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MIVAN TECHNOLOGY P.P. Pattanshetti 1, H.B. Patil 2
Civil Engineering Department, Bhivrabai Sawant College of Engineering, Kennedy Road, Pune 411001,University of Pune, India.
Abstract- Mivan is an aluminum formwork system developed by oneof the construction company from Europe. Mivan is an upcomingtechnology which has empowered and motivated the massconstruction projects throughout the world. In this project, we havediscussed about the pioneering and yet pragmatic approach of thistechnology with provisions of speed, quality, financial incentives and construction aspects which is required for a successful completion of mass housing project, with the help of a case study of a renowned company. The project also includes comparison of aluminumformwork technology and conventional system. This comparisonreveals the reduced total cost. Other aspects include its box type
construction which proves much advantageous as far as earthquakeresistant structure is considered.
Keywords- Components, cost, comparison with conventionalsystem, construction speed.
I. INTRODUCTION
MIVAN is basically an aluminium formwork systemdeveloped by one of the construction company from Europe.In 1990, the MIVAN Company Ltd from Malaysia started themanufacturing of such formwork systems. Now a days morethan 300,000 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 whichhas 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 usingroom size forms to construct walls and slabs in one continuous
pour of concrete. Early removal of forms can be achieved byhot air curing / curing compounds. This facilitates fastconstruction, say two flats per day. All the activities are
planned in assembly line manner and hence results into more
accurate, well controlled and high quality production atoptimum cost and in shortest possible time.
MIVAN is a new technology which has empowered and motivated the mass construction projects throughout theworld. In this project, we have discussed about the pioneering
and yet pragmatic approach of this technology with provisionsof speed, quality, financial incentives and construction aspectswhich is required for a successful completion of mass housing
project, with the help of various case studies of differentcompanies.
II. INNOVATIONS IN CONSTRUCTION:-
The traditional mode of construction for individualhouses comprising load bearing walls with an appropriate roof above or reinforced concrete (RC) framed structureconstruction with infill masonry walls would be totallyinadequate for mass housing construction industry in view of the rapid rate of construction. Further, such constructions are
prone to poor quality control even in case of contractors withsubstantial resources and experience.
For undertaking mass housing works, it isnecessary to have innovative technologies which arecapable of fast rate construction and are able to delivergood quality and durable structure in cost effectivemanner.
III. LOADS ACTING ON FORMWORK:-
In Construction, the formwork has to bear, besides itsown weight, the weight of wet concrete, the live load due tolabour, and the impact due to pouring concrete and workmenon it. The vibration caused due to vibrators used to compactthe concrete should also be taken care off. Thus, the design of the formwork is an essential part during the construction of the building.
For the design of planks and joists in bending &shear, a live load including the impact may be taken as370kg/m. It is however, usual to work with a small factor of safety in the design of formwork. The surfaces of formwork should be dressed in such a manner that after deflection due toweight of concrete and reinforcement, the surface remainshorizontal, or as desired by the designer. The sheathing withfull live load of 370 kg/m should not deflect more than 0.25cm and the joists with 200kg/m of live load should not deflectmore than 0.25cm.
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In the design of formwork for columns or walls, thehydrostatic pressure of the concrete should be taken intoaccount. This pressure depends upon the quantity of water inthe concrete, rate of pouring and the temperature.
IV. ALUMINUM FORMWORK:-
Aluminum as usual is not a very strongmaterial. So the basic elements of the formwork system are
the panel which is a framework of extruded aluminiumsections welded to an aluminium sheet. It consists of highstrength special aluminium components. This produces a lightweight panel with an excellent stiffness-to-weight ratio,yielding minimal deflections when subjected to the load of weight concrete. The panels are manufactured in standard sizes with non-standard elements produced to the required sizeand size to suit the project requirements.
The panels of aluminium formwork are made fromhigh strength aluminium alloy, with the face or contact surfaceof the panel, made up of 4mm thick plate, which is welded toa formwork of specially designed extruded sections, to form arobust component. The panels are held in position by a simple
pin and wedge arrangement system that passes through holesin 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 hassections that are large enough to be effective, yet light enoughin the weight to be handled by a single worker. Individualworkers can handle all the elements necessary for forming thesystem 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 linetechniques to construction site and to ensure quality work, byunskilled or semi-skilled workers.
Trial erection of the formwork is carried out infactory conditions which ensure that all components arecorrectly manufactured and no components are missed out.Also, they are numbered and packed in such a manner so as toenable easy site erection and dismantling.
V. MERITS OF ALUMINIUM FORMWORK:-
1. In contrast to most of the modernconstruction systems, which are machine and equipment oriented, the formwork does not depend upon heavy lifting equipment and can be handled byunskilled labors.
2. Fast construction is assured and is particularly suitable for large magnitude constructionof respective nature at one project site.
