NOVEMBER 2007

HY-RIB
®

Permanent Formwork for Construction Joints

User’s Guide
HY-RIB® USER’S GUIDE
INTRODUCTION

INTRODUCTION

Expamet Hy-Rib® is an expanded metal sheet product, specifically developed for

use as permanent formwork to concrete. The profile of the open mesh, in
combination with the Hy-Rib® tangs, allow the development of dense concrete
nodules and indents on the face of the Hy-Rib®, forming an enhanced mechanical
key for the second phase pour. In the case of visible elements, the resulting
Hy-Rib® surface is suitable to receive a rendered or tiled finish.

Hy-Rib® is primarily used in construction joint applications but it is also used to

form wall, beam and column surfaces and slabs soffits, where the formed surface
will not be seen.

For over 80 years Hy-Rib® has been successfully used as permanent formwork on
innumerable building and infrastructure projects, throughout the world.

Hy-Rib® has an enviable portfolio of technical data. Independent bodies have

undertaken full scale testing programmes to determine and verify Hy-Rib’s
effectiveness in forming construction joints. The result is a product with well
defined engineering properties, established formwork pressure characteristics
and measured improvements to the joint performance. Hy-Rib® is certified for use
as permanent formwork by the British Board of Agrément (BBA).
Hy-Rib® is manufactured within a factory production control system conforming
with BS EN ISO 9001/2000.

REASONS TO USE EXPAMET HY-RIB®

• Reduced risk of Hand and Arm vibration injury (white finger): product featured
in HSE document - Vibration Solutions Ref HS (G) 170

• When Hy-Rib® is used as vertical formwork, the resulting formwork pressure is

significantly less than that developed with traditional forming materials,
reducing the overall support requirement.

• Expamet Hy-Rib® joint surfaces require minimal preparation prior to the next
pour, with the exception of the rebar cover zones. It minimises the labour,
mess and disposal requirements associated with scabbling, chemical
retarders and jet washing.

• A correctly formed Hy-Rib® joint outperforms traditionally prepared joints in

shear and bond.

• Hy-Rib reduces the risk of trapped air and voids within the concrete.

• The range of narrower sheet widths improves site productivity and minimises
wastage.

• Hy-Rib is a proven construction product with comprehensive technical data,

manufactured by an established UK company
HY-RIB® INSTALLATION GUIDE
CONTENTS

SECTION 1
PRODUCT RANGE

SECTION 2
INSTALLATION ESSENTIALS

SECTION 3
CONCRETE

SECTION 4
DESIGN THEORY

Full information at www.hy-rib.com

HY-RIB® USER’S GUIDE
HY-RIB® PRODUCT RANGE

ZINC COATED HY-RIB®

Grade 2811 2611 2411

Type: (BS EN 10327) DX51D + Z275 DX51D + Z275 DX51D + Z275

Thickness (Steel Gauge) 0.4mm 0.5mm 0.75mm

Weight 3.39kg/m2 4.23kg/m2 6.34kg/m2

Sheet Identification ID Colour: Red 2811 ID Colour: Green 2611 ID Colour: Yellow 2411

STAINLESS STEEL HY-RIB®

Grade 2811 S 304 2811 S 316

Type: (BS EN 10088-1) 1.4301 1.4404

Thickness (Steel Gauge) 0.4mm 0.4mm

Weight 3.4kg/m2 3.4kg/m2

Sheet Identification ID Colour: Blue 2811 S 304 ID Colour: Black 2811 S 316

SHEET WIDTHS

HY-RIB® STANDARD SHEET SIZE - ALL GRADES

Width: 445mm
6 Rib
Lengths: 2m, 3m, 4m, 5m

HY-RIB® NARROW WIDTH SHEET SIZE - ZINC COATED GRADES

Width: 356mm
5 Rib
Lengths: 2m, 3m, 4m, 5m
Width: 267mm
4 Rib
Lengths: 2m, 3m, 4m, 5m
Width: 178mm
3 Rib
Lengths: 2m, 3m, 4m, 5m
Width: 89mm
2 Rib
Lengths: 2m, 3m, 4m, 5m

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HY-RIB® USER’S GUIDE
HY-RIB® PRODUCT RANGE

HY-RIB® IS AVAILABLE IN 2000, 3000, 4000 AND 5000mm LENGTHS

ORDER CODING:

Standard Sheet
Quote Grade and Length
e.g. 26113000
or 28113000S304

Galvanised Narrow Width Sheet

Quote Grade, Length and Rib Numbers
e.g. 26113000 - 3rib

CURVED HY-RIB®

Ribs In

Ribs out

ORDER REQUIREMENTS:
Specify
Ribs In or Out
Radius and Arc Length
or
Chord Length and Rise

Dimensions to be given
to concrete face.

