of brackets from below slab

3 De shuttering of recently casted slab's beam sides for bracket fixing

4 Bracket fixing start on casted slab

5 Grid line marking on recently casted slab

6 Scaffold erection for column erection start

Platform fixing on bracket & simultaneously start the vertical scaffold extension
7
for net fixing
8 Deshuttering & shifting of wall panels

9 Erection of vertical scaffold extension & net fixing complete.

10 Reinforcement of all vertical element

11 Form work fixing for walls

12 Form work fixing for decking of slab

13 Beam reinforcement work

14 Levelling work of slab

15 Slab reinforcement work

16 Beam out side shuttering + supporting kicker

17 Pour concrete
Measures to improve cycle time

Use of welded wire mesh

Early removal of props using

concrete maturity method.

Prefabricated frame for plumbing

lines
Common defects in Mivan

Cracks due to shrinkage of concrete are likely to appear.

Loss of capillary water
honey-combing is commonly seen problem.
Due to less thickness of wall
Leakage of grout
Due to complexity and high density of reinforcement at corners
segregation occurs.
Bulging
Inadequate support
Use of old form
‘Disadvantages / Limitations of Mivan Formwork
Aluminum Formwork have high-cost value, so its one-time
investment is quite difficult.
It rental cost is also higher. Unsuitable for small work
Its repair is impossible after the deformation.
Its initial setup takes more time compared to steel formwork.
Modifications/alterations are not possible.
Segregation and stocking require more space
Very less or in fact, no scope for future modifications and
alterations.
‘Disadvantages / Limitations of Mivan Formwork

The shear walls may cause higher generation of heat of

hydration.
Contraction cracks are major problem for mivan formwork.
Even though it provides a smoother finish, the lines will
often be visible because of the minuscule components used
in construction.
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REGISTERED OFFICE:
Shailesh Mirkar – VP Operations
GEM Engserv, A-210, The Great Eastern Chambers, Plot No. 28,
Sector 11, CBD Belapur, Navi Mumbai 400614 +91 99300 03510

NCR Regional Office coming up soon Shailesh.mirkar@gemengserv.com