Types and uses of metal formwork. Steel panel formwork Metal formwork with steel deck

Arranging high-quality formwork is without a doubt the most important stage of any construction project. At its core, formwork is nothing more than a form for creating a reliable and durable foundation for a house. The geometry of the foundation, its stability and load-bearing characteristics depend on how well and technologically competently all the elements of the formwork are assembled.

Metal formwork is most suitable for monolithic and strip foundations

What are the benefits of metal formwork?

There are many types of formwork, but in general it can be divided into wooden and metal. Wooden formwork has been used for many centuries, but today, due to many reasons, its relevance is very doubtful. The foundation, poured into a wooden “mold”, matures with violation of the requirements for ventilation and humidity conditions, and therefore has certain flaws, it is susceptible to cracking, crumbling, etc.

Metal formwork is the best option both for the construction of technical facilities and the foundation of low-rise buildings, and for the construction of monolithic high-rise buildings. Metal, unlike wood, does not have such a high coefficient of moisture absorption, which means that concrete matures within the required time, and its structure is of better quality.

Metal formwork is the best option for the construction of technical facilities and the foundation of low-rise buildings

In addition, smooth metal formwork sheets allow you to save on sanding the facade when it comes to monolithic housing construction. In addition to the above, it can be noted that metal elements can be reused, whereas wooden formwork must always be reassembled.

Features of metal formwork

Removable metal formwork assembly is a complex consisting of fixing, reinforcing and forming elements. Being dismountable and reusable, the metal form for pouring concrete is easy to transport and can be used at the next construction site immediately after dismantling. The use of large equipment is intended only for the construction of large buildings; for a private house or small household structure, several assistants will be enough.

As advantages of metal formwork The following points can be mentioned before the wooden analogue:

• no fiber on the contact surface. This feature allows you to create perfectly smooth surfaces regardless of their size;
• ease of dismantling. It is enough to apply a thin layer of special compounds to the formwork sheets before pouring concrete, so that even a novice builder can disassemble the molding structure after it dries;
• reliability. All formwork joints are connected using special locks with high tensile strength. Unlike a wooden structure, metal formwork can withstand the enormous pressure exerted by pouring liquid concrete.
• efficiency. Elements of removable formwork can last for many years, with proper care and storage rules. They are not afraid of deformation and corrosion, they do not burn and do not become unusable when dismantled.

Metal formwork can be used repeatedly

But metal formwork has several negative features, which, of course, are not as significant in comparison with the advantages. The disadvantages of metal formwork include the heaviness of the main elements. Due to the weight of the contact panels, there is a need for additional labor or hiring special equipment. There are formworks made of light metals, for example, aluminum, but their use is only relevant in private housing construction.

Main construction types

According to the type of construction, metal formwork can be divided into adjustable, large-shield And small shield. Each of the options is used in certain cases, and the choice depends on the selected design solutions:

• adjustable formwork is suitable for the construction of structures of non-standard geometry, small architectural objects, etc.
• large panels are applicable for the implementation of large-scale projects without any geometric refinements;
• small panels are used in the construction of foundations and large buildings with complex geometry and numerous elements.

Small panel metal formwork

Installation of formwork

The high cost of a set of metal formwork requires a certain level of knowledge and a competent approach to its installation. In addition, it is important to ensure the tightness of the form so that there is no need to dismantle and reassemble the entire structure if the concrete leaks. Due to the complexity of installation and the lack of proper qualifications, it is better to turn to specialists, otherwise additional material and time costs may arise.

The main elements required for the construction of metal formwork include: steel sheets (or sheets of other metal), locks for securely fixing frame beams, the beams themselves, etc. Additional elements will also be required, such as PVC tubes that insulate transverse fastening devices in the lower parts of permanent formwork and serve to create insulated through holes needed for laying communication lines, etc.

The sequence of work on the construction of formwork can be called classic. First, support points are installed in the corners of the future structure; here the formwork elements go underground and are not dismantled later (permanent formwork). Next, from the support points, all the formwork elements are connected in stages upward and to the sides, according to the shape of the future building.

