MMBC – VIII

18ARC82

VIII ‘C’ – 2024

MODULE 1 – Part 2
A. FORMWORK IN HIGH-RISE BUILDINGS
Formwork is a temporary structure that is used to support wet concrete until it becomes hard. Six
types of formwork used in construction are:

1 Timber formwork
2 Steel formwork
3 Plywood formwork
4 Aluminium formwork
5 Plastic formwork
6 Fabric formwork
7 Tunnel formwork

Timber and plywood formwork is mostly used for small construction.

Steel, and Aluminum formwork is mostly used for large construction due to its initial cost.

Plastic formwork is an interlock type formwork, which is also useful for small construction.

Fabric formwork is useful for complex shapes of the concrete members.

Tunnel formwork is a special type of formwork. RCC slab and wall, both are constructed
simultaneously by using tunnel formwork. Also, tunnel formwork has a shorter cycle period.
The requirement of good formwork in construction are as follows.

Easy removal
Economy
Less Leakage
Rigidity
Smooth surface
Strength
Supports

1. Easy removal

Formwork design should be such so that it can be easily removed by less hammering so that the
damage to the concrete is also less.
If the formwork can be easily removed, it can be reused at a small cost.
2. Economy

Formwork is not useful for the stability of finished concrete. So, its cost can be reduced by keeping in
mind the safety.

The following steps can be taken to bring economy in formwork cost.

∙ Reduce the use of irregular shapes of form.

∙ Try to keep size of rooms similar.
∙ Using commercial sizes of formwork available in the market.
∙ Reuse as soon as the formwork is removed.

3. Less Leakage

The formwork should be such that leakage between its two joints is minimimum.

4. Rigidity

Formwork should be strong enough to retain its shape without excessive deformation. Deflection
should not exceed span/300 for open visible surfaces and for non-visible surface, deviation should not
exceed span/150.
5. Smooth surface

The surface of formwork exposed to the concrete should be smooth. For which oil is applied on the
inner surface of the formwork. Where raw finish of concrete is needed, special stripping agents are
used on the formwork.

6. Strength

Formwork should be strong enough to bear the weight of wet concrete as well as concrete filling and
equipment, labor, etc.

7. Supports

Formwork should be supported on good, hard and non-flexible supports.

1 Timber formwork
Timber formwork is the oldest type of formwork in construction.

In small construction, timber formwork is mostly used because it is easily usable and it offers
an onsite fabrication for the required size and shape of concrete.

But for large construction, timber formwork becomes a time-consumption formwork. As well as
timber formwork has less life compared to other formwork.

Timber formwork is cheaper than steel or aluminum formwork when used only for smaller works.

Advantages of Timber Formwork:

∙ Its initial cost is low.

∙ Timber formwork is light in weight and can be easily manipulated.
∙ More suitable for small works.
∙ It can be used for anything other than formwork.
∙ In houses where the size of the room does not change much, the timber cut is less, so the timber
formwork is cheaper.
2 Steel formwork

Steel formwork is cheaper if the formwork has to be used multiple times.

Steel formwork costs more to start with, but in large works where the formwork has to be used
frequently it becomes cheaper.

In addition, steel formwork can be easily configured as well as removed.

∙ This makes the concrete surface smooth.

∙ Steel formwork for special works such as circular columns, curved surfaces speeds up the work.
∙ Steel formwork is most popular due to its strength, durability, life and reuses.
Advantages of steel formwork:

∙ Steel formwork is more useful when formwork is to be used frequently.

∙ The initial cost of steel formwork is high. But in large works where formwork has to be used
frequently it becomes cheap.
∙ Steel formwork is easy to apply as well as remove.
∙ It does not suck water from the concrete, so the surface of the concrete is less likely to be
honeycombed.
∙ It does not change shape or shrink. So gives more accuracy and workmanship compared to timber
formwork.
∙ It can be easily adjusted as well as opened so that labor cost is reduced.
∙ It gives smooth surface of concrete and does not require re-finishing of concrete surface.
∙ It has high strength and its durability is much higher than timber formwork
3 Plywood formwork

Plywood formwork is an updated type of timber formwork in construction. In this formwork plywood is
used to support concrete work.

Advantages of Plywood Formwork:

∙ It can be used frequently.

