Improving the demolding process of interior wall template panel systems requires a comprehensive approach encompassing material selection, release agent application, formwork design, construction operations, and post-construction maintenance to reduce concrete damage and enhance construction quality.
The choice of formwork material directly impacts demolding effectiveness. Traditional wooden formwork is prone to water absorption and deformation, leading to defects such as pitting and voids on the concrete surface. Furthermore, its low reusability increases costs. In contrast, metal materials like aluminum alloy and steel formwork offer high strength, rigidity, and resistance to deformation, reducing concrete damage caused by formwork deformation. Additionally, newer materials such as plastic and fiberglass formwork have smooth surfaces, resulting in low friction during demolding and effectively reducing the risk of surface tearing. When selecting formwork materials, it is essential to consider project requirements, cost budget, and construction environment, prioritizing materials with high surface smoothness and low water absorption to lay a solid foundation for the demolding process.
The performance and application method of the release agent are crucial to the demolding process. Inferior release agents can leave residues on the concrete surface, leading to uneven coloring, reduced strength, and even steel reinforcement corrosion. High-quality release agents should be easy to apply, form a uniform film, and leave no residue after demolding. Examples include water-based and chemical release agents, which reduce the adhesion between concrete and formwork, lowering demolding resistance. When applying the release agent, ensure the formwork surface is clean and dry, and apply it evenly, avoiding missed areas or accumulation to prevent uneven distribution and localized demolding difficulties. The timing of application is also crucial; it should be completed before formwork installation and should be avoided in high temperatures or windy conditions to prevent the release agent from drying too quickly and affecting its effectiveness.
Formwork design significantly impacts the demolding process. A well-designed formwork structure reduces stress concentration during demolding, lowering the risk of concrete damage. For example, modular formwork designs reduce joint gaps, preventing surface defects caused by grout leakage; rounded corners reduce stress concentration and prevent concrete cracking during demolding. Furthermore, a well-designed formwork support system ensures stability and prevents deformation during concrete pouring, avoiding surface misalignment and grout leakage due to formwork displacement. The stiffness and stability of the support system directly affect the demolding effect. Appropriate support methods, such as steel pipe supports or timber supports, must be selected based on the project characteristics.
Construction operations are the core of the demolding process. During concrete pouring, the pouring speed and height must be controlled to avoid deformation or displacement of the formwork due to excessive concrete impact. During vibration, layered vibration should be used to ensure concrete compaction while avoiding excessive vibration that could cause the formwork to bond too tightly to the concrete, increasing demolding difficulty. The timing of demolding is crucial. Demolding too early may result in insufficient concrete strength and surface damage; demolding too late may increase demolding resistance due to excessive bonding between the concrete and the formwork. Generally, the optimal demolding time should be determined based on the concrete strength gain and ambient temperature, typically when the concrete strength reaches at least 70% of the design strength.
Demolding operations must follow the principle of "support first, then remove; last support, first remove." Non-load-bearing parts should be removed first, followed by load-bearing parts, to avoid deformation of the formwork or damage to the concrete due to improper removal sequence. When demolding, specialized tools such as pry bars and demolding tools must be used. Avoid directly striking the formwork to prevent defects such as pits and cracks on the concrete surface. For areas difficult to demold, a vibrator can be used to gently vibrate the formwork, or a wooden mallet can be used to tap the outside of the formwork to assist demolding. However, the vibration and tapping force must be controlled to avoid damaging the concrete.
Post-demolding maintenance is crucial for extending the service life of the formwork and reducing concrete damage. After each demolding, the surface of the formwork must be cleaned promptly to remove any residual concrete, release agent, or other debris to prevent affecting demolding results in subsequent uses. Minor damage to the formwork can be repaired by sanding or applying putty. Severely deformed or damaged formwork must be replaced immediately to prevent concrete damage caused by formwork quality issues. Furthermore, proper storage of the formwork is essential. It should be placed in a dry, well-ventilated indoor environment, avoiding exposure to sunlight and rain to prevent deformation or corrosion.
Improving the demolding process of interior wall template panel systems requires addressing multiple aspects, including material selection, release agent application, template design, construction operations, and post-construction maintenance. By optimizing the process parameters and operating methods at each stage, concrete damage can be reduced, and construction quality and efficiency can be improved.