Installation of metal formwork

When the frame is assembled, sheets are mounted on its internal parts, fastened with locks, the type of which is selected individually. After installing and fastening the sheets, the structure is checked for leaks, then a reinforcing rod is installed in the mold and the process of pouring the concrete mixture begins. If necessary, the structure can be strengthened with braces that serve as supports.

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BORA - FORMWORK OF THE EUROPEAN LEVEL

• Profile made of low-alloy steel S355MC produced by VOESTALPINE (Austria).
• The corners of the shields are reinforced with cast elements.
• Guaranteed 600 concreting cycles.
• Corresponds to class I according to GOST R 52085-2003
• The maximum permissible pressure of laid concrete is 90 kN/m2.
• The maximum deflection of the shields is no more than 1/400 of the span.
• Pouring concrete structures up to 3.6 m high without speed limitation.
• Symmetrical boards 3.0 m, including linear boards 2.4 m wide.
• Plywood deck with plastic coating (optional).
• Convenient and quick installation.
• High quality assembly and painting.

TECHNICAL SOLUTIONS

High-quality Austrian VOESTALPINE profile made of high-strength micro-alloy steel S355MC according to DIN EN 10149-2-95. The strength of this steel is 40% higher compared to Steel 20.

Shields 2.4m wide

• This design has better technical characteristics in relation to other elements (in particular, deflections are less compared to other elements).
• Optimal dimensions for transportation, a width of 2.4 m fits normally in vehicles.
• Fewer components used per 1 sq.m of formwork area.
• During installation, there is no need to install plugs in the holes, because Ties pass through all the holes.
• The panels are very advantageously positioned in any direction, which allows you to have 2 heights and widths of the formwork.

All BORA formwork panels are made with a quality that exceeds the requirements for class 1 formwork according to GOST R 52085-2003 "Formwork. General technical conditions."

​An angle of 30 degrees under the lock is most optimal for leveling, mating and ensuring tightness. The profile has a side to protect the edge of the plywood; the space between the side and the plywood is filled with sealant. The presence of a conical bushing allows you to install the screed at an angle of 5 degrees in any direction. This significantly reduces installation time and improves ease of assembly, directly reducing your costs.

Features of the design of formwork panels

Shield design Calculation diagram

The frame is welded using a robotic complex, which guarantees particularly high quality and strength.

The 3m high panels are absolutely symmetrical, which eliminates errors when installing formwork and increases the convenience and speed of formwork assembly.

Comfortable handles make the work of formwork installers easier and provide the necessary safety.

We are convinced that it is possible to create high-class formwork only from high-quality materials, using modern production technologies and innovative design solutions. BORA is the ideal geometry of elements, manufacturability and durability.

Calculation of formwork panels is carried out in accordance with GOST R52085-2003.

Deflection diagram Stress diagram

We have designed a reliable system that meets the needs of modern construction. With changes in the materials used for monolithic construction (for example, when using self-compacting concrete), the load on the formwork structures increases. The ability to use high-strength materials allows you to achieve the best results.

A rectangular distributed load of 90 kN/m2 was taken as the design load. Calculations and tests of the system showed that all technical indicators correspond to acceptable values.

The formwork can withstand concrete pouring up to 3.6 m high without speed limitation.

The frame design is reinforced with cast corners. The recess is designed to conveniently push the panels into the mounting level using a steel crowbar.

Formwork components

Optionally, it is possible to manufacture a deck of panels from plywood with a plastic coating with a thickness of 1.6 mm. A plastic-coated deck is more mechanically resistant ical damage and has a service life 2.5-3 times longer than a deck made of laminated plywood.

Cast locks for connecting BORA formwork panels are manufactured by ARI Ltd. on European quality equipment.

• The KRAMOS cast wedge lock ensures smooth connection of panel boards.
• ​The leveling wedge lock of the formwork ensures better mating of the panels and allows you to install an extension of up to 100 mm between the panels.

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• The extended KRAMOS lock provides connection between panels and extensions up to 250mm.

