This article contains information regarding Sonotubes® and their use.
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Sonotube® is a cylindrical form crafted from layered cardboard, often treated with a wax or laminate finish. These tubes are specifically engineered for pouring concrete to create structural elements like columns and posts. Sonotube® is a registered trademark owned by SPC RESOURCES, INC. The forms are available in diverse materials such as fiber, plastic, and composites, accommodating a wide variety of applications, from DIY home improvements to large-scale construction projects. They come in an array of sizes, ranging from smaller versions found in hardware stores to large tubes several feet in length with diameters that are measured in feet.
In order to use a Sonotube® for creating columns or supports, it must be positioned correctly and secured. Concrete is then poured into the form and allowed to cure. Once the concrete has set and hardened fully, you remove the tube, resulting in a strong and durable column or support.
Sonotubes® are manufactured in a variety of sizes to accommodate different requirements, and the selection of the appropriate size depends on aspects like the structural design, local building codes, and the type of supporting soil. While standard Sonotubes® can resist water exposure for up to 24 hours, customized versions are built to withstand moisture for up to 72 hours.
To create stable concrete columns and structural supports with precise specifications, construction professionals rely on high-quality concrete form tubes like Sonotubes®. These cylindrical forms must feature perfectly smooth interiors and exceptional strength to withstand the hydrostatic pressure from poured concrete while retaining their cylindrical shape. Traditionally, fabricating these supports involved custom carpentry with wooden or steel molds—an approach that was not only labor-intensive and time-consuming but also prone to producing columns with uneven, rough surfaces and inconsistent diameters.
The introduction of Sonotube® concrete forms has revolutionized construction methods by streamlining the process and eliminating the challenges of traditional formwork. Sonotubes® offer contractors and builders a fast, efficient way to create round structural columns and footings with a superior, smooth finish. These forms improve productivity, lower labor costs, and help ensure consistent results in residential, commercial, and industrial concrete construction projects.
The renowned durability of Sonotubes® is achieved by using tightly wound, high-strength fiber materials bonded with specialized adhesives. The manufacturing process involves spirally wrapping strips of heavy-duty paperboard around a mandrel and compressing them with a pressure roller, delivering a form tube with remarkable strength, a moisture-resistant barrier, and a consistently smooth surface for optimal concrete placement.
The innovation behind Sonotube® column forms has transformed industry best practices for architects, general contractors, engineers, and DIY builders alike. These reusable and disposable form tubes offer a flexible, versatile solution for casting round concrete columns, foundations, piers, and footings, eliminating the need for cumbersome traditional molds. By simplifying setup and removal, Sonotubes® dramatically reduce project turnaround time and ensure precise, uniform results in both small-scale and large-scale construction.
Sonotubes® are available in a comprehensive range of standard and custom sizes, making them suitable for a wide array of applications including supporting structures for commercial buildings, residential decks, porch columns, patios, cabanas, lamp posts, fence posts, and light pole foundations. Despite being made from engineered fiberboard, Sonotubes® are robust enough to support the placement of multiple cubic yards of concrete—offering outstanding performance at a competitive price point. Their reliability and ease of use make Sonotube® column forms a preferred choice for concrete contractors, civil engineers, landscapers, and DIY homeowners seeking superior structural support solutions.
The chart below highlights the available standard Sonotube® diameters and the corresponding volume of concrete (in cubic yards) required for common column heights. Referencing this chart helps ensure accurate concrete volume estimation and efficient project planning.
Most manufacturers supply Sonotubes® in a selection of standard industry sizes, but custom Sonotube® forms can also be ordered to meet specialized design and construction requirements, accommodating unique diameter, length, or high-strength specifications.
