Application & Comparison of different Formwork System used within Indian Construction Industry

Application & Comparison of different Formwork
System used within Indian Construction Industry
A Project Report
Submitted by:
ABHISHEK SHAH 090670106002
ABHISHEK ASNANI 100673106003
RUDRADATTSINH CHUDASAMA 090670106049
MANISH VALAND 090670106043
1

SAL INSTITUTE OF TECHNOLOGY AND ENGINEERING RESEARCH
AHMEDABAD
Gujarat Technological University
December 2012
In fulfillment for the award of the degree
Of
BACHELOR OF ENGINEERING
In
CIVIL ENGINEERING DEPARTMENT
2

About the project site:
Name of the project site: Mondeal Square, HN Safal
Location: Near Karnavati Club, S. G. Highway,
Ahmedabad.
About the project site:
• Premium business landmark of Ahmedabad.
• Exclusively designed for business persons.
• No of floors is Ground+11 floors
• Designed by the German Architecture Blocher & Blocher.
• Structure Consultant is Mr. N.K.Shah
• Project Manager is Mr. Akshay Desai.
3

Chapter – 1
Introduction to
Formwork
4

1. Introduction:
1.1 Definition of Formwork:
When concrete is placed, it is in plastic state. It requires to be supported by temporary
supports and castings of desired shape till it becomes sufficiently strong to support its
own weight. This temporary casing is known as the formwork or forms or shuttering.
1.2 General Introduction:
• Formwork plays a key role in concrete construction.
• Forms are the moulds & dies of concrete construction.
• They mould the concrete to the desired size & shape & control its alignment &
position.
• Formwork also carries the weight of freshly placed concrete and itself besides live
load due to materials, equipment and workmen
5

1.3 Importance of Formwork:
•In the Construction of any building concreting and reinforcement binding is the main
activity after that to hold them in their position Formwork is most important
• Formwork constitutes 20% of the standard cost and 60% of the time in concrete
construction.
• Thus a good formwork system helps in achieving speed, quality, economy and safety
in reinforced concrete construction
6

1.4 Requirement of Formwork:
• To obtain the required shape, size, finish, position and alignment of concrete
members.
• To have enough load carrying, or transferring capacity to take pressure or
weight of fresh concrete and any other loads, without distortion, deflection,
leakage, failure or danger to workmen.
• To have design for quick erection and removal.
• To handle easily using available equipment or manpower.
• Joints between formwork must be tight enough to prevent leakage of grout.

1.5 Based on material Various Types of Formwork are :
 Plywood (Fig-1.1)
 Bamboo (Fig-1.2)
 Steel (Fig-1.3)
 Aluminium (Fig-1.4)
 Plastic (Fig-1.5)
8

Plywood :
Fig-1.1 Plywood Formwork
9

Bamboo:
Fig-1.2 Bamboo Formwork
10

Steel:
Fig-1.3 Steel Formwork
11

Aluminum:
Fig-1.4 Aluminium Formwork
12

Plastic:
Fig-1.5 Plastic Formwork
13

Chapter – 2
Mivan Formwork
System
14

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.
Early removal of forms can be achieved by hot air curing / curing compounds.
This facilitates fast construction, say two flats per day.
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.
16

Fig-2.1 Wall Assembly Details
2.3 Mivan 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.
17

Chapter - 3
Procedure For Using
Mivan Formwork
18

3.0 Procedure For Using Mivan Formwork:
3.1 PRE – CONCRETE ACTIVITIES:
a) Receipt of Equipment on Site – The equipments is received in the site as ordered.
b) Level Surveys – Level checking are made to maintain horizontal level check.
c) Setting Out – The setting out of the formwork is done.
d) Control / Correction of Deviation – Deviation or any correction are carried out.
e) Erect Formwork – The formwork is erected on site.
f) Erect Deck Formwork – Deck is erected for labours to work.
g) Setting Kickers – kickers are provided over the beam.
19

i. Dislodging of pins/wedges due to vibration.
ii. Beam/deck props adjacent to drop areas slipping due to vibration.
iii. Ensure all bracing at special areas slipping due to vibration.
iv. Overspill of concrete at window opening etc.
3.2 ON CONCRETE ACTIVITIES:
20

