Wall Panel Steel Formwork

Precast Concrete Wall Panel Molding System Product Brochure

1. Product Introduction

In the prefabricated construction industry, Wall Panel Steel Formwork is the core tooling for producing precast exterior walls and shear walls. Manufactured from high-strength structural steel such as Q345B and Q390B, this product is fabricated via precision blanking, CNC cutting, automated welding, and stress relief processes.

Designed under the principle of"one mold per component", it is engineered based on the geometric configuration, structural joints, and molding quality requirements of precast walls. The 3D split design, including panels, supports, tie bolts, and positioning pins, ensures the mold maintains rigidity and stability during concrete pouring, preventing deformation and grout leakage, and ultimately delivering high-precision, consistent precast wall panels.

2. Product Parameters & Specifications

3. Product Usage Instructions

3.1 Pre-operation Preparation

• Mold Inspection: Inventory all components including panels, supports, bolts, and pins. Check welding quality for cold welds and cracks, and inspect for surface damage such as corrosion and deformation.
• Cleaning & Lubrication: Remove residual concrete and debris. Apply release agent, water-based or oil-based selected by concrete strength, to formwork contact surfaces.
• Rebar & Embedded Parts Positioning: Place the rebar skeleton and embedded parts including sleeves, junction boxes, and connectors into the mold per design coordinates, fixed by magnetic clamps and positioning frames.

3.2 Mold Closing & Reinforcement

• Panel Splicing: Align panels per the disassembly drawing, insert positioning pins and bolts, ensuring tight joints with gap ≤1mm.
• Support System Installation: Arrange diagonal and horizontal supports. Adjust tie bolt pre-tension controlled by torque wrench, typically 30–50N·m, to prevent mold expansion during pouring.

3.3 Concrete Pouring

• Layered Pouring: Use pumping or chute for layered pouring, max 500mm per layer. Vibrate evenly along the inner mold surface, keeping vibrators at least 100mm away from the formwork.
• Temperature Control: Apply sunshade and water-sprinkling in temperatures above 30°C. Apply thermal insulation and heating measures in temperatures below 5°C to prevent early-age cracking.

3.4 Demolding & Curing

• Stripping Timing: Demold when concrete strength reaches ≥75% of design strength, or per code: ≥1.2MPa for non-load-bearing walls, ≥2.5MPa for load-bearing walls.
• Demolding Sequence: Remove tie bolts first, then loosen supports, and finally remove panels one by one. Avoid excessive prying that may damage molds or components.
• Curing & Turnaround: After demolding, clean the mold, scrape off residues, touch up paint, and store in a dry area. Re-inspect before reuse and repair if necessary.

4. Application Scenarios

• Prefabricated Residential Construction: Production of exterior and party wall panels for precast shear wall systems and assembled monolithic structures.
• Public Buildings: Prefabrication of exterior walls and elevator shaft wall panels for schools, hospitals, and office buildings.
• Industrial Buildings: Production of prefabricated exterior walls with vents and equipment openings, and fire-rated wall panels for factories.
• Urban Renewal: Customized production of prefabricated interior and exterior walls for existing building renovation with special-shaped openings and finishes.

5. Safety Precautions

5.1 Operational Safety

• Use dedicated rigging including wire ropes and shackles when handling and lifting molds. Single-point lifting is strictly prohibited. Operators must wear safety helmets, safety shoes, and gloves.
• Erect scaffolding and safety nets and fasten safety harnesses for work at height above 2m. Set up warning zones during mold closing and demolding, and prohibit unauthorized personnel from entering.

5.2 Process Safety

• Strictly control concrete slump within ±20mm during pouring to avoid excessive lateral pressure causing mold expansion.
• Avoid violent prying during demolding to prevent damage to molds and components. Stack removed molds no higher than 1.5m to prevent collapse.

5.3 Maintenance Safety

• Regularly inspect welding joints with annual NDT testing and conduct quarterly sampling of bolt strength. Touch up paint or replace corroded parts promptly.
• Mold storage sites must be hardened, well-drained, and located away from fire sources and corrosive media.

6. OEM & ODM Customization Services

We offer full-process customization services to meet the differentiated needs of global clients:

• Design Customization: 3D split design including structural calculation and joint optimization based on your BIM models or 2D drawings, with CAD/PDF deliverables and process cards.
• Material Customization: Q345B, Q390B, 304 stainless steel, and low-temperature steel such as 16MnDR available for different climates and corrosion environments.
• Size Customization: Custom molds by actual component dimensions and weight up to 50t, supporting extra-large wall panels up to 12m×3m×0.5m.
• Surface Treatment: Hot-dip galvanizing, epoxy coating, powder coating in RAL colors, and Teflon coating for food and clean room requirements.
• Accessory Customization: Custom tie bolts, positioning pins with ±0.1mm precision, magnetic clamps with ≥50kg holding force, and eco-friendly release agents.
• Packaging & Labeling: Export-grade wooden crates with anti-rust film, laser-engraved logo, batch number, and technical parameters, with multilingual manuals available.

7. Why Choose Us?

• Industry Experience: Over 10 years of R&D and manufacturing experience in precast formwork, serving over 20 countries worldwide with more than 10,000 mold sets delivered.
• Technical Strength: In-house BIM design team and CNC machining center enabling full-process digitalization from design to manufacturing to inspection, with precision error ≤2mm.
• Quality Assurance: ISO 9001 certified. Each mold undergoes three-stage inspection plus third-party UT/MT flaw detection before shipment, backed by a 1-year warranty.
• Service Response: 7×24 technical support with 48-hour after-sales response. On-site installation guidance, mold repair, and refurbishment services available.
• Cost Advantage: Factory-direct supply with no middlemen and tiered discounts for bulk orders. Long mold life of ≥200 cycles reduces per-use cost.