THE FORMWORK
NOE board ®
Technical Information
Dated: 12.2011
Technical Information NOEboard
NOEboard – innovative construction NOEboard is a high-tech formwork facing consisting of a thermoplastic facing, a fibreglass loadbearing layer and a PU-foam core. This material combination gives NOEboard a number of outstanding properties. One of the most important is minimal water absorption, which prevents swelling and means the dreaded rippling effect is now a thing of the past. In addition, the innovative NOEboard sandwich construction combines low weight with good loadbearing capacity and ease of processing and handling.
Figure 1: Construction of NOEboard formwork facing Thermoplastic facing, Fibreglass loadbearing layer, PU foam
NOEboard – no swelling Water has no effect on NOEboard formwork facing. Conventional formwork facings usually consist of plywood. Plywood absorbs moisture and swells. This causes dimensional change. A 10% increase in moisture content brings with it expansions of 0.15% longitudinally (4 mm for l = 2650 mm) and 4% in thickness (0.8 mm for d = 21 mm) A further unpleasant accompaniment of swelling is rippling. This happens when the wood swells up at unprotected spots, for example where damage has occurred to the surface coating or the board edges have been left unvarnished. Bulges protrude parallel to fibres and leave ugly marks in the concrete.
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Figure 2: Rippling in plywood formwork facing
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Technical Information NOEboard
There is no danger of this with NOEboard because it does not absorb water. Plywood facings are usually coated with phenolic resin. This coating becomes worn to various degrees after time. As a result, the plywood facing has varying suction properties. The consequence is that new plywood formwork facing creates a different surface colouration to that of used facing. In contrast, the concrete colouration does not change when NOEboard is used, because the suction of the formwork facing remains consistently low. NOEboard does not swell, which allows the board to be an extra 1 mm thick, thus increasing the stiffness of the formwork panels. Further plus points include a less noticeable impression of the formwork frame in the concrete and an improved concrete surface.
Figure 3: Rippling impressions in concrete
Figure 4: NOEboard formwork facing absorbs no moisture and therefore does not swell
Figure 5: With increasing age and damage, plywood formwork facing absorbs moisture and swells
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Technical Information NOEboard
NOEboard – low weight NOEboard weighs less than plywood formwork facing. This is an important factor in how well formwork handles on site is its weight. With its very favourable weight characteristics, NOEboard excels on this point as well: A typical 21-mm-thick plywood formwork facing weighs 14.7 kg per square metre. In comparison, the 1-mm-thicker NOEboard (22 mm) is almost two kilos lighter per square metre (12.8 kg/m²)! The maximum board format is 1500 x 4000 mm for thicknesses between 10 and 22 mm. As a rule, board thicknesses are chosen to be 1 mm thicker than plywood panels, because NOEboard does not swell. The structural stiffness of traditional plywood panels depends on their moisture content. In other words, the higher the moisture content of the plywood panels, the lower their strength. For example, their bending deflection increases by 20% when their moisture content rises by 12%. NOEboard, on the other hand, absorbs no water and therefore water cannot affect its strength! Despite its higher loadbearing capacity, NOEboard is lighter than many other formwork facings. The importance of this should not be underestimated when it comes to handling manually erected formwork.
Facing thickness mm
Approx. weight ca. kg
Bending modulus N/mm²
Shear modulus N/mm²
Bending stress N/mm²
10
07,40
4400
137,90
83
10
07,40
3800
137,90
74
13
08,22
6100
111,50
80
13
08,22
4400
111,50
47
16
09,50
5400
087,50
78
16
09,50
3900
087,50
45
22
12,80
5300
057,20
82
22
12,80
3300
057,20
47
Longitudinal Transverse Table 1: Technical data NOEboard
The following example makes clear the difference in weight: A formwork element 2.70 m high and 0.90 m wide has an area of 2 2.43 m . Thus a lower weight per 2 unit area of 1 kg/m of formwork facing approximates to an element weight reduction of 2.4 kg, while a higher weight per unit 2 area of 2.1 kg/m leads to a formwork element weighing 5 kg more.
The weight advantage gained from NOEboard varies, depending on the material type and facing thickness. Compared with traditional birch plywood formwork facing, the advantage can be up to 1.9 2 kg/m . And against other fully synthetic formwork facings, NOEboard is between 0.8 and 2.3 2 kg/m lighter.
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Technical Information NOEboard
NOEboard – nailed or screwed Just like plywood panels, NOEboard can be nailed or screwed in place. As the holding force on fixings is somewhat below that of wood, we recommend the use of approximately 30% more nails or screws with NOEboard.
