Different Types of Formwork Syetem Used within Indian Construction Industry
213
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
Different Types of Formwork Syetem Used within Indian Construction Industry
1. 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
2. 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
3. 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
4. Chapter 1 Introduction to Formwork 4
5. 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
6. 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
7. 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.
8. 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
9. Plywood : Fig-1.1 Plywood Formwork 9
10. Bamboo: Fig-1.2 Bamboo Formwork 10
11. Steel: Fig-1.3 Steel Formwork 11
12. Aluminum: Fig-1.4 Aluminium Formwork 12
13. Plastic: Fig-1.5 Plastic Formwork 13
14. Chapter 2 Mivan Formwork System 14
15. 15
16. 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
17. 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
18. Chapter - 3 Procedure For Using Mivan Formwork 18
19. 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
20. 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
21. 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
22. 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
23. Fig-3.4.2 Striking of formwork 23
24. Fig-3.4.3 Positioning of Platform 24
25. Chapter 4 Comparison of Mivan Formwork Components with
Actual Sight Photos 25
26. 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
27. 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
28. 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
29. 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
30. 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
31. 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
32. 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
33. 4) Deck Mid Beam: - It supports the middle portion of the
beam. It holds the concrete FIG-4.2.4: DECK MID-BEAM 33
34. 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
35. 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
36. 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
37. FIG-4.3.2: EXTERNAL SOFFIT CORNER 2) External Soffit
Corner:- It forms the external corner between the components
37
38. 3) External Corner: It forms the external corner of the
formwork system. FIG- 4.3.3: EXTENAL CORNER 38
39. 4) Internal Corner: - It connects two pieces of vertical
formwork pieces at their exterior FIG-4.3.4: INTERNAL CORNERS
39
40. 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
41. 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
42. 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
43. 4) Stub Pin: It helps in joining two wall panels. It helps
in joining two joints Fig-4.4.4: STUB PIN 43
44. Chapter 5 Design, Specification, & Work Cycle 44
45. 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.
46. 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
47. 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.
48. 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
49. 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
50. Chapter 6 Conventional ( Traditional ) Formwork system
50
51. 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
52. 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
53. Fig - 6.1.4 Formwork for wall 53 6.1.2 Formwork for Wall:
It consists of Timber sheeting Vertical posts Horizontal members
Wedges
54. 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
55. 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
56. Fig-6.1.10 Formwork for Slab & Beam 56
57. 6.1.5 Formwork for Stairs It consists of Vertical &
inclined posts Inclined members Wooden Planks or sheeting Stringer
Riser Planks 57
58. 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
59. Fig- 6.2.1 Removal of Formwork 59
60. 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
61. 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
63. COFFOR is a patented structural stay in place formwork
system to build load bearing monolithic structures. About COFFOR
Technology
64. 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.
65. Different Parts of COFFOR Formwork System 65
66. COFFOR Construction Technology Pvt. Ltd 66 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)
67. COFFOR Construction Technology Pvt. Ltd 67 Part 2: Rebar
Rebar's are horizontal stiffeners. They are 5 mm MS bars.
68. COFFOR Construction Technology Pvt. Ltd 68 Part 3:
Connector They connects C profile & Rebar. They are made up of
1.6 thick CRCA plate.
69. COFFOR Construction Technology Pvt. Ltd 69 Part 4: Rib Mesh
Rib meshes are filtering grids. They are made up of 0.42 mm thick
GP sheets
70. 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
71. COFFOR Construction Technology Pvt. Ltd 71
72. Installation of COFFOR Panels
73. COFFOR Construction Technology Pvt. Ltd 73 Individual
Bungalow Strip Footing for Coffor Panel Installation Panel
Installation up to Plinth
74. COFFOR Construction Technology Pvt. Ltd 74 Individual
Bungalow Support provided to the panels Structure
Post-Concreting
75. COFFOR Construction Technology Pvt. Ltd 75 Individual
Bungalow Installation of wall panels up to slab level Easy
insertion of electrical / plumbing connections
76. COFFOR Construction Technology Pvt. Ltd 76 Individual