3. Construction carried out by this system hasexceptionally good quality with accurate dimensionsfor all openings to receive windows and doors, rightangles 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.
4. System components are durable and can beused several times without sacrificing the quality or correctness of dimensions and surface.
5. Monolithic construction of load bearingwalls and slabs in concrete produces structurallysuperior quality with very few constructions joined compared to the conventional column and beam slabsconstruction combined with filter brick work or block work subsequently covered by plaster.
6. In view of the four day cycle of castingthe floor together with all slabs as against 14 to 20 day cycle in the conventional method, completed RCC structure is available for subsequent finishtrades much faster, resulting in a saving of 10 to 15days per floor in the overall completion period.
7. As all the walls are cast monolithic and simultaneously with floor slabs requiring no further
plasters finish. Therefore the time required in theconventional method for construction of walls and
plastering is saved.
8. As fully completed structural frame is madeavailable in one stretch for subsequent finishingitems, uninterrupted progress can be planned ensuring, continuity in each trade, thereby providingas cope for employing increased labor force onfinishing item.
9. As the system establishes a kind of Assembly line production phase wise completionin desired groups of buildings can be planned toachieve early utilization of the buildings.
VI. MODULAR FORMWORK:-
In MIVAN formwork we give stress on shear wallrather than conventional framed structure of columns andbeams.
The system of aluminum forms (MIVAN) has been used widely in the construction of residential units and mass
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housing projects. It is fast, simple, adaptable and cost effective. It produces total quality work which requiresminimum maintenance and when durability is the primeconsideration. This system is most suitable for Indiancondition as a tailormade aluminum formwork for castin situ fully concrete structure.
The formwork system is precisely-engineered system
fabricated in aluminium. Using this system, all the elements of a building namely, load bearing walls, columns, beams, floor slabs, stairs, balconies etc can be constructed with cast in
place concrete. The resulting structure has a good qualitysurface finish and accurate dimensional tolerances. Further,the construction speed is high and the work can be done in acost effective manner.
The modular nature of the formwork system allowseasy fixing and removal of formwork and the construction can
proceed speedily with very little deviation in dimensionaltolerances. Further, the system is quite flexible and can beeasily adapted for any variations in the layout.
The availability of concrete from ready mix concretefacility has augured well for the use of this work system.However, the proliferation of RMC facilities in the cities inIndia and the willingness to use mechanized means of transport and placing of concrete, the use of aluminiumformwork system has received a boost. The quality of theresulting concrete is found to be superior.
Structurally speaking, the adoption of the closed boxsystem using monolithic concrete construction has been found to be the most efficient alternatives. The stresses in both theconcrete and steel are observed to be much lower even whenhorizontal forces due to wind or earthquake are taken intoconsideration.
The formwork system can be used for constructionfor all types of concrete systems, that is, for a framed structureinvolving column beam slab elements or for box-typestructure involving slab-walls combination.
VII. FORMWORK COMPONENTS:-
The basic element of the formwork is the panel,which is an extruded aluminium rail section, welded to analuminium sheet. This produces a lightweight panel with anexcellent stiffness to weight ratio, yielding minimal deflectionunder concrete loading. Panels are manufactured in the sizeand shape to suit the requirements of specific projects.
The panels are made from high strength aluminiumalloy with a 4 mm thick skin plate and 6mm thick ribbing
behind to stiffen the panels. The panels are manufactured in
MIVANS dedicated factories in Europe and South East Asia.Once they are assembled they are subjected to a trial erectionin order to eliminate any dimensional or on site problems.
All the formwork components are received at the sitewhining three months after they are ordered. Following are thecomponents that are regularly used in the construction.
A. WALL COMPONENTS:-
1) Wall Panel: - It forms the face of the wall. It is anAluminium sheet properly cut to fit the exact size of the wall.
Fig.1 Wall panel
2) Rocker:- It is a supporting component of wall. It is L-shaped panel having allotment holes for stub pin.
Fig 2 Rocker
3) Kicker:- It forms the wall face at the top of the panels and acts as a ledge to support
Fig 3 KICKER
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4) Stub Pin:- It helps in joining two wall panels. Ithelps in joining two joints .
Fig 4 STUB PIN
B. 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 5 BEAM SIDE PANEL
2) Prop Head for Soffit Beam:- It forms the soffit beam. It is a V-shaped head for easy dislodging of theformwork.
Fig 6 PROP HEAD FOR SOFFIT BEAM.
3) Beam Soffit Panel:- It supports the soffit beam. Itis a plain rectangular structure of aluminum.
Fig 7 BEAM SOFFIT-PANEL
4) Beam Soffit Bulkhead :- It is the bulkhead for beam. It carries most of the bulk load.
Fig 8 Beam Soffit Bulkhead
C. DECK COMPONENT:-
1) Deck Panel:- It forms the horizontal surface for casting of slabs. It is built for proper safety of workers.
