U-boot

U-boot beton is a formwork made of

recycled polypropylene, designed to create
lightened intermediate slabs and raft
foundations in reinforced concrete. The use
of U-boot formworks permits to build
specific mushroom slabs: the mushroom is
part of the slab thickness. Thanks to the
cone shaped foot, U-boot remains dip into
the concrete casting. Thus, a grid of
orthogonal beams, superiorly and inferiorly
closed by plane slabs of different heights, is
obtained without executing two distinct
concrete castings; all that implies a
remarkable saving of concrete and
reinforcement.
U-boot permits to build big spans slabs or
slabs supporting high loads without beams.
Light and easy to pose, thanks to U-boot
modular formworks, the draftsman can
change the geometrical parameters of the
slab, in order to suit any kind of situation.

16

20

24

32

36

40

44

dali orm
T h o s e w h o i n v e n t e d I g l u

48

Le applicazioni
U-boot is used in all applications that require a plate structural solution, along with concrete-savings and therefore
weight-savings. In tower buildings, weight-saving at every floor reduces load on foundations. The fact of avoiding beams
being out of the slab thickness, enables the reduction of height for each floor. Therefore, a higher number of floors can be
built. By using U-boot beton, it is possible to build thick raft foundations with a reduced quantity of concrete (and weight).
U-boot is the ideal solution to create slabs of big spans and/or with a high bearing capacity. In case of difficult access to
the building site or restructuring, U-boot beton permits to build up the horizontal structures without using lifting and
movement devices, because of its stackability, modularity, lightness and manageability. The U-boot system particularly
fits structures that need significant open spaces, like bureaus,industrial and commercial buildings, and civil
constructions as well. The system also allows a more irregular distribution of pillars, since beams are not necessary.

Advantages in short
LIGHT - THIN - BIDIRECTIONAL
[ Designedf or bidirectional slabs
[ Decrease of concrete and weight up to 40%
[ Reduced deformation (maximum stiffness loss
15%)
[ Reduction of load on foundations
[ Reduction of pillar section
FLEXIBLE
[ Spans up to 20 m
[ Absence of beams between pillars
[ Reduction of pillars number
[ Possible use with prefabricated slabs (picture 3)
[ No lifting and movement devices required, ideal
for restructuring
[ Possible creation of monodirectional slabs
thanks to the bridge accessory
ANTISEISMIC
[ Reduced seismic mass
[ Less dimensional limitations of elements
[ Double inferior and superior slab
OPEN SPACES
More spacious rooms
Bigger architectural freedom
Easier change of use

[
[
[

ECONOMIC
[ Less concrete incidence, thickness being equal
[ Less steel incidence
[ Usable height saving on each floor, since
avoiding beams being out of the slab thickness
enables a higher number of floors, height being
equal (tower buildings)
[ Rapidity and easiness of pose (unique twophased casting) (picture 2)
[ Possibility of big spans, load being equal
(picture 5)
[ Possibility of high bearing capacity, spans being
equal
[ Economical transport and easy stocking, since it
is stackable
[ Ready to smooth once the deck is taken off, the
intrados is a plane surface which do not require
false ceilings at an aesthetical level
[ If a false ceiling is necessary, pose is made more
rapidly
SAFE
[ Significant fire resistance (certification REI 180;
concrete cover 3cm)
[ Safety on building site (complete flat deck
avoids plunking down)

Posing

U-boot

U-boot beton formwork is an easy to use product. First, a flat and complete surface has to be prepared with a
wooden deck or any other similar system. Then, the inferior steel reinforcement hasto be posed in the two
orthogonal directions, as designed in the executive project; the lattices are finally posed in order to space out
upper reinforcements.
Afterwards, U-boots are laid down and connected by lateral flaps, respecting the required span between the
lightening space. Thanks to the cone shaped feet, U-boots are raised above the slab intrados, and the concrete
can thus be cast, filling the whole surface below the elements. If double elements are to be used (H32, H36, H40,
H44, H48), it will be necessary to pre-emptively assemble the two parts, that will be delivered in different pallets at
the building site. The reinforcement pose is to be completed by disposing the upper bending steel bars in two
directions, the shear and punching reinforcement, where necessary.
Due to the floating pressure exerted on U-boots, the concrete should be cast in two different phases: (picture 1)
the first casting has to fill a thickness equal to the feet height. The final phase has to be done when the first
concrete layer starts to set and becomes semi-solid.
Casting proceeds each time from the previous starting point. While the casting proceeds, the concrete sets.
Finally the casting has to be levelled up in a traditional way (picture 6).
The U-boot system execution time will be accelerated by using new deck technologies which permit to
disassemble within 2-4 days, or using the carpet reinforcement system, in order to reduce the steel bars posing
time up to 4-6 times.