SECTION 1 PAGE 2 OF 2 www.hy-rib.com

HY-RIB® USER’S GUIDE
INSTALLATION ESSENTIALS

SLAB CONSTRUCTION JOINTS

WALL CONSTRUCTION JOINTS

www.hy-rib.com SECTION 2 PAGE 1 OF 6

HY-RIB® USER’S GUIDE
INSTALLATION ESSENTIALS

HY-RIB® DEFINITIONS

Edge Rib
Tangs
Colour Coding Strip inside the rib
Inner Rib

MEASURING POINTS

Sheet width based on

edge rib to edge rib centres

Sheet length

HY-RIB® SPANNING DIRECTION

Hy-Rib® spans between supports.

Supports at right angles to the ribs

SPAN

SPAN

SPAN

SECTION 2 PAGE 2 OF 6 www.hy-rib.com

HY-RIB® USER’S GUIDE
INSTALLATION ESSENTIALS

FIXING HY-RIB® TO BACKING SUPPORT

 Hy-Rib® sits flat on support

 Ribs point into first phase pour
 Tangs embed in first pour
 Colour coding facing outside

AFTER FIRST PHASE POUR

SIDE LAPPING OF HY-RIB® SHEETS

 Lap edge ribs only: approx 12mm overlap

 Wire tie lapped edge ribs at 300mm centres
(150mm for soffits)

Sheet 1 Sheet 1
Sheet 2
Sheet 2

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HY-RIB® USER’S GUIDE
INSTALLATION ESSENTIALS

END LAPPING OF HY-RIB® SHEETS

Typical end lapping of Hy-Rib® sheets for wall  Small overlap - 25mm - 50mm
stopends and construction joints.  Tie sheets tightly together to
minimise gap
 Butt ends together: zero overlap  Nail or tie Hy-Rib® to supports

25/50
mm

COVER TO HY-RIB® ON CONSTRUCTION JOINTS

Hy-Rib® must have the same cover as the Temporary timber used to form cover zones
reinforcement and is generally fixed between
the outer layers of reinforcement.

SECTION 2 PAGE 4 OF 6 www.hy-rib.com

HY-RIB® USER’S GUIDE
INSTALLATION ESSENTIALS

HY-RIB® SHEET EDGE DETAILS

Hy-Rib® butted to plywood comb

Taper edge of
comb to ease
strike

Large Hy-Rib® sheet cut to size

Ensure the
cut edge is
supported by
timber or
additional
steel bar

Slightly oversized Hy-Rib® sheet

Fold and tie
small return
into pour

www.hy-rib.com SECTION 2 PAGE 5 OF 6

HY-RIB® USER’S GUIDE
INSTALLATION ESSENTIALS

FITTING A HYDROPHILIC SEAL TO A CONSTRUCTION JOINT SUPPORTED BY TIMBER

Fit noggins between vertical Hy-Rib®

support timbers at the position where the hydrophilic
seal will need to be located.

Ensure that the timber noggins are at least as wide as

the hydrophilic waterstop product.

Horizontal
noggins

Timber fillet to locate

hydrophilic seal

Eventual
position of seal

Gap between Hydrophilic seal

Horizontal noggin
Hy-Rib® sheets fixed to concrete

1. Leave a gap between adjacent Hy-Rib® sheets in 2. After the first pour, remove the timber support and
line with the edge of the noggins to ensure a flat noggins and fix the seal to the flat concrete surface as
concrete surface where the seal is to be located. per the manufacturer’s instructions.

SECTION 2 PAGE 6 OF 6 www.hy-rib.com

HY-RIB® USER’S GUIDE
CONCRETING / PLACEMENT

This section illustrates current best practice for placement and compaction of concrete in proximity to Hy-Rib®
stopends. Further consultation should be taken if there is any uncertainty regarding site conditions - pour shape
and size, concrete mix, type of compaction equipment and the Project Specification.

1.5 - 2m

First Layer First Layer

CONCRETE PLACEMENT ADJACENT TO STOP

END: BEST PRACTICE DO’S AND DON’TS

Always follow standard good placement practice to

avoid overloading any stopend.

