GRP Permanent Formwork

Permadec Formwork Panels are primarily used as permanent infill formwork between bridge beams.

Their strength, lightweight composition, durability, and integrated steel reinforcement make them highly versatile — extending their application beyond bridge structures to include platforms, ramps, floors, sewage treatment plants, culverts, jetties, tanks, and capping slabs or roofs.

Permadec Australia offers bespoke panel design tailored to meet specific project requirements. For design support or to discuss your application, contact Permadec on +61 2 9052 4975 or [email protected].

Please note: All panel information is indicative only. For finalised specifications and detailed design, please consult directly with the Permadec team.

Video:

System Overview

Lifting and Handling

Lifting Frame Installation

Lifting Holes can be included in vertical ribs if required

Figure:

Lifting Frame Panel Installation

Manual Installation

Check weight of panel prior to manual lifting

Figure:

Manual Panel Installation

Cutting of Panels

Permadec panels can be cut using a standard Stihl saw (or similar). A steel blade should be used; bearing in mind the panel has a stone like texture with steel content.

For personal safety, please ensure suitable protective clothing, goggles, respiratory mask, leather gloves etc. as standard to be worn for all cutting operations. Should you cut though the ribs of the panels, please note that both ends of each rib still need to be supported prior to concreting. On the cut edges this can normally be supported either off the diaphragm shutter, alternatively by using the shutter to cast a rebate into the concrete to provide a supporting edge. Cutting through a rib will also expose the steel inserts; these should be painted with cold zinc metal paint such as ‘Galvafroid’ or others for protection prior to pouring concrete. If you are cutting more than 2 ribs from a panel or plan to cut for openings, then please check with Permadec that this is suitable. PLEASE NOTE: The responsibility for the implementation of health and safety regulations lies solely with the Contractor once the formwork has been delivered. Panels should be free of all traces of oil and grease at the time of concreting. Any damaged panels should be rejected prior to installation. When placing panels, ensure that the bearing cover is equal on both sides. A minimum bearing of 30mm to Ideally a min bearing of 30mm is required on the surface of the concrete rebate or the steel beam flange. Concrete should be placed and compacted in accordance with the requirements of local codes and should not accumulate in heaps or be dropped from heights greater than the code allows.

Figure:

Cutting panels with a Standard Stihl saw

Sealant Data

Sealants should be applied to steel soffits or concrete rebates once the formwork has been made available locally. Permadec recommends 10 to 20 linear metres to be laid at once, depending on conditions applicable at the time of laying. This can be increased once fluency has been established from the repetitive nature of the work. The formwork panels are to be lifted into position and rested on the sealant. Care should be taken to ensure the adequate bearing to the ends of the formwork panel. The sealant positioned between the panels at the point where the panels butt up against each other should be applied at any point prior to pouring concrete and after positioning. It should be noted that a nominal gap of an average 2mm may appear between the panels, this is anticipated. Once the panel is correctly positioned it is capable of supporting the live weight of the operative and can be walked upon. Caution should be observed working near the edges of panels, especially at heights.

Permadec Butyl 2 x 6 mm Ø Twin-track adhesive butyl bead x 8 m

Figure:

Permadec Butyl 2 x 6 mm Sealant

Apply Permadec Butyl 2 x 6mm Ø Twin-track adhesive butyl bead x 8 mtr length for sealing between Permadec panel and steel beam flange, or concrete rebate. This acts as a long term seal to stop moisture travelling from the soffit of the panels to the beam flange, therefore cannot reach past this to concrete or onto studs/rebar.

Description

High performance strip-bead sealants based on new technology which includes high strength rubber compounded with selected fillers and plasticisers to give very good movement accommodation and adhesion to most building materials.

For use where strong jointing sealants is required which offers good bonding characteristics. Good joint performance requires good initial contact between the strip and both surfaces of the joint.

Approved by: Water Research Council, Nat, Fed Roofing.

Performance: Quality Assured to ISO9001:2000

Movement accommodation +/- 15%

Tensile Strength: 98 kPa

Shear Strength: 46 kPa

Outdoor service temperature: -40°C to +90°C

Permadec Grey adhesive butyl tape with polyester backing 50mm wide x 35mtr length

Figure:

Permadec Grey adhesive butyl tape

Permadec Grey Adhesive Butyl Tape with polyester backing 50mm wide x 35mtr strips with clear polyester backing to one side for sealing joints between butt joints of panels. This stops grout loss and also acts as a long term seal to stop moisture ingress to concrete or rebar.

Application

Surface preparation: All surfaces should be clean, dry and free from frost, grease and loose materials. Apply directly from the reel onto one surface pressing to give adequate initial adhesion. Push firmly to ensure good contact with full area of strip along the length of the joint.

Application temperature: +5°C to +30°C