plastic wall formwork how to install and used
In conclusion, the installation and usage of plastic wall formwork require strict adherence to the standardized step-by-step process. By assembling panels accurately, connecting them properly with through-wall ties and plastic sleeves, reinforcing with steel back beams and diagonal braces
8/6/20264 min read
Installation and Usage Guide for Plastic Wall Formwork
Installation and Usage Guide for Plastic Wall Formwork
Plastic wall formwork has emerged as a preferred choice in modern construction, owing to its lightweight nature, excellent durability, and high reusability. Proper installation and correct usage are critical to guaranteeing the quality of concrete walls and preventing common defects such as leakage, deformation, and uneven thickness. This guide systematically outlines the step-by-step installation and usage process of plastic wall formwork, enabling construction personnel to operate efficiently, accurately, and safely on site.
Step 1: Assemble Plastic Wall Panels to the Required Wall Dimensions
The first step in installing plastic wall formwork is to assemble the panels in accordance with the design dimensions of the wall. Featuring standardized sizes, plastic wall panels can be flexibly combined to form walls of any integer or 50mm-increment dimensions. The assembly process follows three key sub-steps to ensure accuracy and stability:
Pre-assembly Inspection: Thoroughly check all panels for damage, cracks, or deformation to ensure they meet quality standards. Damaged panels must be replaced to prevent concrete leakage or formwork instability.
Panel Layout and Splicing: Lay out the panels on a flat, clean surface according to the wall layout drawing. Align the edges of adjacent panels tightly; most plastic wall panels are equipped with interlocking structures or connecting grooves for quick and secure splicing. For walls with special shapes or openings, cut the panels accurately per design requirements and smooth the cut edges to avoid leakage.
Position Marking: Once the panels are assembled into the desired wall size, mark the positions of subsequent connecting components (through-wall ties, steel back beams, etc.) to facilitate the next installation step and ensure alignment accuracy.
Throughout the assembly process, continuously check the verticality and flatness of the panels to avoid misalignment, as this can directly affect the dimensional accuracy and surface quality of the final concrete wall.
Step 2: Connect Panels with Through-Wall Ties and Control Concrete Thickness with Plastic Sleeves
Once the wall panels are fully assembled, the second step is to connect the two opposite panels with through-wall ties. This step is crucial for maintaining the overall stability of the formwork and precisely controlling the thickness of the concrete wall. It includes two core operations that must be executed with care:
Drilling and Tie Installation: Drill holes at corresponding positions on the two panels according to the design spacing of through-wall ties (usually 600mm-800mm, adjusted based on concrete pressure). Insert the through-wall ties straight through the holes, ensuring no bending that could affect structural stability.
Plastic Sleeve Placement: Slide plastic sleeves over the through-wall ties between the two panels. The length of the plastic sleeve is precisely matched to the design thickness of the concrete wall, ensuring the distance between the two panels aligns with the required wall thickness. Ensure the sleeves are in close contact with the inner surfaces of the panels to avoid gaps.
After completing the installation of through-wall ties and plastic sleeves, use a measuring tool to check the uniformity of the wall thickness and confirm it meets the design standards. It is important to avoid over-tightening the ties at this stage, as this may cause deformation of the plastic panels and compromise the formwork’s integrity.
Step 3: Reinforce Steel Back Beams and Secure with Nuts on Screw Rods
To enhance the overall rigidity and stability of the formwork and effectively resist the lateral pressure exerted by fresh concrete during pouring, the third step is to install and reinforce steel back beams. The detailed reinforcement process is as follows:
Beam Placement: Position steel back beams (usually made of channel steel or square steel) horizontally or vertically on the outer surface of the plastic panels, with a spacing of 500mm-700mm. Ensure the beams fit tightly against the panels to distribute concrete pressure evenly.
Fastening and Tightening: Secure the steel back beams to the through-wall ties using screw rods and nuts. Tighten the nuts gradually and symmetrically to avoid uneven stress on the formwork, which could lead to deformation or bulging.
Gap Inspection: During tightening, check the flatness of the panels and the tightness of the connection between the steel back beams and the panels. If gaps are found, adjust the nuts promptly to ensure a firm connection.
This step is critical for preventing the formwork from shifting or deforming under the pressure of fresh concrete, thus ensuring the structural integrity and dimensional accuracy of the finished wall.
Step 4: Perform Secondary Reinforcement with Diagonal Braces
The final step is to conduct secondary reinforcement with diagonal braces, which further enhances the stability of the formwork—especially for high walls or walls subjected to large concrete pressure. The installation and adjustment process includes three key points to ensure optimal reinforcement effect:
Braces Installation: Install diagonal braces between the steel back beams and the ground or adjacent structural components, with a spacing of 1000mm-1500mm. Fix one end of each brace to the steel back beam with a bolt, and anchor the other end to a reliable support point on the ground.
Angle and Length Adjustment: Ensure each brace forms a 45°-60° angle with the ground. Adjust the length of the brace to make it tightly support the formwork, then lock the adjusting device to prevent loosening during concrete pouring.
Final Inspection: After installation, recheck the verticality of the wall formwork using a theodolite or plumb line. Adjust the diagonal braces if necessary to ensure the wall is perfectly vertical. Additionally, inspect all connecting parts (through-wall ties, nuts, braces) to confirm they are securely fastened before proceeding with concrete pouring, as loose connections may lead to formwork displacement during pouring.
Usage Precautions
To ensure construction safety and the quality of the concrete wall, the following precautions must be strictly followed during concrete pouring and formwork removal:
Concrete Pouring Control: Control the pouring speed to avoid excessive pressure on the formwork; rapid pouring may cause formwork bulging or leakage. Use a vibrator to compact the concrete evenly, but avoid direct contact with the plastic panels to prevent surface damage or deformation.
Formwork Removal: After the concrete reaches the required strength (usually not less than 75% of the design strength), remove the formwork in the reverse order of installation. Handle the components with care to avoid damaging the concrete surface or the formwork itself, which could affect subsequent reuse.
Cleaning and Storage: Thoroughly clean the plastic panels and steel components after removal to remove concrete residue, as residual concrete may affect the splicing accuracy of subsequent use. Store them in a dry, well-ventilated place to prevent rusting or damage, ensuring they can be reused for subsequent projects.
In conclusion, the installation and usage of plastic wall formwork require strict adherence to the standardized step-by-step process. By assembling panels accurately, connecting them properly with through-wall ties and plastic sleeves, reinforcing with steel back beams and diagonal braces, and following the specified usage precautions, construction personnel can effectively ensure the quality of concrete walls, reduce material waste, and improve overall construction efficiency.