ECONOMIC FEASIBILITY STUDY FOR ADOPTING

ALUFORM IN HIGHRISE BUILDING

A Thesis

Submitted in partial fulfilment of the requirements for the award of

Master of Architecture degree in Building Management

By

TAMIL SELVAN R (40840017)

DEPARTMENT OF ARCHITECTURE
SCHOOL OF BUILDING AND ENVIRONMENT

SATHYABAMA
INSTITUTE OF SCIENCE AND TECHNOLOGY
(DEEMED TO BE UNIVERSITY)
Accredited with Grade “A” by NAAC
JEPPIAAR NAGAR, RAJIV GANDHI SALAI, CHENNAI - 600 119

MAY 2022
i
 DEPARTMENT OF ARCHITECTURE

BONAFIDE CERTIFICATE

This is to certify that this Report is the bonafide work of TAMIL SELVAN R (4840017)
who carried out the Pre-Thesis entitled “ECONOMIC FEASIBILITY STUDY FOR
ADOPTING ALUFORM IN HIGHRISE BUILDING” under our supervision from Jan 2022 to
May 2022.

Internal guide Internal Panel Member External guide

(Ar. RAMKUMAR) (Ar. SUKIRTHA SURESH) (Ar. S. KAVIN KUMAR)

DR. DEVYANI GANGOPADHYAY

Head of the Department

Submitted for Viva voce Examination held on 6TH May 2022

Internal Examiner External Examiner

i
 DECLARATION

I TAMIL SELVAN R hereby declare that the Pre-Thesis Report entitled “ECONOMIC
FEASIBILITY STUDY FOR ADOPTING ALUFORM IN HIGHRISE BUILDING” done by me
under the guidance of Ar. RAMKUMAR (Internal) and Mr. S. KAVIN KUMAR (External) at
Sathyabama Institute of Science and Technology is submitted in partial fulfilment of the
requirements for the award of Master of Architecture degree in Building Management.

DATE: 06.05.2022

PLACE: CHENNAI SIGNATURE OF THE CANDIDATE

ii
 ACKNOWLEDGEMENT

I am pleased to acknowledge my sincere thanks to Board of Management of

SATHYABAMA for their kind encouragement in doing this Pre-Thesis project and for
completing it successfully. I am grateful to them.

I convey my thanks to Dr. Devyani Gangopadhyay, Dean and Head of the department,
Dept. of Architecture, School of Building and Environment, for providing me necessary
support and details at the right time during the progressive reviews.

My special thanks to Dr. Suresh Kuppusamy, our Design chair and Mr. S. Kavin Kumar
(External guide) and Ar. Sukirtha Suresh (Thesis Coordinator) for their valuable comments
and guidance during the project work.

I would like to express my sincere and deep sense of gratitude to my Project Guide Ar. RAM
KUMAR for his valuable guidance, suggestions and constant encouragement which paved way for the
successful completion of my project work.

I wish to express my thanks to all Teaching and Non-teaching staff members of the
Department of Architecture who were helpful in many ways for the completion of this Thesis.

iii
 ABSTRACT

The project involves cost and duration analysis of a building constructed by Conventional formwork
building and MIVAN formwork building. The main aim of this project is to determine which type of
formwork is suitable for type of construction and which have less effect in project duration and
cost.

The valuation of real estate is expected when calculating the market value of a property according
to its qualitative characteristics. Based on the basic needs of human housing, real estate prices
increase day by day as the population increases. However, predicting the approximate rate will be
a very complex problem. Since then, all states have many different characteristics due to the
location and use of it. Therefore, the calculation of the exact valuation of any property is becoming
a prerequisite.

On other hand analyzing revenue potential of any property plays an important role. This can
be done by using suitable valuation models. Aspects to be covered in calculating revenue potential
of property are calculating IRR, Payback period, Capitalization rate, ROI and project feasibility.
However this can be done during project planning stage or during preparation of feasibility study.

In this project I will be able to evaluate various valuation models and choose specific model that
will help government in calculating revenue potential and profit recovered from investment. I will
also evaluate the feasibility models pertaining to five aspects like Economical, Technical,
Operational, Legal and Scheduling.

iv
 TABLE OF CONTENTS

CHAPTER No. TITLE PAGE No.

ABSTRACT iv

LIST OF TABLES ix

LIST OF FIGURES
x
1 INTRODUCTION

1.1 INTRODUCTION 1

1.2 AIM OF THE RESEARCH 1

1.3 OBJECTIVE OF RESEARCH 1

1.4 SCOPE OF WORK 1

1.5 RESEARCH METHODOLOGY 2

1.6 ABOUT THE SITE 2

1.7 MERITS OF ALUMINIUM FORMWORK 3

2 LITERATURE REVIEW 4

2.1 COMPARISON OF ALUMINIUM FORM CONSTRUCTION

TECHNIQUE OVER CONVENTIONAL FORMS 4
2.2 COMPARATIVE ANALYSIS ON COST AND DURATION OF MIVAN
FORMWORK BUILDING AND CONVENTIONAL FORMWORK
BUILDING - GANAR A. S. 5

2.2.1 Abstract 5

2.2.2 Main Objective 5

2.2.3 Casestudy 5

2.2.4 Inference 5

2.3 PLANNING AND SCHEDULING OF SHUTTERING SYSTEM FOR

MULTISTOREYED BUILDING - NAVEEN
V.CHIKKAVEERAYANAVAR, NARESH PATIL 6

2.3.1 Abstract 6

2.3.2 Main Objective 6

2.3.3 Casestudy 6

v
 2.3.4 Inference 6

2.4 TIME AND COST OPTIMIZATION OF CONSTRUCTION PROJECT

USING MIVAN TECHNOLOGY - AKSHAY GULGHANE , NIKHIL PITALE
, SANKET SANGHAI. 7

2.4.1 Abstract 7

2.4.2 Main Objective 7

2.4.3 Tools Used For The Project 7

2.4.4 Detailed Material Used 7

2.4.5 Duration Using Mivan Technology 8

2.4.6 Duration Using Conventional Techniques 8

3 LITERATURE CASE STUDY 9

3.1 CASE STUDY ON A MULTI STORY BUILDING AT CHENNAI

FORMWORK SYSTEM USED TUNNEL FROM WORK. 9

3.1.1 PROJECT DESCRIPTION 9

3.1.2 FORMWORK SYSTEM 9

3.1.3 CONVENTIONAL/TRADITIONAL FORMWORK 9

3.1.4 MIVAN FORMWORK 9

3.1.5 TUNNEL FORMWORK SYSTEMS 9

3.1.6 ADVANTAGES RELATED ON TIME& COST BASES 10

3.1.7 CHALLENGES FACED BASED ON DESIGN AND

ARCHITECTURAL ASPECTS 10

3.1.8 CONCLUSION 10

3.2 SPHAGETTI @ KHARGHAR 11

3.2.1 COMPLETED PROJECT WITH MIVAN FORMWORK 11

3.2.2 DISCUSSION ABOUT THIS PROJECT 11

3.2.3 INFERENCE ABOUT THESE CASE STUDIES 12

3.2.4 BENEFITS AND CONCERNS 12

3.2.5 ANALYSIS 12

vi
 3.2.6 COMPARISON TABLE 13

4 LIVE CASE STUDY 14

4.1 NAVIN’S Starwood Towers – Medavakkam, Chennai 14

4.1.1 General Information 14

4.1.2 Construction Information 14

4.1.3 Project Unique Features 14

4.1.4 Alu-Formwork – Technique 15

4.1.5 Advantages of Alu-Formwork 15

4.1.6 Limitations of Alu-Formwork 15

4.1.7 MIVAN Formwork - Assembly 16

4.1.8 Floor Plans 16

4.1.9 Mivan Formwork System : Materials 17

4.1.10 Conclusion 18

4.1.11 Site Pictures 18

4.2 CASESTUDY ON RAHEJA IT PARK @ PALLIKARANAI 19

4.2.1 CONSTRUCTION INFORMATION 19

4.2.2 LOGISTICS PLAN 19

4.2.3 PROJECT EXECUTION STAGES 20

4.2.4 PRE-POUR CHECK LIST 27

4.3 QUESTIONAIRES 28
4.4 LIMITATIONS OF ALU-FORMWORK 29
4.5 FACTORS THAT AFFECT 29
CONSTRUCTION QUALITY
MANAGEMENT
4.6 29
BIGGEST FACTORS AFFECTING YOUR
CONSTRUCTION COSTS