The quality of the interfaces of all surfaces of the formwork panels determines the receipt of an excellent concrete surface, as well as a reduction in the cost of additional components, for example, the number of struts used to level the panels.

Formwork is a temporary form-building structure that is designed to produce reinforced concrete and concrete elements. Various materials are used to make formwork.

Permanent formwork is made from expanded polystyrene and reinforced concrete slabs; metal, wood, combined formwork made of synthetic and rubberized materials is removed after the concrete reaches the required strength.

General requirements for formwork

The timing and quality of constructed objects largely depend on the formwork used. For the manufacture of foundations, especially for buildings with a large number of corners, it is advisable to use inventory formwork - reusable structures that allow a large number of installation options.

Inventory formwork systems must fully comply with the requirements for them:

• have high structural strength and reliability;
• ensure the correctness and immutability of the shape and location of the structure;
• depending on the intended purpose, the formwork must have the necessary resistance to deflections and permissible loads;
• versatility - this indicator characterizes the possibility of using one type of formwork system for constructing a foundation, walls, ceilings, arched structures;
• exact observance of geometric parameters during manufacturing;
• long service life.

The most reliable option is metal formwork GOST 23478. In monolithic construction technology, it is used in the construction of foundations, the construction of other reinforced concrete and concrete structures, and the laying of sidewalks. The effectiveness of the formwork system is assessed by the possibility of operational modification in accordance with the object under construction, simplicity and speed of installation.

Production of metal formwork

Metal formwork and connecting elements for it are produced in workshops for the production of metal structures. Blanks of formwork parts are processed with a high class of accuracy.

Metal inventory formwork panels may have deviations in linear dimensions of no more than 2 mm per linear meter, and in the location of holes for connecting parts - 0.5 mm.

Permissible deviations in the elements of various types of formwork systems are determined for each specific case separately, in accordance with the design instructions for the formwork.

After the manufacture of individual elements, control assembly of the metal formwork is carried out. Parts that will come into contact with the concrete mixture are coated with lubricants, and the remaining surfaces are painted.

All elements of the formwork system are subject to mandatory marking.

Manufacturers of formwork systems pay a lot of attention to the development and production of connecting parts of metal formwork - anchor elements, linings, locks and others.

Factory-made connection elements make it possible to carry out a strong and reliable connection of formwork elements, increase the speed of installation and the quality of the resulting concrete surface.

The connections of the elements are made in such a way that the frame of the formwork system can withstand significant tensile, compressive and bending loads.

Metal foundation formwork with a fastening system can be assembled by hand using the simplest tools. Its advantage is also the minimum number of connecting elements required to impart the required rigidity to the structure.

Removable metal formwork: materials for its manufacture

Metal formwork systems have three most common options:

• volumetric block,
• collapsible,
• sliding.

The most popular materials are steel and aluminum.

For load-bearing elements of metal formwork, galvanized or powder-coated steel is used.

The purpose of the coating is not only to protect formwork elements from corrosion, but also to ensure their quick cleaning after use.

Steel is characterized by:

• high load-bearing capacity,
• increased resistance to deformation.

However, the significant weight and thermal conductivity characteristics of this material somewhat narrow the scope of application of such formwork.

Aluminum is a lightweight metal that is resistant to aggressive environments. To obtain durable formwork systems, an alloy of aluminum and silicon is used. Aluminum alloys are highly resistant to corrosion and do not require additional surface treatment by painting or other methods.

Aluminum formwork is lightweight, three times less than the weight of a steel structure. This quality significantly reduces the monetary and labor costs for transportation and installation of formwork. The installation of the aluminum structure can be carried out without the use of a crane. The introduction of the extrusion method for the manufacture of aluminum formwork made it possible to increase its rigidity.

Advantages and disadvantages of metal formwork for foundation construction

The main advantages of metal formwork systems are:

Arranging the foundation involves installing a formwork structure. Concrete solution is poured into this form. As a rule, wood is used to construct formwork, but more and more often builders are giving preference to polystyrene foam frames, which perform similar functions, but with a higher technical level. Metal formwork is also used, which works well in certain cases.