Figure 6: NOEboard can be nailed or screwed. The advantages: It does not splinter and absorbs no water
Figure 7: Plywood facing splinters on the back. Water entering through the nail hole causes the facing to swell.
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Technical Information NOEboard
NOEboard – simple to clean NOEboard can be cleaned in several ways. Cleaning the NOEboard surface is extremely simple and can be done on site in the same way as for plywood panels. Cleaning with water is an excellent option in the factory or building yard. There are two methods: 1. High-pressure cleaning A high-pressure cleaner with a fan jet nozzle or a high-pressure surface cleaner with flat nozzles is suitable. Max. pressure 500 bar.
Figure 8: Cleaning with a high-pressure cleaner fitted with a fan nozzle
2. Surface cleaning A rotation cleaner with cleaning pad and water is a suitable method.
Figure 10: Cleaning with a high-pressure surface cleaner fitted with a fan nozzle
Figure 9: Rotation cleaner with cleaning pad
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Technical Information NOEboard
NOEboard – easy to use Repair: The frequency of repair is reduced and the repair itself is simple. NOEboard offers another advantage over conventional plywood formwork facing: Drilled holes and screw holes do not have to be repaired. Smaller holes close themselves during the next concreting operation, while projecting defects can be repaired simply using a hotmelt process. A suitable repair kit is available from NOE. Note: NOEboard is made from polyurethane (PU) and can be repaired by gluing. Release agent: Any release agent on the market can be used for NOEboard, so far all have been found to be compatible. However, we recommend that you carry out a test first. In addition, the release agent film should be applied evenly and thinly over the formwork facing, exactly as with plywood.
Figure 11: By using NOEboard, the silicone joint can be smaller than it would be with plywood formwork facings
Installation:
Large formwork elements:
NOEboard has a host of characteristics that make its handling considerably simpler. It does not swell and has a coefficient of thermal expansion similar to that of steel. Therefore the silicone joints can be thinner than is possible with plywood.
Large formwork elements with widths greater than 1500 mm can be fabricated using tongue and groove joints, which allows compliance with very tight flatness tolerances.
In contrast to other synthetic formwork facings, NOEboard provides a good bonding substrate for silicone. This means the joints between frame and panel can be filled or sealed with silicone.
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Technical Information NOEboard
NOEboard – resistant to heat and cold
NOEboard – has a particularly scratch-resistant surface
NOEboard formwork facing can be used in a temperature range of –20 °C to + 80 °C.
Resistance: Resistant to mechanical effects
Within this range, NOEboard can be used without limitations. Even at –20 °C, NOEboard can be nailed or screwed without temperature-related embrittlement.
NOEboard is very resistant to normal mechanical effects encountered on site and has a particularly scratch-resistant surface. The innovative facing skin has no tendency to splinter.
The coefficient of thermal expansion of the formwork facing is extremely small at 11 µStrain/K. The change in length is comparable with that of steel, which results in no gaps forming in the steel frame as a result of temperature differences.
face changes due to swelling. No rippling either. In contrast, moisture penetrating plywood formwork facings or synthetic composite boards with timber cores can cause them to swell and can give rise, in some circumstances, to rippling.
With NOEboard, sites of minor damage, such as nail holes, close themselves during the next concrete pour. There is no risk of sur-
NOEboard – sustainable The best way to recycle NOEboard formwork facing is to use its energy content.
Figure 12: Nail or screw holes close themselves during the next concrete pour
NOEboard can be simply disposed of by incineration with ordinary refuse at temperatures of over 800 °C. The waste gases generated by this process are harmless to health. European Waste Code EWC 170203 applies to the panels.
