Lite Form Reusable Concrete Molds – Replace Polystyrene Blocks

Lite Form Reusable Concrete Molds – Replace Polystyrene Blocks

Replace dangerous polystyrene in your construction projects! Lite Form polymer molds are the smart alternative to Styrofoam blocks in joist and block slab systems. These reusable non-removable formwork products can be used 50+ times, eliminating fire hazards, concrete porousness, and hidden costs of polystyrene. Direct manufacturing from Alborz Ghaleb factory in Karaj, Iran. Shipping across Iran and export to Iraq, Armenia, Russia, and Gulf region.

What is Lite Form and Why Replace Polystyrene?

Lite Form is a hollow, cubic-shaped polymer mold that serves as a direct replacement for polystyrene (Styrofoam) blocks in conventional joist and block slab systems. Unlike polystyrene which is single-use and permanently embedded in the concrete, Lite Form molds are stripped after concrete curing and reused for subsequent floors.

The Core Problem with Polystyrene: Polystyrene melts and drips at high temperatures during fires. Toxic gases from burning polystyrene (cyanide and carbon monoxide) are the primary cause of suffocation in building fires. Additionally, high breakage rates during handling, concrete porousness, and mandatory false ceiling requirements add significant hidden costs to projects.

For more advanced waffle slab systems, consider one-way or two-way waffle formwork as a complete replacement for the joist and block system. For proper execution, you'll also need standard prop jacks.

8 Key Benefits of Lite Form vs. Polystyrene

• 🔐 100% Fire Safety: Full concrete ceiling without flammable foam – Fire department approved
• 💰 Long-term Cost Savings: One purchase = 50+ uses. Fully ROI after just 2-3 projects
• 🛡️ Unbreakable & Durable: High-grade polypropylene molds resist impact, concrete pressure, and harsh site conditions
• 📐 Smooth Exposed Concrete Surface: Eliminates need for rabitz and plaster – saves 15M Toman per 100m²
• 🏗️ Fast & Easy Installation: Lightweight, simple placement by regular joist crew without special training
• 🔄 Reusable + Resale Value: After project completion, sell molds at 40% of purchase price
• 📦 Easy Storage: Stackable, resistant to rain and birds – minimal warehouse space required
• 🌱 Eco-Friendly: Reduces construction waste, 100% recyclable materials

Lite Form Models – Specifications & Pricing

Lite Form Model 46

Dimensions: 100×46cm – Suitable for standard concrete joists with 12cm heel. Height: 20 or 25cm

Price: Contact for quote Get Quote

Lite Form Model 66

Dimensions: 100×66cm – Suitable for steel C-shaped joists (Chromite) with 14cm heel. Height: 20 or 25cm

Price: Contact for quote Get Quote

Accessories (End Caps & Rails)

End Cap 46: Available | End Cap 66: Available | Rail 46: Available | Rail 66: Available

For 100m²: ~200 molds + 100 end caps + 100 rails Get Quote

Types of Polystyrene Alternatives for Concrete Slabs

1. Lite Form – Simplest Direct Replacement

This system directly replaces polystyrene blocks without changing the structural system. Place molds between joists, pour concrete, and strip after curing. Perfect for projects wanting to eliminate polystyrene without changing the overall method.

2. One-Way Waffle Formwork – Upgraded Joist System

In this system, joists are cast in-place within the molds. Rectangular polymer molds create a grid of parallel joists. Main advantage: eliminates need for precast joists and blocks. Requires one-way waffle formwork.

3. Two-Way Waffle Formwork – Long Spans Without Intermediate Beams

Advanced system with orthogonal joist grid. Ideal for parking garages, halls, and spaces requiring long spans (up to 16m) without intermediate columns. Modern ribbed ceiling appearance. See two-way waffle formwork for details.

Lite Form Pricing & Factors Affecting Cost

Factors Affecting Price:

• Mold Dimensions: Model 46 (100×46cm) vs Model 66 (100×66cm) have different prices
• Order Quantity: Bulk orders receive special discounts for large projects
• Mold Height: 20cm or 25cm depending on structural drawings
• Joist Type: Concrete (12cm heel) or Chromite steel (14cm heel)
• Accessories: End caps, rails, connectors based on project needs
• Shipping Distance: Transportation cost to destination

Technical Comparison: Polystyrene vs. Lite Form vs. Waffle

Technical Specifications Checklist Before Buying Lite Form

• ✅ Material: High-grade polypropylene (PP) or polyethylene (PE) – UV and impact resistant
• ✅ Dimensions: Useful width 46 or 66cm, height 20 or 25cm, length 100cm
• ✅ Weight: Each mold approximately 1.5-2kg (lighter than polystyrene block)
• ✅ Interlocking System: Mold edges must fully interlock
• ✅ Water-tightness: No concrete grout leakage from mold seams
• ✅ Washable Surface: Smooth surface for easy cleaning after each use
• ✅ Pressure Tolerance: Resistant to fresh concrete pressure (min. 60 kN/m²)
• ✅ Quality Certification: Factory quality control certificate from manufacturer

Selection Guide: Which Slab System for Your Project?

Lite Form Applications in Construction Projects

Lite Form Maintenance & Safety Guidelines

• 🛢️ Oil Application: Before each concrete pour, apply water-based or diesel form release oil to mold surface for easy stripping
• 📐 Leveling: Fully level prop jacks to prevent ceiling sagging. Use standard cross-head prop jacks
• 🔧 Pre-use Inspection: Check each mold for cracks, breakages, and deformations
• 📦 Storage: Store in covered area away from direct sunlight
• 🚛 Handling: Avoid throwing molds; while unbreakable, severe impacts may damage edges
• 🔄 Service Life: With proper care, usable for 50+ times

Related Products from Alborz Ghaleb

For complete ceiling project execution with Lite Form or waffle systems, you'll need cross-head and construction prop jacks. For walls and foundations, modular metal concrete formwork is the right choice. For safe access to height, modular triangle scaffolding ensures site safety.

For additional equipment, plasto-wood replacing plywood for false ceilings and wall posts for building facade are also available from Alborz Ghaleb.

Why Choose Alborz Ghaleb? – Trust & Credibility

Contact Information:

📱 Mobile: +98 912 139 0683 – +98 935 139 0683

📞 Office: +98 26-3472 0146

📧 Email:

📍 Address: Karaj, Kamalshahr, Behesht Sakineh Blvd, 4th East St, No. 80, Iran

Frequently Asked Questions about Lite Form