| Forms of Sonotubes® | |||||||
|---|---|---|---|---|---|---|---|
| Diameter in Inches | Column Height in Feet | ||||||
| 3 | 6 | 8 | 10 | 12 | 16 | 20 | |
| 6 | 0.02 | 0.04 | 0.06 | 0.07 | 0.09 | 0.12 | 0.15 |
| 8 | 0.04 | 0.08 | 0.1 | 0.13 | 0.16 | 0.21 | 0.26 |
| 10 | 0.06 | 0.12 | 0.16 | 0.2 | 0.24 | 0.32 | 0.4 |
| 12 | 0.09 | 0.18 | 0.23 | 0.29 | 0.35 | 0.47 | 0.58 |
| 14 | 0.12 | 0.24 | 0.32 | 0.4 | 0.48 | 0.63 | 0.79 |
| 16 | 0.16 | 0.31 | 0.41 | 0.52 | 0.62 | 0.83 | 1.03 |
| 18 | 0.2 | 0.39 | 0.52 | 0.65 | 0.79 | 1.05 | 1.31 |
| 20 | 0.24 | 0.49 | 0.65 | 0.81 | 0.97 | 1.29 | 1.62 |
| 22 | 0.28 | 0.59 | 0.78 | 0.98 | 1.17 | 1.57 | 1.96 |
| 24 | 0.35 | 0.7 | 0.93 | 1.16 | 1.4 | 1.86 | 2.33 |
| 26 | 0.41 | 0.82 | 1.09 | 1.37 | 1.64 | 2.19 | 2.73 |
| 28 | 0.48 | 0.95 | 1.27 | 1.58 | 1.9 | 2.53 | 3.17 |
| 30 | 0.55 | 1.09 | 1.45 | 1.82 | 2.18 | 2.91 | 3.64 |
| 32 | 0.62 | 1.24 | 1.66 | 2.07 | 2.48 | 3.31 | 4.14 |
| 34 | 0.7 | 1.4 | 1.87 | 2.34 | 2.8 | 3.74 | 4.67 |
| 36 | 0.79 | 1.57 | 2.09 | 2.62 | 3.14 | 4.19 | 5.24 |
| 40 | 0.97 | 1.94 | 2.59 | 3.23 | 3.88 | 5.17 | 6.46 |
| 42 | 1.07 | 2.14 | 2.85 | 3.56 | 4.28 | 5.7 | 7.13 |
All Sonotubes® are engineered for demanding commercial construction projects and can be used for both above-grade and below-grade applications. The extensive range of Sonotube® form sizes enables professionals to achieve optimal results, whether they are installing deep foundation piers, footings, or decorative architectural columns. Select the correct diameter and length by considering structural loads, soil conditions, and building codes to ensure proper performance and compliance. Additionally, Sonotube® concrete form tubes are recyclable, making them an environmentally friendly option in sustainable construction practices.
Finish-free Sonotubes® are specifically engineered for high-end architectural and commercial projects where an impeccable column appearance is required. These premium forms feature an advanced interior coating that delivers flawless concrete finishes—free from spiral marks, seams, air bubbles, honeycombing, or surface voids. This ensures installers achieve smooth, paint-ready concrete columns and piers with minimal finishing work. Many finish-free Sonotube® forms include an integrated strip cord or rip cord, designed to facilitate fast and easy removal of the form without damaging the surface of the cured concrete.
Finish-free Sonotubes® are generally available in core diameters ranging from 12 inches to 36 inches, accommodating a variety of structural loads and aesthetic requirements. These high-performance form tubes can support concrete volumes from approximately 0.349 cubic yards to 3.142 cubic yards, making them a top choice for visible support columns in entryways, lobbies, and public structures. For best results, always verify compatibility with your project’s concrete mix design and surface finishing requirements.
Commercial Sonotubes® are constructed to meet stringent engineering standards for use on major construction projects, such as bridges, skyscrapers, parking decks, industrial facilities, and other large-scale structures. Manufactured with high-quality, water-resistant paperboard, these form tubes can withstand extended exposure to wet weather—including up to 72 hours of rainfall—without compromising shape or integrity. Their reinforced, tear-resistant poly-woven exteriors allow them to handle tall placements and heavy concrete pours, supporting pressures associated with columns up to 20 feet high or more.
Available in diameters ranging from 6 inches to a massive 60 inches, and lengths between 12 and 20 feet, commercial Sonotubes® offer unmatched versatility for architects, project managers, and concrete contractors. If your construction project requires unique specifications—such as extra-thick walls, oversized diameters, or custom lengths—many manufacturers can produce tailored Sonotube® solutions upon request, helping you meet strict construction tolerances and timelines.
Within the mining and quarrying sectors, blasting Sonotubes® are employed as blast hole casings to retain the borehole’s shape and prevent collapse during explosive operations. These highly specialized tubes are manufactured from dense, water-resistant paperboard, allowing for a watertight seal that ensures the tube holds up under extreme conditions. Durable and engineered to withstand high impact, these tubes preserve borehole dimension and support optimal fragmentation during rock blasting—all critical in mining, tunneling, and geotechnical drilling.