∙ Under normal circumstances timber formwork can be used 10 to 12 times while plywood
formwork can be used 20 to 25 times.
∙ Plywood formwork gives smooth surface of concrete so does not require re-finishing of
concrete surface.
∙ Larger areas can be covered using larger panels, thus reducing labor costs.
4 Aluminium formwork

Aluminium formwork is also known as MIVAN shuttering or Mivan formwork.

It is very similar to steel formwork but it is more economical for large construction compared to other
formworks.
Aluminium formwork is very fast, simple and cost effective.
Aluminium formwork increase the efficiency of work as well as provide a smooth form finish of the
concrete.
Advantages of aluminium formwork:

∙ Aluminium formwork is more useful when formwork is to be used frequently and area of
construction is a large.
∙ It is lightweight compared to steel formwork.
∙ It does not suck water from the concrete, so the surface of the concrete is less likely to be
honeycombed.
∙ Aluminium formwork gives smooth surface of concrete and does not require re-finishing of
concrete surface.
∙ It is Economical for large construction.
5 Plastic formwork

Now a days plastic is also used as a formwork material.

Plastic formworks are lightweight consist interlocking system or modular system.

Advantages of plastic formwork:

∙ It is lightweight.
∙ Easy to clean with water.
∙ Consist a interlocking system due to that size of formwork can be easily adjustable.
∙ Good for both small construction as well as large construction.
∙ Plastic formwork can be use more than 100 times.
6 Fabric formwork

Fabric formwork is an advanced type of formwork in construction specially used for complex shape of
concrete members.

Due its great flexibility, it make formwork very simple and easy for complex shapedmembers.
7 Tunnel formwork

Tunnel formwork is a special type of formwork in construction, which is now the most popular for high
rise buildings.

The tunnel formwork is room formwork in which RCC slab and wall are cast in a continuous pour.
Hot air thermal curing is used to accelerate the curing process of concrete.
The cycle time for tunnel formwork system is 1-3 days only.
The tunnel formwork system is very useful for repetitive room design.
Popular formwork systems for high rise are:

Mivan
Kumkang
Doka
Peri
Coffor
Tabla
Slip
1. MIVAN

A System of Aluminium formwork.

Fast, simple, adaptable and cost-effective.

System developed by a construction company in Europe in 1990s and manufactured by a Malaysian

company called MIVAN Company Ltd.,

It is a popular system and is used globally including India.

Suitable for construction of large number of houses in a short time.by using room size forms for
continuous pour of concrete.

Fast setting chemicals or hot air curing helps early stripping.

Typical formwork is prefabricated in the factory and labelled for easy assembly at site.
Wall assembly details
Stages involved in formwork:
Pre-concrete –
Receipt of consignment/s as ordered at site
Level checking of base
Setting out
Check and correct if needed
Erect framework
Erect deck formwork
Setting kickers (over beams)

Issues to be taken care of before and during Concrete pour –

Dislodging of pins and wedges

Prop slippage
Bracing where slip is imminent
Overspill at wall openings

Post concrete –
Clean all components with scrapers and wire brushes
Shift formwork to next level
Stack in proper order of assembly
Erect formwork
Sequence –
Process follows four day cycle –

Day 1 – Erection of wall reinforcement and one side wall support

Day 2 – Other side of vertical wall support and floor slab supports
Day 3 – Floor slab reinforcement and concrete pour
Day 4 – Vertical formwork removed after 24 Hrs, but props left for 7 days

Advantages:
Dimensional accuracy
High quality finish
Cost effective
Speed
Unskilled labor
Reusability of components upto 250 times

Limitations:
Small panel sizes leads to lines seen in concrete
Variation across floors difficult (plan and elevations)
Modifications not possible as casting is homogeneous
Box type construction may lead to shrinkage cracks
Let’s watch…
How does Mivan shuttering fromwork work (youtube.com)

3 mins

Kumkang Aluminum Formwork 3D presentation (youtube.com)