vii
5 ANALYSIS & FINDINGS 30

5.1 HOUSING SHORTAGE DATA OF INDIA 30

5.2 COMPARISON BETWEEN ALUMINIUM & CONVENTIONAL

FORMWORK SYSTEM 33

5.3 COST COMPARISON BETWEEN CONVENTIONAL &

ALUFORMWORK SYSTEM 37

5.4 COST COMPARISON BETWEEN CONVENTIONAL &

ALUFORMWORK SYSTEM 38

5.5 COST OF THE CONVENTIONAL FORMWORK 39

5.5.1 Cost Of Individual Components 40

5.5.2 Labour Requirement Calculation 41

5.5.3 Plant & Machinery Charges 42

5.5.4 Fuel Cost Calculation For Power Generator 42

5.6 ALU-FORMWORK COSTING: CATERING AREA 43

5.6.1 Alu-Formwork Investment Costing Per Sq.M 43

5.6.2 Materials Cost To The Project 44

5.6.3 Additional Accessories Cost 45

5.6.4 Labour Cost Calculation 45

5.7 STRUCTURE COST COMPARISON BETWEEN FRAMED AND

BOX TYPE STRUCTURE 46

5.7.1 Framed Structure 46

5.7.2 Box Type Structure 47

5.7.3 Duration Comparison Between Framed & Box Type

Construction 49

5.7.4 Benefits On Reducing The Project Duration 49

6 CONCLUSION 50

REFERENCE 51

vii
 LIST OF TABLES

TABLE No. TITLE PAGE No.

2.4.4 Detailed Material Used 7

2.4.5 Duration Using Mivan Technology 8

2.4.6 Duration Using Conventional Techniques 8

3.2.6 Comparison Table 13

4.1.10 Conclusion 18

4.2 Casestudy On Raheja It Park @ Pallikaranai 19

5.1 Housing Shortage Data Of India 30

5.2 Comparison Between Aluminium & 33

Conventionalformwork System
5.3 Cost Comparison Between Conventional & 37
Aluformwork System
5.4 Cost Comparison Between Conventional & 38
Aluformwork System
5.5 Cost Of The Conventional Formwork 39

5.5.1 Cost Of Individual Components 40

5.5.2 Labour Requirement Calculation 41

5.5.3 Plant & Machinery Charges 42

5.5.4 Fuel Cost Calculation For Power Generator 42

5.6 Alu-Formwork Costing: Catering Area 43

5.6.1 Alu-Formwork Investment Costing Per Sq.M 43

5.6.2 Materials Cost To The Project 44

5.6.3 Additional Accessories Cost 45

5.6.4 Labour Cost Calculation 45

5.7.1 Framed Structure 46

5.7.2 Box Type Structure 47

ix
 LIST OF FIGURES

FIGURE No. TITLE PAGE No.

4.1.7 MIVAN Formwork - Assembly 16

4.1.8 Floor Plans 16

4.1.9 Mivan Formwork System : Materials 17

4.1.11 Site Pictures 18

4.2.2 Logistics Plan 19

4.2.3 Project Execution Stages 20

5.1 Housing Shortage Data Of India 30

5.7.2.1 Cost Per Unit For Framed Type Structures 48

5.7.2.2 Cost Per Unit for Box Type Structures 48

5.7.3 Duration Comparison Between Framed & Box 49

Type Construction

x
 CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
The Most Effective Means Available For The Construction Of High, Medium And Low Rise
Mass Housing R/C Structures.
It Is A Precision-Engineered Formwork Fabricated In Aluminium Monolithic Pouring.
Walls, Columns, Slabs & Beam Are Poured Together. Speed - Induces A Disciplined &
Systemized Approach To Construction, Which Creates A Daily Work Cycle, The Essence
Of The Productivity.
The Productivity Generates A Overall Work Cycle, That Can Achieve 4/5 Day Per Floor
Outputs Or Other Cycle Times To Suit Your Project Requirements.

1.2 AIM
The Aim Is To Propose Mixed Use Development In Thirumalisai Using The Aluform
Technology, It Is A Precision-Engineered Formwork Fabricated In Aluminium And How The
Uses Of Aluform, Can Save Time And Money For A Multi-Crore Project.
Benefits Of Aluform Technology Will Be Explained By Comparing It With Conventional
Technology.

1.3 RESEARCH OBJECTIVES

Quantity Estimation Of Construction Material Required For Building By BothMIVAN
Formwork And Conventional Formwork.
To Determine Complete Time Required For Completion Of The Building By BothThe
Above Methods.
To Compare The Cost Of Buildings Based On The Cost Of Materials Required InEach
Of Them.
To Carry Out The Comparative Analysis Between The Mentioned Two Methods Of
Construction And Define Suitability Difference Between Them.

1.4 SCOPE OF WORK

Many Of The Accidents Take Place In Reinforced Cement Concrete (RCC) Construction
Because Of Inferior Formwork And Scaffolding.
Now Focus Has To Be Shifted To Other Key Factor “Formwork”, To Face The Challenges
For The Completion Of Fast Track Projects. By Going In For System Formwork,
Substantial Savings Are Possible By Faster Return On Investments.

1
1.5 RESEARCH METHODOLOGY

STAGE 1 DATA COLLECTION

STAGE 2 CASESTUDY AND SCHEMATIC DESIGN

STAGE 3 INTERPRETATION AND ANALYSIS

STAGE 4 CONCLUSION

1.6 ABOUT THE SITE:

The Site Is Located In Thirumazhisai With An Extent Of 311.05 Acres.
The Tamilnadu Housing Board Is Planned To Develop A Massive Township For 12,000
Peoples About 30 Kms From The City Is Exploiting The Commercial Space For The
Purpose.
The THNB Has 127 Acres Of Land At Thirumazhisai, Of Which About 30 Acres Would Be
Utilized For Infrastructure Facilities Within The Township.
About 20 Acres Has Been Earmarked For Commercial Space.
Located On Chennai – Bengaluru Highway, The Land Parcel Falls Under The
Chennai Metropolitan Area.
The Demand For Housing At Thirumazhisai Would Be From Those Working At The
Industrial Belt Of Irungattukottai And Sriperumbadur.

2
1.7 MERITS OF ALUMINIUM FORMWORK
In Contrast To Most Of The Modern Construction Systems, Which Are Machine And
Equipment Oriented, The Formwork Does Not Depend Upon Heavy Lifting Equipment And
Can Be Handled By Unskilled Labors.
Fast Construction Is Assured And Is Particularly Suitable For Large Magnitude
Construction Of Respective Nature At One Project Site.
Construction Carried Out By This System Has Exceptionally Good Quality With Accurate
Dimensions For All Openings To Receive Windows And Doors, Right Angles At Meeting
Points Of Wall To Wall, Wall To Floor, Wall To Ceiling, Etc, Concrete Surface Finishes Are
Good To Receive Painting Directly Without Plaster.
System Components Are Durable And Can Be Used Several Times WithoutSacrificing The
Quality Or Correctness Of Dimensions And Surface.
As All The Walls Are Cast Monolithic And Simultaneously With Floor Slabs Requiring No
Further Plasters Finish. Therefore The Time Required In The Conventional Method For
Construction Of Walls And Plastering Is Saved.

3
 CHAPTER 2
LITERATURE REVIEW

2.1 COMPARISON OF ALUMINUM FORM CONSTRUCTION TECHNIQUE

OVER CONVENTIONAL FORMS:
More Seismic Resistance: - The Box Type Construction Provides More Seismic
Resistance To The Structure.
Increased Durability: - The Durability Of A Complete Concrete Structure Is MoreThan
Conventional Brick Bat Masonry.
Lesser Number Of Joints Thereby Reducing The Leakages And Enhancing The
Durability.
Higher Carpet Area- Due To Shear Walls The Walls Are Thin Thus IncreasingArea.
Integral And Smooth Finishing Of Wall And Slab- Smooth Finish Of AluminiumCan Be
Seen Vividly On Walls.
Uniform Quality Of Construction – Uniform Grade Of Concrete Is Used.
Negligible Maintenance – Strong Built Up Of Concrete Needs No Maintenance.
Faster Completion – Unsurpassed Construction Speed Can Be Achieved Due ToLight
Weight Of Forms.
Lesser Manual Labour- Less Labour Is Required For Carrying Formworks.
Simplified Foundation Design Due To Consistent Load Distribution.
The Natural Density Of Concrete Wall Result In Better Sound TransmissionCoefficient.