A) 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.
B) TRANSPORTING:
• The heaviest and the longest, which is a full height of wall panel, can be carried up
the nearest stairway. Passes through void areas.
C) STRIKING:
• Once cleaned and transported to the next point of erection, panels should be stacked at
right place and in right order.
•D. Erecting of Formwork:
• After that formwork is erect again on the next floor.
3.3 POST – CONCRETE ACTIVITIES:
21

3.4 Sequence For Striking And Erecting The Wall
Mounted On Working Platform is as follows:
Fig-3.4.1 Erection of Platform On 2nd Floor 22

Fig-3.4.2 Striking of formwork
23

Fig-3.4.3 Positioning of Platform
24

Chapter – 4
Comparison of Mivan
Formwork
Components with
Actual Sight Photos 25

4.0 Comparison of Mivan Formwork Components with Actual Sight
Photos:
4.1 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-4.1.1: BEAM SIDE PANEL 26

2) Prop Head for Soffit Beam:- It forms the soffit beam. It is a V-shaped head for
easy dislodging of the formwork.
FIG-4.1.2: PROP HEAD FOR SOFFIT BEAM
27

3) Beam Soffit Panel:- It supports the soffit beam. It is a plain rectangular structure of
aluminum
FIG-4.1.3: BEAM SOFFIT-PANEL
28

4) Beam Soffit Bulkhead:- It is the bulkhead for beam. It carries most of the bulk load.
Fig-4.1.4: Beam Soffit Bulkhead
29

4.2 Deck Component:
1) Deck Panel:- It forms the horizontal surface for casting of slabs. It is built for proper
safety of workers.
FIG-4.2.1: DECK PANEL 30

2) Deck Prop: - It forms a V-shaped prop head. It supports the deck and bears the load
coming on the deck panel.
FIG-4.2.2: DECK PROP
31

3) Prop Length: - It is the length of the prop. It depends upon the length of the slab.
FIG-4.2.3: DECK PROP LENGTH
32

4) Deck Mid – Beam: - It supports the middle portion of the beam. It holds the concrete
FIG-4.2.4: DECK MID-BEAM 33

5) Soffit Length: - It provides support to the edge of the deck panels at their perimeter
of the room.
FIG-4.2.5: SOFFIT LENGTH 34

6) Deck Beam Bar: It is the deck for the beam. This component supports the deck and
beam.
FIG-4.2.5: DECK BEAM BAR
35

4.3 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-4.3.1: INTERNAL SOFFIT CORNERA
36

FIG-4.3.2: EXTERNAL SOFFIT CORNER
2) External Soffit Corner:- It forms the external corner between the components
37

3) External Corner: It forms the external corner of the formwork system.
FIG- 4.3.3: EXTENAL CORNER 38

4) Internal Corner: - It connects two pieces of vertical formwork pieces at
their exterior
FIG-4.3.4: INTERNAL CORNERS 39

4.4 Wall Components:
1) Wall Panel: It forms the face of the wall. It is an Aluminium sheet properly cut to fit
the exact size of the wall
Fig- 4.4.1: WALL PANEL 40

2) Rocker: It is a supporting component of wall. It is L-shaped panel having allotment
holes for stub pin.
Fig- 4.4.2: ROCKER 41

3) Kicker: It forms the wall face at the top of the panels and acts as a ledge to support
Fig-4.4.3: KICKER 42

4) Stub Pin: It helps in joining two wall panels. It helps in joining two joints
Fig-4.4.4: STUB PIN
43

Chapter – 5
Design,
Specification, &
Work Cycle
44

5.2 Specifications:
1) Aluminium thickness: 0.06 0.08 0.10 0.12 0.15 0.18 0.21 0.25 0.30 0.35 0.40 0.45
0.50mm
2) Panel thickness: 3, 4, 5mm
3) Standard size:-1220x2440x3mm
-1220x2440x4mm
-1220x2440x5mm
45
5.0 Design, Specification, and Speed of Construction (Work Cycle):
5.1 Design Aspects of Mivan:
5.1.1 Buildings are compared as:
i) Conventional RC columns, beams, and slab construction (RC moment resisting framed
structure)
ii) RC load-bearing walls and slabs.