NOEboard – UV resistant The resistance of the surface to ageing caused by UV radiation has been proved in tests. Figure 13: Poker vibrator damage to a NOEboard formwork facing surface
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Technical Information NOEboard
“Burns” caused by internal poker vibrators to plywood formwork facings normally lead to the top veneer being damaged beyond repair. The contractor usually opts to replace the facing or undertake a major repair. With NOEboard, although the poker roughens the surface, the formwork facing can continue to be used. The facing skin can be made smooth again using a K 60 or K 80 sanding pad. Compressive strength: NOEboard has a high compressive strength. This has been proved by NOE in countless tests to determine the impression depth under practical conditions. Chemical resistance: The surface has a very good resistance to aqueous media including dilute acids/alkalis and washing liquors. It also has good resistance to oils/grease, alcohols and aliphatic hydrocarbons. Discolouration of the concrete surface due to the formwork facing skin does not occur with NOEboard. Loadbearing capacity: Despite its light weight, NOEboard excels in its
loadbearing capacity (bending stresses in the direction of span). Thermal expansion: The low coefficient of thermal expansion of NOEboard, differing by less than 10% from that of steel, minimises temperature-related stresses and the gaps between the facing and steel frames, providing that a silicone joint filler is not used. Durability: NOEboard is one of the newer products in the NOE-Schaltechnik range and has been in use on sites since 2008. Several years of experience has shown that the durability of this fully synthetic facing is considerably greater than conventional plywood formwork facings. NOE developed and carried out load tests to investigate the long-term performance of the formwork facing. As part of these tests, NOEboard was placed in a drum along with other facings under identical conditions and subjected to the effects of falling and abrading concrete and steel components.
The results of this series of tests showed that NOEboard is very suitable for resisting the loads from concreting and from other site operations. This leads to us to expect a correspondingly long service life and confirms the findings of years of practical experience.
The first objective of these practical tests was to simulate the loads
Figure 14: Damage to the surface of plywood facing caused by a poker vibrator
Subject to technical modifications.
that act on the formwork facing when concrete is poured and compacted. The second objective was to investigate other mechanical effects that occur on a construction site. This includes contact with reinforcement and poker vibrators, which can come into direct contact with formwork facings, and the effect of stacking formwork elements on top of one another. In addition, a further in-house test determined the effect of a water jet from a high-pressure cleaner striking the facing.
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Figures 15 and 16: Test apparatus to determine wear
Dated: 12.2011 9
Technical Information NOEboard
NOEboard – three important points
n NOEboard excels in particular
because of its good loadbearing capacity (bending in the direction of span) combined with low weight.
n Because the fully synthetic
board does not shrink or swell and its coefficient of thermal expansion differs by less than 10% from that of steel, stresses and gaps between the formwork facing and frame are minimised.
n Many years of practical experi-
ence has shown that NOEboard is very compatible with the loads encountered on site. Further in-house tests indicate it has a correspondingly long service life.
How do you repair NOEboard? NOEboard has the advantage that considerably fewer repairs have to be carried out compared with plywood formwork facings. The reason for this is that NOEboard does not absorb water and therefore does not swell. For this reason, nail holes do not have to be repaired. They close themselves during the next concrete pour Only major damage needs to be repaired. The hotmelt method of repair is very simple and is used in the same way as for plywood formwork facings.
NOEboard – simple to repair 1. Mill out the repair site to a depth of 3 mm using a router.
2. Fill the repair site with NOEboard repair filler (Part No. 844070). To reduce the cooling time, we recommend that the repair site is cooled with a NOEboard cooling block (Part No. 397010).
3. Allow to cure for one minute. Then smooth the repair site using a NOEboard trimming cutter (Part No. 397000).
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Figure 17: Milling out the repair site
Figures 18 and 19: Filling the repair site with NOEboard repair filler and removing the heat with NOEboard cooling blocks.
Figures 20 and 21: Smoothing the repair site with a NOEboard trimming cutter
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THE FORMWORK
NOE-Schaltechnik Georg Meyer-Keller GmbH + Co. KG Kuntzestr. 72, 73079 Suessen, Germany Tel. +49 7162 13-1 Fax +49 7162 13-288
[email protected] www.noe.de www.noeplast.com
Austria NOE-Schaltechnik ww.noe-schaltechnik.at
[email protected]
Croatia NOE oplatna tehnika d.o.o. www.noe.hr
[email protected]
Poland NOE-PL Sp. Zo.o. www.noe.com.pl
[email protected]
Belgium NOE-Bekistingtechniek n.v. www.noe.be
[email protected]
Czech Republic ISD-NOE www.isd-noe.cz
[email protected]
Russia NOE St. Petersburg
[email protected]
Brasil Mills do Brasil Estruturas e Serviços Ltda www.mills.com.br
[email protected]
France NOE-France www.noefrance.fr
[email protected]
Bulgaria NOE-Schaltechnik www.noebg.com
[email protected]
Netherlands NOE-Bekistingtechniek b.v. www.noe.nl
[email protected]
Serbia NOE Sistemske Oplate d.o.o. www.noe-scg.com
[email protected] Switzerland NOE-Schaltechnik www.noe.ch
[email protected]
NS/e 5337400 12.11 2000 RR Subject to technical modifications.