4
2.2 COMPARATIVE ANALYSIS ON COST AND DURATION OF MIVAN FORMWORK
BUILDING AND CONVENTIONAL FORMWORK BUILDING - GANAR A. S.

2.2.1 Abstract:
The Project Involves Cost And Duration Analysis Of A Building Constructed By
Conventional Formwork Building And MIVAN Formwork Building. The Buildings Are Of
G+12 Floors And Area Of Both The Buildings Are 771.92 Sq.M With 2.95 M As The
Height Of Each Floor. The Analysis Involves The Quantity Calculation For Cost For Both
Buildings And Duration Comparison Of Conventional Formwork Building And MIVAN
Formwork Building.

2.2.2 Main Objective:

To Compare The Cost Of Building By Using Conventional Formwork Technique & By
Using MIVAN Formwork Technique.
To Compare The Duration Of Building By Using Conventional Formwork Technique & By
Using MIVAN Formwork Technique.

2.2.3 Casestudy:
This World-Class Project Is Being Designed On 400 Acres Of Land At Dhanori, Which Is
To Be The Center Of Greater Pune Having 1, 2 & 3 BHK Flats/ Apartments.

2.2.4 Inference:
Cost Of MIVAN Formwork Building Is 14.04 Percent Cheaper Than The Conventional
Formwork Building. The Construction Of MIVAN Building Can Be Done In Half Duration Of
Construction Of Conventional Building Of 12 Floors. From The Results Of The Case
Study It Can Be Concluded That Quality And Speed Must Be Given Precisely
Consideration With Regards To Economy.

5
2.3 PLANNING AND SCHEDULING OF SHUTTERING SYSTEM FOR
MULTISTOREYED BUILDING - NAVEEN V.CHIKKAVEERAYANAVAR, NARESH PATIL

2.3.1 Abstract:
The Standard Of The Construction Industry Is Raised With The Use Of Aluminum And
Prefabricated Formwork. The Main Aim Of This Project Is To Determine Which Type Of
Formwork Is Suitable For Type Of Construction And Which HaveLess Effect In Project
Duration And Cost.

2.3.2 Main Objective:

The Main Objective Of This Study Is To Plan, Schedule And Track A Residential Building
Project With The Use Of MSP 2013 Software, Analyzing The Result And Which Method Is
Suitable For Residential Building Project Is Determined And Measure Are Recommended
To The Organization For Enhancing Their Project Planning Skills.

2.3.3 Casestudy:
Project:- Residential Building Location:- Mumbai Design Consultant:- JW Consultant
Built Up Area:- 675.779sqm Number Of Storey:- G+21 Floors

2.3.4 Inference:
A Case Study Was Conducted On A Residential Project And Comparison Between The
Conventional Formwork And Mivan Technology Was Analyzed And Results Were
Determined. Even Though The Initial Investment Of Mivan Technology Is High, It Provides
Cost Efficient Project And Eliminated The Need Of Plastering Work As It Gives A Good
Surface Finish Compared To Conventional Type Of Formwork. The Duration Of Project
Can Be Minimized By Adopting MivanTechnology. And Hence It Is Concluded That Mivan
Technology Is Not Suitable For Small Scale Projects.

6
2.4 TIME AND COST OPTIMIZATION OF CONSTRUCTION PROJECT USING MIVAN
TECHNOLOGY - AKSHAY GULGHANE , NIKHIL PITALE , SANKET SANGHAI

2.4.1 Abstract:
Construction Is One Of The Significant Sectors And Integral Part Of Indian Economy. Also,
It Mivan Is Comparatively A New Construction Technology Upcoming For Successful
Completion Of Mass Project Especially Repetitive In Nature. In This Paper We Have
Discussed About Cost As Well As Time Comparison Of Mivan Technology With
Conventional Formwork Technology.
2.4.2 Main Objective:
Quantity Estimation Of Construction Material Required For Building By Both MIVAN
Formwork And Conventional Formwork.
To Determine Complete Time Required For Completion Of The Building By Both The
Above Methods.
To Compare The Cost Of Buildings Based On The Cost Of Materials Required In Each Of
Them. To Carry Out The Comparative Analysis Between The Mentioned Two Methods Of
Construction And Define Suitability Difference Between Them.

2.4.3 Tools Used For The Project:

1. Cubic Contents Method ,
2. Formwork Planning,
3. Aluminium Formwork System,
4. Ccpm Framework Technique Is Used For Scheduling.

2.4.4 Detailed Material Used

Table No 2.4.4 Detailed Materials Used

SR.NO CONTENT MIVAN CONVENTIONAL

1 Concrete Grade M15,M20, M15,M25, M40

M 25
2 Thickness Of The 140mm 160mm,
Wall , 200mm, 230mm
160mm
3 Steel 8mm, 8mm, 12mm,
12mm 16mm, 25mm,
, 16mm 32mm

4 Slab 130mm 150mm, 175mm

7
2.4.5 Duration Using Mivan Technology
Table No 2.4.5 Duration Using Mivan Technology
SR.N ACTIVITY NO.OF
O DAYS
1 All Shuttering 18
2 Conceal Electrification And Plumbing 18
3 Steel 6
Reinforcement
4 Alignment Checking 3
5 Buffer Time 2
6 Concrete Placing 3
7 Removal Of Vertical Formwork 2
8 Removal Of Other Formwork 14
9 Lifting Of Wall Panels 2
10 Gypsum Plastering & Painting 30
Total 98

2.4.6 Duration Using Conventional Techniques

Table No 2.4.6 Duration Using Conventional Techniques

SR.N ACTIVITY NO.OF
O DAYS
1 Column Shuttering 12
2 Column Steel Reinforcement 12
3 Buffer 2
4 Beam & Slab Shuttering 15
5 Beam & Slab Steel Placing 12
6 Leveling 3
7 Concrete Placing 6
8 Removal Of Other Formwork 15
9 Brickwork 30
10 Plastering 30
11 Finishing 30
Total 167

8
 CHAPTER 3
LITERATURE CASE STUDY

3.1 CASE STUDY ON A MULTI STORY BUILDING AT CHENNAIFORMWORK

SYSTEM USED TUNNEL FROM WORK.

3.1.1 Project Description:

Project Name :Proposed Construction Of Staff Quarters At Chennai
Configuration : Piling. RCC Framed Buildings
Structure : G+18
Total No. Of Villa : 144
Project Duration : 8 Months
Form Work System : Tunnel Form Work
Buildup Area : 181351 sft

3.1.2 Form Work System:

A Formwork System Signifies The Molds Used To Store And Hold Wet Concrete Until
Curing Is Achieved. Concrete Has Been Demonstrated To Be The Most Suitable
Construction Material For Buildings And Foundations Since ItWithstands Fire And Ensures
Protection Against Storms And Extreme Temperatures. In Addition, Concrete Contributes
To The Creative Modern Architectural Design.

3.1.3 Conventional/Traditional Formwork:

The Formwork Is Built On Site Out Of Timber And Plywood Or Moisture-ResistantParticleboard.

3.1.4 Mivan Formwork:

The Formwork System Is Engineered Formwork System Fabricated In Aluminium.

3.1.5 Tunnel Form Systems:

Tunnel Form Systems Are Used To Construct Repetitive Cellular Structures (Such As
Hotels And Apartment Blocks) And Enable The Construction Of Horizontal And Vertical
Elements (Floors And Walls) Together.
Each Unit Is In The Form Of An Inverted L.
Several Units Are Erected Together To Create The Formwork For A Number Of ‘Tunnels’
Consisting Of Walls And Ceiling Slab.
The Normal Dimensions Of Tunnel Form Units Are 8 To 11m Long And 2.4 To 6.8m Wide,
But Individual Units Can Be Joined To Give Tunnels Of Greater Length.

9
3.1.6 Advantages Related On Time& Cost Bases:
The Production Cycle 1-3 Days / Floor Can Be Archived.
The Project Can Be Completed With Short Period Compared ToConventional & Aluminium
Formwork System.
Labour Obtain Specialization & “Zero Defect” Production Pattern IsPossible.
Repetitive Nature Of Buildings Provides Effectiveness In Production AndMinimization Of
Labour Work.
Formwork Cost Per Sqm Can Be Reduced By Using Formwork Up To 500Cycles.

