Formwork Industry Analysis

FORMWORK:
Custom-Made Solutions
Takes Center Stage
MB Bureau Report

I
f there is one market segment among construction equipment
that has maintained a steady pace of growth, despite the
crests and troughs of the uneconomic uncertainties that have
been affecting the market over the last few years, it has to
formwork equipment. While in the case of most other types of
construction equipment, the major driver for demand was the
infrastructure development process, for manufacturers of
formwork and scaffolding equipment, it has not limited to the
infrastructure development activities. Since they also have the
real estate sector to cater to, they have had a far smoother ride
than some other types of equipment. The formwork industry
has been perhaps the biggest beneficiary of the impressive
growth of the Indian construction industry over the last
two decades.

132 The Masterbuilder - July 2012 · www.masterbuilder.co.in


Adding to the good news for manu-
facturers is the fact that even though
modern formwork and scaffolding sys-
tems made their way into the Indian
market in the mid to late 1990s, the
extent of the market tapped till now is
just a minute percentage of the total
potential. In fact, according to industry
estimates, modern formwork systems
form only about 15 percent of the mar-
ket share presently, a figure that is
expected to more than double by the
end of the 12th Five Year Plan period
(2012-17), with the continued impetus
being provided to infrastructure devel-
opment and the growth of the real estate
sector.
Getting organized
The formwork industry in the coun-
try is gradually getting organized due to
the entry of big ticket players in the fray.
Globally reputable names such as Doka,
Meva, Ulma, Paschal, Pranav, Peri, GCI
Composite, Desi etc have established
their presence in the Indian market over
the recent past. There have been two
key factors that have been driving for-
ward the markets momentum- short-
age of labour and increasing pressure
on contractors to adhere to stricter qual-
ity standards and project deadlines.
Continued impetus to infrastructure development projects bodes well for the formwork industry
”Quality assurance on the job
site is sometimes an issue in
India. As of now, there is no
specific certified body to give
quality assurance on site. To
avoid any quality issues we
have our in-house QA-QC
department which monitors
quality at every stage,
beginning from procurement of
raw materials to dispatch. We
encourage our clients to have
the quality inspection done”
Sushil Sahani
Managing Director,
Pranav Construction Systems Pvt. Ltd.
While the recent economic slowdown
has slightly impacted the industry,
there is no denying the fact that the
industry is poised for a period of
www.masterbuilder.co.in · The Masterbuilder - July 2012 133
Formwork Industry Analysis
growth. Speaking about the sectors
that are driving demand for formwork
systems in the country, Mr.Bharat Patel,
Head- Sales & Marketing, Nav Nirman
Beam Technics , pointed out that pres-
ently, “The residential sector and among
the infrastructure sector, metro pro-
jects are among the key market seg-
ments that are propelling demand for
formwork systems.” With the realty focus
shifting to tier II and III cities, formwork
suppliers are now catering to an
increasingly diversified market with dif-
ferent application demands. Contrac-
tors around the country have realized
that in order to meet these two criteria
the use of formwork and scaffolding
systems has become imperative. The
increase in the size of projects, espe-
cially with respect to infrastructure and
high-rise projects has also been a fac-
tor that has been pushing the demand
for formwork equipment.
High rise and Infrastructure Projects
The consistent growth of the form-
work industry in the country has been
enabled by the thrust given to infra-
structure development over the last
decade. Infrastructure project includ-
ing for those of bridges, metro stations,
tunnels, airport projects, flyovers, etc
Doka India's formwork will be used in the
Lokhandwala Minerva skyscraper project
Formwork Industry Analysis
Meva India's formwork during the construction of Palais Royale building in Mumbai
have been behind the rising demand
for formwork systems. Adding to the
demand factor is the 'vertical' growth of
the country. High-rise construction is
an area where specialized formwork
plays a key role. Automated self-climbing
formwork systems that can be lifted up
hydraulically come with a host of fea-
tures including, wide and protective
platforms, apart from provisions for aux-
Paschal formwork systems being used in different types of construction projects
134 The Masterbuilder - July 2012 · www.masterbuilder.co.in
iliary systems like placing booms, apart
from offering adaptability to complex
wall geometries. Almost every player in
the field such as, Doka, Meva, Ulma,
Paschal, Nav Nirman, Pranav, GCI Wall
forms., Peri, Design Desire Construc-
tion Systems to mention only a few are
offering specific products catering to
this growing market segment.
A good example for automated
climbing formworks is available in the
form of Doka India's SKE50 and SKE
100 systems. The company will be report-
edly using these automatic climbing
formwork systems in the construction
of 'Lokhandwala Minerva' a skyscraper
in Mumbai that will top out at 300 m and
feature 82 storeys in two separate tow-
ers. The luxury residential project is
being designed by Hafeez Contractor
and in use will be the SKE 50 and SKE
100 automatic climbing formwork sys-
tems that help in providing an efficient
solution for achieving weather-inde-
pendent construction workflow and
maximum crew safety. The building is
scheduled to be finished in 2014
according to the company.
“A change is always a struggle.
Mindset of influential decision
makers , inadequate/
inappropriate quality codes,
cost factors everything plays a
role in the growth".
Eldo Varghese
General Manager, Paschal Formwork (India) Pvt. Ltd.
Speaking about high-rise construc-
tion and the use of specialized formwork
systems, Meva India is another com-
pany that has been associated with a
landmark project- Palais Royale in
Mumbai. The company had used its
MAC (MEVA Automatic Climbing) sys-
tem, which provides complete protec-
tion for workers with full cladding sur-
rounding the external hanging plat-
forms in the project. No external sec-
ondary platforms are required on the
MAC. The hydraulic system of the auto-
matic climbing system has a capacity
of 20 tons per ram and a non-return
rachet that locks on each cylinder. The
Formwork Industry Analysis