6 mins

Doka - Concrete Formwork - Climbing Systems - YouTube

7 mins
MIVAN System components
DOKA FORMWORK SYSTEM
Doka is a world leader in providing innovative formwork, solutions and services in
all areas of construction. The company is also a global supplier of well-thought-
out scaffolding solutions for a varied spectrum of applications. With more than
160 sales and logistics facilities in over 60 countries, Doka has a high-performing
distribution network for advice, customer service and technical support on the spot
and ensures that equipment is provided swiftly – no matter how big and complex
the project. Doka employs 6,800 people worldwide and is a company of the
Umdasch Group, which has stood for reliability, experience and trustworthiness for
more than 150 years
Wall formworks
Framed formwork Framax Xlife
The high-performing steel-framed formwork for crane-assisted forming of large
areas
Framax Xlife is the framed formwork system that uses only a very few different
panel formats to achieve a consistent 15 cm increment-grid, no matter whether
the panels are stood upright or on their sides. All the connectors and accessories fit
seamlessly into this grid – making for fast forming-times and high efficiency.
Facade formwork Top 50
Safe, economical forming of pre-cast facades
Facade formwork Top 50 speeds up work on pre-cast facades, both with integrated
and set-back CIP columns.
Large-area formwork Top 50
The large-area formwork for all shapes and loads
Large-area formwork Top 50 is a 'construction kit' large-area formwork system that
is pre-assembled on a project-specific basis and is designed to accomplish many
very diverse types of task. The shape, size, tie-hole pattern and form-facing of the
elements can be adapted to suit any requirement.
Column
framework
Column formwork Top 50
The formwork for cast-in-place
columns of any shape and size
Complicated column cross-
sections, large column heights,
many formwork re-use cycles,
tough specifications regarding
the concrete finish – a made-
to-measure Column formwork
Top 50 can handle them all
economically.
Column formwork RS
The steel formwork for round column cross-sections

Exactly round columns, in superlative fair-faced concrete quality, can be achieved using
Column formwork RS
Floor formworks
Panel floor formwork Dokadek 30
The beamless handset system for speed on site. Dokadek 30 is a beam-less, hand-set formwork
system designed as a lightweight steel construction with yellow coated frames faced with a
wood/plastic-composite sheet. Dokadek 30 combines the advantages of a panel floor formwork
system with those of Dokaflex floor-slab formwork, that means its 3 m² large panels make it fast in
typical zones, yet – thanks to Dokaflex – it is also quick and flexible in the infill zones. Dokadek 30 -
with or without drop-head: Slab formwork at its most evolved.
Dokaflex table
The tried-and-tested high-speed tableform
Dokaflex tables are easy and practical to set up and can be shifted and adapted
very quickly. This makes them a cost-effective and efficient way of carrying out
large-area slab projects. Dokaflex tables can of course be combined with
Dokamatic tables.
Climbing formwork K
The crane-jumped formwork assembled from a Folding platform K and a formwork element
The climbing formwork system for structures that need the formwork elements to be moved up in
several casting sections. With only two accessories, the Folding platform K can be turned into a fully
functional crane-jumped formwork directly on the site.
Automatic climbing formwork Xclimb 60
The crane-independent climbing formwork for structures of uncomplicated shape and of any height
Automatic climbing formwork Xclimb 60 is a hydraulically climbed system that can also be quickly
raised by crane if sufficient craneage is available. Because it is guided on the structure at all times,
the system can still be climbed even in windy conditions
System components
Timber formwork beams
Doka timber formwork beams are the basis for many Doka formwork systems and
have a wide range of uses. Hundreds of thousands of these carefully manufactured
beams do sterling service on countless construction sites every day. The H20 top
and H20 eco beams are familiar names all over the world, and are the right choice
for any application.
Floor props

Doka floor props are the right choice for every usage situation, and a sturdy
'support' in the rough-and-tumble of everyday work on the site. The anti-
handtrap and anti-dropout safeguard, forged nut, galvanised finish and
ergonomically shaped fastening clamp are just a few of the features of
these premium tubular steel props that have convinced customers all over
Composite formwork beam
I tec 20 – the high-performance beam that saves on quantities
With its special design and its load-bearing capacity, the I tec 20 beam opens up
some interesting new vistas when it comes to optimising equipment usage on the
site. The plastic facing protecting the flange, and the field-proven end
reinforcements from the 'top' beams, make this an extraordinarily robust
formwork beam.
PERI Formwork systems
PERI India has been pioneer in establishing system formwork and scaffolding in
India. PERI serves its customers across India with innovative solutions and a
comprehensive range of services related to formwork and scaffolding technology.

