Modular formwork systems
The modular molds or concrete molds are designed and constructed based on horizontal dimensions of 5 centimeters (multipliers of the number 5). These types of concrete molds are produced in various dimensions and sizes. They are most commonly used in formwork for various parts of a concrete structure. Concrete forms are manufactured in widths of 10, 15, … and 50 centimeters and lengths of 100, 150, and 200 centimeters. In addition, concrete forms with different dimensions can be custom-made upon the client’s request for connecting two perpendicular faces of the concrete metal formwork using the modular internal or external corners. The corners are designed in a way to be compatible with the modular formwork, thus possessing all the capabilities and specifications of a concrete metal formwork.
In the production of concrete forms, having a standard weight (40 kilograms per square meter) is crucial due to the compactness of the forms, and the panel movement is done manually. Therefore, by having this weight, a balanced format can be maintained both in terms of strength and weight. The sheets used in the concrete metal formwork to maintain this balanced weight are as follows: the thickness of the base sheet (3 millimeters), the thickness of the punched strip sheets around the formwork (5 millimeters), and the thickness of the stiffeners (4 millimeters). _ The distance from axis to axis of the strap punches around the formwork is exactly 5 centimeters. To enhance the usability of modular formwork, in the assembly of wall forms, a number of forms are produced with perforations. Since a 16-millimeter bolt is used to secure the concrete formwork, the diameter of the holes incorporated into the concrete form should be at least 22 millimeters. The first hole on the form is created at a distance of 25 centimeters from the bottom of the form, and the subsequent hole is made at a distance of 50 centimeters from the first one.
This company offers modular forms in three formats: 5-inch beam concrete forms, 6-inch beam concrete forms, and curved edge concrete forms. The use of curved edge concrete forms is more common in projects involving columns, foundations, and beams due to their lightweight design. However, due to the creation of concrete ribs, they are generally not suitable for wall formwork, especially exposed walls. In such cases, strap forms or welded forms are used more frequently than in-wall forms.
Table of Weight for Edge Formwork Type 5
|Formwork Type 5 Weight Table||Width (cm)||Length (cm)||Height (cm)|
|Panel Type 5 Width 10cm||6.5kg||9.7kg||12.4kg|
|Panel Type 5 Width 15cm||8.1kg||11.9kg||15.5kg|
|Panel Type 5 Width 20cm||9.5kg||14kg||18kg|
|Panel Type 5 Width 25cm||10.9kg||16.5kg||20.7kg|
|Panel Type 5 Width 30cm||12.5kg||18.2kg||23.5kg|
|Panel Type 5 Width 35cm||14.3kg||21.1kg||27.9kg|
|Panel Type 5 Width 40cm||17.7kg||23.9kg||31.4kg|
|Panel Type 5 Width 45cm||19.5kg||26kg||32.6kg|
|Panel Type 5 Width 50cm||20.6kg||28.3kg||37kg|
Table of Weight for Corners
|Corner Weight Table||Width (cm)||Length (cm)||Weight (kg)|
|Outer Corner 5×5||6.3kg||9.3kg||12kg|
|Outer Corner 5×10||7.9kg||11kg||14.5kg|
|Outer Corner 10×10||9.2kg||14kg||18.4kg|
|Inner Corner 10×10||8.7kg||12.7kg||12.7kg|
Table of Weight for Edge Formwork Type 6
|Formwork Type 6 Weight Table||Width (cm)||Length (cm)||Height (cm)|
|Panel Type 6 Width 10cm||7.3kg||10.8kg||13.9kg|
|Panel Type 6 Width 15cm||8.8kg||13.1kg||17kg|
|Panel Type 6 Width 20cm||10.6kg||15.4kg||19.9kg|
|Panel Type 6 Width 25cm||12kg||17.7kg||22.8kg|
|Panel Type 6 Width 30cm||13.4kg||20.1kg||25.7kg|
|Panel Type 6 Width 35cm||15kg||22.3kg||28.6kg|
|Panel Type 6 Width 40cm||18.8kg||24.8kg||32.2kg|
|Panel Type 6 Width 45cm||20.3kg||27.1kg||35kg|
|Panel Type 6 Width 50cm||21kg||29.4kg||37.9kg|
Table of Weight for Curved Edge Formwork
|Curved Edge Formwork Weight Table||Width (cm)||Length (cm)||Height (cm)|
|Curved Edge Formwork 10cm||5.3kg||7.8kg||10.5kg|
|Curved Edge Formwork 15cm||6.7kg||10.2kg||13.5kg|
|Curved Edge Formwork 20cm||8.1kg||12kg||15.6kg|
|Curved Edge Formwork 25cm||9.5kg||13.8kg||18.2kg|
|Curved Edge Formwork 30cm||10.8kg||16.3kg||21.1kg|
|Curved Edge Formwork 35cm||12.5kg||18.6kg||23.7kg|
|Curved Edge Formwork 40cm||14.6kg||21kg||28.2kg|
|Curved Edge Formwork 45cm||16.2kg||23kg||30.5kg|
|Curved Edge Formwork 50cm||17.8kg||25kg||33.5kg|
Features of Modular Formworks
Modular formworks are one of the important features of concrete formworks, generally referring to their flexibility and ability to change shape. Below, I will examine the features of modular formworks based on the points you mentioned:
- Very High Strength: Modular formworks, due to the use of high-grade, thick sheets, have very high compressive and mechanical strength. This feature enables the formworks to exhibit adequate resistance when subjected to very high concrete pressures, such as in the construction of tall structures.
