Top 4 innovative formworks in India

Syed Ameen Kader , June 23rd, 2010

Formwork companies are making all efforts to innovate new systems for better and quicker results. Taking cue from the developed world, Indian construction industry has started using some of the world class technologies. Several formwork systems are in use at different places in the world; eventually the systems which are reasonably economical and easy for operation with skilled labour are more useful in India. Leading players in this industry are Doka, Mascon System, MFE Formwork Technology (Mivan), Meva, Waco, Forming Access and Support, Inc (FASI), Peri, BSL Scaffolding, Uday Structurals & Engineers, Paschal and Pranav Construction Systems.

In this article we are listing four exciting innovations from the world of formwork system. Different systems have their own advantages but one needs to choose a formwork which best supports individual project requirement.

MasconThe Mascon Construction System is used for forming the cast-in-place concrete structure of a building. Developed in the late 1970s by WJ Malone, a Canadian engineer, the Mascon System has been used extensively throughout the world. It is fast, simple, adaptable and very cost effective. The System is most effective when combined with loadbearing wall structural design. The Mascon System is unique because it forms all of the concrete in a building including; walls, floor slabs, columns, beams, stairs, window hoods, balconies and various decorative features in exact accordance with the architect’s design. The System consists of hundreds of hand held pieces of formwork equipment, manufactured to fine tolerances. The majority of the equipment is comprised of panels while the rest includes vertical and horizontal corner sections, bulkheads and special floor slab beams that can be dismantled without disturbing the props supporting the floor slab concrete.Ninety-nine percent of the Mascon equipment is made of aluminium, the other one percent is steel. Unlike other construction systems, the use of aluminium allows the larger components to be big enough to be effective, yet light enough (less than 30 kg) to be handled by a single worker. Consequently, the need for cranes or other heavy handling equipment is eliminated. All of the individual pieces of equipment are joined by simple steel pins and wedges and the only tool required in assembly is a hammer. This eliminates the need for skilled workers.The Mascon formwork can be used to form both concrete structural designs – i.e. traditional RCC frame design or loadbearing wall design.

MFE Formwork Technology (Mivan)MFE Formwork Technology (formally known as Mivan Far East) is a revolutionary aluminium formwork construction system, which has been used quite extensively in India. Using this unique formwork, all walls, floor slabs, columns, beams, stairs, balconies, together with door and window openings are cast in place in a single site based operation. The resulting building structure is very strong, accurate in dimensions and tolerances, with a high quality of finished

concrete surface. It is fast, adaptable and very cost effective.MFE Formwork makes use of concrete as the principal building material for the prime reasons of cost and accessibility. It can construct all type of concrete structures.The basic element of MFE Formwork is the panel which is a framework of extruded aluminium sections, welded to an aluminium sheet. This produces a lightweight panel with an excellent stiffness to weight ratio, yielding minimal deflections under concrete loading. Panels are manufactured in standard sizes with non-standard elements produced to the required size and shape to suit the project requirements. The panels are made from a high strength aluminium alloy, with the face or contact surface of the panel, from 4mm thick plate, which is welded to a framework of specially designed extruded sections, to form a robust component. As MFE Formwork can be reused over 250 times, the initial cost appears high; however the ultimate cost per sft of forming area is less when compare to traditional methods.

PaschalThe Paschal Group, specializing in concrete formwork, shoring systems and formwork design software globally, has recently opened their first distribution and production facility in India. Its production company, Paschal Form Work in Visakhapatnam, concentrates on products such as the Modular universal formwork as well as the innovative modular slab formwork E-Deck with steel frame, which can also be used on building sites that have no crane. With the modular slab formwork E-Deck, Paschal presents a particularly robust product, specially designed for use on building sites where no crane is available and, furthermore, can be used everywhere where aluminium should not be used. The frame of the new elements is made from profiled steel and, with a height of 7.5 cm provides very good grid compatibility and flexible application options, for transportation as well as for installation. The facing of the formwork consists of a 9-layer, 12 mm thick sheet of birch plywood, so that the weight of the individual elements is a maximum 20 kilograms and can be used with no problem without a crane. The E-Deck has the advantage that damage to the frame can be repaired, which is not possible on comparable aluminium products. Panel slab formwork has an advantage over flex-formwork that the panels are protected and more durable. Because the panels are attached to one another, as opposed to flex-formwork, they are considerably safer.

PeriOne of the biggest names in the industry, Peri provides innovative formwork and scaffolding systems. With 55 subsidiaries and over 100 large logistical locations around the world, Peri operates in over 70 national markets.The company offers Uno Monolithic Housing Formwork which is used for monolithic construction method. The Uno formwork is predominantly used for residential housing development and similar, whereby large numbers of residential units with identical dimensions are extended horizontally and vertically.The company says all Uno elements, girders and stopend plates are made of aluminium and weigh a maximum 23 kg/m². This means problem-free forming can be done manually. It is very easy to assemble. A hammer is sufficient when working with Uno.Thanks to the new mechanism, the wall formwork elements can easily be dismantled even with slab formwork elements still installed. After dismantling the Spacer Clamps, the wall element is simply unscrewed from the wall/slab transition area. The transition to the horizontal formwork is

flexibly designed so that striking can be easily carried out in this area as well.The design of the slab formwork as drophead formwork allows early striking to take place – usually after only one day. For setting of stopends and box-outs, Uno Stopend Plates are available, which are adapted to the wall thicknesses in 1 cm increments. In addition, the integrated toothed rack of the shuttering strip absorbs the concrete load and thus replaces the formwork tie.

