Setup and Stripping

EzyTube is primarily designed for installation by the top fitting technique ie. The formatube is placed over the reinforcing steel from the top and lowered into position. Care should be taken to avoid scraping the internal layer / plastic liner on the steel rio bars (fitting correct sized spacer wheels and cutting off protruding tie wire are advised) as this may result in marks onto the surface of the concrete column. Ezytube round, square, rectangular or custom shaped forms can accommodate either “Pour Down” or “Pour Up” installation methods to allow the user the opportunity to decide which method is most appropriate for the needs of each specific project.

“Pouring Up” refers to a column set up method whereby the column are erected and poured prior to setting up the formwork for the suspended concrete slab that the columns shall eventually support.

The steel reinforcing (cage) is placed first, a column form is placed over / around the reo, the formwork is securely propped to maintain the correct position, the concrete is poured within the formwork. Upon cure of the concrete, the formwork is removed.

Ezytube Column Forming tubes can accommodate the “Pour Up” method if preferred by the contractor

“Pouring Down” refers to a column set up method whereby the formwork for the suspended slab is set up first, and the reo and column forms are subsequently installed through the deck. The concrete can then be poured at a time convenient to the contractor prior to pouring the suspended slab.

There are often differing opinions to the advantages and disadvantages of both methods, however there are often significant differences / advantages of these 2 methods subject to differing site needs for crane usage, access methods for pouring the concrete, safety implications, overall construction program requirements, formwork/ steel fixing/ concrete trade coordination.

Ezytube products offer the unique ability to offer the use of both “Pour Up” or “Pour Down” installation methods for round, square, rectangular, oval, and most custom shaped column forms.

For a more detailed example view our time saving chart here.

Spiral Round Tubes:

Position the tube so that it is plumb in 2 perpendicular locations, the tube can be set up in either direction unless the Ezy Strip tape option is utilised.

Plastic Lined Round tubes:

Position the tube so that it is plumb in 2 perpendicular locations, the tube can be set up in either direction unless the Ezy Strip tape option is utilised. The outside of the tube shall be marked to indicate the position of the inner liner seam. Turn the column form to a position where this seam shall be least noticed prior to securing the top and base of the tubes.

Foam Core Round Tubes:

These tubes are manufactured with increased reinforcing at the base of the tube, and the level of reinforcing reduces towards the top of the tube. It is therefore critical that these tubes are correctly positioned in the direction marked on the outside of these tubes.

Square, Rectangular and Custom Shaped Tubes:

All tubes shall have external line markings top and bottom at 90, 180, 270 and 360 degree intervals, which correspond to the centre position of the respective inner shape being formed. Mark out the centre positions on the concrete slab / footing, and spin the tube so that the centre markings on the tube and the slab correctly align.

Ezy Strip Tape Option:

The Ezystrip tape runs up the full inside length of the tube, and then runs down the outside of the tube to a height easily accessed at ground level. The base has a small tab which allows for the final stripping process. It is important when using Ezytubes with the Ezystip tape that the tube is install with the long tape section positioned as the top of the tube, and the small tab at the base. It is also preferable that the tube is rotated before securing the base and top of the tube to ensure easy access to the Stripping tape and not having restricted access due to the location of nearby props/frames/shoring.

The top and bottom of Ezytube must be fixed securely in place to prevent movement whilst filling with concrete. The base of the tube is held in place by fixing four equally spaced blocks of wood (kickers) to the slab or footing.

Due to the semi-rigid nature of the tube, it is recommended to secure the base of the tube with 2 pieces of ply cut to the correct radius as shown in the photo below. This will overcome any potential deformation of the tube from isolated contact with the 4 timber restraints.

When fitted, the top edge of the tube is cut so that it is held neatly in place by the slab formwork.

Additional bracing is not normally required on “Pour Down” columns up to a height of 6.0 mtrs . For columns that are longer than 6.0 mtrs, cross bracing supports should be installed at levels of approximately every 5 mtrs in height. This cross brace should not apply pressure to the outside of the tube, and should be a guide only to maintain the plumb nature of the tube.