3.1.7 Challenges Faced Based On Design AndArchitectural Aspects

Dimension Limitation Must Be Considered,
Minimum Room Size2000mm(Approx.) Minimum Wall & Slab Thickness 150mm.
It’s Not Convenient For Theatres &Hall, That Contains Large Span.
Load Bearing Walls Must Be Designed Continuously On The Same AxialSystem Due To
The Resistance Requirements Against Horizontal Forces.
Continuous Footing Or Raft Required.

3.1.8 Conclusion:
Different Formwork Systems Provide A Wide Range Of Concrete Construction Solutions
That Can Be Chosen To Suit The Needs Of A Particular Development.
Traditional Formwork For Concrete Construction Normally Consisted Of Bespoke Solutions
Requiring Skilled Craftsmen.
This Type Of Formwork Often Had Poor Safety Features And Gave Slow Rates Of
Construction On-Site And Huge Levels Of Waste – Inefficient And Unsustainable.
Modern Formwork Systems, Which Are Mostly Modular , Are Designed For Speed And
Efficiency.
They Are Engineered To Provide Increased Accuracy And Minimize Waste In Construction
And Most Have Enhanced Health And SafetyFeatures Built-In.
The Main Systems In Use Are Mivantechnology And Tunnel Form.
This Guide Sets Out Their Key Features – Process Efficiency, Safety, Sustainability
And Other Considerations – In Order To Help Construction Professionals To Take
Advantage Of Them To Achieve Modern, Efficient Concrete Construction.

10
3.2 SPHAGETTI @ KHARGHAR
The City And Industrial Development Corporation And Organization (CIDCO) Of
Maharashtra Are Responsible For The Development Of Navi – Mumbai. It Has
Undertaken Massive Projects To Achieve This Goal And Has Encouraged Use Of Latest
Technologies To Complete The Projects.

3.2.1 Completed Project With Mivan Formwork

Location: Navi – Mumbai.
Country: India.
Client: Cidco And L&T Ecc
Scope: 4 No. Blocks On Each Floor Of 4, 5, 6, And 7 Storey Apts.
Design: Load Bearing Wall & Slab.
Cycle: 8 Days Per Floor.
System Formwork: 6000 Sq.Mt.
Contract Start Date: November 2003.
Project Type (S): High Rise, Residential Building Having 16 Buildings In All.
Architect: Hafeez Contractor.

3.2.2 Discussion About This Project:

The Building In Plan Made An Angle Of 1720, 168º And 1610 With Each Other.
The Quality Of Construction Is Maintained At The Site With The Use Of RMC.
The RMC Plant Has A Capacity Of Producing 90 Cubic Meter Of Concrete Of Concrete
Per Hour.
The Concrete Used Was Of 25 Grades.
The Construction From Foundation Up To Stilt Is Done With Conventional Practice While
The Upper Floors Are Constructed Using ‘MIVAN’ Technology.
The Construction Company Has Imported Three Sets Of Aluminium Forms.
The Cost Is About Rs.500/- Sq.Ft As Against Rs.650/- Sq.Ft Using
Conventional Methods.
Thus It Can Be Said That Even Though The Cost Of Construction Is Little BitHigh It Has
An Unmatched Quality Compared To The Conventional Method.
MIVAN Formwork Played A Vital Role In The Construction Of The Project.
The Project Was Completed Not Only On Stipulated Period Of Time But AlsoPaid Off With
Its Attributes.
Speedy & Quality Dwelling Units Were Provided To The People Of LowIncome
Groups At Very Reasonable Costs.
MIVAN Is A Definitely Future Of This Ever Growing Construction IndustryWith Lots Of
Project Still Awaiting Its Touch Of Excellence.

11
3.2.3 Inference About These Case Studies:
We Have Tried To Cover Each And Every Aspect Related To Aluminium(MIVAN) Form
Construction.
We Thus Infer That MIVAN Form Construction Is Able To Provide High Quality
Construction At Unbelievable Speed And At Reasonable Cost.
This Technology Has Great Potential For Application In India To ProvideAffordable
Housing To Its Rising Population.
Thus It Can Be Concluded That Quality And Speed Must Be Given DueConsideration
With Regards To Economy.
Good Quality Construction Will Never Deter To Projects Speed Nor Will It Be
Uneconomical.
In Fact Time Consuming Repairs And Modification Due To Poor Quality Work
Generally Delay The Job And Cause Additional Financial Impact On The Project.
Some Experts Feel That Housing Alternatives With Low Maintenance
Requirements May Be Preferred Even If At The Higher Initial Cost.

3.2.4 Benefits And Concerns:

The Biggest Benefit Include Savings On Both Cost And Time.
Experts Point That Using Various Materials And Techniques Can Help Reduce The Cost Of
Construction Manifold. “It Is Cost Effective Because Firstly Time Is Money”.
So What You Can Do In One Year, You Can Do In One Fourth Of That Period.
Secondly, The Quality Control Is Much Better As Everything Is Produced In Factories And
Thereby It Is Standardised.
Everything Is Produced In A Factory Including The Panels, Curing Is Done By Steam And
Not By Conventional Way Where An Individual Throws Water On The Walls And There Is
Also Less Wastage, Better Quality And Consistency In TermsOf Strength,”.

3.2.5 Analysis
Aluminium Formwork System Is A Construction System For Forming Cast InPlace
Concrete Structure Of A Building.
This Method Has Several Benefits In Construction Industry Pertaining To CostAnd Time.
In This Analysis Part, I’ve Prepared A Cost Table Comparing ALU FORMWORK& AAC
BLOCKWORK Of A Building Which Is 15,000 Sq.Ft Of Floor Plate And Those
Comparisons And Results Will Be As Follows:

12
Table No 3.2.6 Comparison Table

13
 CHAPTER 4
LIVE CASE STUDY

4.1 NAVIN’S Starwood Towers – Medavakkam, Chennai

4.1.1 General Information

This Apartment Has A Plot Area Of 1 Lakh Sq.Ft
It Has Three Towers – Redwood, Oak & Pine.
Redwood & Oak Has Done With Alu-Formwork Technique &
Pine Tower Employed Conventional Floor Slab With AAC Blocks For WallsFor The
EWS People.
Redwood & Oak Tower Has 8 Flats On Each Floors And Each Tower Has14 Floors.
Pine Tower Has 14 Flats On Each Floors And Each Tower Has 14 Floors.
M30 Grade Concrete Were Used For The Whole Tower Upto 14 Floors.
Only Stilt Floor Was Constructed By Conventional Beams & ColumnsSystem.
It Tooks 125 Days To Complete The Whole Structure And Another 95 DaysFor Entire
Completion.

4.1.2 Construction Information

Internal walls – 100mm.
Exterior walls – 160 mm.
Balcony parapet walls – 75 mm.
Beam – 200 mm in width, 450 mm in height.
Aluminium panel thickness – 75 mm.
Aluminium sheet thickness – 5 mm.
Panels available for every 5 mm.
Jockey placed at a distance of every 1 m.
Oil & Grease were mixed to coat the shuttering.
20mm rods were used for Reinforcement.
Total manpower engineered – 1,49,958.
Total man hours employed – 11,99,664 hrs.
400 cu.m of concrete poured for each floor.

4.1.3 Project Unique Features

The Structure Is Founded On Soil With SBC Of 150 T/Sq.M.
The Structure Is Built With The Latest Alu-Form Construction Technology,Eco-
Friendly Features, Elegant Architecture And Sustainable Design.
The Structure Is A IGBC Gold Certified Project.

14
4.1.4 Alu-Formwork – Technique
3S – System Of Construction – Speed, Strength, Safety.
Column And Beam Construction Are Eliminated.
Walls And Slabs Are Cast In One Operation.
Specially Designed, Easy To Handle Light Weight Pre-EngineeredAluminum
Forms.
More Strength By Monolithic Concrete.
Carrying Out Concreting Of The Walls And Slabs Together.

4.1.5 Advantages of Alu-Formwork

More Seismic Resistance
Increased Durability Of Structure
Monolithic Casting Results - No Leakages - Enhancing The Durability.
Higher Carpet Area- Due To Thin Shear Walls
Integral And Smooth Finishing Of Wall And Slab
Uniform Quality Of Construction
Negligible Maintenance
Faster Completion.
Less Manpower Engagement.
Simplified Foundation Design Due To Consistent Load Distribution.
The Natural Density Of Concrete Wall Result Better Sound Proof.