5.3 Work cycle:
5.3.1 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.
46

Fig-5.4.1: Building Finishes Due To Mivan Formwork
5.4 Quality Advantage of Mivan:
High quality Formwork panels ensure consistency of dimensions.
The high tolerance of the finish means that no further plastering is required.

5.5 The Advantages of Mivan Formwork system:
The MIVAN formwork is specifically designed to allow rapid construction of all types
of architectural layouts.
1) Cost effective.
2) It is more effective for mass housing to be done quickly.
3) Great construction speed.
4) High quality finish.
5) Erected using unskilled labor.
6) Panels can be reused up to 250 times.
48

5.6 Limitation of Mivan Formwork:
1) Because of small sizes finishing lines are seen on the concrete surfaces.
2) It requires uniform planning as well as uniform elevations to be cost effective.
3) Modifications are not possible as all members are caste in RCC.
4) Due to box-type construction shrinkage cracks are likely to appear.
5) Heat of Hydration is high due to shear walls.
49

Chapter – 6
Conventional
( Traditional )
Formwork system
50

6.0 Conventional ( Traditional ) Formwork system:
6.1 In concrete construction formwork is commonly provided for the
following structural members.
• Foundations
• Wall
• Column
• Slabs & Beams
• Stairs
51

6.1.1 Formwork for
foundation
Wall foundations
It consists of
- Plywood Sheeting
- Struts
Column Foundations
It consists of
- Side Supports
- Side Planks
- Cleats 52
Cleat
Side Planks
Side Support

Fig - 6.1.4 Formwork for wall 53
6.1.2 Formwork for Wall:
It consists of
•Timber sheeting
•Vertical posts
•Horizontal members
•Wedges

6.1.3 Formwork for Column :
Fig-6.1.6 Formwork for Column
•It consists of : Side & End Planks, Yokes, & Nut-Bolts
•Two end & two side planks are joined by the yokes and bolts.
• Yokes are the horizontal member which gives support to the side & end planks.
• Yokes are connected to each other by the help of nut & bolts.
54

6.1.4 Formwork for Slabs & beams
It consists of
• Sole plates
• Wedges
• Props
• Head tree
• Planks
• Batten
• Ledgers
• Beam formwork rests on head tree
• Slab form work rests on battens and joists
55

Fig-6.1.10 Formwork for Slab & Beam 56

6.1.5 Formwork for Stairs
It consists of
•Vertical & inclined posts
•Inclined members
•Wooden Planks or sheeting
•Stringer
•Riser Planks
57

6.2 Removal of formwork
Time of formwork removal depends on the following factors
1.Type of Cement
1.Rapid hardening cements require lesser time as compared to OPC (Ordinary
Portland Cement)
2.Ratio of concrete mix
1.Rich ratio concrete gain strength earlier as compared to weak ratio concrete.
3.Weather condition
1.Hydration process accelerates in hot weather conditions as compared to cold and
humid weather conditions
58

Fig- 6.2.1 Removal of Formwork 59

Sr.
No
Structural Member
OPC
(Ordinary Portland
Cement)
Rapid
Hardening
Cement
1 Beam sides, walls & Columns 2-3 Days 2 Days
2 Slab (Vertical Supports remains intact) 4 Days 3 Days
3 Slab (Complete Formwork removal) 10 Days 5 Days
4 Beams (Removal of Sheeting, Props
remains intact)
8 Days 5 Days
5 Beams & Arches (Complete
formwork removal) (up to 6 m span)
14 Days 5-8 Days
6 Beams & Arches (Complete
formwork removal) (more than 6 m span)
21 Days 8-10 Days
6.3 Time of Removal of formwork
60