Areas of use

Installing metal formwork for pouring the foundation is an innovative solution that allows you to achieve high-quality performance. This equipment is used for the construction of objects and structures for various purposes - reinforced concrete foundations, walls, columns, ceilings and other elements of buildings under construction.

Advantages and disadvantages

Steel formwork, like other metal structures, has advantages in terms of strength and load-bearing capabilities. If you install a non-removable type, then a long operational period should be added to the main advantages.

According to this criterion, a metal formwork structure is compared with a polystyrene system, and the performance indicators will be approximately the same.

The fundamental difference lies in the dimensions and shapes - metal sheets are thinner and do not take up much space, but polystyrene is distinguished by the variety of produced forms.

Considering the economic effect, we conclude that metal is somewhat more expensive than wood, but in relation to plastic it is cheaper.

True, delivery of metal formwork to the construction site will take some time and require the use of special lifting equipment. The same condition applies to the installation work.

The installation of an aluminum formwork system looks more simplified, but in this option there are restrictions on the choice of fastening and joining with the reinforcing frame. Reinforcing bars, in extreme cases, are welded into the metal surface of the formwork, and in the case of aluminum panels, expensive welding will be required, which will entail additional costs.

Among the advantages should be added:

• strength and rigidity of metal structures that can withstand the pressure created by concrete mortar;
• the smooth surface of monolithic elements of an object, obtained after pouring into steel formwork. By the way, panels are separated from concrete much easier;
• possibility of repeated use of removable metal formwork – up to five hundred cycles.

Metal formwork panels are protected from corrosion.

Types of metal formwork

The production of metal formwork involves the production of several types of structures, the choice of which depends on the design assignment and the upcoming construction volumes. In most cases, the three most popular options are used.

Beam-transom

An excellent solution for the construction of prefabricated monolithic or monolithic structures of floors, foundations, columns, load-bearing walls.

Beam-transom technology allows you to fill complex structures with certain bending curvature values. The equipment is popular for the construction of objects with elements of architectural decoration.

The formwork is lightweight, easy to install, and can be disassembled quickly. There is the possibility of repeated use without additional cleaning of the shields between cycles. The main advantage is that it can be used in combination with other formwork systems.

Large-shield

The shields are large in size. The structure is prefabricated, reinforced with vertical and horizontal stiffening ribs.

The main task of application is to form large and tall vertical structures. Large-panel formwork is used for concreting walls, because the structure is able to withstand significant load forces created by concrete. By using additional elements, it becomes possible to form a long and tall structure.

Professional builders use adjustable large-panel formwork, because installation and dismantling of the system requires the use of special equipment.

The basis of the set consists of large shields connected to each other with special fasteners. During installation, jacks are used to help adjust the position of each panel.

Small shield

This type of formwork is deservedly popular in both professional and private construction.

The formwork kit consists of:

• panels in direct contact with concrete mortar;
• supporting elements fixing the panels in the required positions;
• fastenings.

The small panel formwork system allows the casting of structures up to fifteen meters in height. It is often used when constructing a foundation, because after the concrete has hardened, the panels can be easily removed and used at the next site.

One of the advantages of such formwork is its versatility. The system can be used not only for the construction of residential buildings, but also for the construction of outbuildings.

Separately, the high economic effect is noted - the formwork is used repeatedly, fully recouping its own costs and helping to quickly begin to make a profit.

Characteristics

When making metal formwork, sheets are used, the thickness of which varies between 2 - 3 mm. Despite the significant cost of the material, its use provides certain advantages, which include:

• the possibility of installing any configuration for the foundation;
• additional waterproofing;
• universality of the system;
• creating smooth surfaces;
• excellent solution for monolithic and strip bases;
• ease of cladding;
• maximum hardness index.

The steel used for the manufacture of formwork has certain technical characteristics:

• shield height – from 0.6 to 3 m;
• width – 0.25 – 1.2 m;
• the frame is used up to 300 times, formwork panels – up to 80;
• deflection indicator – up to 1/400 of the span;
• the maximum pressure of the concrete mixture is 75 - 80 kPa.