 Use correct length of pipe trunking or tremie tube  Don’t dump the concrete from excess height
 Place concrete at least 500mm from Hy-Rib®  Don’t discharge concrete directly against the
stopend Hy-Rib® stopend
 Allow concrete to naturally flow up toward the  Don’t allow concrete to pile up against the
Hy-Rib® stopend Hy-Rib® stopend

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HY-RIB® USER’S GUIDE
CONCRETING / VIBRATION COMPACTION

VIBRATION COMPACTION

Standard Vibration Zone

(continuous vibration)
450mm Reduced
Vibration Zone

Work direction toward

Hy-Rib® stopend

 Where continuous vibration is used keep  Do not use continuous and excessive vibration too
poker about 450mm from the Hy-Rib® close to the Hy-Rib® face. This may result in
 In close proximity to Hy-Rib® stopend, vibrate in excessive loss of concrete fines.
5 second bursts until concrete is compacted  Do not vibrate the stopend.
 Vibrate in this way until cement grout is observed  External vibrators are not recommended for
coming through the open mesh use with Hy-Rib®
 Highly workability and ‘fluid’ mixes may require  Do not vibrate the steel reinforcement
less total vibration effort than ‘stiff’ concrete mixes.

SECTION 3 PAGE 2 OF 3 www.hy-rib.com

HY-RIB® USER’S GUIDE
CONCRETING / FINISH / CLEANING / CURING / NEXT POUR

CONCRETE FINISH

The ideal Hy-Rib®/concrete face suitable for the

subsequent pour is achieved by:  Never disturb the face of the fresh Hy-Rib®/concrete

 Following the placement and compaction guidance  Never brush, scrape or jet-wash the fresh
in this document. Do nothing else! concrete/Hy-Rib® face

CLEANING

 If excess grout builds up on the walings and  Do not disturb the fresh concrete/Hy-Rib® face
supports it is good practice to lightly brush these while removing any overspill and grout build up
clean before the concrete hardens. on the walings.
 Never brush, scrape or jet-wash the fresh
CURING concrete/Hy-Rib® face

 If curing is needed, use well sealed polythene  Do not use curing compounds on any joint or
sheeting pressed over the ends of any projecting Hy-Rib® stopends to which a further pour will be
reinforcement. connected (Many curing agents make excellent
de-bonding agents!)
PREPARING THE JOINT FOR THE NEXT POUR

 Remove the timber cover zone strips and prepare  Do not remove the Hy-Rib® sheet - it is permanent
the exposed concrete band, being careful not to formwork!
damage the edge corners.

 The Hy-Rib® surface itself needs little if any

preparation before the next pour.
Remove any fins and obvious debris.

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HY-RIB® USER’S GUIDE
DESIGN THEORY

REDUCTION IN THE PRESSURE OF CONCRETE ON HY-RIB®

The recommended reduction in design concrete pressure when using Hy-Rib®, compared to the calculated
Construction Industry Research and Information Association (CIRIA) Report 108 values for casting against
impermeable formwork are shown at below. These show that the maximum concrete pressure obtained when
using Hy-Rib® is almost halved for pours up to 3m in height, with an upper limit of 38 kN/m² for walls from 3m
up to 5m in height.
The research work, carried out by the British Cement Association confirmed the significant reduction in the
pressure of concrete placed in vertical sections against Hy-Rib® when compared to the predicted pressure
obtained using the full weight density head of concrete.
The results from five full scale wall pours, each 5m high, are shown plotted below. They were also published in
Concrete magazine. The trials were carried out using concrete with additions and admixtures to provide a very
high workability mix to give extremely fast rates of rise. The CIRIA Report 108 "Concrete pressures on formwork"
categorises these concretes as Group 4, and predicts that at such rates of rise the design maximum pressure
should use the weight density head of concrete. The actual concrete density averaged 23.15 kN/m³ in the
wall trials.

Concrete pressure 0 KEY Hy-Rib both faces

diagram using
Trial 1
Hy-Rib® and group
1,2,3,4 or 5 Trial 3
concrete Trial 4
1
Trial 5
Plywood and Hy-Rib
Trial 2

2
Height from
top of CIRIA 108 pressure value
concrete (m) using density of 23.15kN/m2

Maximum design
pressure when using
Hy-Rib is 38kN/m2
4

5
0 20 40 60 80 100 120
Concrete pressure (kN/m2)

The general method of determining the design concrete pressure uses Table 2 from CIRIA Report 108 with a
weight density of 25 kN/m³, and concrete classified into five groups. Although the full scale tests were carried
out on a very fluid group 4 concrete, the BCA are of the opinion that it is reasonable to assume that the pressure
reductions can also be applied when using Hy-Rib® with the stiffer group 1 and 2 concretes using CEM I, CEM I/R
or + SR with or without any admixture. Hy-Rib® is also effective when used with Group 6 and 7 concrete, and has
been used with concrete of slump 180mm.
In addition the BCA have recorded the same reduction of concrete pressure on a very thick section (8m wide)
whilst pouring a 5m high double faced wall using Hy-Rib® to both faces.

