"MIVAN_An Aluminum Formwork Construction Technique"

1. “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

2.  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

3.  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

4. 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.

5. 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.

6. 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.

7. 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)

8. 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.

9. 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 Details
Image Courtesy: Google

10. FORMWORK ASSEMBLY
Fig.2 – Beam Assembly Details Image Courtesy: Google
 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 rib of each panel. The panels fit precisely, simply
and securely and require no bracing.

11. FORMWORK ASSEMBLY
Buildings 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 HEAD
One 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.

12. CONSTRUCTION WITH MIVAN
A) 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.

13. 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.

14. CONSTRUCTION WITH MIVAN
B). 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.

15. CONSTRUCTION WITH MIVAN
C). 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.

16. 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

17. 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 Platform Image Courtesy: Google

18. POSITIONING OF FORMWORK
Fig.5 – Positioning of Platform Image Courtesy: Google
 Positioning of working platform bracket and securing nuts on tie rod
on inside the building.

19. REMOVAL OF KICKER
Fig.6 – Positioning of Platform Image Courtesy: Google
 Removing of kicker from one floor level and erecting all formwork
on next level.

20. CONSTRUCTION WITH MIVAN
B). 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.

21. 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.

22. 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 Panel Image Courtesy: Google

23. 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 Beam Image Courtesy: Google

24. BEAM COMPONENTS
 3) Beam Soffit Panel: It supports the soffit beam. It is a plain
rectangular structure of aluminum.
Fig.9 – Beam Soffit Panel Image Courtesy: Google

25. BEAM COMPONENTS
 4) Beam Soffit Bulkhead: It is the bulkhead for beam. It carries most
of the bulk load.
Fig.10 – Beam Soffit Bulkhead Image Courtesy: Google

26. 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 Panel Image Courtesy: Google

27. 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 Panel Image Courtesy: Google

28. DECK COMPONENTS
 3) Prop Length: It is the length of the prop. It depends upon the
length of the slab.
Fig.13 – Prop Length Image Courtesy: Google

29. DECK COMPONENTS
 4) Deck Mid – Beam: It supports the middle portion of the beam. It
holds the concrete.
Fig.14 – Deck Mid–Beam Image Courtesy: Google

30. DECK COMPONENTS
 5) Soffit Length: It provides support to the edge of the deck panels at
their perimeter of the room.
Fig.15 – Soffit Length Image Courtesy: Google

31. DECK COMPONENTS
 6) Deck Beam Bar: It is the deck for the beam. This component
supports the deck and beam.
Fig.16 – Deck Beam Bar Image Courtesy: Google

32. 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 Corner Image Courtesy: Google

33. OTHER COMPONENTS
 2) External Soffit Corner: It forms the external corner between the
components
Fig.18 – Internal Soffit Corner Image Courtesy: Google

34. OTHER COMPONENTS
 3) External Corner: It forms the external corner of the formwork
system.
Fig.19 – External Corner Image Courtesy: Google

35. OTHER COMPONENTS
 4) Internal Corner: It connects two pieces of vertical formwork
pieces at their exterior intersections
Fig.20 – Internal Corner Image Courtesy: Google

36. 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 Panel Image Courtesy: Google

37. WALL COMPONENTS
 2) Rocker: It is a supporting component of wall. It is L-shaped panel
having allotment holes for stub pin.
Fig.22 – Rocker Image Courtesy: Google

38. WALL COMPONENTS
 3) Kicker: It forms the wall face at the top of the panels and acts as a
ledge to support.
Fig.23 – Kicker Image Courtesy: Google

39. WALL COMPONENTS
 4) Stub Pin: It helps in joining two wall panels. It helps in joining
two joints.
Fig.24 – Stub Pin Image Courtesy: Google

40. 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.

41. 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.

42. SPEED OF CONSTRUCTION
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.

43. 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.

44. 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.

45. 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.

46. OTHER ADVANTAGE OF MIVAN
The 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.

47. OTHER ADVANTAGE OF MIVAN
The 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.

48. 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.

49. 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.

50. 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.

51. ALUMINUM FORMWORK CONSTRUCTION TECHNIQUE
Video Courtesy: YouTube

52. THANK YOU !