Work on which would be carried out in next semester :
Applications and comparison among different types of formwork system with its merits
and demerits of one or two of following formwork system….
• Doka formwork system.
• Peri formwork system.
• Coffor formwork system.
• Tabla formwork system.
• Slip formwork system.
61

COFFOR Construction
Technology Pvt. Ltd 62
COFFOR INNOVATIVE
STAY-IN-PLACE
FORMWORK

 COFFOR is a patented structural stay in place formwork
system to build load bearing monolithic structures.
About COFFOR Technology

 It is composed of 2 filtering grids made of rib lathe
reinforced by vertical stiffeners.
About COFFOR Technology
• The grids are connected by articulated rebar loops and
connectors that fold for cost effective transportation.

Different Parts of
COFFOR Formwork
System
65

COFFOR Construction
Part – 1: C-Profile
– This are vertical stiffeners,
– They are made up of 0.6 mm thick GP
sheet.
– Area of profile is 60.6 mm2 (i.e > 8 mm
tor bar)

COFFOR Construction
Part – 2: Rebar
– Rebar's are horizontal stiffeners.
– They are 5 mm MS bars.

COFFOR Construction
Part – 3: Connector
– They connects C profile & Rebar.
– They are made up of 1.6 thick CRCA plate.

COFFOR Construction
Part – 4: Rib Mesh
– Rib meshes are filtering grids.
– They are made up of 0.42 mm thick GP
sheets

COFFOR Construction
Technology Pvt. Ltd
Pane
l
Type
T
(m
m)
A
(m
m)
B
(m
m)
W
(m
m)
H
(mm
)
C 10 100 200 100,
200 300,
500,
700,
900
,
1100
0.5 m
To
5 m
C 16 160 200 100,
200
C 20 200 200 100,
200
C 25 250 200 100,
200
T
H
A
W
T
B

COFFOR Construction

COFFOR Construction
Individual Bungalow
Strip Footing for Coffor Panel
Installation
Panel Installation up to Plinth

COFFOR Construction
Individual Bungalow
Support provided to the panels
Structure Post-Concreting

COFFOR Construction
Individual Bungalow
Installation of wall panels up to
slab level
Easy insertion of electrical /
plumbing connections

COFFOR Construction
Individual Bungalow
Support & Concrete pouring of
walls & slab at one go
Monolithic Structure

COFFOR Construction
Individual Bungalow
Plastering is required
All kind of finishing is possible

COFFOR Construction
P+4 Residential Apartment

www.cofforindia.com 81
P + 4 Apartment

Storm Water Drainage
www.cofforindia.com 82

Radius Architectural Designs
COFFOR Construction
Various architectural designs can
be easily done with Coffor
Installation of panels for
underground storage tank

Radius Architectural Designs
COFFOR Construction
Post concrete pouring
Storage tank for explosive material
in Vadodara, Gujarat

Utility Chambers
COFFOR Construction

COFFOR Construction
Shaped Wall
Various shapes/designs are
possible with Coffor for
door/windows openings

COFFOR Construction
Compound Wall
Panel Installation in Nasik,
Maharashtra
Concrete pouring in progress

Inclined Roof
COFFOR Construction

Slabs & Lintels
COFFOR Construction

COFFOR Construction
Swimming Pool

COFFOR Construction
Water Purification Tank

Water Tanks
COFFOR Construction

•Less Volume Required
•No Shuttering Required
•No Crane Required
•Minimum Reinforcement
•Less allied accessories required

•Multiple Creative possibilities
•Semi-skilled labour’s required
•Less no of labour’s required
•No honey comb in concrete
•Easy installation of Electric and plumbing lines
•Rapid Concrete Shrinkage

•Over all reduction in construction time
•Higher Seismic Resistance
•All types of Finishing Possible

L & T DOKA FORMWORK
L&T – INDIA DOKA - AUSTRIA

TYPES OF FORMWORK SYSTEMS
 STAIR TOWER
 WALL & COLUMN FORMWORK
 CLIMBING FORMWORK
 FLEX SYSTEM
 HEAVY DUTY TOWER
 ACCESS SCAFFOLD

