Culvert
Formwork

Culvert formwork is a purpose-built system for constructing the reinforced-concrete culverts used on highway, railway, infrastructure, drainage and watercourse-crossing projects to accurate dimensions, in a consistent and repeatable way. Formwork can be produced for single-cell and multi-cell culverts, as well as for square, rectangular and other project-specific reinforced-concrete cross-sections. Drawing on its experience with slipform and special formwork systems, Rayf Teknik develops mobile, reusable solutions tailored to the dimensions of each project and the conditions on site.

On long culvert runs, the same reinforced-concrete cross-section may be repeated dozens of times. Rather than fully dismantling and re-erecting the formwork at every stage, moving it as a complete unit to the next pour position wherever possible is a major practical advantage. The travelling inner-form carrier, the outer formwork system and the supporting members can be designed together to suit the structure of the project.

Culvert Formwork Developed to Suit Each Project

The width, height, reinforced-concrete wall thicknesses and roof slab of a culvert vary from one project to the next. Rayf Teknik therefore treats the system not as a fixed, off-the-shelf product but as engineered formwork that is developed around the needs of each project. Fresh concrete pressure, the rigidity of the form faces, connection points and the method of moving the system are all assessed before work begins.

The site-organisation experience Rayf Teknik has built up through its slipform work is also applied to mobile culvert formwork. Culvert formwork does not operate on the same principle as a conventional vertical slipform system; however, moving formwork in a controlled manner and planning pour cycles systematically on repetitive reinforced-concrete work calls for a similar engineering discipline.

Once the pour is complete and the concrete has reached the required strength, the form faces are released from the concrete. The system can then be moved on to the next section on wheels, on rails or with a travel mechanism developed specifically for the project. On long culvert projects, the aim is to cut down the repeated cycle of dismantling, transporting and re-erecting the formwork.

A key feature of the culvert formwork system is that it is reusable. Panels, the load-bearing chassis and other suitable components from the first project can be redeployed on later projects. If the new culvert has different dimensions, the existing system can be extended, or selected components can be replaced to adapt it to the new cross-section. This approach carries the upgradable-equipment philosophy of our slipform systems over to culvert projects.

Beyond single-cell culverts, the system can also be developed for multi-cell reinforced-concrete culverts, utility galleries and project-specific crossing structures. Where the formwork is purchased, Rayf Teknik can provide site supervision as required, giving the site team technical support with erection, the first pour and moving the system to the next pour area.

Rayf Teknik's aim with its culvert formwork solutions is not simply to form a reinforced-concrete structure, but to deliver a durable formwork system that can be reused along long project alignments, adapted to different dimensions and used to bring greater order to work on site.