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Girder Shuttering: Strong and Reliable Formwork Solutions

Girder shuttering is the backbone of heavy-duty formwork for infrastructure projects—supporting bridge decks, pier caps, and tunnel linings with precision and safety. At Avanza Steel, our girder shuttering components are engineered from high-grade mild steel, fabricated per IS 1161 tolerances, and finished with industrial-grade dip-paint to withstand site rigors and repeated use Avanza brochure.

What Is Girder Shuttering?

 

Girder shuttering employs steel girders—also known as MS channels or beams—spanning between props or falsework to carry heavy loads of wet concrete. Unlike simple waler supports, these girders handle higher pressures and longer spans without deflection, ensuring uniform slab thickness and flawless finishes.

Core Advantages:

  • Exceptional Load Capacity: Supports concrete pressures up to 80 kN/m² when combined with appropriate props and waler systems.
     

  • Long Spans Without Intermediate Props: Typical spans up to 4.0 m, reducing foundation clutter beneath decks.
     

  • Rapid Setup & Adjustment: Standardized coupling points and bolted splice plates accelerate on-site assembly.
     

Durable Finish: Epoxy-primer dip-paint protects against abrasion and corrosion, extending lifecycle across hundreds of pours Avanza brochure.

Feature
Specification
Compliance
Fabricated to IS 1161 tolerances; welds per IS 4759 standards
Finish
Dip-painted epoxy primer (50 μm) or hot-dip galvanized (85 μm)
Load Rating
Up to 80 kN/m² (with 1.25× safety factor in design)
Splice & Coupler Details
M16 high-tensile bolted splice plates; captive nut couplers
Wall Thickness
5 mm – 6 mm
Section Profiles
U-channel (100×50×5 mm), I-beam (100×50×5 mm)
Lengths
Standard: 3 m, 4 m, 5 m; Custom up to 12 m
Material
MS channel & beam per IS 2062 Grade A

Technical Specifications

 Applications & Use Cases

  1. Bridge Deck & Pier Cap Formwork
    Girder shuttering spans piers to support deck slabs and haunches. Its high stiffness prevents sagging under heavy loads of wet concrete, crucial for highway and railway overpasses Avanza brochure.
     

  2. Tunnel Linings & Underpasses
    In tunnel construction, girders carry side-wall formwork and soffit shutters, enabling smooth, continuous casts without joint irregularities.
     

  3. Elevated Highways & Flyovers
    Adjustable girder lengths bridge between temporary towers or bracket scaffolds, allowing uninterrupted deck pours over traffic lanes.
     

  4. Pier Cap & Box Girder Projects
    Combined with haunch plates, girder shuttering shapes complex cross-sections of pier caps and box girders, ensuring dimensional precision.

Integration with Avanza Formwork Ecosystem

Avanza Steel’s girder shuttering is designed to work seamlessly with our broader formwork ecosystem:

  • Adjustable Props & Base Jacks: Provide vertical support and fine height tuning beneath each girder Avanza brochure.
     

  • Waler Support Channels: MS channel walers tie multiple girders into a rigid framework, distributing loads evenly.
     

  • Tie Rods & Anchor Nuts: Secure shuttering panels and girder ends back into surrounding structure for lateral stability.
     

  • Haunch Plates & Pier Cap Shuttering: Custom-formed steel plates interface with girders to shape haunch profiles precisely Avanza brochure.
     

Installation & Best Practices

  1. Site Layout & Preparation
     

    • Survey and level prop foundations; install MS base plates or sole boards.
       

    • Pre-assemble girder splice plates and captive nut couplers for rapid on-site use.
       

  2. Girder Placement
     

    • Position girders across props or falsework towers; ensure each end bears fully on the props.
       

    • Align girder centers using laser level to within ±2 mm over entire span.
       

  3. Splicing & Bolting
     

    • Slide adjacent girder ends together; insert M16 bolts through splice plates and torque to 30 Nm.
       

    • Check coupler engagement to avoid slippage under concrete loads.
       

  4. Panel & Haunch Integration
     

    • Attach haunch plates to girder webs at pre-marked locations; secure with M12 bolts.
       

    • Mount steel shuttering plates or plywood panels onto girder bearing angles, ensuring tight joints.
       

  5. Pour & Monitoring
     

    • Conduct a trial load test to verify deflection within allowable limits (L/360).
       

    • During pour, monitor for excessive vibration or panel movement; adjust props or walers as needed.

Maintenance & Inspection

  • Pre-Use Checks: Inspect girder webs for corrosion or bends; verify bolted splice integrity.
     

  • Periodic Inspection: Every 20 pours, perform non-destructive load testing on sample girders to 1.25× design load.
     

  • Post-Use Care: Clean concrete residue with low-pressure water; touch up damaged primer coats to prevent rust.
     

Storage: Store girders horizontally on timber supports in a dry, covered yard to avoid warping Shuttering vs. Centerin….

Ready to elevate your infrastructure formwork?


👉 Download the full Product Brochure for detailed part codes, dimensional drawings, and load charts.
 

👉 Contact our team at avanzasteel@gmail.com or +91 33 4000 7575 to request a site-specific quote, arrange a factory tour, or schedule an on-site technical consultation.

  • What makes Cuplock scaffolding faster than traditional tube-and-clamp?
    The cup-and-blade mechanism requires no loose bolts or nuts—each connection locks with a simple downward press, reducing assembly time by up to 40 % compared to tube-and-clamp systems.
  • Are Avanza Steel’s Cuplock standards compatible with other brands?
    Yes, our Vertical Cuplock standards and Horizontal Ledgers maintain a strict tolerance of ± 0.5 mm on cup dimensions and blade ends, ensuring cross-compatibility with any IS 12873‐compliant Cuplock systems.
  • How do I calculate the number of ledgers needed per level?
    Divide the total bay length by 0.50 m (cup spacing) to get the number of ledger connections. For instance, a 3 m bay requires six ledgers per level—plus one spigot pin above for extension continuity.
  • Can Cuplock scaffolding be used on curved façades?
    Yes. Swivel clamps in combination with half-meter cup spacing allow you to create curved geometries. We recommend a maximum curvature radius of 2 m to maintain load distribution and minimize component stress.
  • Where can I find detailed part codes and weights?
    Refer to our Avanza Steel Product Brochure (page 5–6) for the full list of Vertical Cuplock codes (AV-05 to AV-30), corresponding weights, and all complementary accessories.
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