DUO System Formwork

The DUO system formwork is characterized by its low weight and extremely simple
handling. Not only the material used is very innovative, but also the entire concept: with
a minimal number of different system components, walls, columns and slabs can be
easily and efficiently formed with only a minimal number of different system
components. DUO is the optimal solution for small-sized components with lower
surface requirements as well as for restoration work where no crane can be used.
LIWA Panel Formwork

LIWA is the lightest PERI steel panel formwork and deliberately dispensed with more
elaborate equipment features in favour of lower investment costs. LIWA has only a
minimum of different panel elements. In addition, the perforated strip allows each panel to
be used as a multi-purpose panel. This means that corners and columns can also be
formed without requiring any special panels. LIWA is a marketoriented solution if, for
example, users are working with system formwork for the first time.
VARIO GT 24 Girder
Wall Formwork
With girder wall formwork, the
arrangement of the individual system
components can be freely selected.
As a result, the VARIO GT 24 can be
adapted to suit all geometries and
requirements, e.g. tie positions or
acceptable fresh concrete pressure.
The system is used as project
formwork in residential and
industrial construction, bridge
abutments and retaining walls as well
as in particular for architectural
concrete parts
Column formwork
VARIO GT 24 Column Formwork

VARIO GT 24 is always a project-

specific solution consisting of
formwork girders, steel walers and
any selected formlining. It can be
adapted to suit every cross-section,
concreting height and required fresh
concrete pressure. Architectural
concrete requirements can also be
optimally fulfilled with VARIO GT 24.
ALPHADECK Slab Formwork
ALPHADECK Slab Formwork is revolutionising the way slabs are formed on the construction
site. ALPHADECK is the preferred choice for customers who want to switch to system
formwork. Compared to traditional formwork methods, with the reusable aluminium
panels in PERI quality less timber is required.
GRIDFLEX Grid Element Slab Formwork
The lightweight GRIDFLEX Slab Formwork is used for constructing residential and multi-storey
buildings. Slab thicknesses up to 33 cm can be realized with the formwork. In order to concrete
slabs up to 67 cm thick, the panels have to be additionally supported in the centre. The
standard panel weighs only 20 kg and is swivelled upwards from the assembly area by means
of the shuttering aid. Slab props are subsequently hooked in and vertically aligned. On the now
accessible girder grid, the formlining of choice can be installed. The recurring systematic
assembly sequence ensures fast working operations
ACS Self-Climbing System
The range of ACS self-climbing variants
for facades, building cores, shaft
structures as well as inclined bridge
pylons make the construction of high
concrete structures extremely fast, cost-
effective and safe. The climbing units
comprising wall formwork and platforms
are moved from floor to floor by means
of integrated hydraulic systems. The
efficient sequence of operations facilitate
a very high level of productivity and
exceptionally short cycle times.
Simultaneous climbing of several
climbing units ensures fewer leading
edges thus resulting in increased
workplace safety.
CB Climbing Formwork

CB Climbing Formwork is normally used for supporting large-sized, anchored wall

formwork. The climbing unit consists of formwork, working platform, brackets with
formwork carriage and strongbacks as well as fi nishing platform. It can be moved
very quickly by crane.
LPS Lightweight Climbing Enclosure

The LPS with its mesh enclosure is the lightweight alternative to heavy, enclosed protection
panel systems. Nevertheless, the system effectively seals off the inner areas against the
effects of the wind; at the same time, it is light-permeable. LPS is used as a
vertically continuous climbing protection panel; alternatively, an integrated working platform
provides access to the slab stopend formwork. Rail-guided
climbing ensures a safe and fast moving procedure.
Freeform Formwork

For the construction of complex, multi-curved reinforced concrete components, PERI

provides customized freeform formwork. Based on a 3D building model with so-called
freeform surfaces, the formwork units are individually produced in the PERI formwork
assembly facilities. Assembling the individual elements on the construction site is
similar to system formwork. Statically load-bearing elements are usually based on
VARIO GT 24 Girder Wall Formwork. Hence, many individual components can be
further used after project completion.
Let’s watch…

FORMWORK | PERI ALPHADECK Slab Formwork (EN) - YouTube

PRODUCT | PERI DUO Animation – The lightweight formwork for walls,

columns and slabs (EN) - YouTube

The Revolutionary Technology of Climbing Formwork (youtube.com)

Comparison of different types of formworks

Color coded as follows