!W W W

To get up-to-date technical specifications, support material, new photos

and case studies, browse our website www.daliform.com

U-boot lightened slab scheme: note the lack of connection beams between pillars.

U-boot slabs do not need beams between pillars, a perimeter edge beam is enough.
The orthogonal grid of beams transfers all stresses directly on pillars; around which it is enough to leave a massive area,
called mushroom pillar, which is thick as the slab and variable in function of shear stresses.
Table: U-boot slabs characteristics compared to massive slabs
Square
grid
span

Slab thickness
with overload
500 kg/m2

S2

Lightened
slab inertia

Massive
slabinertia

Equivalent
height
percentage
loss

Lightened
slab weight

cm

cm

cm4/m

cm4/m

kg/m2

kg/m2

%
29,09

S1

H
U-boot

cm

Massive
slab weight

Weight
saving

26

16

124802

146467

5,196

460,9

650,0

30

16

203335

225000

3,319

560,9

750,0

25,21

34

24

249430

327533

8,680

563,3

850,0

33,73

10

36

10

16

10

367135

388800

1,893

710,9

900,0

21,01

11

38

24

379163

457267

6,052

663,3

950,0

30,18

12

42

32

426164

617400

11,624

671,8

1050,0

36,02

12

44

10

40

10

631763

709867

3,811

813,3

1100,0

26,06

12

46

32

619897

811133

8,573

771,8

1150,0

32,89

13

50

40

660882

1041667

14,073

774,2

1250,0

38,06

14

52

10

32

10

980497

1171733

5,766

921,8

1300,0

29,09

14

54

40

931415

1312200

10,797

874,2

1350,0

35,24

15

58

48

959465

1625933

16,123

876,6

1450,0

39,54

15

60

10

40

10

1419215

1800000

7,617

1024,2

1500,0

31,72

16

62

48

1319599

1986067

12,740

976,6

1550,0

36,99

18

68

10

48

10

1953799

2620267

20,439

1126,6

1700,0

33,73

IN DEPTH
U-boot lightened slab scheme: note the lack of connection beams between pillars

Solid model deformed structure and stresses

representation

Frame model non-deformed structure

Frame model representing bending stress

Shell model non-deformed structure

Shell model and bending stress representation

U-boot

Shell and solid model non-deformed structure

Raft foundation
Among foundation different typologies, raft foundation is surely one of the most known and used, considering its evident
technical advantages: high stiffness due to its static bidirectional behaviour, and thus load partition capacity on the
ground; it also permits to absorb stresses coming from the building, with differential subsidences close to zero; easy and
quick to carry out. If stresses increase or the ground bearing capacity decreases, the structure may require a thick raft
foundation. This means having more concrete and more pressure on the ground; and therefore higher building costs.
U-boot beton is a formwork made of recycled polypropylene, purposely designed to build lightened plate slabs and raft
foundations.
Once drowned into concrete, it creates an alveolar structure with two slabs of different thickness, joined by an
orthogonal grid of beams of variable width, therefore building an ideal light structure for raft foundations. Statically, it can
be seen as a grid of I beams which means having a rationalized masses distribution for the purpose of inertia, in order to
get high stiffness with a minimum quantity of concrete. This perfect combination of lightness and stiffness permits, in
particular cases, to avoid using foundation piles.

10.000 m2 raft foundation, thickness 68 cm, overloads 3.000 kg/m2. The project initially planned to use foundation piles.

U-boot or polystyrene?
Polystyrene is a widely used material in the world of building, especially if associated to prefabricated slabs, because it is
cheap and malleable. However, in the last few years, the technicalscientific community has been focusing on its
numerous disadvantages.
First of all, the fact that polystyrene releases toxic styrene monomers, at room
temperature. Moreover, some studies carried out by the
Polytechnic University of Milan highlight the fact that a slab
lightened by means of polystyrene explodes after only 20
minutes, if exposed to fire load. This is partially due to the
presence of warm air into the cavities which increases pressure,
and partially due to styrene sublimation. That is the second
problem. In order to avoid slabs explosions, prefabricated slabs
producers recently planned some vents into the slab to maintain
external pressure into cavities. But in this case, the styrene flows out
from the cavity, and it is toxic.
On the contrary, U-boot is made of polypropylene which is not toxic
even if it burns. Moreover, the CSI laboratories carried out a fire test on
a slab lightened by means of U-boot and with a 3 cm concrete cover,
and the structure was certified REI 180 minutes. The certification is
available on request. Finally, polystyrene is a material which needs
huge volumes for transportation and stock on site; U-boot beton is
designed to be stackable.