Kind of Formwork:
 SUBSTRUCTURE FORMWORK
 COLUMN FORWORK
 LIFTWALL FORMWORK
 BEAM FORMWORK
 SLAB FORMWORK
 STAIR CASE FORMWORK

SUBSTUCTURE FORMWORK
STUB COLUMN
STEEL WALERS & H 20
BEAM
SIDE SUPPORT,
PROP

1. FLOOR FORM 2. FORM CLIP
3. FLOOR FORM CORNER
3
2
1

4. PIPE WALER CLAMP 5. PIPE WALER
SIZE
3000,2000,1500
SIZES
1200,900,600
LAPPING PLATE
4
5

7. WALER CONNECTOR6. STEEL WALER
7
6

9. HEAD ADOPTER ASSEMBLY
8. CT PROP
TYPES
CT 250, CT 300, CT 340, CT 410
10. FOOT ADOPTER ASSEMBLY
8
9
10

1. H BEAM (H-16 / H – 20)
4. CT PROP
Types
CT 250, CT 300, CT 340, CT 410,
3. TOP SCAFFOLD
BRACKET 60
6. LIFTING BRACKET
1
2
2. STEEL WALER
3
4
6
5. FLANGE CLAW
ASSEMBLY
5
1
3

COLUMN
7.SPLICE PLATE 8.ANGLE PLATE
U
9. UNIVERSAL OUTSIDE
FIXING
10.UNIVERSAL INSIDE CORNER
10
8
9
7

CONNECTING PIN
11
12
11.HEAD ADOPTER ASSEMBLY
ANCHOR PLATE
12.FOOT ADOPTER ASSEMBLY
WING NUT

TIE ROD CONE PLUG (PVC)
PLUG TO GROUT THE PVC TUBE
TIE ROD TUBE (PVC)
EXPENDABLE TIE SLEEVE
FOR REUSABLE TIE ROD 18 MM
TIE ROD CONE
TO ENSURE THE PROPER
FIXING OF PVC TUBES AT TIE
ROD LOCATION AND TO
PREVENT THE SLURRY LOSS
ADJUSTABLE WALING EXTN.
.65 m, 1.20 m

COLUMN FORMWORK
STEEL SHUTTER PLATES
18 MM PLY INSIDE , STEEL
WALERS, H 20 BEAMS

Application & Comparison of different Formwork System used within Indian Construction Industry

LIFTWALL FORMWORK
PLATFORM FOR
CONCRETING
CT PROP 300
ALIGNMENT
PROP

SECONDARY
BEAM
PRIMARY BEAM
BEAM FORMING
HEAD
CT PROP

FLEX SYSTEM FOR RCC SLAB (Upto 4.5m Height)
FOUR WAY
HEAD

2.CT PROP
Types
CT 250, CT 300, CT 340, CT 410
4.FOLDING TRIPOD
I
1. H BEAM (H-16 / H – 20)
3.FOUR WAY HEAD
1
2
3
4

SUPPORTING HEAD
ASSEMBLY WEDGE CLAMP
BEAM FORMING HEAD

3. ADJUSTABLE BEAM SIDE EXTN.
1. BEAM FORMING SUPPORT
2. BEAM FORMING SUPPORT EXTN.
AVAILABILITY
600,800, 1000,1200
1
2

WORKING PLATFORM AT HEIGHT
HEAVY DUTY
TOWERS
(EACH HDT TOWER CARRIES
25 T LOAD)

Sizes
0.90,1.20,1.50,1.80 M
1. BASIC FRAME 2. HORIZONTAL BRACING AND DIAGONAL
BRACING
4. U-HEAD
1
2 3
4
3. FOOT PLATE
SPRING LOCKED CONNECTING PIN