- Very High Installation and Connection Speed: Modular formworks, thanks to the use of detachable and replaceable components, have the capability for quick and easy assembly and connection. This speeds up the process of installing and disassembling the formworks, reducing project execution time.
- Various Dimensions and Sizes: Modular formworks have the ability to be adjusted to different dimensions and sizes. This feature implies versatility and flexibility in using these formworks, allowing them to be easily customized based on project requirements.
- Multiple Applications: Due to their versatility and flexibility, modular formworks are used in various types of constructions. They can be used in residential, commercial, industrial buildings, and even in tall and complex structures.
- Very Long Lifespan and Easy Mobility: Modular formworks, due to the use of high-quality materials and the ability to repair and reuse in case of damage, have a very long lifespan. Additionally, their design allows for easy movement on the construction site.
- Smooth and Uniform Surface: The use of modular formworks, due to their high precision and accuracy in construction and design, helps create a smooth and uniform surface on the outer layer of concrete. This feature can be very useful in situations where smooth and visually appealing surfaces are needed, such as in the interior design of a building.
- Economical: Modular formworks have significant economic advantages due to their high lifespan and ability to be reused in case of damage. These formworks usually lead to cost reduction in construction, as there is less need for replacement and procurement of new formworks, and maintenance costs are also reduced.
Disadvantages of Modular Formworks
- Heavy Weight of Formworks: One of the disadvantages of modular formworks is their high weight. This weight can pose challenges such as limitations in movement and the need for significant equipment and resources for transporting the formworks.
- Risk during Movement: Moving modular formwork components can carry risks and hazards, such as potential damage to the components and physical harm. Therefore, when moving modular formworks, coordination and sufficient caution are necessary.
A formwork belt, also known as a formwork bolt belt or a cutting wall belt, is recognized by various names. This belt is used for formwork in cutting walls using concrete formwork to assist the formwork and prevent it from opening. In the past, full-thread bolts, nut screws, and washers were used, passing through the center holes of the formwork, and were secured to the formwork by using a washer and a nut as the formwork support structure. However, nowadays, formwork belts with a hexagonal bolt head are used, which are placed between two formworks and connected to the edges of the formworks using a pin and hole. If a perforated concrete formwork is not used, a narrow belt or formwork bolt is used to connect two formwork panels. The formwork belt, formwork bolt belt, or cutting wall belt is used as a simple and efficient solution for cutting wall formwork.
Curved Edge Concrete Formwork
Curved edge concrete formwork is made solely from a cut of ST37 steel sheet. The edges of the formwork are bent using a bending machine, so the edge belts of the formwork are designed in a double shape. This formwork is produced using a pressing machine, and its edges are attached to the base sheet of the formwork and bent only using a bending press. The weight of each square meter of curved edge concrete formwork is approximately 37 kilograms, which is lighter compared to belt formworks. The weight of a formwork with dimensions of 50×100 is approximately 18.5 kilograms.
The edge belts used in curved edge formwork, which go around the base sheet of the curved edge formwork, are of 5 centimeters in width and 3 millimeters in thickness. Curved edge formwork is only produced with Type 5 belts, and Type 6 belts are not used in it. The internal filler belts of curved edge formwork have a thickness of 3 or 4 millimeters and are used to increase the strength of the formwork. The punches of the curved edge formwork are designed accordingly. In the northern half of the country, the use of concrete formwork for curved edges is more prevalent, and contractors show more interest in using this formwork in their concrete structure construction. The main reason for this prevalence is the production of this formwork by concrete formwork manufacturing companies in the northern region of the country. However, over time, the production of various types of modular formworks is underway in various parts of Iran. One of the challenges of curved edge concrete formwork is its non-repairable nature.