4.1.6 Limitations of Alu-Formwork

Concealed services become difficult due to small thickness ofcomponents.
It requires uniform planning as well as uniform elevations to be costeffective.
Modifications are not possible as all members are caste in RCC.
Large volume of work is necessary to be cost effective i.e. at least 200repetitions of the
forms is necessary.
Due to box-type construction shrinkage cracks are likely to appear.
Heat of Hydration is high due to shear walls.

15
4.1.7 MIVAN Formwork - Assembly

Fig. 4.1.7 Mivan Formwork Assembly

4.1.8 Floor Plans:

Fig. 4.1.8 Floor Plans

16
4.1.9 Mivan Formwork System : Materials

Fig. 4.1.9 Mivan Formwork Materials

17
4.1.10 Conclusion

Technique Total Floor ConstructionCost Total Project

Area Per Sq.Ft Duration

Conventional 15000*14 = 2000 Approx. 36

2,10,000 Months
AluformWork 15000*14 = 2200 Approx.10Months
2,10,000

Even Though This Technique Is 10% Costlier Than The ConventionalOne, The
Speed And Quality Of Construction Cannot Be Compared With Each Other.

4.1.11 Site Pictures

26
Fig. 4.1.11 Site Pictures
4.2 CASESTUDY ON RAHEJA IT PARK @ PALLIKARANAI
Table No 4.2 Client & Contractors Details
No. Designation Company Name

1 Client Sycamore Properties Pvt. Ltd

2 Architects Nataraj & Venkat Architects
3 Pmc Cbre South Asia Pvt. Ltd.
4 Str Designtree Service Consultants Pvt. Ltd
5 Str Somadev Nagesh Structural
Consulting Engineer
6 Mep Sunil Nayyar Consulting Engineers Llp
7 Design And Build Division Shapoorji Pallonji & Co. Pvt. Ltd.

4.2.1 Construction Information

Internal Walls – 100mm.
Exterior Walls – 160 Mm.
Balcony Parapet Walls – 75 Mm.
Beam – 200 Mm In Width, 450 Mm In Height.
Aluminium Panel Thickness – 75 Mm.
Aluminium Sheet Thickness – 5 Mm.
Panels Available For Every 5 Mm.
Jockey Placed At A Distance Of Every 1 M.
Oil & Grease Were Mixed To Coat The Shuttering.
20mm Rods Were Used For Reinforcement.
Total Manpower Engineered – 1,49,958.
Total Man Hours Employed – 11,99,664 Hrs.
400 Cu.M Of Concrete Poured For Each Floor.

4.2.2 Logistics Plan

Fig. 4.2 Logistics Plan

19
Logistics Plan
The Main Benefits Of Good Practice Material Logistics Will Contribute To Improved
Project Programming, Best Practice Environmental Performance And Reductions In The
Build Cost.
Financial Benefits: Ordering Materials That Are Not Used In The Project Due To Loss,
Wastage Or Being Surplus To Requirements Has A Cost Which Is Often Over Looked
As It Is Built Into The Project Price And Paid By The Client. The Total Cost Of Poor
Material Logistics Includes The Cost Of Purchase And Delivery, Storage And Handling.
Labour Efficiency: The Efficiency Of The Labour Force On The SiteContributes To The
Project Costs, Duration And Quality. Implementing Efficient Material Logistics Will
Reduce The Number Of Times Materials Are Handled And Prevent Skilled Craftmen
Being Taken Away From The Core Tasks To Handle The Material.
Environmental Benefits: Improving The Project Environmental Performance Helps
Clients And Contractors Demonstrate Their Commitment To Reduce Their Impact In
The Environment.

4.2.3 Project Execution Stages

1. Setting-out

2. Wall / Column Reinforcement

20
3. Installation Of Wall Form

4. Installation Of Beam Soffit

5. Installation Of Slab Soffit

21
6. Slab Reinforcement

7. Staircase Formwork

8. Electrical Wall Conduits

22
9. Cutouts For Plumbing Inlets & Outlets Wall Sleeves

10. Transit Box Cut Out For Lifting Mivan Panels To The Next Floor

11. Formwork Alignment & Level Checking

23
12. Concrete Flow Test

13. Concreting

14. Removal Of Wall Forms

24
15. Removal Of Slab Forms

16. Removal Of Wall Ties & Sleeves.

17. Grouting Of Wall Tie Holes With Anti-Shrinkage WaterproofingGrout

25
18. Support With Back Props

19. Curing

20. Lifting The Formwork To Next Floor

Fig. 4.2.3 Project Execution Stages

26
 4.2.4 Pre-Pour Check List
PROJECT : ….……………………………………………….
FLOOR LEVEL & SECTION : …………………………….
DATE : ………………………………………………………..
Pre-pour check Items
Acceptable: YES / NO
1 All Formwork has been cleaned and coated with an approved release
agentYes /No
2 All Flat Wall Ties installed in good condition.
Yes /No
3 All P.E. wall tie sleeves correctly installed.
Yes /No
4 External & internal wall verticality adjusted accordingly.
Yes /No
5 Verticality and alignment of Door openings
completed. Yes /No
6 Alignment of all internal walls completed.
Yes /No
7 All required Pins and Wedges are installed and secure.
Yes /No
8 All Props positioned vertical.
Yes /No
9 Ensure there is no vertical movement in the Prop lengths.
Yes /No
10 Slab soffit formwork level.
Yes /No
11 Door spacers installed as per Drawings
issued.Yes /No
12 Alignment Walers installed as per Drawings
issued.Yes /No
13 Vertical Soldiers installed as per Drawings
issued.Yes /No
14 All Kickers have been lined and adjusted accordingly.
Yes /No
15 All Kickers Bolts installed correctly.
Yes /No
16 All Rockers have been installed.
Yes /No
17 All excessive spaces between Rocker and floor level have been
sealed.Yes /No
18 All Working Platform Brackets installed as per Drawings issued.
Yes /No
Remarks:

Inspected By : (Name) …………………………………………

Company : ……………………………………………………..
Date : ………………………………………. (Signature)
……………………………
27
4.3 QUESTIONAIRES
1. How Fast Is Mivan Compared To Traditional Construction
Methods?
The Traditional Construction Methods Will Take Up To A 17-Day Cycle ToComplete A
Floor Whereas Mivan Takes Only Up To 7 Days.

2. What Is The Building Process Of Aluminum FormworkTechnology?

The Set-Up Of Formwork Is Used In The Following Stages.
Pre-Concrete,
Concreting,
Post-Concrete.

3. Need For Mivan Construction Technology

Any Innovation Has A Valid Reason For Its Emergence. Likewise, The Real Estate
Sector Is Also
Subjected To Gradual Changes To Meet The Requirements.
At Present, The Demand For Housing And Commercial Spaces Are At An Increased
Rate.
The Lucrative Jobs Along With Home Loan Facilities Have Created The Affordability
To Own A House For The Middle-Class Group.
Key Factor For Adopting Is The Cost Factor For Mivan Shuttering.
Components,Labour & Material Cost Better Than The Traditional Or Conventional
Methods.

4. What Are Themajor Features Of Mivan ConstructionTechnology?

Simple
Fast
Adaptable
Cost-Effective

5. Application Of Formwork
Mivan Formwork Can Be Applied To Both Residential And CommercialVentures.
The Residential Developments Include Affordable Housing Projects,High Rise
Buildings, Townhouses, Single Or Multi-Floor Structures.
Apart From These, Commercial Spaces Include High-Rise Offices,Hotels, Storeyed
Parking Floors.

28
4.4 LIMITATIONS OF ALU-FORMWORK
Concealed Services Become Difficult Due To Small Thickness OfComponents.
It Requires Uniform Planning As Well As Uniform Elevations To Be CostEffective.
Modifications Are Not Possible As All Members Are Caste In RCC.
Large Volume Of Work Is Necessary To Be Cost Effective
I.E. At Least 200Repetitions Of The Forms Is Necessary.
Due To Box-Type Construction Shrinkage Cracks Are Likely To Appear.
Heat Of Hydration Is High Due To Shear Walls.