Note: All innovations mentioned in the 'Top Four Formworks' are presented in an alphabetical order. This list is not exhaustive.

 

 3. Clean, Transport and stack formwork.4. 

Strike Kicker Formwork – The kicker areremoved.5. Strike wall – Mounted on a WorkingPlatform the wall are fitted on next floor.6. Erect Wall – Mount Working Platformand

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 thework 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 theconcrete 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 onsite 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 STUDYAMANORA PARK TOWN, HADAPSAR, PUNEA 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.

 

 TABLE 1TECHNICAL SPECIFICATIONSTABLE 2SALIENT FEATURES OF THE PROJECTSr.No Particulars Details

1. Total Plot Area 45802.00 sq m.2. Total Built Up Area 120001.24 sq m.3. No. of Towers 104. No. of Floors 18-225. Total No of flats 6746. 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 withMivan.viii) Scrap Value.1.Name of Work :Proposed Constructionof R2 sector (10Nos) atAmanora Park Town,Hadapsar.2.

Location :Sade Satara Nalivillage, Pune3.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 /architect5.Grade of Concrete:M256.Slump:180 to 200 mm7.Floor to Floor height: 3.0 m8.Wall thicknessa)External b)Partition wall:: 200 mm100 mm9.Steel

a)Partition(non-structural) b)Structural wallc)Shear wall::: 10 mm dia.12 mm dia.16 mm dia.10.Slab Thicknessa)Hall b)Bedroomc)Kitchen::: 175 mm150 mm125 mm11.Finishinga)External b)Internal:: Texture PaintPaint over Gypsum coat

 

 ACKNOWLEDGEMENTIn 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 thataccomplished 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-Dec2001, pp Editorial.

 www.Mivan.com

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MFE Formwork Technology is a revolutionary aluminium formwork construction system, which has been successfully used and developed over 20 years for forming cast in place reinforced concrete building structures. Using this unique system, all walls, floor slabs, columns, beams, stairs, balconies, lift and duct cores together with door and window openings are cast in place in a single-site based operation. The resulting building structure is very strong, accurate in dimensions and tolerances, with a high-quality finished concrete surface, yet at the same time the MFE is fast, adaptable and very cost effective.

With a reputation for excellence and innovation gained over 20 years, MFE (formerly Mivan Far East) is one of the world leaders in concrete construction using unique MFE aluminium formwork system which has significant advantages over other forming methods.

MFE has recently announced after a recent test carried out in Singapore, it achievement of Band 2 for Buildable Design Appraisal System (BDAS) operated by Buildable and Construction Authority (BCA), an agency under the Ministry of National Development, championing the development of an excellent built environment in Singapore.

MFE formwork technology is a “make to order” formwork and customised.

Key elements of MFE businessDesignMFE’s design team provide a complete service embracing all aspects of architectural and structural design.With over 25 technical designers and using state-of-the-art design software, the formwork is designed to suit project using the most economical assortment of panel sizes.

The combination of bespoke software and the experience of the MFE’s designers guarantees the most efficient construction process, incorporating the optimum assembly procedures, economical panel selection and ultimately minimising capital and operational costs.

ManufacturingThe basic element of MFE Formwork is the panel which is an extruded aluminium sections. This produces a lightweight panel with an excellent stiffness to weight ratio, yielding minimal deflections under concrete loading. Panels are manufactured in standard sizes with non-standard elements made in the sizes and shapes to suit the requirements of specific projects.

The panels are made from a high-strength aluminium alloy. The face of the panel is a 4 mm thick, specially designed extruded sections, welded to form a robust component.

Technical supportUpon arrival of MFE formwork on site, experienced MFE supervisors will assist in the setting up of material on the working slab and to train your site staff in the proper handling of the equipment. Its site staff will also guide clients to achieve the agreed construction work cycle to maximise the efficiency of the formwork and labour force on site.

Safety and environmentLots of importance is given to safety on-site, and that is why MFE has developed an integrated safety, working platform which ensures labour safety during erection and striking of the formwork system. Safety is incorporated into the MFE formwork with integrated brackets to support walkways on external surfaces. It avoids separate scaffolding for safety during shuttering operations. MFE formwork is made entirely from aluminium and 100 per cent recyclable.

The salient features of MFE formwork• Lightweight with simple pin and wedge assembly gives unparallel speed of construction. • With MFE formwork, slab cycle has come down from about 20-30 days to 5-6 days per floor maintaining international standard quality which no one could think of 10 years back.• Standard components can be reused on other projects, reducing cost of formwork. • Repetition is a key to MFE Formwork. • Expert management system.

MFE has now more than 150 projects in India in various stages; the projects are is already completed under design. NextGen Era by Marathon in India is one of the outstanding project considering curved elevation features. The world’s tallest twisting tower — Infinity Tower in Dubai which rotates across the floors by 90 degree - is certainly the most challenging project ever.