Proper blast hole casing not only maximizes the efficiency of each explosive charge but also contributes to safer, more consistent mining operations. Consult with industrial Sonotube® suppliers to select the appropriate size, wall thickness, and material grade for your unique blasting applications.
DIY Sonotubes® empower homeowners, landscapers, and small contractors to achieve professional results on smaller-scale projects. These easy-to-use, lightweight concrete forms feature the same tough fiber construction as commercial models, with diameters typically ranging from 6 inches to 12 inches and standard lengths up to four feet. DIY Sonotubes® are a go-to choice for installing deck post footings, playground anchorings, mailbox and lamp post bases, fencing supports, and other landscaping or hardscaping elements.
Sonotubes® for home use are widely available at major hardware retailers, building supply stores, and online distributors. Their convenience, affordability, and consistent forming ability make them invaluable for precise, code-compliant concrete work in backyards and neighborhoods. Be sure to choose the correct Sonotube® diameter and length for your specific project by consulting local building codes and load requirements before pouring concrete.
How to Select the Right Sonotube® Concrete Form: When choosing Sonotube® column forms for your project, consider the following factors for optimal results:
For technical assistance, design consultation, or large quantity orders, reach out to a trusted Sonotube® supplier or formwork manufacturer to get product recommendations, pricing, or delivery estimates tailored to your construction site.
The production of Sonotubes® follows a similar process to that used for creating tubing for other purposes. However, Sonotubes® are specifically designed with enhanced strength and durability to handle the pressures exerted by poured concrete. This necessitates the use of specialized materials and construction techniques.
Another distinguishing factor in the manufacturing of Sonotubes® is the scale of the equipment used. Since Sonotubes® can have diameters of up to 60 inches, larger mandrels are required for winding the paper strips to accommodate these substantial sizes.
The initial stage in manufacturing Sonotubes® involves cutting cardboard sheets into strips. These sheets are drawn from a large roll of cardboard and fed into a cutting machine that slices them into ribbons of the correct width for winding onto a mandrel. As the sheets are processed, the resulting ribbons are collected on a reel.
The ribbons, which have been wound onto a heavy metal reel, are then transferred to the winding machine. Multiple ribbons are positioned side by side to be wound onto a mandrel—a cylindrical tool with an outer diameter that matches the inner diameter (ID) of the Sonotubes®. The winding is performed in a helical pattern, with the ribbons applied at an angle less than 90 degrees relative to the mandrel. This helical winding enhances the strength and durability of the Sonotubes®.
During the winding process, several layers of cardboard ribbons are applied, which determine both the thickness and the outside diameter (OD) of the Sonotube®. To achieve the required strength and durability, the Sonotubes® are wound multiple times to ensure they meet the specified thickness and performance standards.
As the ribbons are wound around the mandrel, a heavy-duty foam adhesive is applied to ensure the ribbons are securely bonded together, preventing the formation of air pockets, bubbles, or voids that could compromise the smoothness and strength of the Sonotube®. The image below illustrates a simplified depiction of the adhesive application process as the paper ribbons are wound.
Sonotubes® are treated with specially formulated coatings and adhesives that impart water resistance, tear resistance, and exceptional strength. These properties are essential for withstanding the pressure exerted by poured concrete and meeting the required durability standards.
A critical aspect of manufacturing Sonotubes® is ensuring that the cardboard ribbons are securely bonded. The adhesive applied during the winding process holds the ribbons in place, preventing any movement or shifting. Additionally, a pressure roller is used to firmly press the ribbon layers. This roller helps to eliminate any voids, air pockets, or bubbles, ensuring a smooth and uniform final product. The pressure from the roller flattens the ribbons and evenly distributes the adhesive, enhancing the overall quality and durability of the Sonotube®.
Sonotubes® offer a convenient and efficient solution for various construction tasks. Their robust and durable material, combined with their lightweight nature, makes them easy to handle and install. To achieve successful project outcomes, it is essential to follow a series of well-planned steps when using Sonotubes®.
Sonotubes® are favored for their impressive strength relative to their construction material. Traditionally, forming columns involved substantial labor to create the molds for concrete pouring, which was time-consuming and required significant planning and effort. The traditional method also limited the number of columns that could be produced simultaneously due to the time and equipment needed for molding and shaping.