design of the climbing system is such

that the load is carried by concrete that
is already set and this helps in safer
and faster construction.
Ulma India is another leading name
that offers self-climbing formwork sys-
tems for fast, safe, and cost-effective
construction of high rise buildings. Accor-
ding to the company these systems
can be lifted in extreme weather condi-
tion up to maximum wind speed of 72
kmph. They come with wide and pro-
tective working platforms. The form-
work system features provisions for
attachment of auxiliary systems like plac-
ing booms along with the formwork panels.

“The residential sector and

among the infrastructure sector,
metro projects are among the
key market segments that are
propelling demand for formwork
systems”
Ulma India's formwork in action
structures' according to the company
and is used in footings, retaining walls,
columns, beams, internal and external
walls, track hoppers, canal drains, box
culverts, water treatment plants, reser-
voirs, crude oil refinery storage pits,
cooling towers, etc. Paschal is also the
name behind the popular 'e-deck' sys-
tem. The company's formwork systems
have been used in projects including,
Salarpuria Hotel project, Hyderabad,
Golden Jubilee project, Hyderabad,
Panduranga power project, Rajamundry,
Branddix Apparel City, Vishakhapatnam,
TCS Building project, Bhubaneswar,
Defence project , Bellary and Prestige
Forum Mall in Mangalore, to mention
but a few.

Bharat Patel
Head- Sales & Marketing, Nav Nirman Beam Technics

A wide range of climbing formwork

systems is also offered by Peri India,
another trendsetter in the industry. The
company's range includes the FB 180
Platform System, CB Climbing System,
ACS Self Climbing System, RCS Rail
Climbing System, KG 240- KG180
Climbing Systems, and SKS Single Sided
climbing system, to mention only some.
Product Innovations
Manufacturers are banking on spe-
cific product design to cater to different
types of application. The 'Modular Panel
System' from Paschal, a leading name
in the industry is a good example. The
modular panel system from the com-
pany is a 'one system for all vertical Repetition in operational use up to 90-100 times is possible with systems from Nav Nirman Beam Technics

