Box Girder Steel Formwork

Scope of Application

• Engineering Scenarios: Widely applied in key infrastructure projects such as expressway bridges, intercity railways, urban arterial roads, overpasses, viaducts and rail transit bridges.
• Product Specifications: Compatible with long-span cast-in-place box girders, precast small box girders, variable cross-section box girders and narrow-width box girders.
• Construction Scenarios: Suitable for mass standardized prefabrication in large precast girder yards as well as on-site in-situ pouring. Custom moulds with special shapes, variable spans, unique chamfers and reserved prestressing ducts can be produced according to project drawings to meet diverse construction requirements.

Structural & Technical Advantages

1. Core Structural Composition

1. Base Formwork System: Made of thickened high-strength steel plates, matched with I-beam & channel steel supports and adjustable outriggers. It delivers outstanding bearing capacity, precise elevation adjustment and strong anti-deformation performance during concrete pouring.
2. Side Formwork System: Designed in segmented standardized sections, reinforced by dual structures of outer adjustable inclined supports and bottom tie bolts. It effectively prevents concrete bulging and deformation to maintain smooth girder profiles.
3. Inner Formwork System: Divided into hydraulic folding type and pull-out split type. The hydraulic version adopts multi-section hinged folding structure with built-in synchronous hydraulic cylinders for integral contraction and extraction. The split type is ideal for narrow-width and long-span cast-in-place box girders.
4. End Formwork System: Precisely reserved ducts for prestressing strands and positioning seats for steel bar anchorage to ensure neat girder end cross-sections and compatibility with prestressing construction.

2. Core Technical Strengths

1. High Precision & Superior Forming Effect: Fully processed by CNC equipment, with formwork splicing gaps controlled within 1 mm. Standardized flanges and chamfers produce box girders with flat surfaces, sharp edges and smooth lines. Mass-produced girders maintain consistent appearance and require minimal post-pouring repair work.
2. High Rigidity & Anti-Deformation Capacity: Fabricated with national standard high-strength steel through integral welding. The structure features strong bearing capacity and uniform load distribution, resisting lateral pressure and self-weight of mass concrete to eliminate risks of mould bulging, displacement and deflection deformation.
3. Efficient Disassembly & High Safety Performance: Hydraulic folding inner formwork supports one-key section contraction and integral extraction from girder ends, eliminating manual disassembly inside narrow box chambers. It greatly reduces construction risks at heights and in confined spaces and doubles construction efficiency. Split inner formwork is easy to disassemble and adaptable to various site conditions.
4. Outstanding Durability & Cost-Efficiency: Equipped with full anti-corrosion coating to resist wind, rain, wear and aging. Each set can be reused for over 300 pouring cycles. Compared with traditional airbag and wooden formwork, it avoids common defects including air leakage, floating and dimensional deviation, significantly extending service life.
5. High Adjustability & Wide Compatibility: Adjustable support systems and inclined bracing structures can precisely meet requirements for pre-camber and girder lines. Custom moulds with arbitrary spans and cross-section sizes can be manufactured according to project parameters.

Comprehensive Application Functions

1. Precision Forming Function: Fully reproduces box cross-sections, curved surfaces, chamfers and various reserved hole structures of box girders, accurately controlling dimensional tolerance, lines and flatness of girders. It complies with bridge engineering acceptance standards and guarantees qualified prestressing tension and mechanical performance of girders.
2. Standardized Mass Construction Function: Standardized modular design enables convenient assembly, disassembly and relocation, fitting assembly-line mass prefabrication in girder yards, greatly boosting girder production efficiency and meeting tight schedules of large-scale infrastructure projects.
3. Safe & Stable Supporting Function: Multi-layer reinforcement and high-load bearing design steadily withstand impact force and lateral pressure during concrete pouring and vibration, ensuring full construction safety and eliminating hidden dangers such as formwork displacement and collapse.
4. Cost & Schedule Optimization Function: High turnover and low wear reduce expenses on formwork replacement, maintenance and concrete repair. Rapid disassembly shortens production cycle of each girder, saving overall construction duration and labor costs with superior comprehensive cost performance.
5. Compatibility with Special Construction Methods: Adaptable to various construction techniques including in-situ casting, precast erection and cantilever construction. Custom variable cross-section and special-shaped moulds meet construction demands for complex terrains and special bridge structures, applicable to high-end and special infrastructure projects.

Product Overview & Summary of Comprehensive Advantages