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
15
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
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.

Fig-2.1 Wall Assembly Details 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
3.2 ON CONCRETE ACTIVITIES:

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.

20
 3.3 POST – CONCRETE ACTIVITIES:
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. 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
2) External Soffit Corner:- It forms the external corner between the components

FIG-4.3.2: EXTERNAL SOFFIT CORNER

37
3) External Corner: It forms the external corner of the formwork system.

38
FIG- 4.3.3: EXTENAL CORNER
4) Internal Corner: - It connects two pieces of vertical formwork pieces at
their exterior

39
FIG-4.3.4: INTERNAL CORNERS
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
5.0 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.

5.2 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
5.3 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
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.

Fig-5.4.1: Building Finishes Due To Mivan Formwork

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 Side Planks
Cleat
- Cleats Side Support 52
6.1.2 Formwork for Wall:

It consists of
•Timber sheeting
•Vertical posts
•Horizontal members
•Wedges

Fig - 6.1.4 Formwork for wall 53

6.1.3 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
Fig-6.1.6 Formwork for Column
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
 6.3 Time of Removal of formwork

Sr. OPC Rapid

No (Ordinary Portland Hardening
Structural Member
Cement)
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 8 Days 5 Days
remains intact)

5 Beams & Arches (Complete 14 Days 5-8 Days

formwork removal) (up to 6 m span)

6 Beams & Arches (Complete 21 Days 8-10 Days

formwork removal) (more than 6 m span)

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 INNOVATIVE
STAY-IN-PLACE
FORMWORK

COFFOR Construction
Technology Pvt. Ltd 62
About COFFOR Technology
 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.

• The grids are connected by articulated rebar loops and

connectors that fold for cost effective transportation.
 Different Parts of
COFFOR Formwork
System
65
 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
Technology Pvt. Ltd 66
 Part – 2: Rebar
– Rebar's are horizontal stiffeners.
– They are 5 mm MS bars.

COFFOR Construction
Technology Pvt. Ltd 67
 Part – 3: Connector
– They connects C profile & Rebar.
– They are made up of 1.6 thick CRCA plate.

COFFOR Construction
Technology Pvt. Ltd 68
 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 69
 T Pane T A B W H
l (m (m (m (m (mm
T Type m) m) m) m) )
A
C 10 100 200 100,
200 300,
500, 0.5 m
C 16 160 200 100, 700, To
H 200 900 5 m
,
C 20 200 200 100,
1100
200
B C 25 250 200 100,
200

COFFOR Construction
Technology Pvt. Ltd
COFFOR Construction
Technology Pvt. Ltd 71
Installation of COFFOR Panels
Individual Bungalow
Strip Footing for Coffor Panel
Installation

Panel Installation up to Plinth

COFFOR Construction
Technology Pvt. Ltd 73
Individual Bungalow
Support provided to the panels

Structure Post-Concreting

COFFOR Construction
Technology Pvt. Ltd 74
Individual Bungalow
Installation of wall panels up to
slab level

Easy insertion of electrical /

plumbing connections

COFFOR Construction
Technology Pvt. Ltd 75
Individual Bungalow
Support & Concrete pouring of
walls & slab at one go

Monolithic Structure

COFFOR Construction
Technology Pvt. Ltd 76
Applications of COFFOR
Individual Bungalow
Plastering is required

All kind of finishing is possible

COFFOR Construction
Technology Pvt. Ltd 78
P+4 Residential Apartment

COFFOR Construction
Technology Pvt. Ltd 79
P+4 Residential Apartment

COFFOR Construction
Technology Pvt. Ltd 80
P + 4 Apartment

www.cofforindia.com 81
Storm Water Drainage

www.cofforindia.com 82
Radius Architectural Designs
Various architectural designs can
be easily done with Coffor

Installation of panels for

underground storage tank

COFFOR Construction
Technology Pvt. Ltd 83
Radius Architectural Designs
Post concrete pouring

Storage tank for explosive material

in Vadodara, Gujarat

COFFOR Construction
Technology Pvt. Ltd 84
Utility Chambers

COFFOR Construction
Technology Pvt. Ltd 85
Utility Chambers

86
Shaped Wall
Various shapes/designs are
possible with Coffor for
door/windows openings

COFFOR Construction
Technology Pvt. Ltd 87
Compound Wall
Panel Installation in Nasik,
Maharashtra

Concrete pouring in progress

COFFOR Construction
Technology Pvt. Ltd 88
Inclined Roof

COFFOR Construction
Technology Pvt. Ltd 89
Slabs & Lintels

COFFOR Construction
Technology Pvt. Ltd 90
Swimming Pool

COFFOR Construction
Technology Pvt. Ltd 91
Water Purification Tank

COFFOR Construction
Technology Pvt. Ltd 92
Water Purification Tank

COFFOR Construction
Technology Pvt. Ltd 93
Water Tanks

COFFOR Construction
Technology Pvt. Ltd 94
•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
FOUNDATION FORMWORK
 1. FLOOR FORM 2. FORM CLIP