The panel frame is represented by a closed contour made of a rectangular or edge profile. When creating wood-metal formwork, plywood sheet material is used, the thickness of which reaches two centimeters.

Installation

You can assemble metal formwork yourself. Installation is carried out with separate panels or pre-assembled panels of five to six panels.

The formwork elements are connected with tension screws threaded into the conical holes of the frames. Before connecting, it is best to place the screw in a tube of plastic material to protect it from being flooded with solution. The length of the tube is determined by the thickness of the structure being built.

To install formwork in one tier using panels 1.2 - 2.5 m in height, you will need a pair of tie elements. If you plan to install a two-tier structure, then three ties are needed for each panel. Unused technological holes are closed with plastic plugs.

The connection of adjacent panel elements is carried out with locks, the number of which depends on the height of the tier and the location of the joints to the corner sections. To fasten the outer shield, they use pins rather than locks. All horizontal elements are secured with screw ties.

To connect the extensions with the main elements of the formwork, a pair of wedge locks are installed. If the structure exceeds 2.5 m in height, the connection is made using a wedge device and a leveling beam with a pivot. The number of connecting elements is determined by the width of the additional panels.

Quite often, the panels of a wall structure are connected by inserts. If their size is less than 0.2 m, then fastening is carried out with a universal lock. Installation of inserts exceeding this length requires the use of locks and alignment beams.

Additional inserts guarantee maximum tensile strength of the system.

First of all, external panels are installed, which are fixed with struts. Then the inner row shields are attached.

Proper installation guarantees:

• reliability of fastening of embedded parts;
• density of joining of structural elements with the concrete surface and additional elements;
• strength of fixation of strut elements and brackets;
• compliance with horizontal and vertical axes.

What type of structure is called steel formwork?

Depending on the requirements of the construction project, a special collapsible adjustable structure in the form of steel formwork is used. It gives any monolithic structure a certain geometric shape. The design includes shields, as well as additional components and connecting elements.

Large panel formwork is produced in accordance with the standards of GOST 52085 of 2003.
In order for the steel formwork to be a finished and stable structure, it is necessary to pre-fabricate the panels. To produce them in accordance with regulatory requirements, high-quality profiles are used. The finished frame is lined with laminated plywood, which acts as a protective coating.
The height of one steel shield can reach three meters. If it is necessary to “increase” the height of the structure, the use of so-called additional panels is allowed. The elements can be of different types at the request of the customer in accordance with the requirements of the construction project.

In modern monolithic construction, permanent formwork is most often used. According to its characteristics, it is universal, as it can easily be adapted to other buildings.
High-quality formwork should be characterized by high load-bearing capacity, resistance to deformation, strength and stable geometric dimensions.

Steel panel formwork

The monolithic structure receives its final geometric shape thanks to high-quality steel panels. Depending on the type of construction project, panels come in different types:
- hinged shield
This element allows you to form large angles up to 135 degrees.
- angle of internal, external and zero type
For the construction of structures with right angles.
- universal shield
Used on straight sections.
- stripping corner
- radial shield

What auxiliary elements are used for formwork?

These can be various components, ranging from locks to pins, couplers, struts, spacers, grips, scaffolding, depending on the type of formwork and technical requirements.
What is steel formwork?
We are talking about large-panel formwork, which is necessary for the construction of industrial, road or civil complexes. Thanks to the auxiliary structure, it is possible to create strong and stable monolithic structures, erect walls, and form columns.
The Formwork Leader Group company will supply panel formwork that meets all construction standards. The products are reliable, safe, durable, and have an affordable price.
Why steel formwork?

In construction, it is important that every element of the finished structure is reliable and strong. Formwork can be considered the basis of the future building. Therefore, it is recommended to approach its choice responsibly and competently. You need to pay attention to the following points:
- on product quality;
- for a guaranteed service life;
- compliance with building codes;
- a list of declared characteristics;
- on the price of the structure;
- on design features.