Steel Bridge Deck Forms: Eurocode EN 1993-2 & AS 5100 For Composite Construction-1

Steel bridge deck forms are a type of permanent or stay-in-place formwork system used for cast-in-place concrete layers on steel bridge decks, directly supported on steel beams or longitudinal ribs, serving both as temporary construction support and participating in structural load-bearing during the operational phase.

2.Product Highlights

✔Demolition-Free Design: Retained in the structure as a permanent formwork, eliminating the need for removal and saving labor and construction time.

✔Composite Load-Bearing Capability: The formwork works together with cast-in-place concrete, improving the overall stiffness and load-bearing capacity of the bridge deck.

✔Fast Construction Speed: Easy to install, with single panels quickly positioned and welded/bolted, significantly shortening the bridge deck construction cycle.

✔Smooth and Aesthetic Bottom: The bottom surface of the formwork does not require secondary treatment, directly forming a flat and clean underside appearance.

✔High Safety: Provides an immediate working platform for workers, reducing the risk of falls from height.

✔Strong Adaptability: Can be cut or perforated to accommodate various reserved embedded parts and irregular bridge deck profiles.

3.Product Materials

●Base Material: Hot-rolled or cold-rolled carbon structural steel, commonly Q235B or Q355B (or US standard ASTM A36, A1011).

●Steel Plate Thickness: Usually 0.75mm to 1.5mm, depending on the formwork span and concrete pour thickness.

●Surface Treatment: Hot-dip galvanizing (coating thickness ≥ 275 g/m²) or zinc-aluminum-magnesium alloy coating, providing long-lasting corrosion protection.

●Ribs/Stiffeners: Cold-formed from the same steel into trapezoidal or U-shaped ribs, resistance-welded to the bottom plate.

●Connectors: Galvanized self-tapping screws, stainless steel clips, or welded studs for connections between formwork panels and between panels and main beams.

4.Design Features

👉Cross-Section Type: Commonly closed trapezoidal ribs or open U-shaped ribs, rib height usually 50mm-80mm, rib spacing 150mm-300mm.

👉Standard Panel Widths: 450mm, 600mm, 750mm (to fit common steel beam spacing).

👉Standard Panel Lengths: Customized according to bridge girder spacing, typically 3m-12m.

👉Lap Design: Longitudinal ends set with lap edges (≥50mm), lateral sides with clips or overlapping edges to prevent concrete leakage.

👉Reserved Openings: Shear studs or equipment lifting holes can be pre-set, no secondary cutting required on site.

👉Calculation Basis: Verified separately for construction phase (wet concrete construction load) and service phase (composite section stress participation).

5.Core Advantages

⭐Low Overall Cost: Although unit price is higher than timber formwork, it saves labor for removal, shortens the construction period, and reduces scaffolding use, significantly lowering the overall cost.

⭐Quality Control: Factory-standardized production, high geometric accuracy, uniform coating thickness, with no common site issues such as timber formwork deformation or concrete leakage.

⭐Shortened Construction Period: Compared to timber formwork with full-support scaffolding, construction time for the bridge deck can be reduced by 40%-60%.

⭐Reduced Structural Weight: Thin steel plates (≤1.5mm) have minimal impact on the underlying structure compared to solutions that increase concrete slab thickness.

⭐Safe and Civilized Construction: No need to stockpile large amounts of timber formwork and steel pipe fasteners, reducing on-site fire hazards and improving site image.

⭐Green and Environmentally Friendly: Permanent formwork is entirely made of recyclable steel, no timber waste pollution, meeting green construction requirements.

6.Global Standards Compliance

7.Why Choose Us

Experienced: Many years of experience in steel formwork production and export, with projects covering highways, high-speed rail, and municipal bridge engineering.

Drawing Development Capability: Able to provide formwork layout drawings, detailed node drawings, and calculation books based on bridge design drawings, reducing on-site design workload.

Customized Production: Supports non-standard sizes, special openings, irregular shapes, and varying coating thicknesses according to customer requirements.

Full Process Quality Control: Incoming material inspection → steel plate stamping → resistance welding → coating inspection → factory pre-assembly, with full inspection of key processes.

Fast Delivery: Standard specifications kept in stock; customized orders completed and shipped within 15-25 days.