Fig 9 DECK PANEL
2) Deck Prop:- It forms a V-shaped prop head. Itsupports the deck and bears the load coming on the deck
panel.
Fig 10 DECK PROP
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3) Prop Length:- It is the length of the prop. Itdepends upon the length of the slab.
Fig 11 DECK PROP LENGTH
4) Deck Mid Beam:- It supports the middle portion of the beam. It holds the concrete.
Fig 12 DECK MID-BEAM
5) Soffit Length:- It provides support to the edge of the deck panels at their perimeter of the room.
Fig 13 SOFFIT LENGTH
6) Deck Beam Bar:- It is the deck for the beam. Thiscomponent supports the deck and beam.
Fig 14 DECK BEAM BAR
D.
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 15 INTERNAL SOFFIT CORNER
2) External Soffit Corner:- It forms the external corner
between the components.
Fig 16 EXTERNAL SOFFIT CORNER
3) External Corner:- It forms the external corner of the formwork system.
Fig 17 EXTERNAL CORNER
4) Internal Corner:- It connects two pieces of verticalformwork pieces at their exterior intersections.
Fig 18 INTERNAL CORNERS
VIII. FORMWORKS ASSEMBLY:-
Mivan aims in using modern constructiontechniques and equipment in all its projects. On leaving theMIVAN factory all panels are clearly labeled to ensure thatthey are easily identifiable on site and can be smoothly fitted together using the formwork modulation drawings. Allformwork begins at a corner and proceeds from there.
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Fig 19 WALL ASSEMBLY DETAILS
IX. 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 ribof each panel. The panels fit precisely, simply and securelyand require no bracing. Buildings can be constructed quicklyand easily by unskilled labour with hammer being the onlytool required. Once the panels have been numbered,measuring is not necessary. As the erection process ismanually, tower cranes are not required. The result is a typical4 to 5 day cycle for floor to floor construction.
X. EFFICIENT QUICK STRIP PROP HEAD:-
One of the principal technical features which enablesthis aped to be attained using a single set of formwork panel isthe 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.
XI. CONSTRUCTION ACTIVITIES WITH MIVAN ASFORMWORK:-
The construction activities are divided as pre concrete activities, during concreting and post concreteactivities. They are as follows:
A. PRE CONCRETE ACTIVITIES:-
a) Receipt of Equipment on Site The equipments isreceived in the site as ordered.
b) Level Surveys Level checking are made to maintainhorizontal level check.
c) Setting Out The setting out of the formwork is done.
d) Control / Correction of Deviation Deviation or anycorrection are carried out.
e) Erect Formwork The formwork is erected on site.
f) Erect Deck Formwork Deck is erected for labours towork.
g) Setting Kickers kickers are provided over the beam.
After the above activities have been completed it isnecessary to check the following.
1. All formwork should be cleaned and coated
with approved realize agent.2. Ensure wall formwork is erected to the
setting out lines.
3. Check all openings are of correctdimensions, not twist.
4. Check all horizontal formwork (deck soffit,and beam soffit etc.) in level.
5. Ensure deck and beam props are vertical and there is vertical movement in the proplengths.
6. Check wall ties, pins and wedges are all in position and secure.
7. Any surplus material or items to be cleared from the area to be cast.
B. ON CONCRETE ACTIVITIES:-
At least two operatives should be on standby duringconcreting for checking pins, wedges and wall ties as the pour is in progress. Pins, wedges or wall ties missing could lead toa movement of the formwork and possibility of the formwork
being damaged. This affected area will then required remedialwork after striking of the formwork.
Things to look for during concreting:
1. Dislodging of pins / wedges due tovibration.
2. Beam / deck props adjacent to drop areasslipping due to vibration.
3. Ensure all bracing at special areas slippingdue to vibration.
4. Overspill of concrete at window openingetc.
C. POST CONCRETE ACTIVITIES:-1. Strike Wall Form- It is required to strike
down the wall form.2. Strike Deck Form- The deck form is then
removed.
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3. Clean, Transport and stack formwork.4. Strike Kicker Formwork The kicker are
removed.5. Strike wall Mounted on a Working
Platform the wall are fitted on next floor.6. Erect Wall Mount Working Platform
and the wall is erected.
Normally all formwork can be struck after 12 hours.The post concreting activities includes:-
1. CLEANING:-
All components should be cleaned with scrapers and wire brushes as soon as they are struck. Wire brush is to beused 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 theyare struck.
2. TRANSPORTING:-
There are basic three methods recommended whentransporting to the next floor:
1. The heaviest and the longest, which is afull height wall panel, can be carried upthe nearest stairway.
2. Passes through void areas.
3. Rose through slots specially formed inthe floor slab for this purpose. Oncethey have served their purpose they areclosed by casting in concrete filter.