Should the Ezytube form be required to be placed and filled prior to forming the slab “Pour Up”, a foam or timber collar should be applied approximately 0.5 mtr from the top of the tube. 3-4 props fixed to the collar running diagonally away from the column to a secure fixing at a level equal to the base of the tube. Under no circumstances should the props be positioned in direct contact with the Ezytube form. Alternatively, a full frame support may be constructed around the tube form to support the tube.

Ezytube ensures ease in stripping which is unachievable by any other type of formwork tubing. After waiting for the concrete to set, simply use a Stanley/Utility knife (or similar) and perform a straight vertical cut from the top of the tube to the base. Pull the two sections apart and slide the Ezytube form off the concrete column. One person can perform this operation generally in a few minutes per column.

Ezystrip Tape has been developed by our R&D division to create an extremely fast and safe way of removing Ezytube forms after pouring.

Ezystrip Tape is a fibreglass tape that is an optional extra on spiral, plastic lined, and square or rectangular tube forms. Ezystrip has been developed with safety as the primary objective, fast removal and lower costs are added benefits.

Not only do your feet not have to leave the ground but the use of a knife is not necessary it is a simple procedure which is to pull down on the tape. A column can be striped in under a minute.

EzyStrip Demonstration Video

Most alternative rigid tube forms require power saw’s or alternative electrical saws to trim to length or remove from the poured concrete.

Ezytube is simply and safely cut using a hand held utility knife or saw.

Ezytube easily accommodates cuts for projections such as plumbing or electrical conduits, installation is simple and strength is assured.

Please see the cutting instructions below to assure a safe and effective tube cutting technique is achieved.

Joining our tubes is a simple task. Using our approved high strength filament tapes we have successfully joined thousands of tubes for a wide range of construction requirements.

See our pdf of the joining procedure that explains this process in detail. For any specific enquiries or concerns, please contact our technical department before performing major tube joins.

Where it is not possible to install the formwork tube by the “Top Fitting Technique”, Ezytube may be installed using the Wrap process 

Here are some features of the process:

  • For difficult column forming situations where top fitting is not possible, EzyWrap system can be side fitted
  • Used to encase around I beams.
  • Also used to form larger diameter columns around existing smaller diameter concrete columns.
  • Can be reused multiple times onsite.
  • Comprises of a dual tube system, the inner tube which can be spiral or plastic lined depending on required finish, and outer tube for reinforcement and strength.

 

For fitting procedure refer to these instructions and video.

  1. Mark a straight line between the top and bottom marks, which correspond with the internal liner join.
  2. Cut along this line with a Stanley knife (or similar) and a straight edge guide to ensure a straight, fine cut.
  3. Alternatively, Ezytube can supply the tubes already cut with edges and internal liners taped
  4. Wrap the cut Ezytube form around the steel cage (or I beam) by gently spreading the tube at the cut edges.
  5. Pull the 2 edges together using small amounts of packaging tape for the full height of the tube, ensure that the ends are square.
  6. Run a packaging tape over the full length of the cut surface to prevent water, fine cement and sand from running out.
  7. Take a second Ezytube and cut the same way as indicated in steps 1 & 2 above. Place this second Ezytube form around the inner Ezytube, ensuring that the join in the inner and outer tubes are on opposing sides (180 degrees apart).
  8. After referring to the “Ezytube Recommended Wrap Tube Taping Table” Using Ezytube approved reinforced tape, start at the base of the tube and wrap the full circumference of the tube with the prescribed number of layers of “Ezytube Approved Reinforcing Tape” , leave a gap of 100mm and repeat until up to the 2 meter high point, then continue with the spacing and number of full circumferences as specified thereafter to the top of the tube.
  9. Fill the tube with concrete and remove the EzyTube in reverse order upon adequate cure of the concrete.
  10. The inner and outer tubes can be re-used many times using this procedure, increased re use is possible with plastic lined inner tubes.
  11. Columns up to 5.0mtrs in height can be successfully poured using this method, however it is critical to abide by the correct positioning and usage of the reinforced tape.