5.TOWER SPINDLE WITH LEVER
NUT
LOAD BEARING MEMBER FOR
BEAM
TO ADJUST THE HEIGHT OF TOWER
7.SHORT PROP
IT IS USED IN SLAB AND BEAM
FORMWORK FOR TRANSFERRING
THE SLAB LOAD TO THE BEARING
TOWERS THROUGH STANDARD
WALERS
8.LTS-WHEEL B
TO BE FIXED WITH
BOTTOM FRAME OF STAIR
TOWER / HDT TO SHIFT ONE
PLACE TO ANOTHER PLACE
5
6
7
8
HD COUPLER
BEAM SPAN 1525
6.BEAM SPAN 2230

STAIR TOWER / ACCESS SCAFFOLD
STAIR TOWER /
ACCESS
SCAFFOLD

ADVANTAGES
● HIGH LABOR PRODUCTIVITY (APPROX 8 TO 10 SQ.M
PER MAN-DAY)
● SIMPLE DESHUTTERING OPERATION
● MINIMIZES MAKING / ASSEMBLY TIME AND COST AT
SITE
● ENTIRE ASSEMBLY CAN BE LIFTED WITH CRANE
● SYSTEM IS RIGID AND STABLE
● CLEAN ACCURATE AND SMOOTH CONCRETE FINISH

It is a German base Company
Now a days it is used in our city
Ahmedabad at two places
1. BRTS Bus Stop
2. Savvy Swaraj Sports City

Peri form materials are available in
1.Plywood as well as in
2. Steel

Basic Components of Peri
Formwork

Cup-lock
Threaded Anchor Plate
Wing Nut

Steel Waller
Steel
Tension
Rod

Tripod is the main
basic component of
the system.
It needs hard and
good resting surface.
All the loads
coming through the
slab, beam and
column is transferred
to the Tripod through
the CT Props.

Height
should be
adjust by
this jacking
system
through
threads.

Distance
between 2 ct -
props are 30 cms

Trio
Secondary
Girder
Main
Girder

Plywood
Sheet
supported on
Secondary
Beam which
is supported
on Primary
Beam which
rests on Four-
head CT
Props

VT-20
Girder
Plates
supported
on CT
Props

Two VT-
20 Girders
are joined
through
the Steel
Rod and
Threaded
anchor
plate

GT-24 Girder
Main Props
Intermediate Props

Photo of
VT-20
Girders
from the
Top Slab
Level

Peri Sky Deck
Alluminium Forms

Cover strip
(Required when
Drop head is
used)

Arrangement
of Wall
Panels Before
Concreting

Two
Panels
are
joined
through
Cup-lock

Two
Parallel
wall
panels are
joined
through
the Steel
Tension
Rod

Steel
Waller to
Join Two
Column
Panels

Joining of
four panels
through
Cup - lock,
Steel Rod,
and Steel
Waller

Cross Head
CT Prop
Beam Head
Locker
Tripod

Stacking of different
types of forms
on Site

Comparison of different kinds
of Formworks used with in
Indian Construction Industry
207

BEST
GOOD
MEDIUM
In comparison we have given the
score as per below colour code

209
Factors Affecting Conventional Mivan Coffor Peri Doka
Initial Cost
Weight
Re-use
Maintenance cost
Scrap Value
Construction speed
Volume of Required
material
Seismic Resistance
Formwork Material
Pilferage
Formwork Material
Shrinkage
Possibility of Damage
Handling of Equipment

210
Factors Affecting Conventional Mivan Coffor Peri Doka
Finishing
No. of labour’s required
Reinforcement
Requirement
Monolithic Structure
Allied Accessories
Supply & Availability of
Formwork
During Concreting Quality
Check
On site assembly of
formwork
Labour Skill set required
No of post concrete
procedures
BEST GOOD MEDIUM

• Summary:
The structural form of the building is one of the critical factors to
determine the choice of formwork
System products contribute much in the success of formwork
application
The choice and arrangement of utilizing formwork is highly depended
on individual site/project environment
More collaboration between client, design teams and contractor can
help in the effective use of more advance formwork systems

Application & Comparison of different Formwork System used within Indian Construction Industry

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