EN
Magnetic shuttering is most commonly employed in manufacturing flat precast concrete elements, such as walls and slabs, with typical wall thicknesses ranging from 100 to 500 mm, as well as for filigree elements in the range of 50 to 100 mm. The configuration of such formwork in terms of metal thickness, number of magnets, adhesion force and magnet position is designed for these applications.
In practice, however, solutions for significantly larger cross-sections – up to 1,000 mm and beyond – are regularly needed. It is precisely in such applications that magnetic shuttering technology offers decisive advantages: high flexibility, adaptability to differing geometries, and significantly lower investment in comparison with project-specific steel formwork.
Over the past few years, Ratec has developed a range of be-spoke solutions based on specific customer requirements and focussed on expanding the scope of application for magnetic shuttering. The following report provides an overview of selected approaches.
Easy Form Columns – expansion of the modular shuttering system
The addition of new components to the Easy Form System opens up this flexible modular system for new applications. The solution enables formwork to be created for beam-type elements such as columns and trusses, as well as more complex geometries such as lift shafts or stairway elements.
Technically, the system is designed so that base supports with brackets are positioned vertically on the SPB Standard Pro Magnetic Box. A turnbuckle is used to ensure precise alignment at 90°. This creates a versatile formwork system that can be adapted to different project requirements with relatively little effort.
Features and benefits
- Suitable for complex geometries and variable dimensions in manufacturing beam-type elements such as columns and beams
- Minimal effort required thanks to the simple assembly of the Easy Form modular system
- Suitable for continuous reinforcement
One example of this Easy Form configuration was its use in the construction of external columns up to 18 metres high and weighing over 40 tonnes for a new stadium in Austria.
In 2025, Easy Form shuttering was installed in Japan for the first time and employed there to produce concrete columns with element heights of up to 1,350 mm. Ultra-high-performance concrete (UHPC) with compressive strengths exceeding 120 N/mm² was utilised in this project.
MHS Modular Wood Shuttering
Another solution for creating taller elements is based on the Modular Wood Shuttering (MHS) system. At the heart of the system is a MHS base shuttering with a length of up to 7,980 mm, which, depending on the version, is fitted with a corresponding number of integrated automatic magnetic systems.
Its height is achieved by means of a support bracket to which the shuttering wood is attached using C channels. The base shuttering and the support bracket are not permanently connected, so that, in theory, the base shuttering can also be used for other assemblies. This solution was used in a specific application to construct columns up to 800 mm in height.
Special formwork for SPB magnetic boxes
Ratec has developed a special column formwork system for manufacturing elements with wall thicknesses of up to 1,200 mm. This system is currently in operation at a custom-er's site for manufacturing 840 mm thick sandwich panels. The formwork features easy handling, good stability and a crane-transportable design. It is securely fixed in place using the SPB2100 and can be assembled quickly thanks to its key-hole system. An important feature is the formwork's two-part design. This allows the system to be employed flexibly even for thinner wall thicknesses, thereby enhancing cost-effective-ness particularly in the case of varying production requirements.
Features and Benefits:
- Rapid positioning with reduced manual effort
- Crane-transportable design
- Good stability even with greater element thicknesses
- Particularly suitable for standardised elements with a high repetition rate
Special solution for upper chord formwork
Existing steel formwork can also be used more flexibly with customised magnetic shuttering solutions. For a customer in Austria, for example, a magnetic shuttering solution was developed for producing variable upper chord profiles in existing beam formwork. The aim was to be able to produce different I beam geometries with minimal changeover effort. The challenge was to develop a system that guarantees the customer maximum flexibility whilst keeping the time, mate-rial consumption and wear and tear involved in changeovers to a minimum.
The solution was derived from the Ratec Standard Automatic Shuttering (SAS) system and based on special formwork stops fitted with integrated assembly magnets, each with an adhesion force of 2,100 kg. These act as side shuttering elements in the beam formwork system.
The actual shape is achieved by means of standardised wooden boxes, which are attached to the stops at the rear using a steel strip. The geometry of the upper chord is defined by the vertical positioning of the stops, as well as by the height and depth of the wooden boxes installed.
This principle allows for a high degree of flexibility whilst minimising changeover time. All shuttering elements are also designed to be crane-liftable, thus ensuring quick changeovers.
Advantages:
- Great flexibility in producing different upper chord profiles
- Reduced changeover times and costs
- Quick and secure positioning of shuttering components
- Minimises wear and tear on existing beam formwork
Magnetic shuttering solution for manufacturing variable upper chord profiles in existing beam formwork
Summary
The examples shown demonstrate that magnetic shuttering technology is no longer limited to traditional applications in wall and floor production. Thanks to targeted advances and project-specific adaptations, the range of applications has been significantly expanded – particularly in the field of solid and geometrically sophisticated construction elements.
This opens up new opportunities for precast concrete production facilities, both in terms of expanding their product range as well as enhancing production efficiency and flexibility.