3. FLOOR FORM CORNER 1

 4. PIPE WALER CLAMP 5. PIPE WALER
SIZE
3000,2000,1500

LAPPING PLATE 5
SIZES
1200,900,600
 6. STEEL WALER 7. WALER CONNECTOR

6
 9. HEAD ADOPTER ASSEMBLY

9
8. CT PROP

TYPES
CT 250, CT 300, CT 340, CT 410

10. FOOT ADOPTER ASSEMBLY

10
COLUMN / WALL FORMWORK
 3. TOP SCAFFOLD 4. CT PROP
1. H BEAM (H-16 / H – 20) 2. STEEL WALER BRACKET 60 Types
CT 250, CT 300, CT 340, CT 410,

3
3

1 1 6

4 5
5. FLANGE CLAW
ASSEMBLY
2 6. LIFTING BRACKET
 9

7
10
7.SPLICE PLATE 8.ANGLE PLATE
U

COLUMN

9. UNIVERSAL OUTSIDE 10.UNIVERSAL INSIDE CORNER

FIXING
11.HEAD ADOPTER ASSEMBLY 12.FOOT ADOPTER ASSEMBLY CONNECTING PIN

11

ANCHOR PLATE
WING NUT

12
 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.

TIE ROD CONE PLUG (PVC) .65 m, 1.20 m

PLUG TO GROUT THE PVC TUBE

 18 MM PLY INSIDE , STEEL

COLUMN FORMWORK WALERS, H 20 BEAMS

STEEL SHUTTER PLATES

LIFTWALL FORMWORK
PLATFORM FOR
CONCRETING

CT PROP 300

ALIGNMENT
PROP
SLAB FORMWORK
 SECONDARY
BEAM

PRIMARY BEAM

BEAM FORMING
HEAD
CT PROP
FLEX SYSTEM FOR RCC SLAB (Upto 4.5m Height)

FOUR WAY
HEAD
FLEX SYSTEM
 3
1

1. H BEAM (H-16 / H – 20) 2.CT PROP

Types
CT 250, CT 300, CT 340, CT 410

3.FOUR WAY HEAD

4
4.FOLDING TRIPOD
I
 SUPPORTING HEAD

ASSEMBLY WEDGE CLAMP

BEAM FORMING HEAD

BEAM FORMING
SUPPORT
 3. ADJUSTABLE BEAM SIDE EXTN.

1. BEAM FORMING SUPPORT

1

2. BEAM FORMING SUPPORT EXTN.

AVAILABILITY
600,800, 1000,1200
BEAM SIDE SUPPORTS
FLEX TABLE SYSTEM
18 MM PLY
WOOD
STAIRCASE FORMWORK
WORKING PLATFORM AT HEIGHT

(EACH HDT TOWER CARRIES

25 T LOAD)

HEAVY DUTY
TOWERS
 4

1. BASIC FRAME 2. HORIZONTAL BRACING AND DIAGONAL

Sizes 1 BRACING
0.90,1.20,1.50,1.80 M

2 3

4. U-HEAD

3. FOOT PLATE

SPRING LOCKED CONNECTING PIN

 HD COUPLER
BEAM SPAN 1525
6.BEAM SPAN 2230
5.TOWER SPINDLE WITH LEVER LOAD BEARING MEMBER FOR
NUT BEAM
TO ADJUST THE HEIGHT OF TOWER 7

7.SHORT PROP
8.LTS-WHEEL B
IT IS USED IN SLAB AND BEAM
FORMWORK FOR TRANSFERRING TO BE FIXED WITH 8
THE SLAB LOAD TO THE BEARING
BOTTOM FRAME OF STAIR
TOWERS THROUGH STANDARD
TOWER / HDT TO SHIFT ONE
WALERS
PLACE TO ANOTHER PLACE
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
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.
CT-Prop
Height
should be
adjust by
this jacking
system
through
threads.
Column
Panels
Four Way
Head CT-
Prop
Slab Formwork
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)
Wall Formwork
Wall
Panel
Arrangement
of Wall
Panels Before
Concreting
Two
Adjacent
Wall
Panel
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
Column Formwork
Column
Panel

Supports
Beam Formwork
Beam Head

Cross Head

CT Prop

Locker

Tripod
Stacking of different
types of forms
on Site
Finishing Work
 Some Site
Photographs
Comparison of different kinds
of Formworks used with in
Indian Construction Industry

207
In comparison we have given the
score as per below colour code

BEST

GOOD

MEDIUM
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 209

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 210