XII.
SPEED OF CONSTRUCTION:-Mivan is a system for scheduling & controlling the
work of other connected construction trades such as steelreinforcement, concrete placements & electrical inserts. Thework at site hence follows a particular sequence. The work cycle begins with the deshuttering of the panels. It takes about12-15hrs. It is followed by positioning of the brackets& platforms on the level. It takes about 10-15hrssimultaneously.
The deshuttered panels are lifted & fixed on the floor .The activity requires 7-10 hrs.Kicker & External shutters arefixed in 7 hrs. The wall shutters are erected in 6-8 hrs One of the major activity reinforcement requires 10-12 hrs. Thefixing 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 nextcycle. This work schedule has been planned for 1010-1080 sq m of formwork with 72-25cu m of concreting & approximatereinforcement.
The formwork assembling at the site is a quick &easy process. On leaving the MIVAN factory all panels areclearly 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 verticalreinforcement 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 thesecond side of the vertical formwork and formwork for thefloor.
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 slabformwork in place for 2.5 days.
XIII. CASE STUDY
AMANORA PARK TOWN, HADAPSAR, PUNE
A case study on planning aspects for use of MIVANin building construction in the department of planning atAMANORA PARK TOWN, Hadapsar, Pune.
In this case study we have tried to focus on thevarious properties of shuttering formwork system in view of
project management and planning process.
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TABLE 1
TECHNICAL SPECIFICATIONS
TABLE 2
SALIENT FEATURES OF THE PROJECT
Sr.No Particulars Details
1. Total Plot Area 45802.00 sq m.
2. Total Built Up Area 120001.24 sq m.
3. No. of Towers 10
4. No. of Floors 18-22
5. Total No of flats 674
6. 3 BHK 1980 sq.ft.
7. 3.5 BHK 2085 sq.ft.
8. 2 BHK 1350 sq.ft.
9. 2.5 BHK 1600 sq.ft.
10. 4 BHK 3190 sq.ft.
XIV. CONCLUSION:
We will be concluding this topic in this seminar interms of economics, quality, and value analysis.
Selection of appropriate material for delivering aquality product in minimum expenditure and with stipulated span of time is the basis of planning department. In designing
phase all the calculations regarding material, time, and cost isdone and the product is finalized.
We have chosen Mivan formwork as our paper topic because of its speed in construction, quality of product and many such things which are very useful for the effectiveexecution of any project.
Following are some of the aspects which makeMIVAN a super Formwork System
. i) Achieving quality objective of planning department.ii) Minimize schedule and cost variances.iii) Enhanced labour productivity.iv) Repetitions for a township.v) Rotations of Mivan shuttering.vi) Useful life of the formwork.vii) Cost comparison of different types of formwork with
Mivan.viii) Scrap Value.
1. Name of Work : Proposed Constructionof R2 sector (10Nos) atAmanora Park Town,Hadapsar.
2. Location : Sade Satara Nalivillage, Pune
3. Time of Completion : As per 25+2 calendar months commencing 16August,2007.
4. Defects LiabilityPeriod
: 12 months from thedate of Finalcompletion certificateissued by the Client/PMC /architect
5. Grade of Concrete :M25
6. Slump : 180 to 200 mm
7. Floor to Floor height : 3.0 m
8. Wall thickness
a)External
b)Partition wall
:
:
200 mm
100 mm
9. Steel
a)Partition(non-structural)
b)Structural wall
c)Shear wall
:
:
:
10 mm dia.
12 mm dia.
16 mm dia.
10.
Slab Thickness
a)Hall
b)Bedroom
c)Kitchen
:
:
:
175 mm
150 mm
125 mm
11.
Finishing
a)External
b)Internal
:
:
Texture Paint
Paint over Gypsum coat
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ACKNOWLEDGEMENT
In regards we are extremely fortunate in havingProf. N N MORE (DEPARTMENT OF CIVILENGINEERING) as our project guide. Had it been not hisincredible help coupled with valuable suggestions, relentlesseffort and constructive ideas, more over his optimistic attitude,guidance and understanding making us believe all that
accomplished was our effort for which we will ever remainindebted to him. He is essentially the first person who sharesour joy. We would like to express our gratitude to Dr K MSHARMA, H.O.D. of the DEPARTMENT OF CIVILENGINEERING for his escorting role in meeting our objectives. We would also like to express our sincere gratitudeto our PRINCIPAL, Dr D V JADHAV. At this moment, wecannot forget to pay sincere regards to our PARENTS who area big source of inspiration and blessings.
REFRENCES:
Census of India. (2001) Table 500-012.Pp-48. National Building Organization. (2001). Pp-25. Book Bliss Indian Concrete Journal, July2005, Volume 79, pp.
55-59. Times Journal Construction and Design. Oct-Dec
2001, pp Editorial. www.Mivan.com