In contrast, Sonotubes® are designed for single-use and do not need external support to stay in place. This allows for multiple columns to be placed simultaneously, significantly reducing both construction costs and time. Additionally, Sonotubes® are made from recyclable, biodegradable paper, which can be repurposed to produce new Sonotubes®.
Using Sonotubes® is significantly more cost-effective compared to purchasing pre-fabricated concrete columns or other support structures. Companies can buy multiple Sonotubes® for a fraction of the cost of acquiring a set of pre-manufactured columns, which also incurs additional expenses for delivery and storage.
Typically, Sonotubes® are partially embedded in the ground and are supported by a footing form that stabilizes the column and prevents it from shifting. Footings are crucial when the supporting soil is problematic. As the concrete column will be partly buried, it's essential to ensure that the bottom of the hole is level. Additionally, the hole must be free of water, as moisture can disrupt the proper placement of the Sonotube®.
The base of the footing can be either round or square and is typically made from plastic. For the Sonotube® to fit correctly, the top of the footing should be trimmed to match the diameter of the Sonotube®. Larger Sonotubes® may require more substantial footings, which should be solid and robust. The footing should fit tightly around the Sonotube® to prevent any movement when the tube is filled with concrete.
It is crucial to ensure that the Sonotube® is level upon placement and verify that it is properly plumbed.
Alternatively, footings can be constructed from concrete and shaped within the hole using wood forms and rebar. These footings can either be premade and inserted into the hole with rebar or constructed on-site with concrete poured into the forms.
Before pouring concrete, the area around the footing and base of the Sonotube® should be backfilled with soil, taking care not to dislodge the Sonotube® or affect its plumb alignment. Properly compacting the soil around the tube will enhance its stability and facilitate a smoother and more efficient concrete application.
Various types of concrete can be used with Sonotubes®, depending on factors such as your location, the type of column being constructed, and the load the columns will bear. It’s important to distinguish between concrete and cement, as cement is just one component of concrete.
Concrete was developed in the 1980s as an improvement over traditional cement by incorporating ingredients that reduce the amount of water remaining after hydration. This mix decreases the size of water-filled pores, thereby enhancing the material's strength.
For added stability, it may be necessary to incorporate rebar into the Sonotube® based on the type of structure being supported. Rebar reinforces the concrete mix and should be positioned during the pouring process so that the concrete can adequately embed it.
Concrete typically consists of 60% to 75% sand, gravel, and rock, 15% to 20% cement, and 15% to 20% water by volume. The water chemically reacts with the cement to form a binding agent that solidifies the concrete into a strong, cohesive material.
The curing time for concrete depends on its composition and the weather conditions. While full curing typically takes about a month, concrete can often be used much sooner. The usual curing process follows this general pattern:
These times are approximate and can vary based on site conditions and environmental factors. A proper curing process is crucial for enhancing the concrete's strength, durability, water resistance, and wear resistance. The strength of concrete relies on the formation of crystals within its matrix, which develop through the chemical reaction between cement and water.
Sonotubes® offer an eco-friendly, cost-effective, and efficient solution for creating cylindrical column structures. They are particularly well-suited for forming underground footings, helping to lower labor costs. The design of Sonotubes® allows for easy cutting and removal, eliminating the need for additional machinery or equipment.
The rounded design of Sonotubes® ensures they fit seamlessly into various structures. Without sharp edges that might chip or crack, they feature smooth surfaces that blend well with the overall design of a construction project.
Sonotube® forms are more cost-effective compared to metal or fiberglass alternatives, allowing you to buy several Sonotubes® for the price of a single fiberglass form. Their availability in various sizes means you can purchase all the sizes needed for a project in one go.
One of the key advantages of Sonotubes® is their lightweight nature, which simplifies handling and reduces labor costs. Their ease of transport, maneuverability, placement, and storage makes them less cumbersome compared to heavier alternatives. Additionally, after use, the cardboard material of Sonotubes® can be repurposed, recycled, or reused, contributing to their environmental sustainability.
One of the most noticeable advantages of Sonotubes® is their ease of installation. They don’t require complex construction or heavy equipment, as they can be handled and positioned by hand. Once in place with appropriate supports, concrete can be poured quickly and easily.
Sonotubes® are perfect for projects involving multiple columns. Rather than waiting for each column to set before starting the next, you can place several columns simultaneously, significantly reducing the overall construction time. This allows for the pouring of all columns in one go.
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