GLI APPROFONDIMENTI

U-boot

Boroli La Brunella wine cellar - Castiglione Falletto (CN) - Architectural project Arch. Guido Boroli - Structural Project Carosso &
Daliform - Spans 7.5mx5m - Overloads 3000 kg/m2 - surface 400 m2

Nola Interport - Nola (NA) - Architectural project: Renzo Piano Building Workshop - Structural project : Favero&Milan
En - Spans 10mx10m - Overloads700 kg/m2

Direction center Treviso 2 - Treviso (TV) - Architectonic project Arch. Mario Botta - Structural project Studio Vitaliani - span
10mx10m - overload 600 kg/m2 - Surface 500 000 m2

U-boot - Data sheet

Elements for project specification
Supply of recycled plastic U-boot elements, with a truncated pyramid shape and a lower base 52x52 cm. U-boot is composed of feet,
lateral flaps and upper tips used as spacers, in order to create an alveolar void in concrete massive slabs. Elements are to be posed on
site on a predisposed deck, or in factory on a pre-cast slab. Elements height: 16, 20, 24, 32, 36, 40, 44, 48 cm; feet of 0, 5, 7,
10cm; flaps of 12, 14, 16 ,18, 20 cm.

Parameters and consumption table

Formwork

Base
B
cm

Height
H

Feet
P

cm

cm
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10
0-5-7-10

u-16

52x52

16

u-20

52x52

20

u-24

52x52

24

u-32

52x52

32

u-36

52x52

36

u-40

52x52

40

u-44

52x52

44

u-48

52x52

48

Spacers
d
cm
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0
0
0
0
0
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5
0 e 1,5

Beam
width

Beam
interax

U-boot
incidence

cm
12
14
16
18
20
12
14
16
18
20
12
14
16
18
20
12
14
16
18
20
12
14
16
18
20
12
14
16
18
20
12
14
16
18
20
12
14
16
18
20

cm
64
66
68
70
72
64
66
68
70
72
64
66
68
70
72
64
66
68
70
72
64
66
68
70
72
64
66
68
70
72
64
66
68
70
72
64
66
68
70
72

pz/mq
2,44
2,30
2,16
2,04
1,93
2,44
2,30
2,16
2,04
1,93
2,44
2,30
2,16
2,04
1,93
2,44
2,30
2,16
2,04
1,93
2,44
2,30
2,16
2,04
1,93
2,44
2,30
2,16
2,04
1,93
2,44
2,30
2,16
2,04
1,93
2,44
2,30
2,16
2,04
1,93

Concrete saving

mc/pz
0,031
0,031
0,031
0,031
0,031
0,039
0,039
0,039
0,039
0,039
0,047
0,047
0,047
0,047
0,047
0,062
0,062
0,062
0,062
0,062
0,070
0,070
0,070
0,070
0,070
0,078
0,078
0,078
0,078
0,078
0,086
0,086
0,086
0,086
0,086
0,094
0,094
0,094
0,094
0,094

Concrete
consumption

mc/mq
0,076
0,071
0,067
0,063
0,060
0,095
0,090
0,084
0,079
0,075
0,115
0,108
0,102
0,096
0,091
0,151
0,142
0,134
0,127
0,120
0,171
0,161
0,151
0,143
0,135
0,190
0,179
0,169
0,159
0,150
0,210
0,198
0,186
0,175
0,166
0,229
0,216
0,203
0,192
0,181

52

d
H

H
p
d
p

Certification
On customer request, Daliform provides load tests on formworks and reinforced plates, certified by the University of Padova

mc/mq
0,084
0,089
0,093
0,097
0,100
0,105
0,110
0,116
0,121
0,125
0,125
0,132
0,138
0,144
0,149
0,169
0,178
0,186
0,193
0,200
0,189
0,199
0,209
0,217
0,225
0,210
0,221
0,231
0,241
0,250
0,230
0,242
0,254
0,265
0,274
0,251
0,264
0,277
0,288
0,299