SECTION 4 PAGE 1 OF 4 www.hy-rib.com

HY-RIB® USER’S GUIDE
DESIGN THEORY

PERFORMANCE OF EXPAMET HY-RIB®

Tests have been carried out to verify the performance

of Hy-Rib® at construction joints.
Assessment of shear, flexure and concrete strength at
the joint confirms that the use of Hy-Rib® can improve
the load achieved at this location.
Examination of cores taken at concreted Hy-Rib®
joints shows full compaction around the Hy-Rib® ribs
and grout penetration at overlapping joints.
Test details are available at www.hy-rib.com.

PROPERTIES OF EXPAMET HY-RIB®

GRADE 2411 2611 2811 COMMENT

Section Modulus
Zjoint mm3/m 1710 1125 952 Rib in tension
Zspan mm3/m 2233 1488 1266 Face in tension

Moment of resistance kNm/m 0.330 0.217 0.184 At supports (rib away from load)
(working) (fZ) kNm/m 0.431 0.287 0.244 At midspan (rib towards load)

Bending stiffness (EI) kNm2/m 3.94 2.53 2.00 See notes

Working maximum reaction kNm/m 19.94 14.90 10.88 See notes
Assumed max. working shear kNm/m 9.97 7.45 5.44 See notes

Notes:

1. The properties assume that the Hy-Rib® is used with the ribs pointing into the concrete to be placed first and
spanning in the strong direction between supports with the ribs parallel with the span.

2. The Hy-Rib® is considered a single use sacrificial material with a minimum factor of safety of 1.4 on ultimate
failure. The failure stress being the minimum ultimate tensile strength of the Hy-Rib® sheet material.

3. The bending stiffness values should only be used for estimating deflections. They allow for the complex
geometric changes in properties and shape as Hy-Rib® deflects.

www.hy-rib.com SECTION 4 PAGE 2 OF 4

HY-RIB® USER’S GUIDE
DESIGN THEORY

SLAB CONSTRUCTION JOINTS: MAXIMUM SPACING ON TIMBER SUPPORTS

All temporary works must be designed by Span

a competent Temporary Works Designer

Overall
Depth

INDICATIVE CLEAR DISTANCE BETWEEN SUPPORTS AT SLAB JOINTS

MAXIMUM CONCRETE PRESSURE CLEAR HY-RIB SPAN BETWEEN SUPPORTS

Overall depth Theoretical* Assumed for Grade Grade Grade 2811

of slab joint Table 2 Hy-Rib 2411 2611 Grade 2811 S 304
CIRIA 108 Grade 2811 S 316
2 2
mm kN/m kN/m mm mm mm

250 6.25 3.20 1250 1025 950

500 12.50 6.30 900 725 675
750 18.75 9.50 725 600 550

1000 25.00 12.70 625 500 475

1250 31.25 15.80 575 450 425
1500 37.50 19.00 525 425 400

2000 50.00 25.30 450 375 350

2500 62.50 31.70 400 325 300
3000 75.00 38.00 375 300 275

Notes:
1. The Hy-Rib® is used in horizontal sheets with the ribs pointing into the concrete to be placed, and
spanned in the strong direction between vertical supports.
2. The theoretical maximum pressure is that calculated using Table 2 in CIRIA report 108 with a concrete density
of 25kN/m3, for EITHER a wall, base or column; AND applies to concrete groups 1 to 5 inclusive.
3. The Hy-Rib® pressure diagram up to 3m in height of joint is assumed to be triangular. The permissible spans
calculated from a uniformly applied concrete have been increased by a factor of 1.2 to allow for the triangular
shape of the concrete pressure diagram. The maximum pressure only applies at the very bottom of the joint.