Bungalow Support & Concrete pouring of walls & slab at one
go Monolithic Structure
77. Applications of COFFOR
78. COFFOR Construction Technology Pvt. Ltd 78 Individual
Bungalow Plastering is required All kind of finishing is
possible
79. COFFOR Construction Technology Pvt. Ltd 79 P+4 Residential
Apartment
80. COFFOR Construction Technology Pvt. Ltd 80 P+4 Residential
Apartment
81. www.cofforindia.com 81 P + 4 Apartment
82. Storm Water Drainage www.cofforindia.com 82
83. Radius Architectural Designs COFFOR Construction Technology
Pvt. Ltd 83 Various architectural designs can be easily done with
Coffor Installation of panels for underground storage tank
84. Radius Architectural Designs COFFOR Construction Technology
Pvt. Ltd 84 Post concrete pouring Storage tank for explosive
material in Vadodara, Gujarat
85. Utility Chambers COFFOR Construction Technology Pvt. Ltd
85
86. Utility Chambers 86
87. COFFOR Construction Technology Pvt. Ltd 87 Shaped Wall
Various shapes/designs are possible with Coffor for door/windows
openings
88. COFFOR Construction Technology Pvt. Ltd 88 Compound Wall
Panel Installation in Nasik, Maharashtra Concrete pouring in
progress
89. Inclined Roof COFFOR Construction Technology Pvt. Ltd
89
90. Slabs & Lintels COFFOR Construction Technology Pvt. Ltd
90
91. COFFOR Construction Technology Pvt. Ltd 91 Swimming
Pool
92. COFFOR Construction Technology Pvt. Ltd 92 Water
Purification Tank
93. COFFOR Construction Technology Pvt. Ltd 93 Water
Purification Tank
94. Water Tanks COFFOR Construction Technology Pvt. Ltd 94
95. Less Volume Required No Shuttering Required No Crane
Required Minimum Reinforcement Less allied accessories
required
96. Multiple Creative possibilities Semi-skilled labours
required Less no of labours required No honey comb in concrete Easy
installation of Electric and plumbing lines Rapid Concrete
Shrinkage
97. Over all reduction in construction time Higher Seismic
Resistance All types of Finishing Possible
98. L & T DOKA FORMWORK L&T INDIA DOKA - AUSTRIA
99. TYPES OF FORMWORK SYSTEMS STAIR TOWER WALL & COLUMN
FORMWORK CLIMBING FORMWORK FLEX SYSTEM HEAVY DUTY TOWER ACCESS
SCAFFOLD
100. Kind of Formwork: SUBSTRUCTURE FORMWORK COLUMN FORWORK
LIFTWALL FORMWORK BEAM FORMWORK SLAB FORMWORK STAIR CASE
FORMWORK
101. SUBSTUCTURE FORMWORK STUB COLUMN STEEL WALERS & H 20
BEAM SIDE SUPPORT, PROP
102. FOUNDATION FORMWORK
103. 1. FLOOR FORM 2. FORM CLIP 3. FLOOR FORM CORNER 3 2 1
111. 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
112. COLUMN FORMWORK STEEL SHUTTER PLATES 18 MM PLY INSIDE ,
STEEL WALERS, H 20 BEAMS
115. SECONDARY BEAM PRIMARY BEAM BEAM FORMING HEAD CT PROP
116. FLEX SYSTEM FOR RCC SLAB (Upto 4.5m Height) FOUR WAY
HEAD
117. FLEX SYSTEM
118. 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
119. SUPPORTING HEAD ASSEMBLY WEDGE CLAMP BEAM FORMING
HEAD
120. BEAM FORMING SUPPORT
121. 3. ADJUSTABLE BEAM SIDE EXTN. 1. BEAM FORMING SUPPORT 2.
BEAM FORMING SUPPORT EXTN. AVAILABILITY 600,800, 1000,1200 1 2
122. BEAM SIDE SUPPORTS
123. FLEX TABLE SYSTEM
124. 18 MM PLY WOOD
125. STAIRCASE FORMWORK
126. WORKING PLATFORM AT HEIGHT HEAVY DUTY TOWERS (EACH HDT
TOWER CARRIES 25 T LOAD)
127. 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
128. 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
130. 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
131. 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
132. Peri form materials are available in 1.Plywood as well as
in 2. Steel
133. Basic Components of Peri Formwork
134. Cup-lock Threaded Anchor Plate Wing Nut
135. Steel Waller Steel Tension Rod
136. Tripod
137. 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.
138. CT-Prop
139. Height should be adjust by this jacking system through
threads.
140. Column Panels
141. Four Way Head CT- Prop
142. Slab Formwork
143. Distance between 2 ct - props are 30 cms
144. Trio Secondary Girder Main Girder
145. Plywood Sheet supported on Secondary Beam which is
supported on Primary Beam which rests on Four- head CT Props
146. VT-20 Girder Plates supported on CT Props
147. Two VT- 20 Girders are joined through the Steel Rod and
Threaded anchor plate
148. GT-24 Girder Main Props Intermediate Props
149. Photo of VT-20 Girders from the Top Slab Level
150. Peri Sky Deck Alluminium Forms
151. Cover strip (Required when Drop head is used)
152. Wall Formwork
153. Wall Panel
154. Arrangement of Wall Panels Before Concreting
155. Two Adjacent Wall Panel
156. Two Panels are joined through Cup-lock
157. Two Parallel wall panels are joined through the Steel
Tension Rod
158. Steel Waller to Join Two Column Panels
159. Joining of four panels through Cup - lock, Steel Rod, and
Steel Waller
160. Column Formwork
161. Column Panel Supports
162. Beam Formwork
163. Cross Head CT Prop Beam Head Locker Tripod
164. Stacking of different types of forms on Site
165. Finishing Work
166. Some Site Photographs
167. Comparison of different kinds of Formworks used with in
Indian Construction Industry 207
168. BEST GOOD MEDIUM In comparison we have given the score as
per below colour code
169. 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
170. 210 Factors Affecting Conventional Mivan Coffor Peri Doka
Finishing No. of labours 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
171. Conclusion of the Project
172. 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