136 The Masterbuilder - July 2012 · www.masterbuilder.co.in


Metro projects have emerged as a key demand driver for formwork systems
Pranav Construction Systems Pvt
Ltd, is one more player which offers a
range of innovative formwork systems.
The company has this year introduced
a range of new generation systems ,
which are not only light weight but have
optimum life of up to even 1000 repeti-
tions. The range includes, 'Alvert'- alu-
minum light weight panel system for
walls, columns and lift cores, 'Modvert/
Steelvert'- alloy steel light weight panel
system for retaining walls, rafts, col-
umns, abutments with ply/steel facing
and 'Aludek'- aluminum light weight
modular system with drop head for
faster cycle time. The company has been
involved with several key projects includ-
ing Palm Jebel Ali, Dubai, Doha Inter-
national Airport, Bandra-Worli Sea Link,
Nivedita Setu (second Vivekananda
Setu) bridge in Kolkata; the Dubai,
Delhi, Mumbai, Bangalore, Chennai,
Kolkata, Hyderabad and Navi Mumbai
metro projects, to mention only a few.
In fact the company has the distinction
of supplying formwork materials to
every metro being consructed in India.
Another good example for product
innovation is available in the of the
'H-Beams' from Nav Nirman Beam
Technics, which are easy to handle,
light in weight, ready to use and give
perfect form finish, free from bulging
and distortion. Repetition in opera-
tional use up to 90-100 times is possi-
ble with the H-Beams which are used in
the construction of residential and com-
mercial projects, industrial projects, water
resources engineering, roads and
bridges, and stadiums, among others.
Rental Push
The Indian formwork industry has
evolved the years and one of the signs
of maturity is available in the form of a
developing rental market. Rental solu-
tions have come in handy, especially
for smaller contractors for whom out-
right purchase of the equipment is
often a difficult proposition. In fact,
rental solutions have also been instru-
mental in formwork equipment now
entering the hitherto unexplored areas
of the country. With the realty market
passing through a phase of difficulty in
metros, due to a variety of factors includ-
ing rising property prices and interest
rates, the scene has now shifted to
smaller tier II and III cities and towns.
Formwork systems have come as a boon
to contractors in these smaller locations.
Another key reason for the develop-
ment of the rental market is storage
space, often a neglected factor in our
www.masterbuilder.co.in · The Masterbuilder - July 2012 137
Formwork Industry Analysis
country. It is in fact one of the reasons
why even bigger developers are opting
for rental solutions since they need not
worry about storing formwork equip-
ment. Even in the case of the rental mar-
ket, according to industry analysts, the
market potential realized is just the tip
of the iceberg and there is a huge mar-
ket that is lying untapped. Industry ana-
lysts feel that the gradual rise in the
number of rental companies would
automatically streamline several other
processes including improvement in
logistics and setting up of formwork
systems at work sites in the near future.
Challenges ahead
While there is no denying the growth
of the Indian formwork and scaffolding
industry, there are still a set of chal-
lenges that the industry needs to sur-
mount, as the country enters into a sec-
ond phase of infrastructure develop-
ment. Fluctuating cost of steel, sales
tax and excise duty are some factors
that have been said to be inhibiting the
growth of the industry. The movement
of the sector towards light weight and
stronger materials such as aluminium
has meant that higher levies are
another inhibiting factor these days.
Manufacturers are looking up to the
Formwork Industry Analysis
Alvert System, Industrial Project ,Gujarat from Pranav System
government to help them procure raw
materials at a reasonable price in order
to give the much needed fillip to an
industry. The government needs to
remember that India has the potential
to emerge as a key exporter of formwork
and scaffolding equipment. The encour-
aging news has come in the form of an
evolving customer. Different stakeholders
in the construction industry including,
contractors and engineers, are now
accepting formwork systems as an inte-
gral part of the construction process.
Dwelling on this key point, Mr. Eldo
GCI Wall Form Systems
138 The Masterbuilder - July 2012 · www.masterbuilder.co.in
Varghese, General Manager, Paschal
Formwork (India) Pvt Ltd, said, “A 'change'
is always a struggle. Mindset of influen-
tial decision makers (engineering / con-
struction fraternity), inadequate / inap-
propriate quality codes, cost factors
everything plays a role in the growth.
Engineering community is not reluctant
to change but updating themselves
towards an overall change in the pro-
cedure or system, so that the transition
is easier. More and more engineers are
getting involved in this drastic change
though their experience in other coun-
tries and the pace will definitely improve
as the number goes up. Formwork is
still in the inception stage in India and
change is inevitable towards better
growth rate. It is directly connected to
time. Lack of adequate codes and the
cost factors are also the reasons for the
growth rate. Both are directly linked to
the volume of formwork in usage. As
the volume and usage of modern
formwork goes up as both these fac-
tors will be tackled,” a thought with
which almost all leading manufacturers
will agree.
Another important challenge that
suppliers need to take care of is quality
assurance at the job site. Giving an
insight into how they tackle the issue,
Mr. Sushil Sahani, Managing Director
of Pranav Construction Systems said,”
Quality assurance on the job site is
sometimes an issue in India. As of now,
there is no specific certified body to
give quality assurance on site. To avoid
any quality issues we have our in-
house QA-QC department which moni-
tors quality at every stage, beginning
from procurement of raw materials to
dispatch. We encourage our clients to
have the quality inspection done,” a
strategy which is well worth emulation.
Many industry analysts believe that
the formwork industry needs specific
certification bodies for inspecting and
then certifying formwork systems, as
otherwise the largely unorganized
nature of the construction industry could
mean that quality sometimes could
take a backseat. This apart, an evolving
market also presents another chal-
lenge in the form of a maturing cus-
tomer. The customer of today wants
equipment that is easier to handle,
adds to the sustainability quotient of
the building process, is reusable and
importantly, is also competitively priced.
With policy initiatives expected to
increase inflow of funds into infrastruc-
ture development, the formwork indus-
try is entering a crucial growth and con-
solidation phase.
Photo Courtesy:
www.meva.de, www.archiproducts.com
www.doka.com, www.skyscrapercity.com