SECTION 4 PAGE 3 OF 4 www.hy-rib.com

HY-RIB® USER’S GUIDE
DESIGN THEORY

1
THIN WALL CONSTRUCTION JOINTS:
MAXIMUM SPACING ON TIMBER SUPPORTS 2

3
All temporary works must be designed by
4
a competent Temporary Works Designer
5
6
7
8

INDICATIVE SPACING OF SUPPORTS TO

HY-RIB® AT A VERTICAL JOINT IN A WALL

Centre to centre spacing of the supports (mm) and the approximate height of wall (mm)
Position of the Grade 2811
support Grade 2411 Grade 2611 Grade 2811 S 304
measured from Grade 2811 S 316
the top of the support approximate support approximate support approximate
wall spacing wall height spacing wall height spacing wall height

1 see note 5 see note 5 see note 5

650 575 550
2 see note 5 see note 5 see note 5
575 525 500
3 see note 5 see note 5 see note 5
525 475 450
4 1750 1575 1500
475 425 400
5 2225 2000 1900
425 375 375
6 2650 2375 2275
375 325 325
7 3025 2700 2600
375 300 275
8 3400 3000 2875

Load in the
approximately 14.3 kN/m approximately 11.4 kN/m approximately 10.5 kN/m
supports

Notes:
1. The Hy-Rib® is used in vertical sheets with the ribs pointing into the concrete.
2. The value of the support spacing is measured centre to centre of the vertical supports and is NOT the clear distance.
3. The supports to the Hy-Rib® are horizontal and are a minimum of 50mm wide.
4. The approximate load per metre of the supporting members is given as a guide only.
5. It is assumed that the Hy-Rib® is continuous over at least three spans (i.e. over four horizontal supports).
If this is not the case, refer to a designer for the increase in load on the supports.

www.hy-rib.com SECTION 4 PAGE 4 OF 4

HY-RIB® USER’S GUIDE
HEALTH AND SAFETY INFORMATION

HY-RIB® HEALTH AND SAFETY DATA SHEET

1. IDENTIFICATION 8. EXPOSURE CONTROLS

®
Hy-Rib expanded metal sheet Wear personal protection such as gloves, safety goggles and
Expamet Building Products Limited appropriate mask when handling and cutting sections.
Greatham Street Some products may have a film of soluble cutting fluid after
Longhill Industrial Estate (North) manufacture; therefore carry out personal hygiene, including
Hartlepool TS25 1PR proper washing of hands, after contact.
Tel: +44 (0)1429 866688
Fax: +44 (0)1429 866633
9. PHYSICAL AND CHEMICAL PROPERTIES
Hy-Rib® is supplied in various lengths, widths and gauges.
2. COMPOSITION
Metallic grey appearance.
Galvanised steel
DX51D+Z275 (Fe PO 2 G Z275) to BS EN 10327
10. STABILITY AND REACTIVITY
Stainless steel
Hy-Rib® is stable under normal conditions but if subjected to
X5CrNi8-10 (1.4301) to BS EN 10088-1
high temperatures, fumes are produced.
X2CrNiMo17-12-2 (1.4404) to BS EN 10088-1

11. TOXICOLOGICAL INFORMATION

3. HAZARDS IDENTIFICATION
Abrasive cutting of Hy-Rib may produce dust of the same
Possible cuts from steel edges. composition as the coating and base metal.
Toxic and irritant fumes from high temperatures.
High temperatures can produce fumes.
Dust and noise from cutting with abrasive wheels.

12. ECOLOGICAL INFORMATION

4. FIRST AID MEASURES
No known hazard.
Skin and eye contact: treat cuts from steel edges as required.
Ingestion: not applicable.
Inhalation: remove from source of fumes and dust. 13. DISPOSAL CONSIDERATIONS
Recycle or dispose of in accordance with Waste Management
Licensing Regulations.
5. FIRE FIGHTING MEASURES
Non-flammable material.
14. TRANSPORT INFORMATION
Not classified as hazardous for transport.
6. ACCIDENTAL RELEASE MEASURES
Not applicable.
15. REGULATORY INFORMATION
Hy-Rib is an article therefore not subject to CHIP3.
7. HANDLING AND STORAGE
Bands and straps must not be used for lifting.
16. OTHER INFORMATION
Use suitable PPE when handling the Hy-Rib sections.
Assess manual handling risks before lifting. All products must be installed in accordance with Expamet
Bundles of Hy-Rib should be stacked on firm level ground Building Products’ published instructions.
in dry conditions. The Hy-Rib® Health and Safety Data Sheet is not a product
specification guide.

Any arrangement of reinforcing steel shown in this brochure is indicative only.

Actual reinforcement installations must comply with current Health and Safety requirements.

HEALTH AND SAFETY INFO www.hy-rib.com