StayForm is the most cost effective solution for forming bulkheads, tunnels or any below-grade structure. StayForm is easy-to-cut when forming construction joints, keyways and curved shapes, saving valuable time. StayForm eliminates the need for traditional concrete forms that have to be removed, cleaned and transported. Using StayForm can result in up to a 35 percent savings in labor; and StayForm is always an American made product.
When a contractor has to form a concrete wall within a few inches of an existing structure, Stay-Form is an excellent product. By utilizing Stay-Form with rebar studs, hook ties, and a modular form system, a one-sided form or blindside wall can be constructed. If you do not have the luxury or room to strip formwork, Stay-Form is the right product for the job.
- The V ribs run perpendicular to the vertical rebar studs which gives the Stay-Form the rigidity to withstand the concrete pressures (see detail).
- Stay-Form can be slit with tin snips or handheld grinder to accommodate the rebar hook tie (see detail).
- Stay-Form is commonly used for concrete pour rates of 4 to 7 feet per hour.*
Stay-Form is an excellent product for forming bulkheads because it does not have to be stripped out after the concrete pour. (Plywood and modular forms have to be stripped.) There is also no scrabbling required in order to prepare the surface for the next pour.
- Rebar or metal fabricated bracings are left in place – no stripping is required.
- The sheets are lightweight and can easily be bent to form a keyway.
- Stay-Form can be cut in order to accommodate any rebar or conduit penetrations.
- Visual inspection of the concrete consolidation is also accomplished due to the openings in the mesh.
Test reports prove that when forming bulkheads, Stay-Form provides 21% greater shear bond strength to concrete than does plywood.
When forming below grade structures like a pile cap, Stay-Form can save a considerable amount of time and labor. You have no labor for stripping forms. If rebar or metal is used for bracing, it stays in place. (Wood bracing has to be removed.) Some contractors backfill around the Stay-Form prior to the pour therefore they minimize bracing and prevent a blowout of the form.
- Contractors can cut the V ribs in order to bend the sheets to any shape.
- During the concrete pour any water in the form will run out of the Stay-Form as it is displaced by the concrete (no pumping it out).
- Concrete finish is not a concern since backfill or a slab-on-grade concrete pour is a typical design with a pile cap foundation.
Grade beams are easily formed using Stay-Form and rebar or lumber as bracing. Some contractors prefer to backfill 75 to 90 percent up the grade beam prior to the concrete pour in order to minimize the required bracing. Backfilling acts as the bracing which will stop the formwork from spreading during the pour.
- Attaching with tie wire around the Stay-Form ribs and rebar or lumber makes installation easy.
- Since the Stay-Form is not stripped, the excavation required is less than what would be needed using conventional formwork.
- Some contractors use Stay-Form to hold the surrounding soil from falling in on the grade beam excavation and reinforcing steel.
Electrical contractors find it easier to form ductbanks with Stay-Form than with plywood or conventional forming systems. The learning curve to train personnel how to install Stay-Form is quick, and the labor savings are significant due to the fact that form stripping is not necessary.
- Attaching Stay-Form to rebar supports is easily accomplished with tie wire.
- Attaching a 2×4 (from rebar to rebar) across the top of the ductbank prevents the formwork from spreading during the pour.
- Visual inspection of the concrete consolidation is also an advantage when using Stay-Form in order to avoid honeycombing.
Contractors frequently use Stay-Form on bridge projects to form footings, edge forms and bulkheads. When building a cast-in-place segmental box girder bridge, forming the bulkheads has significant labor savings because the bulkhead does not have to be stripped.
- Test reports prove that when forming a bulkhead, Stay-Form provides 21% greater shear bond strength to concrete than does plywood.
- Unlike plywood-formed bulkheads, Stay-Form bulkheads do not require scabbling of the concrete. This means additional labor savings.
Using Stay-Form as a backstop for shotcrete applications has many advantages. It can be bent to any radius and is easily wire-tied to the reinforcing steel that will form the structure. The open herringbone mesh and V ribs do a great job in catching the shotcrete while minimizing the amount of rebound.
- To visually see both sides of the shotcrete formwork is advantageous.
- The lightweight sheets are user-friendly to install for any shotcrete application.
- Contractors can shotcrete one side of the formwork one day and the other side the following day.