4.5 FACTORS THAT AFFECT CONSTRUCTION QUALITY MANAGEMENT

In Any Project, Every Stakeholder’s Intention Is To Have The Best Quality In Order
To Minimize Rework. But There Are A Few Hurdles That Come Up During The
Tenure Of A Project That Can Compromise The Quality If Not Handled Wisely. 10
Such Factors Are Discussed Hereafter.
1. Complex Design
2. Supplier and Vendor Failures
3. Low Quality Materials
4. Poor Project Management
5. Miscommunication Between Teams
6. Failure to Document Changes and Practices
7. Subcontractor Mishandling
8. Scope Creep
9. Ignored Audits and Testing
10. Last-Minute Changes

4.6 BIGGEST FACTORS AFFECTING YOUR CONSTRUCTION COSTS?

Managing Your Budget Is A Really Important Part Of Realising Your Dream Project.
There Are Lots Of Things That Can Have A Big Impact On The Cost Of Your Project.
I’ve Outlined Some Of The Key Ones Below.
Site access constraints
Site slope
Size
Complexity
Construction method
Finishes

29
 CHAPTER 5
ANALYSIS & FINDINGS

5.1 HOUSING SHORTAGE DATA OF INDIA

CATEGORY URBAN HOUSING SHORTAGE IN MILLIONS

EWS 10.55

LIG 7.41

MIG 0.82

HIG

TOTAL 18.78

Fig. 5.1 Housing shortage in India

30
 Table No 5.1 Housing Shortage Data Of India
SI NO NAME OF THE STATES HOUSING
SHORTAGE
1 Andhra Pradesh 1.27

2 Arunachal Pradesh 0.03

3 Assam 0.28
4 Bihar 1.19
5 Chhattisgarh 0.35
6 NCT of Delhi 0.49
7 Goa 0.06
8 Gujarat 0.99
9 Haryana 0.42
10 Himachal Pradesh 0.04
11 Jammu & Kashmir 0.13
12 Jharkhand 0.63
13 Karnataka 1.02
14 Kerala 0.54
15 Madhya Pradesh 1.10
16 Maharashtra 1.94
17 Manipur 0.08
18 Meghalaya 0.03
19 Mizoram 0.02
20 Nagaland 0.21
21 Orissa 0.41
22 Puducherry 0.07
23 Punjab 0.39
24 Rajasthan 1.15
25 Sikkim 0.01
26 Tamil Nadu 1.25
27 Tripura 0.03
28 Uttar Pradesh 3.07
29 Uttarakhand 0.16
30 West Bengal 1.33
31 Andaman & Nicobar Island 0.00
32 Chandigarh 0.02
33 Dadra & Nagar Haveli 0.05
34 Daman & Diu 0.01
35 Lakshadweep 0.01
India 18.78

31
32
 5.2 COMPARISON BETWEEN ALUMINIUM & CONVENTIONALFORMWORK SYSTEM
Table no 5.2 Comparison Between Aluminium & ConventionalFormwork System

SI No. Description Aluminium Formwork Conventional

System Formwork System

A SAFETY
1. Strength Related
a. Type Of Construction Box Type Construction As Framed Structure As Per
Per IS 4326-1998 IS 4326-1998

b. Design Life Of The 60 Years 50 Years

Building
As Per IS 875-1987

c. Fire Rating Capacity 150mm Wall Thickness – 200mm Thick Solid Block
As Per IS 1642-1989 2 Hours Rating – 4 Hours Rating

d. Wall Thickness Thickness Of Any Part Of Minimum Dimension Of

As per IS 13920-1993 The Wall Shall Preferably, The Member Shall Not Be
Not Less Than 150 Mm. Less Than 200mm.

2. Earthquake Resistance All Walls Are Reinforced Column & Beam With
Concrete Walls Which Reinforced Concrete
Increase The Stiffness & Member, Block Works Are
Lateral Load Carrying Used To Fill The Space
Capacity Of Overall Between The Two Column
Structure. Which Gives Less
Stiffness & Lateral Load
Carrying Capacity Of The
Structure.

No Separate Bracing Brick Infill’s Acts As A

Elements Required Bracing Elements

3. Methodology Integrated Safety Additional Arrangements

Arrangement Available Required To Ensure The
Such As Working Platform Safety Working At Heights
Brackets With Catch Net Such As Scaffolds And
& Walkways. Personal Protective
Equipment.
4. Accident Rate: Total Man Hours Engaged Total Man Hours Engaged
) Fatality – 9.28 Millions – 6.64 Millions
) Unsafe Conditions a) Nil a) Nil
) First Aid Cases b) Number Of Unsafe b) Number Of Unsafe
) Accident Potential Rate Conditions – Conditions –
3926 4857
c) Number Of First c) Number Of First
AidCases – 39 AidCases – 182
d) Average Accident d) Average Accident
Potential Rate – 458 Potential Rate – 848
(Reference : Site Data) (Reference : Site Data)

33
B QUALITY

. Method Of Monolithic Construction (Vertical Two Stage Construction (Stage 1:

Construction & Horizontal Elements Casted Vertical Elements Casting, Stage 2:
Together In Single Pour). Horizontal Elements Casting).
No Construction Joint In Single Construction Joints At Column & Beam
Floor Which Reduces The Junctions Which Are More Vulnerable To
Seismic Effects. Seismic Effect.

2. Surface Form Finish (No Plastering Is Surface Finish Depends On The Quality
Finish Required). Of Plastering.

3. Durability Of This System Is Made Up Of This System Works With The

Formwork Aluminum Alloy (6061-T6) & Combination Of Plywood, Timber & Steel
Having High Tensile Strength Of Members.
260 N/Mm2 (ASTM B22`M-02, Tensile Strength Of The Plywood Is 22.5
Table 2) N/Mm2 (IS 4990-1993, Clause 10.1.6) &
Very High Corrosive Resistant For Steel, It Ranges From 290-590
Which Increases The Lifespan N/Mm2 (IS 2062-2000, Table 2, Clause
Of The Materials. 5.10.3 & 10.3.1)
Corrosion Resistance Is Poor In This
System Which Leads Lesser Life Of The
Material.
4. Accuracy High Precision In Fabricating Very Less Precision Since The
The Formwork, Which Results Formwork Is Made At Site Itself With
InAccurate & Consistent TheAvailable Resources Which Leads
Formation Of Structure. To Poor Quality Of Work & Also
Average Deviation In Verticality Reduces The Strength Of The Building.
Of The Building Absorbed At Average Deviation In Verticality Of The
The Site Is 25mm For The Building Absorbed At The Site Is 55mm
Height Of 51mm In Navin’s For The Height Of 51m Commander’s
Project. Court.

34
C STRENGTH
PARAMETER
1. Bending Bending Moment Capacity For Bending Moment Capacity For
Moment Sheathing Member Is 0.29 Kn.M Sheathing Member Is 0.20 Kn.M
(BS 8118-1990, Part 1). (IS 4990-1993, Clause 10.1.6).

2. Deflection Allowable Deflection L/360 (Or) Allowable Deflection L/360 (Or) 1.5mm
1.5mm Whichever Is Less. Whichever Is Less.

3. Tensile Minimum Tensile Strength – 250 Parallel To Grain – 32.5

Strength N/Mm2 N/Mm2 Perpendicular To
(BS 8118-1990) Grain – 22.5 N/Mm2

4. Density 2710 Kg/M3 (BS 8118-1990) Plywood – 780 Kg/M3 (IS 303-1989)

5. Life Span Of 150 Repetitions Plywood – 7 – 12

The Materials Repetitions Steel –
120 Repetitions
6. Scrap Value Around 30-40 % Of Purchasing Nil
Cost

7. Strength Of Aluminum Is An Excellent Heat Strength Of Concrete Will Attain

Concrete Conductor, This Property Will Gradually, Since Plywood Is Poor
Accelerate The Heat Of In Heat Conductivity.
Hydration Of Concrete, Which
Enables The Early Strength Of
Concrete.

8. Environmenta l 100% Recycling Is Possible Recycling Of Plywood & Timber

Benefits In Aluminum. Waste Is Not Possible.
Recycling 1 Kg Of Aluminum Will No Proper Timber Waste Disposal Is
Saves Up to 6kg Of Bauxite, 4kg Happening At Construction Projects,
Of Chemical Products And Actual Practice Is Landfill & Open
14kwh Of Electricity. Burning.
Reduces Litter & Landfill. Burning Of Waste Timber Based
No Burning Of Waste Timbers Products Will Emits Smoke, Fine
O Construction Site Reduces Particles & Co-2, Which Will
Haze & Pollution. Potentially Dangerous To Human
Every 1mt Of Aluminum Health And The Environment.
Recycles Saves 10mt Co-2 Almost One Tree Is Required To
Equivalent. Cut For The Production Of Ten
Many Trees Will Be Saved By Nos. Of Plywood; Hence
The Elimination Of Wood & Conventional Formwork Is Not An
Plywood Framing, Hence Environmental Friendly System.
Aluminum Formwork Is An More
Environment Friendly System.

35
15 Modules Per Floor Floor Plate Area - 12,000 Sq.Ft

1 & 2 BHK MODULE – FLOOR PLAN

36
 5.3 COST COMPARISON BETWEEN CONVENTIONAL & ALUFORMWORK SYSTEM
Table no 5.3 Cost Comparison Between Conventional & Aluformwork System

Si Description UOM Conventional Alu- Remarks

No: Formwork Formwork

1. CATERING AREA REQUIRED:

a. No Of Towers Number 5 5
s

b. No Of Typical Floors Number 16 16

s
c. Structure Duration In Months Sq.M 12 8

d. Duration For Mobilization & Month 2 2

De- mobilization

e. Total Duration Of Usage Month 14 10

f. Planned Cycle Time Days 25 10

g. Average Number Of Number 14 16

Repetitions s
h. Catering Area Sq.M 11,197 15,390

i. Total Shuttering To Be Sq.M 1,56,75 2,46,24

Executed 8 0

37
 5.4 COST COMPARISON BETWEEN CONVENTIONAL & ALUFORMWORK SYSTEM

Table no 5.4 Cost Comparison Between Conventional & Aluformwork System

Si Description UOM Conventional Alu- Remarks

No: Formwork Formwork

2. COST OF THE FORMWORK (M+L+P):

a. Material Charges (M) Rs 445 244

/sq.m

Steel Components Rs. 2,54,24,388 4,44,20,129

H-Beam (Timber) Rs. 1,30,74,032

Plywood Rs. 1,09,91,138 27,79,517 Accessories

cost for Alu-
Timber Rs. 89,42,466 Form

Consumables – Form Oil, Rs. 75,76,158 86,30,970

Nails Etc.,

Transportation Charges Rs. 32,18,921 16,67,300

Maintenance Charges Rs. 13,89,840 26,93,331

Total Material Cost Rs. 6,97,57,310 6,00,82,560

b. Labour charges (L) Rs. / 221 103

sq.m

Labour cost 3,46,43,518 2,53,62,720

c. Plant charges (P) Rs. 43 20

/
sq.
m
Plant cost 67,40,594 49,24,800

3. Formwork (Material + Rs. 11,11,41,422 9,03,70,080

Labour + Plant) Amount

Formwork (Material + Rs. 709 367

Labour + Plant) Cost per /
sq.m sq.
m

From the above analysis, it is been observed that, while using Alu-formwork system,
around 45% of cost savings can be done over conventional formwork system.

38
 5.5 COST OF THE CONVENTIONAL FORMWORK :

Catering Area : Table no 5.5 Cost Of The Conventional Formwork

SI RC Element Type Of Scope Structur Numbe Plann Number Cateri

No Description Formwor Of e r Of ed Of ng
: k System Formwor Duration Workin Cycle Repetiti Area
k In Sq.m In g Days Time o n –’E’ In
Months In In Sq.M
Month Days –’F’
(A) (B) (C) (D) (E)=(B) (F)=
*( C) (A)/(E
/(D) )
1. COLUMN COLUM 36,350 12 25 12 26 1,398
N
FORMW
O RK
2. BEAM & FLEX 1,20,408 12 25 25 12 10,034
SLAB SYSTEM

TOTAL 1,56,758 11,432

Materials Required:

SI RC Caterin Repetitio Items UOM Quanti Material Total

No Element g Area n ty Producti Requi
: Descriptio Require Requir vity In r ed
n d e d Per Terms
Sq.m Of
For Repetiti
Makin on
g
1. Column 1,398 26 Steel Mt 134 kg 120 188
Compon
e nts

H– M 6.5m 100 9097

Beams

39
 5.5.1 Cost Of Individual Components:
Table no 5.5.1 Cost Of Individual Components
Steel Components:

SI No: Description UOM Quantity

1. Required Quantity Mt 726

2. Hire Charges Per Month / MT Rs. 2500

3. Duration Of Usage (Including Mobilization & Months 14

Demobilization)

4. Amount Rs. 2,54,10,000

Plywood :
SI No: Description UOM Quantity
1. Required Quantity Mt 14288

2. Rate Of Plywood (12mm Thick) Numbe 2290

r
3. Rate Of Plywood (12mm Thick) Per Sq.M Sq.m 769

4. Amount Rs. 1,09,87,472

H - Beam:
SI No: Description UOM Quantity
1. Required Quantity m 60045

2. Value Of H – Beam Per Rmt Rs. 425

3. Depreciation Charges Per Month % 5%

4. Duration Of Usage ( Including Mobilization & De- Months 14

mobilization)

5. Total Percentage Depreciation To Site % 51%

6. Amount Rs. 1,25,04,371

Timber :
SI No: Description UOM Quantity
1. Required Quantity cft 15,314

2. Rate Of Timber cft 585

3. Amount Rs. 89,58,690

40
 5.5.2 Labour Requirement Calculation:
Table no 5.5.2 Labour Requirement Calculation

SI Description UOM Making Works Fixing & Removal Total

No: Requirement
Column Slab Column Slab

1. Scope Of Work Sq.m 1,398 10,034 36,350 1,20,408

2. No. Of Times Sq.m 2.5 2

3. Total Scope Of Sq.m 3,496 20,068 36,350 1,20,408

Work

4. Labour Sq.m / 2.5 2 2.75 1.1

Productivity man-day

5. Labour Numbers 1,398 10,034 13,218 1,09,461

Requirement

Skill Wise Requirement:

6. Carpenter Numbers 698 3250 4411 37050 45,409

7. Helper Numbers 700 6,784 8807 72,411 88,702

Labour Cost :
SI Skill Requiremen Wages per Day Amount in Rs.
No: t

1. Carpenter 45,409 800 3,63,27,200

2. helper 88,702 700 6,20,91,400

TOTAL COST 9,84,18,600

41
 5.5.3 Plant & Machinery Charges :

Table no: 5.5.3 Plant & Machinery Charges

SI Description of Requiremen Duration Hire charges formwork

No: item with t in numbers (machin
specification e hours) Charges / Total Pro-rata Amount
month hiring percentage (Rs.)
charges

1. WOOD WORK EQUIPMENTS :

1 a. Circular saw 2 14 2000 28,000 100% 28,000

machine

1 b. Surface planer 2 14 1000 14,000 100% 14,000

2. MATERIAL HANDLING EQUIPMENTS :

2 a. Tower crane 3 12 3,75,000 45,00,000 40% 18,00,000

2 b. Passenger cum 5 12 1,10,000 13,20,000 40% 5,28,000

material hoist

2 c. Tractor 2 14 30,000 4,20,000 100% 4,20,000

2 d. Truck 1 14 30,000 4,90,000 100% 4,90,000

3. POWER

3 a. Power generator 1 12 40,000 4,80,000 70% 3,36,000

– 250 KvA

3 b. Fuel charges 1 12 7,30,800 87,69,600 100% 87,69,600

TOTAL AMOUNT (Rs) 1,23,85,6

00

5.5.4 Fuel Cost Calculation For Power Generator (250 Kva)

SI Description Calculation UOM Quantity
No:

a. Number Of DG Set Numbers 1

b. Running Hours Per Day Hours 12

c. Working Days Per Month Assumed Days 25

d. Total Running Hours Per D= A*B*C Hours 300

Month

e. Fuel Consumption Per Hour Data Litre 24

f. Total Fuel Consumption Per F= D*E Litre 7200

Month

g. Fuel Rate (Diesel) Data Rs. 101.5

h. Total Fuel Cost Per Month H= F*G Rs. 7,30,800

42
 5.6 ALU-FORMWORK COSTING: CATERING AREA

SL Description UOM Area Per Block

No:
1. Formwork Quantity Per
Floor

1 a. Wall Sq.m 2250

1 b. Slab Sq.m 650

Total Sq.m 2900

2. No. Of Floors 16

3. No. Of Blocks 5

Sub Total 2,32,000

5.6.1 Alu-Formwork Investment Costing Per Sq.M :

Table no 5.6.1Alu-form Investment Costing per sq.m

SL Description UOM Percentage Import Local Manufacturing Quality

No: Quality
1. Basic materials cost Rs. 6,500 6,000

2. Custom duty & clearance Rs. 33% 2,145 -

charges

3. Excise duty charges Rs. 14% - 840

A Basic cost of the material / Rs. 8,645 6,840

sq.m

4. Design fee charges Rs. 30% 2,593 2,052

5. Service tax Rs. 12.5% 324 256

B Cost for design fees / Rs. 2,917 2,308

sq.m

C Material landing cost per Rs. D= A+B 11,562 9,148

sq.m

43
 5.6.2 Materials Cost To The Project :
Table no 5.6.2 Material Cost to the Project
By Depreciation Basis :
SI No: Description UOM Quantity

1. Investment cost per sq.m Rs. 11,562*

2. Expected repetition Numbers 150

3. Formwork required quantity Sq.m 14,500*

4. Cost of formwork Rs. 16,76,49,000

5. Depreciation charges per month – based on their 3%

value

6. Duration of usage (including mobilization & de- Months 10

mobilization)

7. Total percentage of depreciation to the site 26%

8. Cost to the project Rs. 4,40,20,582

By Repetition Basis :
SI No: Description UOM Quantity

1. Investment cost per sq.m Rs. 11,562/

2. Expected repetition Numbers 150

3. Formwork required quantity Sq.m 14,500*

4. Cost per sq.m per repetition Rs. 77*

5. Number of repetition planned Numbers 16*

6. Duration of usage (including mobilization & de- Months 1,78,64,000

mobilization)

Maintenance Cost :
SI No: items UOM Rate per unit Quantity Amount in Rs.
1. Aluminium Rs. 200 14,500 29,00,000
panels
44
 5.6.3 Additional Accessories Cost :
Table no 5.6.3 Additional Accessories Cost

SI Accessories Unit Required Per Total Cost / Unit In Cost In

No: Description Sq.M Required Rs. Rs.

1. Stub pin 50mm Nos 0.15 34,800 25 8,70,000

2. Pin standard wedge Nos 0.250 58,000 5 2,90,000

(WG)

3. Wall tie (TI) Nos 0.040 9,280 39 3,61,920

4. Dywidag tie-rod Nos 0.025 5,800 120 6,96,000

5. Dywidag wing nut Nos 0.025 5,800 140 8,12,000

TOTAL 30,29,920

5.6.4 Labour Cost Calculation:

Labour Requirement :
Table no 5.6.4 Labour Cost Calculation

SI No: Description UOM Quantity

1. Scope of work Sq.m 2,32,000

2. Labour productivity Sq.m / Manday 2.5

3. Labour requirement Numbers 92,800

4. Skill wise requirement :

4 a. Carpenter Numbers 32,500

4 b. Helper Numbers 60,300

Labour Charges :
SI No: Skill Requirement Wages per Amount in Rs.
day
1. Carpenter 32,500 800 2,60,00,000
2. Helper 60,300 700 4,22,10,000
TOTAL 6,82,10,000

45
 5.7. STRUCTURE COST COMPARISON BETWEEN FRAMED AND BOX TYPE STRUCTURE
5.7.1 Framed Structure :
Table no 5.7.1 Cost of Framed Structure

SI Item Description UO Quantit Unit Rate Amount

No: M y (Rs.)
Labou Material Plan Total
r s t Rate
1. REINFORCED CEMENT CONCRETE

1 a. M40 Grade For Columns Cu. 4500 550 4500 800 5850 2,63,25,000
m

1 b. M30 Grade For Beams & Cu. 13000 900 3500 600 5000 6,50,00,000
Columns m

2. REINFORCEMENT WORKS

Reinforcement works Mt 2250 12000 45000 300 57300 12,89,25,000

3. FORMWORK
3 a. Column Sq. 32000 200 300 50 550 1,76,00,000
m

3 b. Beam & slab Sq. 120000 300 400 50 750 9,00,00,000

m

4. BLOCKWORK

4 a. 200 mm thick Sq. 37000 350 800 50 1200 4,44,00,000

m

4 b. 100 mm thick Sq. 24000 375 600 50 1025 2,46,00,000

m

5. PLASTERING WORKS

5 a. Ceiling plastering Sq. 77500 200 150 40 390 3,02,25,000

m

5 b. Internal plastering Sq. 46750 150 125 35 310 1,44,92,500

m

5 c. External plastering Sq. 27000 200 200 225 625 1,68,75,000

m

STRUCTURE COST FOR THE TYPICAL FLOORS 45,84,42,50

0

Built-up area in sq.ft 7,20,000

Construction cost per sq.ft Rs.638-

640

46
 5.7.2. Box Type Structure :

Table no 5.7.2 Cost of Box Type Structure

SI Item UOM Quantity Unit Rate Amount

No: Description (Rs.)
Labour Materials Plant Total
Rate
1. REINFORCED CEMENT CONCRETE

1 a. M30 Grade Cu.m 22650 500 4500 700 5,700 12,91,05,000

(Self Compaction
Concrete)
2. REINFORCEMENT WORKS

Reinforcement Mt 1750 10200 45000 2000 57,200 10,01,00,000

Works

3. FORMWORK

3 a. Wall Sq.m 191000 200 250 20 470 8,97,70,000

3 b. Slab Sq.m 56000 2,63,20,000

STRUCTURE COST FOR THE TYPICAL FLOORS 34,52,95,000

Built-up area in sq.ft 6,25,000

Construction cost per sq.ft Rs.552-555

Inference From The Above Tables:

The Above Two Table Shows The Cost Comparison Between Framed And Box Type Structure.
In Typical Floor Construction, Around 15% Of Cost Saving Is Possible In Box Type Over Framed
Structure.

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Cost Per Unit For Framed Structures

Fig. 5.7.2.1- Cost Per Unit for Framed Structures

Cost Per Unit For Box Type Structures

Fig. 5.7.2.2- Cost Per Unit for Box Type Structures

48
5.7.3 Duration Comparison Between Framed & Box Type Construction

Fig. 5.7.3- Duration Comparison Between Framed & Box Type Construction

5.7.4 Benefits On Reducing The Project Duration:

Construction cost escalation,
Labour rates increases every year at the percentage of 3-5%.
Cement and steel prices increases every year at the percentage of 10-15%.
Around 5-8% of savings in project cost is possible on reducing overheads by early
completion of projects,
High and rapid return on investment is possible.

49
 CHAPTER 6
CONCLUSION

The Task Of Housing Due To The Rising Population Of The Country Is Becoming
Increasingly Monumental.
In Terms Of Technical Capabilities To Face The Challenge, The Potential Is Enormous. It
Only Needs To Be Judiciously Exploited.
Traditionally, Construction Firms All Over The World Have Been Slow To Adopt The
Innovation And Changes.
Contractors Are A Conservative Lot. It Is The Need Of Time To Analyze The Depth Of
The Problem And Find Effective Solutions.
Aluminum Formwork Serves As A Cost Effective And Efficient Tool To Solve The
Problems Of Mass Housing Project All Over The World.
Aluminum Formwork Aims To Maximize The Use Of Modern Construction
Technique And Equipment On Its Entire Project.
From The Results Obtained, We Can Come To A Conclusion That When The Aluminum
Formwork Is Used In The Construction Project, The Total Project Cost And The
Duration Of The Project Is Lesser Than The Conventional Formwork System.
Floor Cycle Will Be 7 – 10 Days When The Aluminum Formwork Is Used In Typical
Floors, And Hence The Structure Duration Will Be Reduced By 35 – 40% Over The
Conventional Period Of Construction.
At The Same Time, There Will Not Be Any Additional Activities Such As Blockwork And
Plastering, Which Further Reduces The Overall Project Duration In The Tune Of 5 – 6
Months.
The Aluminum Formwork System Can Achieve Not Only Faster Rate Of Construction But
Can Also Bring Down The Structural Cost By 20 – 25% Over The Conventional
Method With Lesser Labor Inputs.
Not Only The Direct Benefits, There Are Many Indirect Benefits Of Using Aluminum
Formwork System In The Mass Housing Construction Projects.
For Example, Aluminum Is The 100% Recyclable Materials, Which Saves Our
Environments From Extraction Of Natural Resources Such As Mining Of Bauxite &
Reduces The Cutting Down Of Trees.

50
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